Hydrocone Manual S223.360.01.En
Short Description
Descrição: HIDROCONE...
Description
Maintenance Instruction Manual and Spare Parts Lists
1
Safety regulations
S 050.012 en S 223.380 en
2
General & Technical information
S 000.001 en S 223.361 en
3
Installation
S 223.362 en + enclosures
S 223.360.01 en
4
Electrical system
S 223.392 en + enclosures
Maintenance Instruction Manual and Spare Parts Lists for 1800-Series Hydrocones
5
Starting up
S 223.367 en
6
Lubrication system
S 223.363 en
H2800
S2800
7
Heat exchanger
S 223.393 en
H3800
S3800
8
Hydroset system
S 223.364 en
H4800
S4800
9
Lubricant recommendations
H6800
S6800
10
Topshell assembly & concave ring
S 223.370 en
11
Spider bearing
S 223.394 en
12
Mainshaft assembly & mantle
S 223.371 en
13
Bottomshell assembly
S 223.372 en
14
Pinionshaft assembly
S 223.373 en
15
Bevel gears
S 223.374 en
16
Drive arrangement
S 223.389 en
17
Routine maintenance
S 223.368 en S 223.405 en
18
Fault tracing
S 223.369 en
19
Backing with plastic composition
S 223.375 en S 966.001 en
20
ASR
According to order
21
Over-pressure dust sealing
S 223.408 en
22
Operating in low temperatures
S 223.410 en + enclosures
24
Optional extra equipment
S 223.366 en
25
Motor instruction booklet
2003-06-10
S 223.365 en
23
26 27
Spare Parts List – Crusher
28
Spare Parts List – Oil tank
29
Spare Parts List – ASR
According to order
30 31
Declaration of Conformity
S 058.039 en
Accumulator certificate
1800-Series Hydrocone crushers
S 223.380.00 en 1 (6)
Safety Regulations for Hydrocone Crushers
2001-11-15
Safety Regulations for Hydrocone Crushers
Warning!!!
These regulations must be studied in detail before a crusher is put into operation. If you disregard these regulations there is a risk of serious injury to personnel.
Field of use Hydrocone crushers are intended for use as size reduction machines for rocks, minerals and similar materials within the aggregates and mining industries. All other use is forbidden.
Handling materials Backing with plastic composition The unhardened components of the plastic composition can with some people cause skin irritation and allergic reactions. See Section 19 for information on how to avoid such problems. Flame cutting When cutting manganese steel and plastic composition with a gas torch there is a risk of gases and dust which are dangerous to health. A breathing mask with a filter must be used. Make sure that there is good ventilation at the work-place. Oil products Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant supplier’s instructions and safety directions when handling oils and greases. Fluorinated rubber H-type and S-type 4800 Hydrocones incorporate radial seals made of fluorinated rubber in the pinionshaft housing assembly. If such seals have been subjected to extreme temperatures (i.e. they are burnt) they must be handled in the same way as corrosive acids.
Accumulator To avoid the risk of an explosion, use only nitrogen gas (N2) in the accumulator(s). Do not subject the accumulator(s) to mechanical or thermal damage (impact, welding, etc.)
1800-Series Hydrocone crushers
S 223.380.00 en 2 (6)
Safety Regulations for Hydrocone Crushers
2001-11-15
Dust Crushing always creates dust. Such dust can be more or less dangerous to health, depending on the type of material. Use a breathing mask. To reduce the risks caused by dust, the plant should be dust encapsulated and fitted with a dust-extraction system. (Dust encapsulation, dust extraction and/or water-spraying equipment are not included in the crusher’s standard specification).
Stones in motion In any crushing operation it is possible that individual stones have such a size, shape or surface texture that they are not properly gripped by the crushing liners. Such stones can be ejected upwards out of the crushing chamber at high speed and then fall back close to the crusher. Falling stones can also cause injury to personnel at transition points – for example where a conveyor or a feeder discharges into a crusher. Provide adequate guarding against such ejected or falling stones and place warning signs at appropriate places around the danger area. Use safety glasses and a safety helmet! This is especially important if the crusher’s feed hopper is open (unencapsulated) since this is an area where falling stones and stone fragments may be encountered. The feed hopper has inspection doors. These must not be opened during crushing. If an inspection door is to be opened while the crusher is idling, open it carefully and make sure that no material can fall down whilst the inspection is being carried out. There are inspection holes in the crusher’s bottomshell. Do not remove the covers over these holes during crushing. Do not put a hand inside the crusher while it is running. Pipes and hoses must be protected against falling material to avoid damage and subsequent leakage. Material spillage over the top of the feed hopper can be prevented by installing a level monitor which stops the feed to the crusher if the level of material in the feed hopper is too high. (A level monitor is not included in the crusher’s standard specification). Dust encapsulation reduces the risk of ejected and falling stones. (Dust encapsulation is not included in the crusher’s standard specification).
1800-Series Hydrocone crushers
S 223.380.00 en 3 (6)
Safety Regulations for Hydrocone Crushers
2001-11-15
Guarding Fixed guarding must be used over the moving parts of the crusher’s drive. The crusher is normally driven with V-belts and in such a case there should be a possibility of checking the tension in the belts. The guarding must be constructed in such a way that it conforms to the applicable regulations for access guarding. (The V-belt guard is not included in the crusher’s standard specification).
Risk of pinching
35
When the crusher is mounted on rubber vibration dampers there can be a risk of pinching between the oscillating parts of the crusher and the stationary frame. During normal operation the crusher will oscillate horizontally up to ±15 mm. During starting and stopping the movement is greater – up to ±35 mm.
Falling objects Do not stand inside the crusher when concaves are being removed.
35
Explosion risk Do not use explosives to loosen wearing parts. Do not use explosives to break up stone blockages in the crusher’s feed opening.
Lifting Use lifting equipment with sufficient capacity. Lifting eyes and lifting tools are supplied with the crusher. Follow the instructions for assembly and disassembly. Information about lifting weights is given in Section 2. For information on the weights which must be lifted when the crusher is installed, see Section 3.
Electrical installation (The electrical components inside the oil tank unit are wired up before the crusher is delivered. All components are wired to a connection box on the outside of the tank. Other electrical equipment is not included in the crusher’s standard specification). Follow the applicable regulations when installing electrical equipment. The necessary interlocks are shown in the circuit diagrams – see Section 4.
1800-Series Hydrocone crushers
S 223.380.00 en 4 (6)
Safety Regulations for Hydrocone Crushers
2001-11-15
Access The person in charge of the crusher’s installation is responsible for the provision of access to the crusher and that guarding is provided to prevent people and animals falling into the crusher. Walkways, stairs and (step)ladders must be constructed in accordance with the applicable regulations. (Walkways, stairs and (step)ladders are not included in the crusher’s standard specification).
Noise Dangerous noise levels occur during crushing. Use ear protection! Vibration dampers and dust encapsulation result in lower noise levels. (Dust encapsulation is not included in the crusher’s standard specification). Noise levels and measuring conditions Machine
Hydrocone crusher
Test running in the factory (without material)
Typical values when crushing
dB(A)
dB(A)
≤ 95
95 - 106
The values given above are equivalent continuous sound levels (Leq) measured during a period of 60 seconds with an integrating sound level meter. The values are measured at a distance of approx. 1 m from the machine and approx. 1.6 m above ground level or above a platform alongside the machine. The sound levels given are approximate values. The sound level depends on many factors, e.g. whether or not the crusher has dust encapsulation, how the equipment is installed, how the feed arrangement is designed, the size and impact strength of the feed material, the size of the drive motor, etc.
Training The plant personnel must be trained for their duties and must be given safety instructions.
1800-Series Hydrocone crushers
S 223.380.00 en 5 (6)
Safety Regulations for Hydrocone Crushers
2001-11-15
Safety signs To increase the safety of the personnel working on and around crushers, they carry warning signs with the texts explained below.
Not to be opened/removed during operation. See (A) in the figure on the next page. This sign is placed adjacent to the inspection doors in the feed hopper. See Section 3.1. The same sign is also placed adjacent to the inspection holes in the bottomshell. See section 13.2.
Guards must be in place before operating equipment. See B in the figure on the next page. This sign is placed on the bottomshell adjacent to the drive to underline that the crusher must not be put into operation unless the fixed guarding is in place over the moving parts of the drive. See Section 16.
Read safety regulations in enclosed maintenance instruction manual before operating equipment See C in the figure on the next page. This sign is placed on the bottomshell adjacent to the drive. The purpose of this sign is to encourage the plant personnel to familiarize themselves with the applicable safety regulations and crusher maintenance procedures before putting the crusher into operation.
1800-Series Hydrocone crushers
S 223.380.00 en 6 (6)
Safety Regulations for Hydrocone Crushers
2001-11-15
Positions of safety signs
Safety Regulations - General
S 050.012.02 en 1 (10) 2003-02-25
Contents
Page
Introduction
2
Extra safety precautions
3
General safety precautions
4
Personnel safety
4
Work area safety
5
Electrical safety
6
Flammable and hazardous materials safety
7
Pressurized systems safety (air and hydraulic)
8
Welding safety
9
Ten safety rules
10
Safety Regulations - General
S 050.012.02 en 2 (10) 2003-02-25
Warning !!!
This manual must be studied in detail before the installation work starts. If you disregard the instructions given in this manual there is a risk of serious injury to personnel and/or damage to your equipment.
Introduction Sandvik Rock Processing manufacture crushers, screens and feeders as well as mobile crushing and screening units for the mining and construction industries. During the design and manufacture of the machines, a lot of effort is put into the avoidance of health and safety risks. Warning !!!
Since Sandvik Rock Processing’s machines are used for the handling and/or processing of minerals and other materials which can give rise to health risks for human beings and animals, it is the responsibility of the user to follow the relevant rules and regulations intended to prevent health risks - for example specific regulations applying to asbestos, quartzite, radon, etc.
A single machine, delivered from Sandvik Rock Processing, will always be used as a component in a mineral processing plant. It is therefore virtually impossible for us as suppliers to provide operator instructions for every conceivable control system configuration in which the machine could operate. This manual gives information on safe installation, operation and maintenance. It is not intended as a detailed manual for a specific machine. Its purpose is instead to alert customers, operators and maintenance personnel to the general hazards and risks which can be encountered in a crushing plant. Our maintenance instruction manuals for individual machines give more detailed information regarding your equipment. Despite this, additional training by Sandvik Rock Processing may be necessary. Never hesitate to contact our service organization. Historically, most injuries in crushing and screening plants occur during maintenance, although some occur during the inspection of moving parts or while clearing material blockages, so this safety manual emphasize safety precautions when these activities are undertaken.
Safety Regulations - General
S 050.012.02 en 3 (10) 2003-02-25
To avoid potential safety risks it is important that:
The recommendations in instruction manuals are studied and followed. Personnel are regularly given training on maintenance and safety. General and official safety regulations are followed. Dangerous areas are marked with warning signs. The appropriate equipment and tools are available. The owner and management live up to their responsibility to make sure that effective safety programmes and regulations are worked out and are followed by all personnel.
Extra safety precautions Our instruction manuals and other documentation contain important information which must be read and understood by all users before they operate the equipment. To make it easier to notice information in our instruction manuals directly concerning USER SAFETY and the avoidance of problems with the EQUIPMENT, we use the terms and symbols shown below: Warning !!!
Important information which alerts you to a situation which could lead to serious injury or death if you do not follow the instructions given.
Caution !!
Important information which describes how you avoid damage to a machine and its systems or how you avoid a situation which could cause personal injury.
Note !
Advice about operation, inspection and maintenance of a machine and its systems.
Safety Regulations - General
S 050.012.02 en 4 (10) 2003-02-25
General safety precautions Warning !!!
The following list of general safety precautions should be considered as a guide only. There may be other conditions and variations in the operation of this equipment that are not covered in these general safety precautions. The purpose of these general safety precautions is to make all personnel aware of the general hazards and dangerous situations that exist around the equipment and the work area.
Personnel safety 1.
Read and understand each of the warnings, cautions and instructions in the instruction manual and on all signs and information plates on and around the equipment. If anything is unclear, make sure that all of your questions are answered before work is started.
2.
Report all accidents immediately to your supervisor. Consult a doctor or medical personnel as soon as possible if personal injury is involved.
3.
Keep a list of emergency telephone numbers close to the telephone and inform all work area personnel about the location of the list.
4.
Do not operate or work around equipment while under the influence of alcohol, medicines, tranquilizers or other drugs that can make you less alert or affect your judgement.
5.
When moving about on or around the machine, use the hand grips, ladders, guard rails and other safety equipment provided. Use a safety harness if this is required.
6.
Take precautions to keep hair and loose fitting clothing from being caught on moving parts or controls.
7.
Wear safety glasses whenever there is any danger of flying debris, stone fragments, objects or dust that could enter the eyes, and when required by operating regulations. Be extra safe - always wear eye protection. Take good care of your eyes.
8.
Wear gloves whenever possible to protect hands and fingers from cuts, scrapes, burns and solvents.
9.
Always wear a helmet and safety shoes when appropriate for the work being done and always when required by local or national regulations. Around and beneath material transfer points - between conveyors or feeders and crushers, for example there can be a risk of falling material. Make sure that suitable guards and warning signs are provided.
10.
Remove rings, watches, necklaces and bracelets before working in the plant.
Safety Regulations - General
S 050.012.02 en 5 (10) 2003-02-25
11.
In areas where noise levels are high, wear hearing protection devices.
12.
Wear a breathing apparatus or mask whenever appropriate i.e. when painting or working with chemicals, solvents and other substances that may be hazardous to your health. Remember that there is a risk of silicosis when there is silicious dust in the air.
13.
Do not take chances with your back. Use lifting and moving devices to help you with your work. Always lift with your legs, not with your back.
Work Area Safety 1.
Keep the general work area clean and free of debris. Avoid stone or other material build-ups on walkways, platforms, ladders and under conveyors.
2.
Do not allow unauthorized personnel in or around the work area. Keep a constant check on who is in your work area. If necessary, keep a list.
3.
Keep equipment surfaces that will be touched by hands and feet clean, dry and free of oil or grease.
4.
Keep parts and tools in the designated places when not in use.
5.
Keep safety equipment in a designated place and ensure that work area personnel know the location and the proper use of the safety equipment.
6.
Make a daily check of starting alarms and warning devices in the work area, and ensure that each device is working properly before starting or operating the equipment.
7.
Do not stand under or allow anyone else to stand under equipment that is being hoisted or suspended. Use a safety hook or hook with a safety latch when hoisting equipment and use spreader bars when necessary.
8.
Learn the weight limitations and clearances in and around your work area and for the equipment in use.
9.
Do not overload walkways. They are intended for personnel, not equipment.
10.
Be alert to conditions that may obscure vision in and around your work area.
11.
Always isolate the drive motor(s) of equipment before removing guards or carrying out any inspection or maintenance work.
12.
Ensure that the machine and the working area are sufficiently well illuminated.
Safety Regulations - General
S 050.012.02 en 6 (10) 2003-02-25
Electrical safety 1. Warning !!!
Permit only trained and competent personnel to work on electrical components, in the plant or on any equipment.
2.
Always assume that an electrical circuit is live until it is proven dead by proper testing procedures.
3.
Lock out the appropriate safety isolating switch or the main breaker, and display the ”Work in progress” warning sign in an appropriate place before performing any inspection, maintenance, lubrication or adjustment procedure on a machine.
4.
Repair or replace electrical wires, cables and connectors that are broken or damaged in any way.
5.
Check that electrical earth wires, motor and power cable connections are properly and securely connected before starting any equipment.
6.
Make sure you know the location of all power lines and underground cables. Use extreme caution when working around these areas. Memorize the location of all main electrical isolating switches.
7.
Never work on electrical equipment while it is raining or while standing in water or on wet surfaces unless you know that the power is disconnected.
8.
Be alert when working around or with electricity. Report any electrical hazard immediately to your supervisor.
Safety Regulations - General
S 050.012.02 en 7 (10) 2003-02-25
Flammable and Hazardous Materials safety 1.
Store flammable, combustible or hazardous materials in a safe place and in containers specifically designed for that purpose and clearly marked in accordance with the relevant regulations.
2.
Store used and oily cleaning rags in a properly designed container as required by national and local rules and regulations, and away from flammable and combustible materials.
3.
Do not store flammable or combustible materials in, on or around the equipment, electrical installations or personnel facilities. Caution !!
Do not permit smoking or an open flame around fuel tanks or other storage facilities for combustible materials.
4.
Keep several fully charged fire extinguishers located throughout the work area. Make sure that all personnel know their location and how to operate them. Have them readily available during fueling operations or when other fire hazards are present. Check the charge on each fire extinguisher at least once a month or when otherwise specified.
5.
Shut down all engines and motors when fueling or transferring flammable, combustible or hazardous materials. Follow the recommended fueling and transfer procedures for the substance or material being worked with.
6.
Fill fuel storage tanks and other combustible materials storage facilities in a well ventilated area, well away from equipment which can cause sparks and thus ignite flammable materials.
7.
When refueling or transferring flammable or combustible materials, ground the nozzle or spout to prevent sparks caused by static electricity.
8.
Never start a diesel or gasoline engine in an enclosed area unless there is adequate ventilation. Exhaust fumes can kill ! Warning !!!
9.
Do not use flammable or combustible substances such as gasoline, kerosene or diesel fuel for cleaning parts, unless specifically mentioned in our instruction manual. In other cases, always use a nonflammable solvent for cleaning.
Safety Regulations - General
S 050.012.02 en 8 (10) 2003-02-25
10.
When using epoxy-resin based materials, follow the manufacturer's recommended procedures and precautions. Warning !!!
11.
Mix and pour epoxy materials in an open or well ventilated area. Do not burn cured resin without adequate ventilation. Avoid skin contact with uncured epoxy-resin materials.
Always inspect and charge batteries in an open or well ventilated area. Do not permit smoking or open flames near batteries. Remember that batteries can contain explosive gas. Warning !!!
12.
Properly dispose of waste, drained fluids and hazardous materials with due regard to and in full accordance with all national and local environmental, safety, transportation, and other regulations and ordinances. Make sure that all personnel are familiar with these regulations.
13.
Wear the appropriate clothing and protection devices, and follow the recommended procedures when working with hazardous, flammable and combustible materials.
Pressurized Systems (Air, Hydraulic) 1. Caution !!
Do not perform maintenance on pressurized system components without first relieving ALL pressure in the system.
2.
Do not make internal checks on pressurized oil or fluid system reservoirs or levels until ALL pressure in the system has been relieved. Pressurized oil and air are dangerous if released incorrectly. Oil and air under pressure can get very hot; use extreme caution and allow the system to cool before working on it.
3.
Do not attempt to disconnect an air line or hydraulic line from a cylinder or other component unless ALL pressure in the system has been relieved.
4.
Do not operate pressurized systems with worn or damaged hoses, valves or fittings. Replace defective components before pressurizing the system.
5.
Do not attempt to remove an air or hydraulic cylinder clevis from its attachment unless ALL pressure in the system has been relieved. Do not attempt to disassemble air or hydraulic cylinders unless you have been trained and authorized for such maintenance.
Safety Regulations - General
S 050.012.02 en 9 (10) 2003-02-25
6. Caution !!
7.
Never adjust pressure relief valves beyond the recommended values.
Follow the manufacturer's recommended inspection and maintenance procedures for pressurized systems to ensure that safe operating conditions exist at all times. 8. Warning !!!
Take extreme care when working with hydraulic accumulators. They must never be heated or subjected to welding or mechanical damage.
Welding Safety 1.
Any welding or cutting operations should only be performed by experienced welders who are familiar with the welding equipment and the materials to be welded.
2.
Take all necessary precautions to avoid dropping sparks or welding splatter on belts, hoses, tanks or other parts of equipment, or on personnel in the work area. Always keep the risk of fire in mind. 3. Caution !!
Attach the welding earth cable as close as possible to the piece being welded to avoid damage to the equipment and potential injury to personnel.
4.
Always consult with the manufacturers of the equipment to be welded before any welding operation.
5.
Never weld vessels or pipework which are pressurized.
6.
If a radio control system is installed, disconnect the radio system – including the antenna – before starting any welding work. This is in order to avoid damage to the radio equipment.
Safety Regulations - General
S 050.012.02 en 10 (10) 2003-02-25
TEN SAFETY RULES 1.
Support all efforts to make your work-area safe and healthy.
2.
Act responsibly and with concern for the safety of others, as well as yourself.
3.
Check all tools and protective equipment frequently, to make sure they are in safe working order.
4.
Educate yourself and others in the hazards associated with your job so that they can be avoided in a safe manner.
5.
To avoid injury and damage, familiarize yourself in advance with the risks and safety aspects of procedures which are new to you.
6.
Think over accident and injury possibilities before starting on any project. Take appropriate precautions to protect yourself and others. Revise and improve working procedures regularly.
7.
Warn others of the possibility of accidents and injuries if you see them working unsafely or creating potential hazards.
8.
Be alert for changes in working conditions and process characteristics.
9.
Report unsafe acts and conditions immediately to your supervisor. Don't assume that someone else will do it.
10.
Keep your work area and your tools clean. Pick up tools and materials after use and return them to the appropriate storage place.
Maintenance Instruction Manual
S 000.001.04 en 1 (2)
General information
2001-11-15
General maintenance conditions The person who carries out maintenance work on this machine must be well acquainted with its design. The person who is responsible for the operation of the machine must have good knowledge of the machine and must know when and how adjustments should be made. He must also be familiar with the machine's permissible load limits. For this reason you should read carefully through this maintenance instruction manual and study the spare parts list and the drawings included therein before you install or operate the machine. In addition, make sure that the operator responsible for the machine has a copy of this manual. It is especially important to read the safety regulations included in the instruction manual.
Guarantee and spare parts policies Guarantee policy In addition to the information given in the general delivery conditions, we should like to point out the following: Sandvik Rock Processing undertakes to correct faults in machines sold by us, under the condition that: -
the fault is due to defective design, material or manufacturing.
-
the fault is reported to Sandvik Rock Processings' representatives within the applicable guarantee period.
-
the machine is used only in accordance with the operating conditions specified by us and in applications for which it is intended.
-
maintenance work and repairs are carried out by competent service personnel, in accordance with Sandvik Rock Processings' recommendations.
-
only genuine Sandvik Rock Processing parts are used.
Maintenance Instruction Manual
S 000.001.04 en 2 (2)
General information
2001-11-15
Our obligation thus does not cover faults caused by the use of non-genuine parts, inadequate maintenance, incorrect installation, incorrect operation, incorrectly carried out repairs or normal wear. Sandvik Rock Processing takes no responsibility for damage beyond what is mentioned above - neither injuries to people, damage to property nor consequential damage. We reserve the right to alter the design and specifications of our products without prior notice. Spare parts policy In order to achieve optimal reliability and operating economics throughout the entire life of the machine, only genuine Sandvik Rock Processing original parts may be used. The use of genuine Sandvik Rock Processing parts automatically gives access to the development and quality advances constantly made by Sandvik Rock Processing. Sandvik Rock Processing guarantees that spare parts will be available for at least 10 years after the cessation of manufacture of the machine in question. To ensure that spare parts deliveries are correct, consult the applicable spare parts list and with all orders, specify the following: * * *
machine type serial number/SW-number description, part number and quantity required.
Service assistance Service work or service personnel can be ordered through the nearest Sandvik Rock Processing company, agent or representative or directly from: Sandvik SRP AB Service Dept. S-233 81 SVEDALA Sweden
Telephone Telefax
+ 46-40-409000 + 46-40-409264
1800-Series Hydrocone crushers
S 223.361.00 en 1 (22)
2. General technical information
2001-11-15
2. General technical information
Contents
Page
2.1
Introduction
2
2.2
Important notes
12
2.3
Damage during transport
12
2.4
Pre-delivery rust prevention treatment
13
2.5
Storage of assembled crusher
13
2.6
Storage of partly assembled crusher
14
2.7
Starting up
15
2.8
Tightening threaded fasteners
15
2.9
Welding
17
2.10
Weights
19
1800-Series Hydrocone crushers
S 223.361.00 en 2 (22)
2. General technical information
2001-11-15
2.1 Introduction Type designation Hydrocone is a trade name - registered by Sandvik Rock Processing - for our crushers of the type known as "cone crushers". These are manufactured in two versions – H-type and S-type respectively. Another trade name registered by Sandvik Rock Processing is Hydroset, the name used to describe the safety and setting adjustment system which is incorporated in the two types. H-type and S-type Hydrocone crushers have different cone angles on the crushing mantle. The mantle of an S-type has a smaller included angle than the mantle of an H-type crusher. This means that the downward crushing force is larger in an H-type than in an S-type crusher. Pivot point
S-type
H-type Figure 2.1.1
1800-Series Hydrocone crushers
S 223.361.00 en 3 (22)
2. General technical information
2001-11-15
Size designation The 2800, 3800, 4800 and 6800 Hydrocones are crushers of different sizes in the so-called “1800-Series". The designation H2800 merely indicates the crusher's position in this series. The H4800, for instance, has larger dimensions and higher performance than the H2800. The designation system shown below is used to describe the type, size and main data of the crusher. Table 2.1.2 Designation system
H4800-MC/A/MC-16/20/24/13:01 TYPE OF CRUSHER H=H-type S=S-type SIZE 2800 3800 4800 6800
MARK NUMBER
ECCENTRIC THROW (mm) CONCAVE RING EF=EXTRA FINE F=FINE MF=MEDIUM FINE M=MEDIUM MC=MEDIUM COARSE C=COARSE EC=EXTRA COARSE
MANTLE A, B, HC
FILLER RING MF, M, MC, C
1. 2. 3. 4. 5. 6. 7.
1800-Series Hydrocone crushers
S 223.361.00 en 4 (22)
2. General technical information
2001-11-15
Wearing plate Locating bar Headcentre Head nut Spider bushing Spider cap Mainshaft
8. 9. 10. 11. 12. 13. 14.
Concave ring Mantle Topshell Bottomshell Dust seal ring Bottomshell bushing Eccentric
15. 16. 17. 18. 19. 20. 21.
Eccentric bushing Step bearing Hydroset piston Pinionshaft Pinionshaft housing Crusher pulley Filler ring
Figure 2.1.3 H2800 Hydrocone: Crusher nomenclature
1. 2. 3. 4. 5. 6. 7.
1800-Series Hydrocone crushers
S 223.361.00 en 5 (22)
2. General technical information
2001-11-15
Crusher pulley Locating bar Dust seal ring Mantle Headcentre Mainshaft Head nut
8. 9. 10. 11. 12. 13. 14.
Spider cap Spider bushing Concave Concave ring, lower Topshell Bottomshell Wearing plate
15. 16. 17. 18. 19. 20. 21.
Bottomshell bushing Eccentric bushing Eccentric Step bearing Hydroset piston Pinionshaft Pinionshaft housing
Figure 2.1.4 S2800 Hydrocone: Crusher nomenclature
1. 2. 3. 4. 5. 6. 7.
1800-Series Hydrocone crushers
S 223.361.00 en 6 (22)
2. General technical information
2001-11-15
Locating bar Filler ring Head nut Spider cap Spider bushing Mainshaft Concave ring
8. 9. 10. 11. 12. 13. 14.
Topshell Bottomshell Mantle Headcentre Dust seal ring Wearing plate Bottomshell bushing
15. 16. 17. 18. 19. 20. 21.
Eccentric Eccentric bushing Step bearing Hydroset piston Pinionshaft Pinionshaft housing Crusher pulley
Figure 2.1.5 H3800 Hydrocone: Crusher nomenclature
1. 2. 3. 4. 5. 6. 7.
1800-Series Hydrocone crushers
S 223.361.00 en 7 (22)
2. General technical information
2001-11-15
Locating bar Head nut Spider cap Spider bushing Mainshaft Concave Concave ring, lower
8. 9. 10. 11. 12. 13. 14.
Topshell Bottomshell Mantle Headcentre Dust seal ring Wearing plate Bottomshell bushing
15. 16. 17. 18. 19. 20. 21.
Eccentric Eccentric bushing Step bearing Hydroset piston Pinionshaft Pinionshaft housing Crusher pulley
Figure 2.1.6 S3800 Hydrocone: Crusher nomenclature
1. 2. 3. 4. 5. 6. 7.
1800-Series Hydrocone crushers
S 223.361.00 en 8 (22)
2. General technical information
2001-11-15
Locating bar Filler ring Head nut Spider cap Spider bushing Mainshaft Concave ring
8. 9. 10. 11. 12. 13. 14.
Topshell Bottomshell Mantle Headcentre Dust seal ring Wearing plate Bottomshell bushing
15. 16. 17. 18. 19. 20.
Eccentric Eccentric bushing Step bearing Hydroset piston Pinionshaft Pinionshaft housing
Figure 2.1.7 H4800 Hydrocone: Crusher nomenclature
1. 2. 3. 4. 5. 6. 7.
1800-Series Hydrocone crushers
S 223.361.00 en 9 (22)
2. General technical information
2001-11-15
Locating bar Head nut Spider cap Spider bushing Mainshaft Concave Concave ring, lower
8. 9. 10. 11. 12. 13. 14.
Topshell Bottomshell Mantle Headcentre Dust seal ring Wearing plate Bottomshell bushing
15. 16. 17. 18. 19. 20. 21.
Eccentric Eccentric bushing Step bearing Hydroset piston Pinionshaft Pinionshaft housing Crusher pulley
Figure 2.1.8 S4800 Hydrocone: Crusher nomenclature
1. 2. 3. 4. 5. 6. 7.
1800-Series Hydrocone crushers
S 223.361.00 en 10 (22)
2. General technical information
2001-11-15
Locating bar Filler ring Head nut Spider cap Spider bushing Mainshaft Concave ring
8. 9. 10. 11. 12. 13. 14.
Topshell Bottomshell Mantle Headcentre Dust seal ring Wearing plate Bottomshell bushing
15. 16. 17. 18. 19. 20. 21.
Eccentric Eccentric bushing Step bearing Hydroset piston Pinionshaft Pinionshaft housing Crusher pulley
Figure 2.1.9 H6800 Hydrocone: Crusher nomenclature
1. 2. 3. 4. 5. 6. 7. 8.
1800-Series Hydrocone crushers
S 223.361.00 en 11 (22)
2. General technical information
2001-11-15
Locating bar Head nut Spider cap Spider bushing Mainshaft Concave ring, upper Convave ring, lower Spider
9. 10. 11. 12. 13. 14. 15. 16.
Topshell Bottomshell Mantle Headcentre Dust seal ring Wearing plate Bottomshell bushing Eccentric
17. 18. 19. 20. 21. 22.
Eccentric bushing Step bearing Hydroset piston Pinionshaft Pinionshaft housing Crusher pulley
Figure 2.1.10 S6800 Hydrocone: Crusher nomenclature
1800-Series Hydrocone crushers
S 223.361.00 en 12 (22)
2. General technical information
2001-11-15
2.2 Important notes Each crusher is checked and test-run before delivery. The crusher is only test-run without load and is thus not run-in. Normally, the crusher is delivered on a transport frame and the tank unit is shipped in a crate.
Caution !!
Great care must always be taken when handling crusher components to avoid damaging bearing surfaces or other machined surfaces. Always use timber supports and never place components directly on the ground. Never transport an assembled crusher unless the mainshaft is locked. This is done by lowering the mainshaft to its lowest position and driving in suitable timber wedges in the crushing chamber. If the mainshaft is allowed to move up and down or if the crusher is subjected to severe buffeting, the step bearing components can be destroyed. For the same reason it is important to use care when lifting the crusher. Never lay the crusher on its side as the step bearing components will then be disturbed from their correct positions. Lifting equipment must be dimensioned for the lift which is to be carried out. Weights of the various components are given on the installation drawing and in Section 2.10 below. If chains are used for lifting, protect machined surfaces.
If a travelling hoist is installed above the crusher, the hoist travel direction must coincide with the axis of the pinionshaft. This will make it easier to remove the pinionshaft assembly. There must also be a storage area beneath the hoist's track so that crusher components can be set down.
2.3 Damage during transport Since the shipping agent is responsible for loss or damage which occurs during shipment, inspect the delivery carefully when it arrives and check it against the packing list. In the event of any shortage or damage, send in a claim to the shipping agent at once and inform us at the same time so that we can recheck the delivery. It is always the responsibility of the consignee - and not of the supplier - to send in a claim to the shipping agent. Ensure that the goods are immediately brought under cover or are otherwise protected from rain.
1800-Series Hydrocone crushers
S 223.361.00 en 13 (22)
2. General technical information
2001-11-15
2.4 Pre-delivery rust prevention treatment Before delivery from the factory, the crusher is treated with rust preventatives sufficient for approx. 30 days of transport and storage. In special cases, additional rust prevention treatment can be specified in the order. The crusher is normally delivered fully assembled. Before delivery from the factory, all crushers are test-run for a number of hours with oil circulating through the crusher. When test-running has been completed, the inlet and outlet holes for lubrication and Hydroset oil are plugged. This means that the internal bearing surfaces of the crusher are covered with oil and then sealed off from the outside environment. The same procedure is followed for the tank unit. A completely assembled crusher which has been test-run before delivery will therefore withstand about 30 days of transport and storage before installation and starting up, as long as it is protected from the elements by covering it with a tarpaulin. If the machine is not put into operation within 30 days after it has been dispatched from the factory, follow the instructions given in Section 2.5, Storage of assembled crusher.
2.5 Storage of assembled crusher When the crusher has arrived at the storage site, carry out the following: 1.
Inspect the crusher and tank unit for external damage (see Section 2.3, Damage during transport).
2.
Inspect the rust prevention treatment and touch-up or repeat the treatment if necessary.
3.
Do not place heavy components directly on the ground. Use properly arranged timber supports.
4.
Inspect the stored crusher regularly and check that the rust prevention film is intact and that no damage has occured.
If the assembled crusher is not to be put into operation within 30 days after it has been dispatched from the factory, carry out the following: -
Use the crusher's oil system to fill the bottomshell with lubricating oil until a little oil overflows over the dust collar. Plug the oil return line so that the oil cannot run out from the crusher. Close the valve(s) between the tank and the pump to prevent oil running back from the crusher through the pump.
1800-Series Hydrocone crushers
S 223.361.00 en 14 (22)
2. General technical information
2001-11-15
-
Fill the spider bushing with grease to prevent condensation on bearing surfaces.
-
Rotate the crusher pulley by hand through at least four revolutions every 14th day.
-
Coat the exposed part of the mainshaft sleeve (between the spider and the head nut) with grease.
-
If the lubrication and Hydroset oil tank unit is stored separately from the crusher, fill the pumps with oil.
These recommendations apply also for crushers which are taken out of operation for a period of more than 30 days.
2.6 Storage of partly assembled crusher When the crusher components have arrived at the storage site, carry out the following: -
Inspect the rust prevention treatment and touch-up or repeat the treatment if necessary.
-
Do not place heavy components on the ground. Use properly arranged timber supports.
-
Screw in the lifting eye in the top end of the mainshaft. Lift the mainshaft assembly out of its transport frame and set it down on wooden blocks placed beneath the lifting eye and the lower edge of the mantle. Avoid contact with the bearing surfaces on the two ends of the mainshaft.
-
Inspect the stored components regularly and check that the rust prevention film is intact and that the components have not been damaged.
-
Cover the oil tank unit with a tarpaulin if it is stored outdoors.
-
Store seals and gaskets in a dark, dust-free, dry place. Keep them in their packaging until they are required. If possible, keep the store area at normal room temperature. Never tie seals with steel wire or hang them on nails or pins during storage. Rubber components must be stored free from any stresses in order to avoid cracking and deformation.
1800-Series Hydrocone crushers
S 223.361.00 en 15 (22)
2. General technical information
2001-11-15
2.7 Starting up Before the crusher is started up, drain out all oil from components which have previously been filled. Carefully inspect all components to ensure that there is no corrosion or damage which could interfere with the proper operation of the machine. Install the crusher in accordance with the installation drawing and the instructions given in this manual. Start-up the crusher with the help of service personnel from Sandvik Rock Processing. For more information about putting the crusher into operation, see Section 5, Starting up.
2.8 Tightening threaded fasteners The threaded fasteners used in the crusher must be tightened to the correct torque for the size in question, as given in Table 2.8.1. General requirements for ”normal” joints with threaded fasteners are described in Section 2.8.2. Sections 2.8.3 - 2.8.6 describe ”special joints” for which there are additional requirements for spread of tightening torques in a joint, tightening method and working procedure. Table 2.8.1 Tightening torques in Nm (foot pounds). THREAD M (mm)
STRENGTH GRADE (SS-ISO 898/1) 8.8
10.9
12.9
8
24 (18)
33 (24)
40 (30)
10
47 (35)
65 (48)
79 (58)
12
81 (60)
114 (84)
136 (100)
16
197 (145)
277 (204)
333 (246)
20
385 (284)
541 (399)
649 (479)
24
665 (490)
935 (690)
1120 (826)
30
1310 (966)
1840 (1357)
2210 (1630)
36
2280 (1682)
3210 (2368)
3850 (2840)
42
3640 (2685)
5110 (3769)
6140 (4529)
48
5450 (4020)
7660 (5650)
9190 (6778)
1800-Series Hydrocone crushers
S 223.361.00 en 16 (22)
2. General technical information
2001-11-15
2.8.2 General requirements for joints with threaded fasteners - "normal" joints -
Steel screws of grade 8.8, with surface finish dependent on dimensions: (zink coated or hot-dip galvanized).
-
Hardened washers - at least HB200 (zink coated).
-
Lightly oiled components.
-
Threads in castings cleaned out.
-
Tightening carried out with a torque wrench which can be calibrated, or with a bolt/nut runner with a torque limiter.
-
Max. permissible torque spread: + 30%.
Unless otherwise specified, joints are of "normal" type.
2.8.3 The Hydroset cylinder/bottomshell joint - a "special" joint and 2.8.4 The Hydroset cylinder cover/Hydroset cylinder joint - a "special" joint. -
Grade 8.8 hot-dip galvanized steel screws.
-
Hardened washers - at least HB200. (Zink coated).
-
Lightly oiled screws.
-
Threads in the bottomshell cleaned out.
-
Tightening carried out with a torque wrench which can be calibrated, or with a bolt/nut runner with a torque limiter.
-
Screws are tightened in stages, and in diagonal rotation.
-
Max. permissible torque spread: + 10%.
1800-Series Hydrocone crushers
S 223.361.00 en 17 (22)
2. General technical information
2001-11-15
2.8.5 The locating bar/dust collar joint - a "special" joint. The tightening torque for this joint is calculated with the strength of the threads in the locating bar taken into consideration, and is thus independent of the grade of screw used. Before assembly starts, apply Loctite 243 (or an equivalent) to the threads. -
Tightening torque: Max. permissible torque spread:
45Nm ( 33 ft lbs) + 10%
2.8.6 The eccentric gear/gear carrier joint - a "special" joint -
Untreated grade 12.9 steel screws. Hardened washers - at least HB 400-470. Lightly oiled screws. Threads in the eccentric gear cleaned out. Tightening carried out with a torque wrench which can be calibrated, or with a bolt/nut runner with a torque limiter. The screws are tightened in stages, in diagonal rotation. Max. permissible torque spread: + 10%.
2.8.7 Locking fluid for threaded fasteners In some places in this instruction manual you will come across the recommendation to use locking fluid. Unless otherwise stated, this normally means using Loctite 243 or an equivalent. Use Loctite 577 or an equivalent to seal pipe threads in the lubrication system, where no other sealing is used. For pipes up to 3/4" in size - and in the Hydroset system use Loctite 543, or an equivalent. When a previously used screw is to be reinstalled, it is important to clean oil and Loctite from the threads first. Follow the manufacturer's instruction for the application of locking fluid.
2.9 Welding Under some circumstances it can be necessary to undertake welding during maintenance work on the crusher. If good results are to be obtained, it is important that the welding work is carried out by competent personnel and that the correct electrode is used. Below we give instructions for some of the welding jobs which may be required. Follow the welding instructions for the electrode being used and earth as close as possible to the working area. Do not allow the welding current to pass through important bearing components, etc.
1800-Series Hydrocone crushers
S 223.361.00 en 18 (22)
2. General technical information
2001-11-15
2.9.1 Welding manganese wearing liners to the crusher's topshell and bottomshell etc. Use an ESAB OK 63.35 or equivalent electrode. Liners on bottomshell arms. Fettle the liners and fit them in place. Weld to the inner surface of the bottomshell with three runs of weld 50-100 mm long. Use an A-dimension of 4-6 mm for H & S 2800, 3800 and 4800 crushers, and 6-8 mm for the H & S 6800. Liners on the topshell spider arms (H-type crushers). Fettle the liners and fit them in place. Make a continuous weld around the attachment slots. Use an A-dimension of 4-6 mm for H2800, 3800 and 4800 crushers, and 6-8 mm for the H6800. Liners on topshell spider arms and spider rim (S-type crushers). Fettle the liner support pads and make a continuous weld all around each against the rear side of the liner. Use an ESAB OK 63.35 electrode or an equivalent, with an A-dimension of 4-6 mm for S2800, 3800 and 4800 crushers, and 5-7 mm for the S6800.
2.9.2 Welding liner plates to the inside of the bottomshell After fettling the plates, weld them to the inside of the bottomshell in the holes provided. Use an ESAB OK 48.00 electrode or an equivalent, as directed on the drawing in the spare parts list. Use an A-dimension of 5-6 mm for H & S 2800, 3800 and 4800 crushers, and 68 mm for the H & S 6800.
2.9.3 Welding the head nut and the mantle See Section 12.3.
2.9.4 Lifting lugs on mantles and concave rings If lifting lugs are to be welded on crushing liners, use an electrode suitable for welding to manganese steel, for example ESAB OK Selectrode 67.45 (or an equivalent).
1800-Series Hydrocone crushers
S 223.361.00 en 19 (22)
2. General technical information
2001-11-15
2.10 Weights Table 2.10.1 gives details of the weights of components which can require handling during normal maintenance and repair work. The weights given here are intended for the selection of lifting equipment etc. and must not be considered to be exact. The weights given for concave rings, for example, apply for the heaviest concave ring for each model. Table 2.10.1 Lifting weights (kg) Cat. No.
Component
H2800
S2800
H3800
S3800
H4800
S4800
H6800
S6800
4175-0
Mantle
240
460
480
760
775
1300
1160
2210
6005-0
Concave ring
360
-
590
-
860
-
1290
-
6390-0
Concave, upper
-
45
-
80
-
100
-
-
6305-0
Concave ring, lower
-
400
-
600
-
1050
-
2000
6395-0
Concave ring, upper
-
-
-
-
-
-
-
1900
5650-0
Spider cap
75
75
130
130
160
300
370
370
5660-0
Protective cap
-
-
-
-
-
-
-
420
4205-0
Head nut
15
15
25
25
50
50
85
85
6050-0
Support ring
45
-
-
-
135
-
180
-
-
Mainshaft assembly with mantle
1180
1600
1840
2730
3500
5100
6000
7900
Topshell assembly, with filler ring and concave ring
1800
-
2900
-
4700
-
7400
-
Topshell assembly with concave ring
1600
2300
2520
5100
4100
8100
6800
9600
6006-0
Filler ring
210
-
620
-
500
-
1000
-
5150-0
Arm liner, topshell
-
55
-
270
-
290
-
525
5110-0
Liner plate, topshell
15
-
-
30
-
65
-
60
-
Feed hopper
120
260
310
340
330
840
750
1800
-
-
1800-Series Hydrocone crushers
S 223.361.00 en 20 (22)
2. General technical information
2001-11-15
Table 2.10.1 Lifting weights (kg) – Continued Cat. No.
Component
H2800
S2800
H3800
S3800
H4800
S4800
H6800
S6800
1400-0
Dust collar
70
70
110
110
180
180
265
265
1200-0
Bottomshell bushing 45
45
60
60
100
100
180
180
40
40
75
75
130
130
250
250
15
15
15
15
30
30
20
20
15
15
30
30
45
45
85
85
5
5
10
10
15
15
20
20
25
25
55
55
70
70
95
95
10
10
15
15
25
25
40
40
10
10
15
15
25
25
45
45
10
10
15
15
25
25
35
35
85
85
110
110
185
185
345
345
50
50
85
85
130
130
265
265
21
21
30
30
50
50
85
85
15
15
35
35
70
70
90
90
10
10
15
15
20
20
40
40
50
50
80
80
100
100
150
200
Eccentric bushing 1810-0 1880-0
Eccentric wearing plate Mainshaft sleeve
4025-0 Dust seal ring 4305-0 4350-0
Retaining ring for dust seal ring Mainshaft step
4075-0 Step washer 2280-0 Piston wearing plate 2260-0 Hydroset piston 2205-0 2505-0
Hydroset cylinder cover Hydroset bushing
2050-0 Spider bushing 5675-0 Pinion 3050-0 Crusher pulley 8875-0 -
-
-
-
Topshell assembly with spider, liners and concave rings
16 000
Spider assembly with liner plates Eccentric assembly incl. eccentric bushing Hydroset assembly with step bearing Pinionshaft assembly, excl. crusher pulley
6100 260
260
410
410
700
700
1170
1170
360
360
520
520
610
610
1380
1380
120
120
180
180
280
280
420
420
270
270
270
270
520
520
520
520
Oil tank excl. oil
1800-Series Hydrocone crushers
S 223.361.00 en 21 (22)
2. General technical information
2001-11-15
Table 2.10.2 Lifting weights (lbs) Cat. No.
Component
H2800
S2800
H3800
S3800
H4800
S4800
H6800
S6800
4175-0
Mantle
525
1010
1050
1670
1700
2860
2550
4860
6005-0
Concave ring
790
-
1290
-
1890
-
2840
-
6390-0
Concave, upper
-
95
-
175
-
220
-
-
6305-0
Concave ring, lower
-
880
-
1320
-
2310
-
4400
6395-0
Concave ring, upper
-
-
-
-
-
-
-
4180
5650-0
Spider cap
165
165
285
285
350
660
810
810
5660-0
Protective cap
-
-
-
-
-
-
-
925
4205-0
Head nut
30
30
55
55
110
110
185
185
6050-0
Support ring
95
-
-
-
290
-
390
-
-
Mainshaft assembly with mantle
2590
3520
4050
6010
7700
11230
13200
17400
Topshell assembly, with filler ring and concave ring
3960
-
6380
-
10350
-
16290
-
Topshell assembly with concave ring
3520
5060
5550
11230
9030
17840
14970
21140
6006-0
Filler ring
460
-
1360
-
1100
-
2200
-
5150-0
Arm liner, topshell
-
120
-
590
-
630
-
1150
5110-0
Liner plate, topshell
30
-
-
65
-
140
-
130
-
Feed hopper
260
570
680
740
720
1850
1650
3960
-
-
1800-Series Hydrocone crushers
S 223.361.00 en 22 (22)
2. General technical information
2001-11-15
Table 2.10.2 Lifting weights (lbs) – Continued Cat.No.
Component
H2800
S2800
H3800
S3800
H4800
S4800
H6800
S6800
1400-0
Dust collar
150
150
240
240
390
390
580
580
1200-0
Bottomshell bushing
95
95
130
130
220
220
390
390
1810-0
Eccentric bushing 85
85
165
165
280
280
550
550
1880-0
Eccentric wearing plate
30
30
30
30
65
65
40
40
4025-0
Mainshaft sleeve
30
30
65
65
95
95
185
185
4305-0
Dust seal ring
10
10
20
20
30
30
40
40
4350-0
Retaining ring for dust seal ring
55
55
120
120
150
150
205
205
4075-0
Mainshaft step
20
20
30
30
55
55
85
85
2280-0
Step washer
20
20
30
30
55
55
95
95
2260-0
Piston wearing plate
20
20
30
30
55
55
75
75
2205-0
Hydroset piston
185
185
240
240
405
405
755
755
2505-0
Hydroset cylinder cover
110
110
185
185
285
285
580
580
2050-0
Hydroset bushing
45
45
65
65
110
110
185
185
5675-0
Spider bushing
30
30
75
75
150
150
195
195
3050-0
Pinion
20
20
30
30
40
40
85
85
8875-0
Crusher pulley
110
110
175
175
220
220
330
440
-
Topshell assembly with spider, liners and concave rings
35 200
-
Spider assembly with liner plates
13 400
-
Eccentric assembly incl. eccentric bushing
570
570
900
900
1540
1540
2575
2575
-
Hydroset assembly with step bearing
790
790
1140
1140
1340
1340
3030
3030
-
Pinionshaft assembly, excl. crusher pulley
260
260
390
390
610
610
920
920
-
Oil tank excl. oil
590
590
590
590
1140
1140
1140
1140
1800-Series Hydrocone crushers
S 223.362.00 en 1 (13)
3. Installation
2001-11-15
3. Installation
Contents
Page
3.1
Installation, general
2
3.2
Erection
3
3.3
Feed and discharge arrangements - general information
3
3.4
Feed arrangements for H-type Hydrocone crushers
5
3.5
Feed arrangements for fine crushing
7
3.6
Feed arrangements for S-type Hydrocone crushers
8
3.7
Discharge arrangements
9
3.8
Drive arrangement
12
3.9
Lubrication system
12
3.10
Hydroset system
13
3.11
Electrical system
13
3.12
Over-pressure dust sealing equipment
13
1800-Series Hydrocone crushers
S 223.362.00 en 2 (13)
3. Installation
2001-11-15
3.1 Installation, general For every crusher we supply an installation drawing with installation instructions. The installation drawing gives details of the space required for dismantling and also gives information about the weights of the heaviest components. Information on weights can also be found in Section 2.10. Install lifting gear so that the installation and removal of wearing parts can be carried out quickly. Ensure that there is sufficient space beneath the crusher to remove components from the Hydroset cylinder. To reduce the stresses in the foundation or supporting structure, it is advisable to install the crusher on anti-vibration compression mountings which absorb the vibrations generated when the crusher is running. To ensure that the crusher's motion is harmonic, the compression mountings should be adjusted vertically so that they are equally loaded. When running normally, the crusher will gyrate up to + 15 mm in the horizontal plane, but during starting and stopping the movement is larger. A clearance of at least 35 mm should therefore be provided all around the crusher.
Warning !!!
There is a risk of pinching fingers etc. when the machine is running, especially when starting and stopping.
If the crusher is delivered on a supporting structure or transportable frame, make sure that it is mounted horizontally and rests on a firm foundation. If the foundation is not sufficiently stable, the supporting structure will vibrate and thus be subjected to abnormal stresses. The crusher has a divided feed hopper so that the machine can be disassembled without the need to remove the feed conveyor or feeder.
Warning !!!
Warning !!!
The feed hopper has inspection doors. Never open these when the machine is crushing. If a door must be opened when the machine is running empty, open it carefully and make sure that no material can fall from chutes etc. while the inspection is being carried out. Use protective glasses and a helmet. This is especially important in the case of an open (unencapsulated) feed hopper where stones and stone fragments may be thrown out of the machine. When the crusher is operating - even when it is idling occasional stones which are not properly gripped in the crushing chamber can be thrown violently up out of the crusher and fall down in the vicinity of the machine. Falling material can also cause injury in the vicinity of transfer points - between conveyors or feeders and crushers, for example. Provide suitable guards to give protection against these ejected or falling stones.
1800-Series Hydrocone crushers
S 223.362.00 en 3 (13)
3. Installation
2001-11-15
3.2 Erection On a steel supporting structure Make sure that the crusher mounting points are level and attach the rubber compression mountings to the crusher. Lower the crusher into place and weld the lower fixing plates to the supporting structure. If the compression mountings are instead to be bolted to the supporting structure, mark the positions of the fixing holes. Lift the crusher out of the way, drill the holes for the fixing bolts and then lower the crusher back into place and install the fixing bolts. On a concrete foundation The concreting work should be carried out by experienced personnel. Anchor plates (not supplied with the crusher) must be cast into the foundation. Carefully clean any dust and oil from the concrete areas around the anchor plate pockets. Put the anchor plates into position in the foundation. Fix the rubber compression mountings to the crusher/sub-frame and lower the crusher until it is just above the foundation. Position four blocks between the crusher/sub-frame and the foundation so that the bottoms of the mountings are at least 25 mm above the foundation. Make sure that the crusher is level. Lift the anchor plates and weld the lower attachment plates of the mountings to the top surfaces of the anchor plates. Grout around the anchor plates with a grouting mortar. Keep these areas wet for at least 24 hours. The crusher can also be mounted directly on a foundation without the rubber compression mountings. In such a case, use foundation bolts (not supplied with the crusher).
3.3 Feed and discharge arrangements - general information One of the most important factors for long crusher life and low operating costs is that the feed arrangement is designed so that the material is evenly distributed around the crushing chamber and the crushing chamber is full. If you have any doubts about the feed and discharge arrangements you intend to use, contact Sandvik Rock Processing for advice.
Caution !!
The feed system must be amply dimensioned so that the crusher can receive a sufficient quantity of material. The material should be level with the top of the spider cap. A metal detector should be installed to prevent uncrushable objects from falling into the crusher.
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3. Installation
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A level monitor should be mounted in the feed hopper to stop the feed to the crusher if the material level rises too high. The feeder or feed conveyor should be electrically connected in such a way that it cannot be started before the crusher and the discharge system are running. Depending on the size of the feed material, feed hoppers with conical guide plates or a feed distributor can be fitted.
Note !
As can be seen in Fig. 3.3.1, the topshell of an S-type or an H-type Hydrocone without a feed distributor should always be turned so that the spider arms are aligned with the feeder or feed conveyor. An H-type Hydrocone with a feed distributor should have the topshell turned so that the spider arms are aligned at 90° to the axis of the feeder or feed conveyor. See Fig. 3.3.2.
Figure 3.3.1
S-type Hydrocone (left) and H-type Hydrocone without feed distributor (right)
Figure 3.3.2 H-type Hydrocone with feed distributor
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3. Installation
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The crusher must not be put into full-scale operation until you have established that the feed material is correctly distributed around the crushing chamber, at all rates of feed. If the feed is not evenly distributed around the crushing chamber, or if the finer material enters on one side whilst the coarser material enters on the other side, uneven loads will result. This can lead to bearing failure or shortened bearing life. In addition, the manganese liners will be worn unevenly, thus reducing manganese life. Incorrect feeding arrangements cause: -
Higher power consumption = higher bearing loads Lower capacity Higher manganese wear Lower reduction Poorer product shape Higher costs
If a belt conveyor or a chute is used to feed the crusher, the coarser material will tend to separate from the finer material (segregation). It is thus important to homogenize the feed before it reaches the crusher. This can be accomplished with a feed box above the crusher's feed hopper, as shown in figs. 3.4.1 and 3.4.2. The feed box should be so designed that it can be moved longitudinally to correctly guide the material. A feed box can also be used when a feeder is installed. See Fig. 3.4.3.
3.4 Feed arrangements for H-type Hydrocone crushers
Figure 3.4.1 Feeding from a belt conveyor
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Figure 3.4.2 Feeding from a chute. The chute can be attached to a conveyor or a bin.
Figure 3.4.3 Feeding from a vibrating feeder, direct onto the spider cap. The feeder's supports must be such that it is easy to adjust the position of the feeder to obtain correct material distribution in the crusher. A feed box of the type shown in figs. 3.4.1 and 3.4.2 can also be used.
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3. Installation
2001-11-15
Figure 3.4.4 Feeding from a belt conveyor to a crusher with a feed distributor. A feed distributor can also be used when the material comes from a chute or a feeder.
3.5 Feed arrangements for fine crushing Of the different types of crushing duty, fine crushing gives rise to the highest loads on the crusher. To obtain correct feeding, a feed distributor should be used with feed sizes up to 80 mm. The distributor prevents segregation and also distributes the material evenly around the crushing chamber. For installation dimensions of the feed distributor and the feed hopper, see the installation drawing. The topshell arms must be correctly oriented relative to the distributor - see Fig. 3.3.2. The material must be led into the distributor through the chain-dotted area shown in Fig. 3.5.1. This can be arranged by using a cover plate over the feed hopper and cutting an appropriate opening. The function of the distributor is to split the material into several non-segregated streams which provide an even distribution around the crushing chamber. It rests on the spider cap, which forms the bottom of the middle "compartment". The width of this middle compartment can be adjusted by slackening off the screws (not shown in Fig. 3.5.1) between the distributor and the supporting angle profile across the feed hopper. After a short period of operation, three "cushions" of stone (not shown in Fig. 3.5.1) will be formed and these will reduce the wear on the plate components.
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2001-11-15
Feed
Adjustable
Figure 3.5.1 Feed distributor
3.6 Feed arrangements for S-type Hydrocone crushers (and H-type Hydrocone crushers with EC or C crushing chamber) To prevent damage to the crusher and unnecessary wear on the spider cap and the rim and arm liners, the feed to the crusher must be arranged so that the material falls onto a "stone box" before it falls into the crusher itself. This reduces the drop height and reduces the speed of the material and is particularly important for S-type crushers and H-type crushers with EC (or C) crushing chambers as these machines are fed with relatively coarse material. In such cases it is advisable to keep the level of material in the feed hopper a little lower than with fine or medium crushing chambers due to the risk of bridging. The "stone box" also contributes to a reduction of segregation in the feed material.
"Stone box"
Figure 3.6.1 Feeding from a belt conveyor
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3. Installation
2001-11-15
Figure 3.6.2 Feeding from a chute. The chute can be attached to a conveyor or a bin
The feeder's supports must be such that it is easy to adjust the position of the feeder to obtain correct material distribution in the crusher. A feed box of the type shown in figs. 3.6.1 and 3.6.2 can also be used.
Figure 3.6.3 Feeding from a vibrating feeder, direct onto the spider cap
3.7 Discharge arrangements Caution !!
The discharge arrangement must be designed so that there is no possibility of material building up beneath the crusher. If material does build up, the crusher's dust seal ring can be damaged, thus allowing contamination to enter the lubrication oil. Protect the lubrication and Hydroset lines from falling material.
To facilitate removal of components from the Hydroset cylinder there must be sufficient height between the discharge conveyor and the crusher, or the conveyor must be easily removable. See the installation drawing.
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3. Installation
2001-11-15
Figure 3.7.1 Crusher mounted on concrete foundation or steel supporting structure with discharge hole in floor. Openings in the foundation are blanked off with plate or planks.
Figure 3.7.2
Crusher mounted on concrete foundation where the foundation forms two sides of the discharge hopper. The two remaining sides and the hopper bottom are attached to anchor plates cast into the foundation.
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Figure 3.7.3 Crusher mounted on sub-frame or steel supporting structure with discharge hopper attached to the sub-frame or structure.The conical part of the hopper is of wearing rubber.
Figure 3.7.4
Crusher mounted on sub-frame or steel supporting structure with discharge hopper attached to the subframe or structure. The hopper has a flat bottom of plate.
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3. Installation
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3.8 Drive arrangement See Section 16.
3.9 Lubrication system Warning !!!
Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant supplier's instructions and safety directions when handling oils and greases.
See the installation drawing in the spare parts list for the crusher. The tank unit should be situated so that it is both easily accessible and protected against falling objects, stones and water etc. Ensure that there is sufficient room to drain out oil. Place the tank unit as close to the crusher as possible to give the shortest possible return pipe and thus reduce the return pipe resistance to a minimum. The hoses supplied for inlet and outlet connections must be fitted to the crusher to prevent the transmission of vibrations to the tank unit. Pipes for connection between these hoses and the tank unit are not supplied with the crusher, but normal water pipe can be used. Regarding pipe thread sealing, see Section 2.8.7.
Caution !!
The return pipe must have an even slope of at least 1 in 12 (5°). If the pipe is longer than 3 m, increase the slope to 10° to prevent the formation of air pockets. If the pipe is to include changes of direction, avoid pipe elbows. Use large radius pipe bends instead to reduce resistance in the pipe. Oil is supplied to the crusher through one or two lines. Make sure that the piping is free from burrs, metal shavings and dirt before it is connected to the crusher and tank unit. The piping should be run so that it is protected against falling stones and it should be securely supported to avoid vibration.
If a water/oil heat exchanger is used, it can be mounted on the tank unit with the hoses supplied. If the water/oil heat exchanger is mounted elsewhere, pipes can be used between the hoses and the tank unit. If an air/oil heat exchanger is mounted on the back of the tank unit, the hoses supplied with the crusher will be sufficient. If the heat exchanger is installed in some other place, use pipes to connect the tank unit to the hoses. Attach only hoses to the air/oil heat exchanger. To reduce as far as possible the amount of dust which settles in the radiator matrix, the air/oil heat exchanger is best placed so that its fan blows towards the crusher.
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If the ambient air contains a lot of dust, it is advisable to lead fresh air to the heat exchanger through a duct from a dust-free place. The duct must not be so long that air flow is restricted and it must not be rigidly connected to the heat exchanger.
3.10
Hydroset system
The Hydroset tank unit is combined with the lubrication tank unit. See figures 6.1.1 and 6.1.2. The crusher is connected to the Hydroset control valve in the tank unit by a hose and piping.
Note !
Caution !!
A hose is supplied with the crusher. This hose must be connected to the crusher so that vibrations are not transmitted to the tank. Carefully de-burr and clean out any rust, scale etc. from the bore of the pipes before erection. Sharp pipe bends should be avoided since they can lead to unnecessary pipe resistance. Support the pipework properly. Regarding pipe thread sealing, see Section 2.8.7. The rest of the Hydroset line must be made of high-pressure pipe which can withstand a pressure of 20 MPa.
The Hydroset tank must be inspected and if necessary cleaned before it is filled with oil. Before starting up the hydraulic system, it must be cleaned out with separate, suitable cleaning equipment. Cleanliness is the best insurance against disturbances in operation.
Warning !!!
3.11
Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant supplier's instructions and safety directions when handling oils and greases.
Electrical system
See Section 4.
3.12
Over-pressure dust sealing
See Section 21.
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4. Electrical system
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4. Electrical system
Contents 4.
Electrical system
Page 2
4.
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4. Electrical system
2001-11-15
Electrical system Caution !!
The crusher’s drive motor must be interlocked in such a way that it cannot be started unless the lubrication system is in operation, i.e. the lubricating oil pump is running, the oil flows to and from the crusher are correct and the oil is not too hot. On crushers which have a circulatory system for pinionshaft lubrication (H/S4800 and H/S6800) this pump must be interlocked in such a way that it starts when the crusher’s drive motor starts. If any of the safety interlocks listed above are activated, the crusher motor will stop. To avoid stoppages when the crusher is full of material, the interlocks can be arranged so that the feed stops immediately and the crusher’s drive motor stops approx. 10 (max. 15) seconds later. Important! The oil pump must not be stopped until after the crusher has stopped. If the crusher drive motor and the lubrication oil pump are started and stopped with a common push button, interlocks must be provided to ensure that the oil pump starts first. The crusher drive motor must start only when the thermostat and return oil flow switch are activated and indicate "crusher ready for start". When the machine is to be shut down, the oil pump should not be stopped until about one minute after the crusher drive motor has stopped. The feeding system must be connected in such a way that feeding is impossible until both the crusher and the discharge system are running and the crusher's pinionshaft speed is correct. The feed must stop if the discharge system and/or the crusher stops.
The components inside the oil tank are wired to the connection box on the outside of the tank.
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5. Starting up
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5. Starting up
Contents
Page
5.1 General
2
5.2 Running in
4
5.3 Checking the setting
6
5.4 Maximum load
6
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5.1 General Before a new or overhauled crusher is started, follow the sequence described below: 1.
Check that the lubrication and Hydroset lines between the crusher and the tank unit are correctly installed and that the oil return line has sufficient fall and is adequately dimensioned.
2.
Check that the voltage and frequency of the electrical supply match the data given on the motors and heaters.
3.
Check that the motor overload protection relays are set to the correct current values.
4.
Fill the lubrication and Hydroset tanks with oil. For oil types and quantities, see Section 9 – Lubricant recommendations.
NOTE! The same type of oil is used in both tanks, but with different viscosities. 5.
Check the setting of the heater thermostat (TG3). For operating conditions which differ from normal, thermostat TG 3 must be reset. See Table 6.15.1 in Section 6.
6.
Switch on the oil heaters.
7.
Check that the shut-off valves are open on the suction lines to the lubrication and Hydroset pumps.
8.
Check that the pinionshaft housing of an H or S 2800 or 3800 crusher has been filled with oil up to the top of the oil level tube. For oil type and quantity, see Section 9 – Lubricant recommendations. Before starting a new or overhauled crusher for the first time, fill the pinionshaft housing with oil up to the correct level, even if the crusher has a circulatory lubrication system. This is because the pinionshaft lubrication pump starts at the same time as the crusher's drive motor and it takes a little time for oil to reach the pinionshaft housing.
9.
Check that the spider bearing is filled with grease up to the top of the bushing when the mainshaft is in its lowest position. For grease recommendations, see Section 9.5 – Spider bearing lubrication.
10.
Check the direction of rotation of the motor on the lubrication oil pump. See Section 6.6 – Oil Pump.
11.
In the case of an H or S 4800 or 6800 crusher, check the direction of rotation of the pinionshaft lubrication pump. See Section 6 – Lubrication system.
12.
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If the crusher is fitted with an air/oil heat exchanger, check the direction of rotation of the fan motor and the air flow direction. Air should be sucked through the cooler matrix. If a water/oil heat exchanger is fitted, check that cooling water is available and that the water lines do not leak.
13.
Start the lubrication oil pump and check that there is no leakage in the oil lines. Run the pump for about 30 minutes and then clean off any contaminants (e.g. remnants of sealing compound etc.) that have collected on the return oil strainer or in the dirt trap. Start the pump again.
14.
Raise and lower the mainshaft slightly several times and check that the electrical setting control circuits are correctly connected.
15.
Bleed all air out of the Hydroset system. See Section 8.3 – Starting up.
16.
Lower the mainshaft to its lowest position and measure the distance between the head nut and the underside of the spider and record this dimension (="A-dimension"). This will later permit the determination of the wear on the step bearing without taking the crusher apart.
17.
Raise the mainshaft 10-15 mm from its lowest position.
18.
Check that the crusher's drive is correctly aligned and that the V-belts are correctly tensioned.
19.
Start the crusher's drive motor and check that the direction of rotation is correct. See Section 16 – Drive arrangement. Run the crusher without load until the return oil temperature reaches about 40°C (104°F).
20.
In the case of an H or S 4800 or 6800 crusher, check that the pinionshaft lubrication pump starts when the crusher drive motor starts.
21.
Check the operation of the return oil flow switch and, if necessary, adjust (See Section 6 – Lubrication system).
22.
Bleed the Hydroset system again.
The crusher's drive motor must stop when the following checks are made: 23.
Depress the float on the return oil flow switch.
24.
Adjust the protective thermostat TG1 to a temperature just below the return oil temperature (on the temperature gauge). When the check has been carried out, reset the thermostat to the correct setting, as given in section 6.14 – Thermostats.
25.
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Stop the crusher's drive motor and the lubrication pump motor.
IMPORTANT! The lubrication pump must never be stopped until the crusher has stopped completely. 26.
Clean the return oil strainer and the dirt trap.
Note !
Check that material cannot be fed to the crusher unless both the crusher and the discharge system are running.
Starting a crusher in extremely low temperatures At extremely low temperatures it may be found that oil overflows over the dust collar when the crusher is started (before normal operating temperature is reached). Stop the oil pump and allow the oil to run back to the tank. Start and stop the oil pump repeatedly at 10 second intervals until the "Crusher ready for start" signal is obtained. Start the crusher and allow it to run idle. Check that the oil flow is normal. For more information, see Section 22 – Operating in low temperatures.
5.2 Running in The appropriate parts of this section apply also after repair work and the fitting of new parts. 1.
Start the lubrication oil pump.
2.
When the "Crusher ready for start" lamp lights up, start the crusher's drive motor.
3.
Check and adjust the setting. See Section 5.3 – Checking the setting. During the running-in period the setting should be a little larger than the smallest recommended.
4.
Operate the crusher carefully and gradually increase the load until it reaches 75% of the maximum motor load and Hydroset pressure values given in Section 5.4. The load is altered by changing the setting.
Caution !!
The crushing chamber should be full. The crusher will not be run-in by idling. The crusher is normally run-in after approximately 16 hours operating at 75% load. Thereafter increase the load gradually up to full load. Depending on the availability of material, and for other process engineering reasons, running-in can take longer. It is important that points 5, 6 and 7 are followed carefully during the entire running-in procedure.
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5.
Check the return oil temperature regularly. This temperature should normally lie between 40°C (104°F) and 45°C (113°F).
6.
Check that the cooling system cuts in at 45°C (113°F) and cuts out at 40°C (104°F) oil temp. If operating conditions differ from normal and an oil with ISO VG 220 or ISO VG 100 viscosity is used, set the thermostats at the correct values, as given in Table 6.14.2 in Section 6.14 – Thermostats.
7.
Inspect and clean the oil strainer regularly. Quite often, a small quantity of fine steel and bronze particles can be found on the oil strainer during the initial running period.
8.
Bleed the Hydroset system again.
9.
Check that there is no movement between the topshell and bottomshell.
10.
Check that there are no oil leaks from the lubrication and Hydroset lines.
11.
Check that the indicating pointer of the Hydroset pressure gauge moves steadily. (See Section 8.10 - Damping valve for pressure gauge).
12.
Check the temperature of the pinionshaft housing with a thermometer. The normal temperature is 50-60°C (122-140°F).
13.
Check that the feed is correctly distributed around the crushing chamber. See Sections 3.3-3.6.
14.
Check the power consumption and Hydroset pressure.
15.
Check and record the lubricating oil pressure(s) (Main lubrication system, plus – on an H or S 4800 or 6800 crusher – also the pinionshaft lubrication system).
16.
Shut off the feed to the crusher and listen for abnormal noises. A ringing sound can indicate a loose mantle or concave ring.
17.
Check that there are no grease leaks from the spider bearing.
18.
Check the oil level in the pinionshaft housing when the oil is hot and the crusher is standing still (H or S 2800 or 3800 crusher).
19.
After running-in is completed, retighten all bolts and re-tension the V-belt drive.
20.
It is very important to clean the dirt trap on the suction side of the lubrication oil pump, since it is quite common for sealing compound from the oil lines to settle here.
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5.3 Checking the setting The C.S.S. (Closed Side Setting) is most easily checked by using a lump of lead fastened to a steel wire and lowering it slowly into the discharge area of the crushing chamber. The lead lump will be squeezed and its thickness will then correspond to the setting. The lead lump must of course be so large that it really does get squeezed. The setting should occasionally be checked at 4 points, evenlyspaced around the crushing chamber. This will enable you to detect uneven wear, which indicates an unsatisfactory feed arrangement. The setting must never be so small that the crusher’s power draw exceeds the limit given in Table 5.4.3. In addition, the Hydroset pressure must not exceed the limit given in Table 5.4.4.
Caution !!
5.4 Maximum Load The power drawn by the crusher and the Hydroset pressure during operation are dependent on the crushing chamber, the eccentric throw, the crusher's setting and the feed material's crushability, size analysis, moisture content, etc. Tables 5.4.1.1-4 and 5.4.2 show the average power which is normally required. However, the power draw – if it is even and without peaks – can be higher as long as the Hydroset pressure does not exceed the value given in Table 5.4.4. The average power draw must not exceed the value given in Table 5.4.3.
Average power in kW (measured on the motor shaft). Table 5.4.1.1
Throw 13 16 18 20 22 25 28
EF
F
61 68 75
47 52 56 61 68 75
H2800 HYDROCONE MF M 45 50 54 55 59 60 65 65 70 73 78 80
C 51 61 67 74 80 90
EC 54 65 71 78 85
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Tabell 5.4.1.2
Throw 16 19 22 25 29 32 34 36
EF
F
94 102 108 113
75 83 94 102 108 113
H3800 HYDROCONE MF M MC 67 73 77 79 83 87 88 92 97 99 105 110 108 114 120 114 120 126 120 127 132
C 70 81 92 102 116 127
EC 74 85 97 108 123 132
C 99 119 139 159 179 198 218
EC 104 125 145 166 187 208
Table 5.4.1.3
Throw 16 20 24 28 32 36 40 44
EF
F
145 161 176 192
114 129 145 161 176 192
H4800 HYDROCONE MF M MC 96 109 115 119 127 133 136 145 152 152 163 171 169 180 190 185 198 209 202 216
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Table 5.4.1.4 Throw 18 20 24 28 32 36 40 44 48 50
EF
F
197 216 235 254 264
190 211 231 251 272 282
H6800 HYDROCONE MF M MC 139 151 167 176 180 190 200 202 213 225 224 237 250 245 260 275 267 283 299 289 307 300 315
C 145 158 184 211 237 263 289 315
EC 152 165 193 221 248 276 304
Table 5.4.2 Throw C 54 65 78
16 20 25 30 35 36 40
S2800 EC 61 74 90
S-type HYDROCONE S3800 S4800 C EC C EC 76 86 92 105 111 124 111 127 134 150 131 150 156 175 184
Tabell 5.4.3 Crusher
Max. average power in kW
H2800
90
H3800
132
H4800
220
H6800
315
S2800
90
S3800
150
S4800
220
S6800
315
C
S6800 EC
136 164 191 218
153 184 215 247
245
278
207
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Max. average Hydroset pressure in MPa. H- & S-type Hydrocones Table 5.4.4 Crusher H2800
H3800
H4800
H6800
S2800 S3800 S4800 S6800
Crushing chamber EF, F MF, M C EC EF, F MF, M MC, C EC EF, F MF, M MC C EC EF, F MF, M MC C EC C, EC C, EC C, EC C, EC
(MPa /Psi) 3.5/507 3.2/464 3.0/435 2.8/406 4.0/580 3.8/551 3.6/522 3.4/493 4.2/609 4.0/580 3.8/551 3.6/522 3.4/493 3.6/522 3.4/493 3.2/464 3.0/435 2.8/406 2.1/304 2.5/363 2.5/363 2.5/363
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6. Lubrication system
2001-11-15
6. Lubrication system
Contents
Page
6.1
Introduction
2
6.2
Description
4
6.3
Flow diagrams
5
6.4
Cleaning
7
6.5
Dirt trap
7
6.6
Oil pump
8
6.7
Temperature gauge
13
6.8
Pressure gauge
14
6.9
Pressure drop indicator
14
6.10
Oil filter
14
6.11
Pressure relief valve
16
6.12
Return oil flow switch
17
6.13
Oil strainer
18
6.14
Thermostats
19
6.15
Oil heating
21
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6. Lubrication system
2001-11-15
6.1 Introduction To ensure that it has sufficient and efficient lubrication and cooling, the crusher is equipped with a lubrication tank with safety and monitoring devices and a heat exchanger.
Warning !!!
Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant supplier's instructions and safety directions when handling oils and greases.
The lubrication oil tank is combined with the Hydroset oil tank. All tank units including instruments and valves are checked and adjusted at the factory to the correct settings for normal operating conditions (max. 32°C, 90°F ambient air temperature and oil viscosity ISO VG 150).
Note !
Even though the tank unit has been checked, all instruments and gauges must be rechecked before the crusher is put into operation.
Under normal conditions, all checks and adjustments must be made at a return oil temperature of 40-45°C (104-113°F). For operation under conditions which differ from normal, thermostats TG1, TG2 and TG3 must be adjusted to the values shown in Tables 6.14.2 and 6.15.1, and a different grade of lubricating oil must be used. See Sections 9.1 and 9.2. For operation at elevated temperatures, the adjustments must be made at a return oil temperature of 47-51°C (117-124°F). For operation in low temperatures, the adjustments must be made at a return oil temperature of 33-37°C (91-99°F). The lubricating oil is cooled by a heat exchanger, either air/oil or water/oil.
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6. Lubrication system
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Figure 6.1.1 Tank unit for H2800, H3800, S2800 and S3800
1. 2.
From crusher To crusher
3. 4.
Hydroset line To pinionshaft housing
Figure 6.1.2 Tank unit for H4800, H6800, S4800 and S6800
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6. Lubrication system
2001-11-15
6.2 Description The free-standing tank unit (see Figs. 6.1.1 and 6.1.2) consists of a front component cabinet and - at the rear - lubrication and Hydroset oil tanks. The component cabinet contains the motor-driven lubrication oil pump(s), oil filter(s), and various protective devices. Lubrication oil is pumped from the tank, through the filter and heat exchanger to the crusher's oil inlet. Oil entering the crusher is pressed through the step bearing and up between the eccentric bushing and the mainshaft and between the bottomshell bushing and the eccentric to lubricate these bearings. The oil lubricates the wearing plate and the bevel gears before running back to the tank unit by gravity. In the case of an H2800, H3800, S2800 or S3800 crusher, the pinionshaft has oil-bath lubrication. The oil level is regulated by a level tube. The oil level must be checked by regular inspection and topped up if necessary. In the case of an H4800, H6800, S4800 or S6800 crusher, the pinionshaft bearings are lubricated by a separate circulatory system. A small amount of oil is bled off from the main lubrication system between the filter and the heat exchanger. This bleed oil is pumped through a separate filter to the oil inlet in the top of the pinionshaft. The oil level in the pinionshaft housing is regulated by a level tube and excess oil returns to the tank by gravity.
See flow diagram 6.3.1 for an H2800, H3800, S2800 or S3800 crusher. See flow diagram 6.3.2 for an H4800, H6800, S4800 or S6800 crusher.
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6. Lubrication system
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6.3 Flow diagrams 1. 2. 3. 4. 5. 6.
Shut-off valve Dirt trap Oil pump Pressure gauge Oil filter with pressure drop indicator and by-pass valve Heat exchanger
7. 8. 9. 10. OG1 TG1 TG2
Return oil temperature gauge Oil strainer Pressure relief valve Tank Return oil flow switch Protective thermostat Thermostat for heat exchanger
Figure 6.3.1 Lubrication oil flow diagram for an H2800, H3800, S2800 or S3800 Hydrocone crusher
1. 2. 3. 4. 5. 6. 7. 8. 9.
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6. Lubrication system
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Shut-off valve Dirt trap Main oil pump Pressure gauge Oil filter with pressure drop indicator and by-pass valve Oil filter with by-pass valve Pressure relief valve Heat exchanger Oil pump for pinionshaft bearing lubrication
10. 11.
Pressure gauge Oil filter with pressure drop indicator and by-pass valve 12. Non-return valve 13. Oil strainer 14. Tank 15. Return oil temperature gauge TG1 Protective thermostat TG2 Thermostat for heat exchanger OG1 Return oil flow switch
Figure 6.3.2 Lubrication oil flow diagram for an H4800, H6800, S4800 or S6800 Hydrocone crusher
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S 223.363.00 en 7 (21)
6. Lubrication system
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6.4 Cleaning Contaminants such as stone dust, water etc., which enter the lubricating oil will to a certain degree sink towards the bottom of the tank. This should therefore be cleaned out a couple of times a year, if this proves to be necessary. This periodical cleaning prevents sludge following with the oil which is withdrawn from the tank through the outlet just above the tank bottom. Condensation water can be removed by taking out the screw in the drain plug. When the tank is to be cleaned, remove the oil hose from the heat exchanger (or break the circuit at another suitable point) and pump out the oil into a drum.
Caution !!
Stop the pump when the oil level has dropped to just above the suction outlet, as there will otherwise be a major risk of pump damage.
Remove the drain plug in the tank. Drain out the remaining oil. Clean out the tank with white spirit, or other suitable solvent.
6.5 Dirt trap The dirt trap (Fig. 6.5.1) protects the oil pump and is mounted ahead of it. If it is not cleaned but is allowed to clog, cavitation will occur in the pump. This can result in pump breakdown. The shut-off valve ahead of the dirt trap must be closed before the plug is unscrewed. Have a bucket ready to catch the oil which runs out. During the running-in period, and when the tank has been cleaned, check the dirt trap daily. The gauze element must not, under any circumstances, be left out or replaced by another with a different mesh.
1. 2.
Plug Gauze element
Figure 6.5.1 Dirt trap
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6. Lubrication system
2001-11-15
6.6 Oil pump A gear-type oil pump is used. The pump requires very little attention. If clean oil is used, very little wear will occur. Wear can, however, be considerable if the oil contains stone dust or similar contaminants. The most usual sign of pump wear is a reduction in oil flow. Pump capacity (main pump, RB5 and RB6) The pump's total capacity at normal operating temperature and pressure, when the motor is connected to a 50 Hz supply, is shown in Table 6.6.1. If the motor is connected to a 60 Hz supply, the pump speed will be 20% higher and the delivery will increase. The oil pump must be changed when the delivery has dropped below the minimum figure given in the relevant column in Table 6.6.1. Oil delivery can conveniently be checked by measuring the return oil flow. Position a bucket with a known volume beneath the opening in the float chamber and measure the time taken to fill the bucket. Example. A 10 lit. bucket takes 7.3s to fill. The oil flow is thus: 10x60 = 82 lit/min. 7.3 Table 6.6.1 Lubrication oil flow
50 Hz supply
Normal capacity lit/min (US. gal./min) Min. capacity lit/min (US. Gal/min)
60 Hz supply
Normal capacity lit/min (US. gal./min) Min. capacity lit/min (US. gal./min)
H2800 S2800
H3800 S3800
H4800 S4800
H6800 S6800
33
38
82
120
(8.72)
(10.04)
(21.66)
(31.70)
27
32
70
100
(7.13)
(8.45)
(18.49)
(26.42)
40
46
98
144
(10.57)
(12.15)
(25.89)
(38.04)
27
32
70
100
(7.13)
(8.45)
(18.49)
(26.42)
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6. Lubrication system
2001-11-15
Pump capacity (pinionshaft pump) applies to H4800, H6800, S4800 and S6800 crushers only The pinionshaft pump has a total capacity of 0.7 lit./min (0.18 US gal./min) at normal operating temperature and pressure, when the motor is connected to a 50 Hz supply. If the motor is connected to a 60 Hz supply, the pump speed will be 20 % higher and the delivery will increase to 0.8 lit./min (0.21 US gal./min). An HPI pump is used. It is always delivered set up for anti-clockwise rotation. The pinionshaft oil pump should be changed when the delivery has dropped to 0.5 lit./min (0.13 US gal./min). Oil delivery can conveniently be checked by disconnecting the inlet line from the pinionshaft housing and measuring the time taken to fill a bucket with a known volume. Carry out this check above the opening in the oil tank unit - after removing the cover - to avoid oil spillage. RB5 and RB6 pumps Starting the pump When the pump is started, the oil tank must be full of oil so that the pump does not operate dry. Note that the pump's direction of rotation must correspond to the arrow on the pump body. Before starting the pump, check that the shut-off valve ahead of the dirt trap is open. Direction of rotation When a new pump is fitted, check that its direction of rotation is correct. The pump can be changed from anti-clockwise rotation to clockwise (and vice-versa) by loosening the shaft-end cover plate and rotating it through 180°. The upper arrow indicates the correct direction of rotation. See Fig. 6.6.2.
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6. Lubrication system
2001-11-15
Anti-clockwise rotation: H2800, H3800, S2800 and S3800
Clockwise rotation: H4800, H6800, S4800 and S6800
1. 2. 3.
Pressure connection Suction connection Suction side
Figure 6.6.2 Pump rotation direction (seen from shaft end)
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6. Lubrication system
2001-11-15
Shaft seal The pump is fitted with a mechanical rubbing packing system which is self-sealing. It needs no adjustment or tightening. This seal is intended for liquids which are relatively free from solid contaminants and with a maximum working temperature of 175°C (345°F). Occasionally, slight leakage may occur when the pump is started, but this usually disappears after a short time. Leakage from the shaft seal can be due to a damaged packing, damaged sealing surfaces or incorrect assembly. Replacement of seal ( see Fig. 6.6.3) 1.
Remove the coupling half and the key (24). Use an extractor.
2.
Remove any burrs on the shaft (8) or in its keyway.
3.
Unscrew the gland nut or the cover and remove all of the components from the shaft.
4.
Remove the O-ring (16) and fit a new one.
5.
Fit the retaining ring (19) and check that it sits properly in the groove on the shaft. Fit the inner washer (20) with the chamfer towards the retaining ring.
6a.
With some types of packing, the spring (21) and the outer washer (20) are then fitted. Next, carefully pull a new rubber ring/O-ring (22) on to the shaft. Be careful to avoid damage when sliding it over the keyway! Fit the rotor ring (23) so that the rubber ring/O-ring (22) is pressed into the correct position in the rotor ring. Take care to avoid damaging the sealing surface.
6b.
On other types of packing, items 20, 21, 22 and 23 are integrated into a single component which must be fitted in place carefully, without damaging the sealing surfaces. Before screwing on the gland nut/cover, fit a new O-ring (17) inside. Press the new stator ring (18) into position inside the O-ring (17). Take care to avoid damaging the sealing surface. Tighten the gland nut/cover.
7.
Finally, fit the key (24) in position and press the coupling half onto the shaft with light blows. Lock it in position with the stop screw. The play between the coupling halves must be 2 mm.
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6. Lubrication system
2001-11-15
Figure 6.6.3 Mechanical rubbing seal
Extra spacer
Figure 6.6.3 Mechanical rubbing seal
Axial play When a disassembled pump is reassembled, it is very important that the rotor's axial play is correct. This can be measured by using a dial gauge against the end of the shaft. The axial play must be 0.07 mm (0.0028") for the RB5 and RB6. Measure the play when the pump is clean and dry.
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6. Lubrication system
2001-11-15
Faults and possible causes (RB5 and RB6 ) Low capacity or low pressure 1. 2. 3. 4. 5.
The pump sucks air through a leak in the suction line. The pump sucks air through the shaft seal. The suction line is completely or partially blocked. The pump rotates in the wrong direction. Low capacity due to high pressure and wrong type of oil.
The pump does not suck 1. 2. 3. 4.
The pump is too dry - fill with oil. The pump sucks air through the suction line or the shaft seal. The pump rotates in the wrong direction. The suction line is blocked or the shut-off valve is closed.
Abnormal noise from the pump 1. 2. 3. 4. 5.
Cavitation in the pump. There is air in the oil - there is a leak in the suction line or the shaft seal is worn. The gear teeth in the pump are worn. The dirt trap on the suction side is blocked, causing cavitation. The pump is not correctly aligned.
6.7 Temperature gauge An indicating temperature gauge is built into the tank unit to monitor the temperature of the return oil. The return oil flow passes over the sensing head of the gauge. The normal return oil temperature depends on the ambient air temperature and the viscosity of the lubricating oil. See Section 6.14 – Thermostats. The gauge should be checked once a year against a reference thermometer to ensure that it reads correctly. The check should be carried out at an oil temperature of 40-50°C (104-122°F).
1800-Series Hydrocone crushers
S 223.363.00 en 14 (21)
6. Lubrication system
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6.8 Pressure gauge The pressure gauge is situated between the oil pump and the filter (two pressure gauges on an H4800, H6800, S4800 or S6800 crusher). Check the pressure(s) at regular intervals and keep a record of the readings. At operating temperature, the pressure in the main system is normally 0.15-0.5 MPa (21.8-72.5 psi), depending on tank installation. If the pressure ahead of the oil filter rises, this is a sign that the filter should be changed. An abnormally low pressure can mean that the pump is worn, or that the dirt trap is choked.
6.9 Pressure drop indicator (PG2, PG3) The pressure drop indicator monitors the pressure drop across the filter and gives a signal when the pressure drop exceeds 0.22 MPa (32 psi). This signal indicates that the filter element(s) should be changed. The signal is given both electrically - to a lamp on the outside of the tank unit - and in the form of a red button which protrudes (about 4 mm) from the top of the indicator. During a cold start, the indicator can give an incorrect signal. The electrical signal will automatically be reset when working temperature has been reached, but the mechanical signal (the red button) must be reset manually. If the red button jumps out again immediately, or if the lamp does not go out when working temperature has been reached, the filter element(s) must be changed.
6.10 Oil filter The oil filters used in the lubrication system are of the full-flow type. This means that all oil pumped to the crusher is filtered. The filter is of simple design and it is very easy to remove and replace the filter elements, which are of the throw-away type. An H2800, H3800, S2800 or S3800 crusher has a single filter for the circulatory oil system (1 filter element). An H4800, H6800, S4800 or S6800 crusher is fitted with two parallel filters (4 filter elements). In addition, an H4800, H6800, S4800 or S6800 crusher has a separate filter (one filter element) in the pinionshaft lubrication line. A by-pass valve is built into the filter and it opens when the pressure drop across the filter element exceeds 0.35 MPa (51 psi). When the valve is open, part of the oil flow by-passes the filter element and is thus not filtered.
1800-Series Hydrocone crushers
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6. Lubrication system
2001-11-15
The filter element must be changed when the pressure drop is 0.22 MPa (32 psi) at normal operating temperature. The pressure drop indicator and the pressure gauge are of great help when planning filter changes. Before changing the filter, close the shut-off valves between the filter and the heat exchanger and between the tank and the dirt trap to avoid oil spillage. Regular checks should be made on the pressure drop across each filter so that new filter elements can be ordered in good time for the next replacement. Note! When the fan of the air/oil heat exchanger is running, the pressure in the oil system generally rises. Avoid reading off the pressure at such times. If filter elements have to be changed often, the crusher's dust sealing system must be checked.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Filter element Filter base Differential pressure sensor and electrical connector Sensor body By-pass valve Seal Piston Spring Magnet Locking ring Seal ring Circlip O-ring O-ring Red button
Figure 6.10.1 Oil filter
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6. Lubrication system
2001-11-15
6.11 Pressure relief valve A pressure relief valve (see Fig. 6.11.1) is fitted between the main filter and the heat exchanger. Note! Different types are used for H2800, H3800, S2800 and S3800 crushers and for H4800, H6800, S4800 and S6800 crushers. Its duty is to decrease the pressure over the pump and heat exchanger when starting the crusher at low temperature. The oil in the pipes to the crusher – and particularly in the heat exchanger – becomes thicker and more viscous due to the low temperature. Under extreme conditions it can be advisable to take one or more of the measures described in Section 22. The valve is set at 0.7 MPa (102 psi). IMPORTANT! This valve setting must not be altered. If a new pressure relief valve is fitted, its setting must be checked. To do this, close the shut-off valve between the relief valve and the heat exchanger. Start the pump and slacken or tighten the adjusting screw in the relief valve until the pressure gauge shows a reading of 0.7 MPa (102 psi). Don't forget to re-open the shut-off valve, after the relief valve setting has been adjusted.
1.
For H2800, H3800, S2800 and S3800 crushers
Adjusting screw
For H4800, H6800, S4800 and S6800 crushers
Figure 6.11.1 Pressure relief valve
1800-Series Hydrocone crushers
S 223.363.00 en 17 (21)
6. Lubrication system
2001-11-15
6.12 Return oil flow switch (OG1) An automatic check on the return oil flow is provided by an oil flow switch which is built into the return oil discharge in the oil tank. The duty of the return oil flow switch is to ensure that the oil pumped to the crusher also returns to the tank unit, i.e. there is no break in a hose or pipe or any blockages in a line. The return oil flow switch consists of a level monitor placed in an oil chamber at the point where the return line enters the tank unit. This return oil chamber has an adjustable lower outlet and an overflow weir. The level monitor consists of a float and a microswitch. When the float moves up and down, the microswitch will be activated and a changeover contact function is obtained. The level monitor is connected in such a way that the crusher's drive motor cannot be started unless sufficient oil is pumped to the crusher and thus back to the tank via the return oil flow switch. In addition, the level monitor is connected to the starting circuit of the lubrication pump motor so that the pump cannot be started unless the level monitor is functioning properly from an electrical viewpoint. When the correct amount of oil is returning to the tank, the oil level in the return chamber should be 5 mm (0.2") above the weir. See Fig. 6.12.1.
Caution !!
The weir is adjusted at the factory before delivery and must not be adjusted later as the pump wears.
With this oil level in the return chamber, the float is completely immersed in the oil but the lifting force from the oil means that the float is held up against its upper stop. If the oil flow to the tank decreases, the oil level will drop in the return chamber. When the oil level has dropped about 15 mm (5/8"), the float will be floating on the oil with its upper surface about 5 mm (0.2") below the upper stop. In this position the contact inside the level monitor will open and stop the crusher's drive motor. The correct operation of the level monitor can be checked by pushing the float down about 5 mm (0.2") from its upper stop. The crusher's drive motor should then stop.
1800-Series Hydrocone crushers
S 223.363.00 en 18 (21)
6. Lubrication system
2001-11-15
Float
Weir
Adjustable lower outlet Figure 6.12.1 Return oil flow switch
6.13 Oil strainer The oil strainer's functions are to separate coarser contaminants from the oil and to deaerate the oil. The strainer can be removed for cleaning through the opening in the top of the tank.
Note !
The oil strainer requires careful inspection, and especially during the running-in period, it should be checked daily. An abnormal amount of metal particles on the strainer can indicate trouble in the crusher, and the cause should be investigated to forestall possible damage.
In the tank for an H4800, H6800, S4800 or S6800 there is an additional de-aeration screen beneath the oil strainer. The purpose of the de-aeration screen is to remove any air bubbles which are present in the oil returning to the tank and to prevent them going back to the crusher through the pump. The de-aeration screen normally requires no attention.
1. Oil strainer 2. De-aeration screen
1
2
Figure 6.13.1
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6. Lubrication system
2001-11-15
6.14 Thermostats Two thermostats are mounted at the return oil discharge in the oil tank (see Fig. 6.14.1). One of them controls the cooling of the oil pumped to the crusher, whilst the other stops the crusher drive motor if the oil temperature is too high.
1. 2. 1. 2.
Protective thermostat TG 1 Thermostat for heat exchanger TG 2 Figure 6.14.1
It is extremely important that thermostats TG 1 and TG 2 are set according to the recommendations given for different operating conditions in Table 6.14.2. Table 6.14.2 Normal operating conditions Ambient air Max. 32°C temperature (90°F) Oil viscosity ISO VG 150 Protective thermostat TG 1 Basic setting 60°C (140°F) Closes at 60°C (140°F) Opens at 63°C (145°F) Differential setting 1 Electrical connections 1-2 Cooling control thermostat TG 2 Basic setting 40°C (104°F) Closes at 45°C (113°F) Opens at 40°C (104°F) Differential setting 4 Electrical connections 1-4
Operation at elevated temperature Max. 40°C (104°F) ISO VG 220
Operation in low temperatures
65°C (149°F) 65°C (149°F) 68°C (154°F) 1 1-2
52°C (126°F) 52°C (126°F) 55°C (131°F) 1 1-2
47°C (117°F) 51°C (124°F) 47°C (117°F) 3 1-4
33°C (91°F) 37°C (99°F) 33°C (91°F) 3 1-4
Below 0°C (32°F) ISO VG 100
Note !
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6. Lubrication system
2001-11-15
The protective thermostat (TG 1) described above operates when a serious fault occurs in the lubrication system, for instance when the oil temperature rises excessively or the cooling system doesn't work correctly. It is therefore important that none of the instruments should be bypassed if the protective system trips out the crusher drive motor starter for some reason. Investigate the cause of the stoppage and correct it before the crusher is restarted.
The thermostats can be checked by immersing the sensing head in a slowly warmed oil bath together with a thermometer. Make a note of the temperature at which the contacts break and then allow the oil to cool and make a note of the temperature at which the contacts close. The cooling control thermostat (TG 2) can be checked by holding a thermometer near the sensing head and noting the temperatures at which the cooling fan or water pump starts and stops or at which the water valve opens and closes. If the thermostat does not make and break at the desired temperatures, remove the protective cover and rotate the shaft clockwise or anti-clockwise until the required impulse is obtained. When this has been done, loosen the screw which locks the temperature scale and re-set it to the correct temperature. When this adjustment is made, make sure that the differential setting is correct for the thermostat in question.
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6. Lubrication system
2001-11-15
6.15 Oil heating The oil should be heated to the temperature given in Table 6.15.1 before the crusher is started. This is to prevent oil overflowing over the dust collar. The standard oil tank unit is fitted with electrical immersion oil heaters. The heating elements are installed in tubes so that the oil is heated indirectly. There is a separate control thermostat, TG 3, mounted on the wall of the oil tank. Table 6.15.1
Ambient air temperature
Normal operating conditions
Max. 32°C (90°F) Oil viscosity ISO VG 150 Suitable oil temperature 30°C before crusher is started (86°F) Heating control thermostat TG3 Basic setting 30°C (86°F) Closes at 30°C (86°F) Opens at 35°C (95°F) Differential setting 3 Electrical connections 1-2
Operation in low temperatures
Operation at elevated temperature Max. 40°C (104°F) ISO VG 220 37°C (99°F)
Below 0°C (32°F) ISO VG 100 25°C (77°F)
37°C (99°F) 37°C (99°F) 42°C (108°F) 3 1-2
20°C (68°F) 20°C (68°F) 25°C (77°F) 3 1-2
The heating should be on all day. Shutdown occurs automatically by means of a thermostat.
Note !
Make sure that the heater element tubes and thermostat are always covered by oil during operation.
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S 223.393.00 en 1 (4)
7. Heat exchanger
2001-11-15
7. Heat exchanger
Contents 7.
Heat exchanger
Page 2
Air/oil heat exchanger
2
Water/oil heat exchanger
3
7.
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7. Heat exchanger
2001-11-15
Heat exchanger
To provide cooling for the oil, a heat exchanger is fitted, of either air/oil or water/oil type. All of the oil passes through this heat exchanger. Air/oil heat exchanger To maximize the effect of the heat exchanger, it should be regularly cleaned on the outside. Compressed air or water is normally sufficient. If the core is very dirty, it can be cleaned with a high-pressure water jet.
Caution !!
If a high-pressure water jet is used, the water jet must be kept parallel to the fins in order to avoid damage.
Note !
Cleaning additives can be added to the water but it is important that such additives have no corrosive effect on aluminium.
Oil and grease can be washed off with hot water. If the heat exchanger is cleaned with water, cover up the motor and wait until the heat exchanger has cooled down before starting. If there is vibration in the fan wheel, clean it or fit a new one. If this is not done, the heat exchanger will sooner or later be damaged. When the oil is changed, the heat exchanger should be flushed out internally with diesel oil. Clean out the tank and pour in diesel oil. Disconnect the return hose from the heat exchanger and arrange it so that the diesel oil will return to the tank instead of being pumped through the crusher. Pump the diesel oil through the heat exchanger. Finish off the cleaning procedure by flushing out the tank, oil lines and heat exchanger with clean new oil to remove all traces of diesel oil. Fill the tank with clean new oil. See Section 9.2. To provide the maximum possible cooling effect, the air must be sucked through the radiator matrix. This is determined by the direction of rotation of the fan. See Fig. 7.1. Since there is a relatively large oil flow through the heat exchanger, the oil inlet to the radiator matrix can be either at the top for the bottom. It is normally unnecessary to bleed air from the heat exchanger.
1800-Series Hydrocone crushers
S 223.393.00 en 3 (4)
7. Heat exchanger
2001-11-15
Air
Figure 7.1 Air/oil heat exchanger The fan motor is controlled by thermostat TG 2. Thermostat settings are given in Table 6.14.2.
Water/oil heat exchanger Plate type water/oil heat exchanger The plate-type heat exchanger consists of thin, profiled stainless steel plates. The plates are profiled to give optimum heat transfer and to form channels for the oil and water flows. See Fig. 7.2. Plate-type heat exchangers normally need no maintenance. If the oil channels do get blocked up, clean them out in the same way as described above for air/oil heat exchangers. If the water channels are blocked by dirty water, flush them out by reversing the water flow direction. If the water channels are blocked by lime, clean them out with a deliming agent, e.g. a 15 % hydrochloric acid solution which is then neutralized with a 5 % soda solution and finally flushed out with clean water.
Note !
The water connections must be open when a deliming agent is used, to provide ventilation for any gas which may be produced.
1. 2. 3. 4.
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7. Heat exchanger
2001-11-15
Oil in Water out Water in Oil out
Figure 7.2 Plate type water/oil heat exchanger Temperature control is provided by thermostat TG 2.
Note !
If a water/oil heat exchanger is used, set the thermostats at the values given for "normal operating conditions", whatever the ambient air temperature. See Table 6.14.2.
If a separate water pump is used, it can be started and stopped by thermostat TG 2. If the heat exchanger is connected to a water main, an electrically operated water valve can be incorporated in the supply pipe. Again, thermostat TG 2 can be used to control the water valve. The amount of water required depends on the water temperature, etc. Clean fresh water must be used. If only contaminated water is available, contact Sandvik Rock Processing first! Note !
Don't forget to drain all water out of the heat exchanger when the crusher is shut down during the winter.
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8. Hydroset system
2001-11-15
8. Hydroset system
Contents
Page
8.1
Description
2
8.2
Flow diagrams
4
8.3
Starting up
6
8.4
Hydroset pump
6
8.5
Control valve
7
8.6
Dirt trap (magnetic plug)
10
8.7
Oil filter
10
8.8
Safety valve
11
8.9
Pressure gauge
11
8.10
Damping valve for pressure gauge
11
8.11
Flow regulator (H2800, H3800, H4800 & H6800)
12
8.12
Accumulator (H2800, H3800, H4800 & H6800)
12
8.13
User's responsibility
15
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8. Hydroset system
2001-11-15
8.1 Description The hydraulic system used in Hydrocone crushers - the Hydroset system - is shown schematically in figure 8.1.1. The Hydroset system enables setting changes to be made easily and quickly. In addition, setting control can be automated in a simple way. To protect an H-type crusher against overloads - for example, when tramp iron enters the crushing chamber - the Hydroset system incorporates an accumulator. In addition, there is a relief valve in the Hydroset system of both H & S types to protect the piping and other components. The setting of the crusher is changed by raising (setting decrease) or lowering (setting increase) the Hydroset piston and the mainshaft assembly (complete with mantle) which is supported by this Hydroset piston. When the setting is to be reduced, oil is pumped into the Hydroset cylinder by a motor-driven pump. When the setting is to be increased, oil is pumped back to the Hydroset tank. On the tank unit is a pressure gauge which indicates the pressure in the Hydroset system.
Warning !!!
Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant supplier's instructions and safety directions when handling oils and greases.
Flow diagrams See figures 8.2.1 and 8.2.2.
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8. Hydroset system
2001-11-15
Setting decrease Oil is pumped from the tank to the Hydroset cylinder to raise the mantle to the desired position.
Setting increase Oil is pumped from the Hydroset cylinder back to the Hydroset tank, allowing the mantle to sink to the desired position.
Increase of setting due to overload (applies only to an H-type crusher). Oil is forced out of the Hydroset cylinder and into the accumulator, allowing the mantle to sink far enough to let the tramp iron pass through the crushing chamber. The gas pressure in the accumulator forces the oil back into the Hydroset cylinder as soon as the tramp iron has left the crushing chamber. Figure 8.1.1
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8. Hydroset system
2001-11-15
8.2 Flow diagrams 1. 2. 3. 4. 5. 6.
Shut-off valve Hydroset pump Safety valve Control valve Damping valve Pressure gauge
7. 8. 9. 10. 11.
PG1 (for ASR) Magnetic plug Flow regulator Accumulator Filter
Figure 8.2.1 Flow diagram for an H2800, H3800, H4800 or H6800 Hydrocone
1. 2. 3. 4. 5.
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8. Hydroset system
2001-11-15
Shut-off valve Hydroset pump Safety valve Control valve Damping valve
6. 7. 8. 9.
Pressure gauge PG1 (for ASR) Magnetic plug Filter
Figure 8.2.2 Flow diagram for an S2800, S3800, S4800 or S6800 Hydrocone
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8. Hydroset system
2001-11-15
8.3 Starting up Filling the system with oil When the Hydroset tank and piping have been connected up and thoroughly cleaned, fill the tank with clean new oil. Information on oil type, viscosity and quantity can be found in Section 9.3 – Oil for Hydroset system. Bleeding air from the system Open the shut-off valve between the tank and the Hydroset pump. Start the pump with the "reduce setting" push button to pump oil to the crusher and raise the mainshaft a few mm. Open the upper air bleed screw until bubble-free oil comes out. Raise the mainshaft a few mm more.
Note !
On an H2800, H3800, H4800 or H6800 Hydrocone, the upper air bleed screw is mounted on the throat of the accumulator. See figure 8.12.1, item 2. In the case of a S-type, which has no accumulator, the upper air bleed screw is mounted in the connection block on the mounting flange of the bottomshell.
Use a 5 mm hexagon key to open the air bleed screw in the Hydroset cylinder cover so that any air can escape. Raise and lower the mainshaft a few mm, several times. Repeat the air bleeding procedure at both points until completely bubble-free oil flows out.
8.4 Hydroset pump The Hydroset pump is a reversible gear pump. When the pump is started there must be oil in the tank and the valve on the suction line between the tank and the control valve must be fully open.
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8. Hydroset system
2001-11-15
Figure 8.4.1 Hydroset pump
Note !
At the bottom of the pump (see arrow "A" in figure 8.4.1) there is a drain port which is connected to the Hydroset tank. The drain line valve "B" on the tank must always be fully open.
8.5 Control valve Between the crusher and the Hydroset pump is a specially manufactured flow-actuated non-return valve. It incorporates a relief valve to protect the pump. Operating principle The flow-actuated control valve assembly consists of a base plate where all the external connections are made, and a valve block which is bolted to the base plate. See figure 8.5.1. Setting decrease 1.
The Hydroset pump is started and oil is sucked from the tank through ports T and A in the valve.
2.
The oil flow moves the sleeve 1 over towards the right so that the oil flow area is increased.
3.
Oil is pumped to port B and pushes the spindle 2 towards the right.
4.
The pump pressure opens the main non-return valve 3 which allows the oil to pass freely to the crusher.
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8. Hydroset system
2001-11-15
Setting increase 1.
The pump is started in the other direction and oil is sucked from the tank through port T, non-return valve 4 and port B.
2.
The pump pressure at port A pushes the spindle 2 to the left and opens the main nonreturn valve 3.
3.
There is now a direct connection from the crusher.
4.
Non-return valve 4 closes and the pump now sucks oil from the crusher through the valve.
5.
The excess oil pumped to port A opens the pressure limiting valve 6 and oil flows through filter 11 back to the tank.
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8. Hydroset system
2001-11-15
Correct setting 1.
The Hydroset pump is stationary and the pressure in the Hydroset system keeps the main non-return valve 3 closed.
An adjustable pressure limiting valve 5 is provided to protect the pump from overloads when the setting is being decreased. This valve is set at the correct pressure before delivery.
Setting increase
Setting decrease
Figure 8.5.1 Control valve Emergency manual valve actuation The control valve has a manual actuation facility for emergency use if contamination in the oil has blocked the valve so that normal motorized setting increase is impossible. This manual actuation facility is provided by components 7-10, shown in Figure 8.5.1. Manual operation is carried out as follows: Unscrew cap 8. Push in pin 7. If this cannot be done by hand, place a 10 mm dia. ball or other suitable object in the cap and screw it back on so that the pin is pushed in.
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8. Hydroset system
2001-11-15
Start the pump for setting increase and lower the mainshaft to the desired position. Stop the pump. If the valve still does not operate correctly, it must be removed and cleaned. If the valve does operate correctly, replace the cap. To reduce the risk that contamination interferes with the correct operation of the valve, the Hydroset system must always be kept clean.
8.6 Dirt trap (magnetic plug) Mounted in the Hydroset line to the crusher, next to the control valve, is a T-coupling with a magnetic plug fitted in the third branch. The purpose of the magnetic plug is to remove magnetic particles from the system. The magnetic plug is easy to unscrew and clean when the pressure in the system has been relieved, i.e. when the mainshaft and the Hydroset piston are at the bottom of their travel. Watch out for escaping oil.
8.7 Oil filter The oil filter mounted between the control valve and the Hydroset tank is of the full-flow type. This means that all of the oil passing through is filtered. The filter is of simple design and it is easy to remove and replace the filter element, which is of the throw-away type. When a filter change is carried out - which should be each time the Hydroset oil is changed or every six months - relieve the pressure in the system by lowering the mainshaft and Hydroset piston to their bottom positions. Unscrew the filter element and replace it with a new one. At the same time, clean out the dirt trap (see Section 8.6).
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8. Hydroset system
2001-11-15
8.8 Safety valve The safety valve is mounted on the base plate of the control valve. It is tested at a setting of 7.5 MPa (1088 psi) and sealed before delivery. See also Section 8.13 - User's Responsibility.
8.9 Pressure gauge A pressure gauge is fitted on the tank unit so that the operating pressure in the Hydroset system can be observed. A special pressure transducer can be fitted to give remote indication of the Hydroset pressure on the control cabinet of an ASR system.
8.10 Damping valve for pressure gauge To prevent damage to the pressure gauge indicating pointer due to vibration when the crusher is in operation, a damping valve is fitted between the Hydroset line and the pressure gauge. This damping valve must be mounted as shown in figure 8.10.1, with the arrow pointing towards the pressure gauge. Open the valve once each week to clean out the needle valve. When this has been done, close the valve until the indicating pointer of the gauge moves smoothly during normal operation.
Figure 8.10.1. Damping valve
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8. Hydroset system
2001-11-15
8.11 Flow regulator (H2800, H3800, H4800 and H6800 Hydrocone crushers only) To prevent the mainshaft rising too quickly after tramp iron has passed through the crusher, a throttling check valve - the flow regulator - is fitted between the Hydroset cylinder and the accumulator. See figure 8.12.1. When oil flows from the crusher to the accumulator, it passes unhindered through the flow regulator. When the oil returns from the accumulator, it is slowed down so that the mantle is slowly raised to its original position.
8.12 Accumulator (H2800, H3800, H4800 and H6800 Hydrocone crushers only) The accumulator (see figure 8.12.1) consists of a cylindrical steel pressure vessel which contains a rubber bladder fixed at the top of the vessel by a valve. The rubber bladder is filled with Nitrogen at the pressure shown in Table 8.12.2.
Warning !!!
1. 2. 3.
Use only Nitrogen (N2) in the accumulator. Do not subject the accumulator to mechanical or thermal damage (impact, welding, etc).
Accumulator Upper air bleed screw Flow regulator
Figure 8.12.1 Accumulator
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8. Hydroset system
2001-11-15
Table 8.12.2 Accumulator charging pressure H2800
4.2 MPa (609 psi) ± 5%
H3800
5.0 MPa (725 psi) ± 5%
H4800
5.0 MPa (725 psi) ± 5%
H6800
4.2 MPa (609 psi) ± 5%
Pressure gauge/charging kit A special pressure gauge/charging kit can be used to check the gas pressure in the accumulator and to add nitrogen when necessary. This pressure gauge/charging kit is not included in the crusher's normal toolkit but can be ordered as an extra-cost option. The pressure gauge/charging kit consists of a connection assembly with a pressure gauge, a hose and an adapter for connection to the accumulator. See Fig. 8.12.3.
Figure 8.12.3 Checking the gas pressure in the accumulator Fitting the pressure gauge/charging kit Unscrew the spindle (item 3 in Fig. 8.12.3) as far as it will go and close the bleed valve (4). The connection assembly body incorporates a non-return valve so that it is unnecessary to connect the kit to a nitrogen bottle when the accumulator's gas pressure is to be checked. Unscrew the protective cap from the accumulator's charging valve. Attach the pressure gauge/charging kit by screwing on the swivel adapter (2). Tighten by hand sufficiently to prevent gas leakage. Screw down the spindle (3) so that the valve in the accumulator opens and then read off the charging pressure on the pressure gauge. Removing the charging kit
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Unscrew the spindle (3) and then open the bleed valve (4). The swivel adapter (2) can then be unscrewed easily and the charging kit can be removed. Refil the protective cap on he accumulator's charging valve. Charging the accumulator Use only nitrogen gas N2 to fill the accumulator bladder. Warning !!! Unscrew the spindle (item 3 in Fig. 8.12.3) as far as it will go and close the bleed valve (4) before you attach the pressure gauge/charging kit to the nitrogen gas bottle. Unscrew the protective cap from the accumulator's charging valve. Attach the pressure gauge/ charging kit to the accumulator by screwing on the swivel adapter (2). Tighten by hand sufficiently to prevent gas leakage. Screw down the spindle (3) so that the gas can pass freely through the charging valve. Carefully open the valve on the nitrogen gas bottle so that the bladder expands slowly inside the accumulator and closes the oil valve. Check that this is the case before raising the pressure to the full charging pressure. Note !
Take into account that the pressure in the accumulator will drop slightly when the compressed gas cools down. Charge the accumulator bladder to 20% above the desired pressure.
Close the valve on the nitrogen gas bottle and wait for five minutes. Check the pressure. If the pressure is too high, release a little gas through the bleed valve (4). Recheck the charging pressure after 1, 2 and 3 weeks and thereafter at 6-month intervals. Unscrew the spindle (3) and the swivel adapter (2). Check that there is no gas leakage from the valve. Use soapy water or oil for this check. Refit the protective cap on the accumulator's charging valve. Remove the pressure gauge/charging kit from the nitrogen gas bottle.
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8. Hydroset system
2001-11-15
8.13 User's responsibility It is the responsibility of the crusher's user to arrange for recertification of the accumulator and the relief valve if there are grounds to suspect that the accumulator has been damaged or if the seal on the relief valve has been broken. New components are best obtained from Sandvik Rock Processing.
9.
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9. Lubricant recommendations
2001-11-15
Lubricant recommendations
Contents
Page
9.1 General
2
9.2 Oil for lubrication system
2
9.3 Oil for Hydroset system
6
9.4 Pinionshaft lubrication
8
9.5 Spider bearing lubrication
10
1800-Series Hydrocone crushers
S 223.365.00 en 2 (12)
9. Lubricant recommendations
2001-11-15
9.1 General If the crusher is to be utilized optimally, stringent demands must be made on the lubricants that are used. Lubricants which do not meet Sandvik Rock Processing’s requirements must not be used during the warranty period.
Warning !!!
Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant supplier's instructions and safety directions when handling oils and greases.
Miscibility Care should be exercised when changing the brand and/or the type of lubricant. Different brands and types of lubricant cannot always be mixed. If non-miscible lubricants are mixed, the result can be an expensive breakdown. Normally the old lubricant must be flushed out very carefully before a change is made. The lubricant manufacturer(s) can provide information on whether mixing can take place. Storage Store the lubricant in a clean room and in accordance with the instructions given by the lubricant supplier. Clean the caps before opening cans and drums. Use only well-cleaned containers. If water finds its way into the oil system - through condensation, for example - or if a lot of dust has got into the oil, change the oil. A change in oil colour may indicate the presence of water or dirt.
9.2 Oil for lubrication system The oil we recommend must have mild EP-additives and must comply with the following demands and with the requirements specified in Table 9.2.1 Normally, an oil with ISO VG 150 viscosity is used. If the ambient temperature is so high that the cooling system cannot keep the return oil temperature below 50°C, it may be necessary to permit operation at an elevated temperature. In such a case, contact Sandvik Rock Processing. At the same time, a change must be made to a lubricating oil with higher viscosity. See "Operation at elevated temperature" in Table 9.2.1.
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9. Lubricant recommendations
2001-11-15
In extremely low temperatures, it can sometimes be advisable to change to a less viscous oil. See "Operation in low temperatures" in Table 9.2.1. If such a change is made, thermostats TG1, TG2 and TG3 must be reset. See Tables 6.14.2 and 6.15.1. Important! When a change is made back to the normal oil, the thermostats must be reset again. Requirement specification General: The oil shall comply with the demands of DIN 51 517-CLP for the respective viscosity values and shall contain additives to prevent oxidation and foaming and also contain antiwear additives. Copper alloys are used in the crusher’s bearings, which is why the oil must be harmless for these materials. Table 9.2.1 below specifies lubricating oil types for use under different operating conditions. Table 9.2.1. Lubricating oil specification.
Ambient air temperature Oil viscosity Specification Properties Test method Base oil viscosity at DIN 51 519 40°C in mm2/s (cSt) Viscosity Index DIN ISO 2909 FZG DIN 51 354 Lowest pour point DIN ISO 3016 EP-additives
OPERATING CONDITIONS Normal Operation at elevated temperature Max. 32°C Max. 40°C ISO VG 150 ISO VG 220 DIN 51 517-CLP DIN 51 517-CLP 150 220 Requirement Requirement 150 220
Under 0°C ISO VG 100 DIN 51 517-CLP 100 Requirement 100
≥ 100
≥ 100
≥ 100
≥ 12 ≤ -9°C
≥ 12 ≤ -6°C
≥ 12 ≤ -12°C
Sulphur/ Phosphorus
Sulphur / Phosphorus
Sulphur / Phosphorus
Operation in low temperatures
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9. Lubricant recommendations
2001-11-15
Example of oils for lubrication system The examples below are lubricants which – according to the respective manufacturer – comply with Sandvik Rock Processing’s requirements. We have received this information from the manufacturers. Local variations can occur in different countries. For safety’s sake, check with your supplier that the selected lubricant complies with the requirements in question. In addition to the lubricants listed, a number of other brands and qualities meet Sandvik Rock Processing’s requirements and are accordingly also usable. Mineral oils For operation under normal conditions: BP Energol GR-XP 150 ESSO Spartan EP 150 Klüber Klüberoil GEM 1-150 Mobil Mobilgear 629
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 630
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 627
Molub-Alloy Tribol 1100/100 Shell Omala 100 Statoil LoadWay EP 100 Texaco Meropa 100
Biologically degradable oil If an oil of this kind is to be used, we recommend that only a 100% synthetic oil of ester type is selected. Due to the higher viscosity index of this type of oil, an ISO VG 150 grade can normally be used all year round. If the ambient air temperature is over 32°C (90°F), it may still be necessary to reset thermostats TG1 and TG2 for "Operation at elevated temperatures" since TG1 could otherwise trip because of excessively high oil temperature and thus stop the crusher. Tribol Bio Top 1418/150 (VI > 170)
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9. Lubricant recommendations
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Oil quantity The lubricating oil tank volume is given in Table 9.2.2. When the crusher is running, the oil level must be above the minimum level mark. See the oil level indicator in the tank unit. Table 9.2.2. Oil quantity H-type
H2800
H3800
H4800
H6800
S-type
S2800
S3800
S4800
S6800
150 (40)
400 (105)
400 (105)
Oil volume lit. 150 (US. gal.) (40)
A certain amount of oil will remain in the crusher and the oil supply lines, and the tank should therefore be topped up after test-running. To prevent oil flooding over the oil strainer when oil drains back to the tank after the crusher has been stopped, you should be very restrictive with topping-up if the oil lines between the tank and the crusher are long.
Caution !!
Make sure that the heating element tubes and their thermostat are always covered with oil during operation. This is to avoid overheating in the heating elements.
Oil changes To keep a check on the condition of the oil, it is advisable to send an oil sample to the oil supplier each month so that suitable oil change intervals can be established in cooperation with the supplier. When oil is to be changed to a different brand or type, all of the oil must be changed. This is especially important if the change is from an oil with a lead additive to an oil with sulphur/phosphorus additives. The oil which is trapped in the crusher must be drained out by breaking the supply line at a suitable point between the crusher and the tank unit. When this is done, the mainshaft must be raised to its highest position so that the oil in the Hydroset piston runs out.
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9. Lubricant recommendations
2001-11-15
9.3 Oil for Hydroset system Caution !!
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.
The oil must comply with DIN 51 517-CLP 68. Table 9.3.1. Hydroset oil specification. Properties
Test method
Requirement
Base oil viscosity at DIN 51 519 40°C in mm²/s (cSt)
68
Viscosity Index
DIN ISO 2909
≥100
FZG
DIN 51 354
≥12
Lowest pour point
DIN ISO 3016
≤-15°C
EP additives
Note !
Sulphur/Phosphorus Never use oil thicker than ISO VG 68, nor normal hydraulic oils.
In the case of a crusher which operates outdoors in very low temperatures, there can be problems with the normally recommended oil. If this is the case, contact Sandvik Rock Processing for information on a change to an oil with lower viscosity. Examples of oils for Hydroset system The examples below are oils which – according to the respective manufacturer – comply with Sandvik Rock Processing’s requirements. We have received this information from the manufacturers. Local variations can occur in different countries. For safety’s sake, check with your supplier that the selected oil complies with the requirements in question. In addition to the lubricants listed, a number of other brands and qualities meet Sandvik Rock Processing’s requirements and are accordingly also usable.
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9. Lubricant recommendations
2001-11-15
Mineral oils BP Energol GR-XP 68 ESSO Spartan EP 68 Klüber Klüberoil GEM 1-68 Mobil Mobilgear 626
Molub-Alloy Tribol 1100/68 Shell Omala 68 Statoil LoadWay EP 68 Texaco Meropa 68
Biologically degradable oil If an oil of this kind is to be used, we recommend that only a 100% synthetic oil of ester type is selected. Tribol Bio Top 1448/68 Oil quantity When the Hydroset tank is filled, the mainshaft must be in its lowest position. If the tank is filled when the mainshaft is in its highest position, there may not be sufficient room in the tank for all of the oil when the mainshaft is lowered. Oil quantities are given in Table 9.3.2. Table 9.3.2 H-type
H2800
H3800
H4800
H6800
S-type
S2800
S3800
S4800
S6800
Oil volume lit. (US. gal.)
40 (10.7)
40 (10.7)
85 (22.5)
85 (22.5)
Oil changes The oil in the Hydroset system should be changed when the lubricating oil is changed. See Section 9.2 – Oil for lubrication system – Oil changes.
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9. Lubricant recommendations
2001-11-15
9.4 Pinionshaft lubrication Two different principles are used for pinionshaft lubrication: an oil bath for the H2800, H3800, S2800 and S3800 and a circulatory system for the H4800, H6800, S4800 and S6800. Oil bath lubrication for H2800, H3800, S2800 and S3800 Close to the pinionshaft there is a decal which shows the type of oil in the pinionshaft housing when the crusher is delivered from the factory. Do not mix different types of oil. The oil used for pinionshaft lubrication is the same as the oil in the main circulatory lubrication system. See Section 9.2 - Oil for lubrication system. The pinionshaft housing has an oil level tube to provide the correct oil level and is topped up manually. Oil quantities are given in Table 9.4.1. Table 9.4.1 Oil quantity for pinionshaft housing H2800 S2800
0.8 liter (0.21 US. gal.)
H3800 S3800
1.5 liter (0.40 US. gal)
The drain plug and oil level tube are mounted in the bottom of the pinionshaft housing, as shown in Figure 9.4.2. When oil is added, the drain plug must be in place. Slightly more than the required quantity should be added. When the oil level has stabilized in the pinionshaft housing, the excess oil can be drained out through the level tube when the plug has been taken out. Top up and drain off excess oil every time the oil level is to be checked since there is otherwise a risk that a small amount of oil in the level tube will run out and give the impression that the oil level is high, even though it is in fact low.
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9. Lubricant recommendations
2001-11-15
1. 2. 3. 4.
TREDO-ring Oil level Level tube Drain plug
Figure 9.4.2 (H & S 2800 and 3800) Oil changes Check the oil level regularly and change the oil after approx. 2000 operating hours or about once a year. Drain out the oil by unscrewing the level tube and drain plug. The filler plug on the top of the pinionshaft housing is fitted with an air vent nipple. This nipple should be cleaned at intervals of about two months as there is otherwise a risk of damage to the seals and leakage could then occur. Circulatory lubrication system for H4800, H6800, S4800 and S6800 The pinionshaft housing receives an automatically controlled flow of oil. See Section 14 - Pinionshaft assembly and Section 6 - Lubrication system. Oil quantity The volume of oil in the pinionshaft housing is limited by the level tube. See Figure 9.4.4. See also Section 5.1 – Paragraph 8. Table 9.4.3 Oil quantity for pinionshaft housing H4800 S4800
1.3 liter (0.34 US. gal.)
H6800 S6800
3.0 liter (0.79 US. gal.)
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9. Lubricant recommendations
2001-11-15
Remove the drain plug (magnetic plug) and clean it at least twice a year. This will also drain out any sediment from the pinionshaft housing.
1. Oil level 2. Level plug 3. Discharge tube
Figure 9.4.4 (H & S 4800 and 6800)
9.5 Spider bearing lubrication The motion of the mainshaft in the spider bearing is both gyratory and rotary. The speed is relatively low and the pressure is high. It is important that the correct grade of lubricant is used so that the grease can penetrate to the bearing surfaces. Requirement specification The grease must comply with the demands in the table below in order to guarantee lubrication of the spider bearing for long periods, under conditions of vibration and extremely high loads. In addition, the grease must provide good protection against corrosion. The spider bearing contains components of alloyed steel, cast iron and nitrile rubber. The grease must therefore be harmless to these materials. Table 9.5.1 Spider bearing grease specification. Properties
Test method
Requirements
Consistency
NLGI
0 or 00
Base oil viscosity at 40°C in mm2/s (cSt)
≥ 400
Thickening agent
Lithium or Sodium
Drop point
DIN ISO 2176
≥ 140°C
Corrosion protection
DIN 51 802 SKF Emcor
Approved
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9. Lubricant recommendations
2001-11-15
Other properties: - Must contain EP additives - Must be pumpable The recommended operating temperature range is -10°C to +100°C. For operation under extreme ambient temperatures, contact the lubricant supplier. Examples of greases The examples below are greases which – according to the respective manufacturers – comply with Sandvik Rock Processing’s requirements. We have received this information from the manufacturers. Local variations can occur in different countries. For safety’s sake, check with your supplier that the selected grease complies with the requirements in question. In addition to the greases listed, a number of other brands and qualities meet Sandvik Rock Processing’s requirements and are accordingly also usable. Mobil Mobilith SHC 007 (643569) Molub-Alloy Tribol 3020/1000-00
Statoil GreaseWay LiCaX90 Texaco Marfak 00 (01907)
Grease quantity The grease must fill the spider bearing up to the top of the spider bushing. See Table 9.5.2. When the spider bearing is being greased, the mainshaft must be in its lowest position. Grease can be pumped in through a channel in one of the topshell spider arms. Checking and changing the grease During the first few weeks of operation, the grease level should be checked daily by unscrewing the plug in the spider cap. If an unusually large quantity of grease is observed on the mainshaft beneath the spider bearing, it is possible that the spider bearing seal has been damaged. It is important to keep the mainshaft free of grease and stone dust accumulations to prevent such contamination being pressed into the spider bearing through the spider bearing seal each time the mainshaft is raised. The grease level should be checked frequently and new grease should be added when necessary. Naturally, the spider bearing seal must be replaced as quickly as possible. See Sections 11.1 and 11.2. Alongside the grease nipple on one of the topshell arms there is a decal which shows the type of grease pumped into the spider bearing before delivery. Do not mix greases of different types. When a new mantle and/or concave is fitted, the spider bearing and seal should be carefully cleaned and then filled with new grease. To avoid unscheduled stoppages, we recommend that the spider bearing seal should be changed each time the liners are changed.
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9. Lubricant recommendations
2001-11-15
Table 9.5.2 Grease quantity Crusher
Grease quantity kg (lbs)
H2800 S2800
3-4 (6.6-8.8)
H3800 S3800
4-6 (8.8-13.2)
H4800 S4800
6-8 (13.2-17.6)
H6800 S6800
7-9 (15.4-19.8)
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10. Topshell assembly & concave ring
2003-06-10
10. Topshell assembly & concave ring
Contents
Page
10.1
Evaluation of liner wear
2
10.2
Checks prior to removal
4
10.3
Removal and reinstallation of topshell
4
10.4
Replacement of concave ring - H2800 Hydrocone
6
10.5
Replacement of concave ring - H3800 Hydrocone
10
10.6
Replacement of concave ring - H4800 Hydrocone
15
10.7
Replacement of concave ring - H6800 Hydrocone
19
10.8
Filler ring
24
10.9
Replacement of concaves and lower concave ring S2800 Hydrocone
29
10.10
Replacement of concaves and lower concave ring S3800 Hydrocone
32
10.11
Replacement of concaves and lower concave ring S4800 Hydrocone
35
10.12
Replacement of upper and lower concave rings S6800 Hydrocone
39
10.13
Replacement of lower concave ring only S-type Hydrocones
42
10.14
Crushing hard but less abrasive material
44
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10. Topshell assembly & concave ring
2003-06-10
10.1 Evaluation of liner wear Apart from the recommended annual removal for cleaning and inspection, the topshell is usually removed for liner replacement. Inspection of crushing chamber: 1.
Inspection of the liners must be carried out at the correct intervals. See Section 17 – Routine maintenance. A new machine must be inspected at frequent intervals. After one or two liner changes, the intervals between inspections can be successively increased.
2.
These routine inspections will give an indication of when the liners must be changed. It is difficult to give an exact limit at which the liners are worn out. They can be said to be worn out when capacity drops off or when the thickness has been reduced so much that indentations or cracks have occurred.
Extreme operating conditions can require liner replacement before the liners are "worn out". One reason can be incorrect feeding so that increased wear occurs over a certain section of the concave ring or concaves. This also means that the setting varies according to where measurement is carried out around the crushing chamber. The feed arrangement must be such that the feed material is evenly distributed around the crushing chamber, segregation is prevented and the crushing chamber is kept full. Examples of different feed arrangements are given in Section 3 – Installation. Incorrect feeding arrangements cause very poor liner utilization, higher power consumption (= higher bearing loads), lower capacity, lower reduction and poorer product shape. Inspection of the liners is a preventive measure intended to avoid: 3.
Expensive damage to the contact surfaces of the topshell and the headcentre. In addition, the liners must be replaced if the maintenance of the desired setting entails raising the mainshaft so high that the distance between the head nut and the underside of the spider is less than 15 mm ("A-dim." in Fig. 10.1.1).
4.
Loss of production due to reduced capacity or an incorrect final product or because of an unscheduled shutdown.
Problems similar to those caused by an incorrect feeding arrangement can also be experienced if the feed material is not an evenly graded mixture. The crushing chamber is selected on the basis of the maximum feed size. If almost all of the feed is close to the maximum size, crushing will be concentrated to the upper portion of the chamber. This can give rise to an annular groove around the entire crushing chamber (see B in Fig. 10.1.1). A preponderance of fine material in the feed concentrates crushing to the lower part of the chamber, with the result shown by C in Fig. 10.1.1.
1800-Series Hydrocone crushers
S 223.370.01 en 3 (44)
10. Topshell assembly & concave ring
2003-06-10
Figure 10.1.1 Liner wear
Note !
The crusher must not be put into full-scale operation until it has been established that the feed arrangement functions correctly and that the feed size is correct.
The benefits gained by continuing to crush with worn liners are small in comparison with the disadvantages described in 3 and 4 above. Planned liner replacement at the right time always gives optimum operating economics. These recommendations also apply to crushers fitted with automatic setting regulation equipment. Liner wear is compensated for by hydraulically raising the mainshaft so that the desired setting can be maintained.
1800-Series Hydrocone crushers
S 223.370.01 en 4 (44)
10. Topshell assembly & concave ring
2003-06-10
Dimension A is an indication of the position of the mainshaft inside the crusher.
Caution !!
The mainshaft must not be raised so far that the A-dimension, as shown in Fig. 10.1.1, is less than 15 mm for an H or S 2800, 3800 or 4800 crusher, or 20 mm for an H or S 6800 crusher. If the mainshaft is raised further, expensive damage can be caused to the spider bearing in the topshell.
Note! The liners are normally worn out before this limit is reached.
10.2 Checks prior to removal Note !
Whenever a crusher is to be dismantled, the checks described below must be carried out in good time before the topshell is removed. This is so that an idea can be obtained about how far the crusher needs to be stripped down, for instance when a liner change is planned.
1.
Check the play between the mainshaft sleeve and the spider bearing. (See Section 11.1).
2.
Check the play between the dust seal ring and the dust collar. (See Section 12.9 – Dust seal ring).
3.
Check the backlash in the gears. (See Section 15.3 – Gear backlash).
4.
Inspect the return oil strainer for any contamination. If an unusual amount or type of contamination is found - metal particles, for example - the cause must be investigated at once.
10.3 Removal and reinstallation of topshell Remove the bolts which clamp the topshell to the bottomshell. There are four press screws in the topshell flange to facilitate splitting the joint. Remove the spider cap to prevent a vacuum which can cause the mainshaft to rise a little when the topshell is lifted. The air breather and air channel could be blocked.
Caution !!
Use amply dimensioned lifting gear (strops etc.). Take great care when lifting the topshell to avoid damaging the mainshaft, the spider bushing and other machined surfaces.
1800-Series Hydrocone crushers
S 223.370.01 en 5 (44)
10. Topshell assembly & concave ring
2003-06-10
Inspection Check that the tapered mating surfaces are free from rust. Check to see if there has been any motion between the topshell and the bottomshell which has resulted in damage to the tapered mating surfaces. If this is the case, the surfaces must be built up by welding and remachined. Consult Sandvik Rock Processing. Thoroughly clean and oil the tapered mating surfaces on the topshell and bottomshell. Place the topshell on timber supports (planks or similar) so that the machined surfaces are not damaged. Reinstallation Coat the tapered mating surfaces and the contact faces of the flanges with grease or thick oil. The use of a grease or oil containing molybdenum disulphide will reduce the risk of contact corrosion. Grease the spider bushing, the spider bearing seal and the mainshaft sleeve. Use the normal spider bearing grease - see Section 9.5 – Spider bearing lubrication.
Caution !!
Note !
Lower the topshell carefully and make sure that the spider bearing seal is not damaged by the mainshaft. When the topshell is resting on the bottomshell there is a gap of about 3 mm between the flanges. Tighten the bolts in diagonal rotation until the flanges lie flush. After the machine has been crushing for a few hours, retighten these bolts. In the meantime, check occasionally that there is no relative movement by placing a finger across the joint.
Fill the spider bearing up to the top with grease. This should be done with the mainshaft lowered, i.e. with the Hydroset piston at the bottom of its travel. See Section 9.5 – Spider bearing lubrication. Grease the contact surfaces of the spider cap and its seating. Inspect the spider bearing seal. Refit the spider cap. See Section 11.2 – Replacement of spider bushing and seal.
1800-Series Hydrocone crushers
S 223.370.01 en 6 (44)
10. Topshell assembly & concave ring
2003-06-10 H2800
10.4 Replacement of concave ring - H2800 Hydrocone crusher The design of the H2800 Hydrocone is such that all concave rings - from EF to EC - can be fitted into a single topshell. This is made possible - despite the great difference in shape of the various concave rings - by using a filler ring. See Section 10.8 - Filler ring. The filler ring is installed with a metal-to-metal taper fit in the topshell and the concave ring is in turn a metal-to-metal fit inside the filler ring. The EC concave ring is an exception: it fits directly inside the topshell without a filler ring. The concave ring is clamped with four bolts through the attachment lugs at the bottom. See Fig. 10.4.1. If lifting lugs are to be welded to the concave ring, make sure they are amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Concave ring Filler ring Sealing compound Locking ring O-ring Sleeve Disc spring Clamping ring Plank Gap between clamping ring and topshell
Figure 10.4.1 H2800
1800-Series Hydrocone crushers
S 223.370.01 en 7 (44)
10. Topshell assembly & concave ring
2003-06-10 H2800
Removal When the topshell has been lifted off the crusher, position it on planks so that the concave ring is unobstructed. Remove the bolts which clamp the concave ring in the topshell. Make a note of the way the disc springs are arranged. See Fig. 10.4.3.
Note !
The screws in the top of the topshell hold the filler ring and should not be removed during a normal liner change.
It should be possible to remove the concave ring from the topshell with a few heavy blows on the top rim. If the concave ring does not come loose, two jacks can be positioned between the top rim of the concave ring and the topshell arms. See Fig. 10.4.2. Hit the concave ring around its top rim at the same time as the jacks are operated.
Figure 10.4.2
1800-Series Hydrocone crushers
S 223.370.01 en 8 (44)
10. Topshell assembly & concave ring
2003-06-10 H2800
Inspection Lift up the topshell and inspect the contact surface in the topshell or filler ring. If any ridges or depressions have been formed in the topshell or filler ring by the machined contact surfaces of the concave ring, they must be ground off before reassembly is started. If there is serious wear or if the concave ring has worn deep grooves in the topshell or filler ring, contact Sandvik Rock Processing for advice about the appropriate course of action. Check that the filler ring is securely installed in the topshell. If the filler ring has come loose it must be taken out for inspection of the contact surfaces and the retaining ring screws. See Section 10.8 - Filler ring. Reassembly In principle, the concave ring is installed in the following way: Place the clamping ring on planks with the four clamping bolts positioned in their holes. See Fig. 10.4.1. Position the concave ring with its locating bosses in the appropriate recesses in the clamping ring. Check that the locating dowels are properly screwed into the lower edge of the topshell. To increase the life of the clamping ring (wear on the inside diameter), it can be rotated relative to the topshell. Lower the topshell onto the clamping ring, using the locating dowels to ensure correct positioning. Check that the gap between the clamping ring and the topshell is even all round. See Fig. 10.4.1. Fit the washers, disc springs, sleeves and nuts. See Fig. 10.4.1. Measure dimension "T" before tightening the nuts. See Fig. 10.4.3.
Note !
When installing the concave ring, ensure that there is an even fit all around the topshell by tightening the bolts in diagonal rotation until the dimension T-3.2 mm is reached. This corresponds to 460° rotation of the nut.
When you have tightened the bolts, check with a feeler gauge that there is no play between the topshell or filler ring and the lower part of the concave ring. When the concave ring clamping bolts have been tightened, fill the space between the concave ring and the topshell or filler ring with a sealing foam (sealing compound) to prevent penetration by dust or moisture.
1800-Series Hydrocone crushers
S 223.370.01 en 9 (44)
10. Topshell assembly & concave ring
2003-06-10 H2800
Check the tightness of the clamping bolts after a short period of operation.
Figure 10.4.3 Concave ring clamping bolts and nuts
1800-Series Hydrocone crushers
S 223.370.01 en 10 (44)
10. Topshell assembly & concave ring
2003-06-10 H3800 800800
10.5 Replacement of concave ring - H3800 Hydrocone crusher The design of the H3800 Hydrocone is such that all concave rings - from EF to EC - can be fitted into a single topshell. This is made possible - despite the great difference in shape of the various concave rings - by using filler rings. See Section 10.8 - Filler ring. The filler ring is installed with a metal-to-metal taper fit in the topshell and the concave ring is in turn a metal-to-metal fit inside the filler ring. The EC concave ring is an exception: it fits directly inside the topshell without a filler ring. When the EF concave ring is used, a 2-piece wearing ring is welded to the locking ring with the help of the four 10 x 10 x 75mm bars supplied. Use an A-dimension of 3 - 4mm. See Fig. 10.5.1. The concave ring is clamped with four bolts through the attachment lugs at the bottom. See Fig. 10.5.1. If lifting lugs are to be welded to the concave ring, make sure they are amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4.
1800-Series Hydrocone crushers
S 223.370.01 en 11 (44)
10. Topshell assembly & concave ring
2003-06-10 H3800
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Concave ring Filler ring Sealing compound Locking ring O-ring Sleeve Disc spring Spherical washer and conical seat Plank Wearing plate (Only with EF crushing chamber)
EF crushing chamber
Figure 10.5.1 H3800
1800-Series Hydrocone crushers
S 223.370.01 en 12 (44)
10. Topshell assembly & concave ring
2003-06-10 H3800
Removal When the topshell has been lifted off the crusher, position it on planks so that the concave ring is unobstructed. Remove the bolts which clamp the concave ring in the topshell. Make a note of the way the disc springs are arranged. See Fig. 10.5.3.
Note !
The screws in the top of the topshell hold the filler ring and should not be removed during a normal liner change.
The locating blocks for the concave ring need not be removed. They are adjusted when the new concave ring is being installed. It should be possible to remove the concave ring from the topshell with a few heavy blows on the top rim. If the concave ring does not come loose, two jacks can be positioned between the top rim of the concave ring and the topshell arms. See Fig. 10.5.2. Hit the concave ring around its top rim at the same time as the jacks are operated.
Figure 10.5.2
1800-Series Hydrocone crushers
S 223.370.01 en 13 (44)
10. Topshell assembly & concave ring
2003-06-10 H3800
Inspection Lift up the topshell and inspect the contact surface in the topshell or filler ring. If any ridges or depressions have been formed in the topshell or filler ring by the machined contact surfaces of the concave ring, they must be ground off before reassembly is started. If there is serious wear or if the concave ring has worn deep grooves in the topshell or filler ring, contact Sandvik Rock Processing for advice about the appropriate course of action. Check that the filler ring is securely installed in the topshell. If the filler ring has come loose it must be taken out for inspection of the contact surfaces and the retaining ring screws. See Section 10.8 - Filler ring. Reassembly In principle, the concave ring is installed in the following way: Place the concave ring on planks and position the four clamping bolts - complete with the spherical washers and conical seats - in the attachment lug slots. Lower the topshell down onto the concave ring and screws and fit the washers, disc springs, sleeves and nuts. See Fig. 10.5.1. Measure dimension "T" before tightening the nuts. See Fig. 10.5.3.
Note !
When installing the concave ring, ensure that there is an even fit all around the topshell by tightening the bolts in diagonal rotation until the dimension T-3.5 mm is reached. This corresponds to 420° rotation of the nut.
When you have tightened the bolts, check with a feeler gauge that there is no play between the topshell or filler ring and the lower part of the concave ring. Check and adjust the locating blocks so that they butt against the lugs on the concave ring. These locating blocks have an eccentrically placed hole so that good alignment against the concave ring lugs can easily be obtained. When the concave ring clamping bolts have been tightened, fill the space between the concave ring and the topshell or filler ring with a sealing foam (sealing compound) to prevent penetration by dust or moisture. Check the tightness of the clamping bolts after a short period of operation.
1800-Series Hydrocone crushers
S 223.370.01 en 14 (44)
10. Topshell assembly & concave ring
2003-06-10 H3800
Figure 10.5.3 Concave ring clamping bolts and nuts
1800-Series Hydrocone crushers
S 223.370.01 en 15 (44)
10. Topshell assembly & concave ring
2003-06-10 H4800
10.6 Replacement of concave ring - H4800 Hydrocone crusher The design of the H4800 Hydrocone is such that all concave rings - from EF to EC - can be fitted into a single topshell. This is made possible - despite the great differences in shape of the various concave rings - by using filler rings. See Section 10.8 - Filler ring. No filler ring is used with C and EC concave rings. These are mounted direct in the topshell with plastic backing. The concave ring is pulled into the topshell by a clamping ring with six clamping bolts. The concave ring has locating bosses which fit into recesses in the clamping ring, whilst the ring itself is positioned against the topshell by locating dowels. See Fig. 10.6.1. If lifting lugs are to be welded to the concave ring, make sure they are amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4.
1. 2. 3. 4. 5. 6. 7. 8.
Concave ring Filler ring Locking ring Shim Gap between clamping ring and topshell Clamping ring Plank Lifting hole/plastic backing level hole
Figure 10.6.1 H4800
1800-Series Hydrocone crushers
S 223.370.01 en 16 (44)
10. Topshell assembly & concave ring
2003-06-10 H4800
Removal When the topshell has been removed from the crusher, position it on planks so that the concave ring is unobstructed. See Fig. 10.6.2. Remove the bolts which hold the concave ring in the topshell. Make a note of the way the disc springs are arranged. See Fig. 10.6.3.
Note !
The screws in the top of the topshell hold the filler ring and should not be removed during a normal liner change.
Since the concave ring of an H4800 Hydrocone is backed with plastic composition, it may remain in the topshell and must then be driven out. Hit the top rim of the concave ring with a sledge hammer. If the concave ring does not come loose, two jacks can be positioned between the top rim of the concave ring and the topshell arms. See Fig. 10.6.2. Hit the concave ring around its top rim at the same time as the jacks are operated.
Figure 10.6.2
1800-Series Hydrocone crushers
S 223.370.01 en 17 (44)
10. Topshell assembly & concave ring
2003-06-10 H4800
If the concave ring does not come loose when these methods are used, it must be split with a cutting torch. Take great care to avoid damage to the topshell and filler ring.
Warning !!!
Use a breathing mask when cutting liners and plastic backing. Make sure the work-place is well ventilated. We advise against using explosives to loosen the concave ring. This would entail risks of injury for personnel and damage to equipment. The cost of resultant damage can far outweigh any time-saving during liner replacement.
Inspection Lift up the topshell and inspect the contact surface in the topshell. If any ridges or depressions have been formed in the topshell by the machined contact surfaces of the concave ring, they must be ground off so that they do not prevent good contact between the new concave ring and the topshell. If there is serious wear or if the concave ring has worn deep grooves in the topshell, contact Sandvik Rock Processing for advice about the appropriate course of action. Check that the filler ring is securely installed in the topshell. If the filler ring has come loose it must be taken out for inspection of the contact surfaces and the retaining screws. See Section 10.8 - Filler ring. Reassembly In principle, the H4800 concave ring is installed in the following way: Place the clamping ring on planks with the six clamping bolts positioned in their holes. See Fig. 10.6.1. Position the concave ring with its six locating bosses in the appropriate recesses in the clamping ring. Check that the locating dowels are properly screwed into the lower edge of the topshell. Coat the topshell/filler ring surfaces which will be in contact with plastic backing with a thin layer of grease or silicon spray to facilitate removal and cleaning next time the liners are changed. To increase the life of the clamping ring (wear on the inside diameter), it can be rotated relative to the topshell (6x60°). Lower the topshell onto the clamping ring, using the locating dowels to ensure correct positioning. Check that the gap between the clamping ring and the topshell is even all round. See Fig. 10.6.1.
1800-Series Hydrocone crushers
S 223.370.01 en 18 (44)
10. Topshell assembly & concave ring
2003-06-10 H4800
Fit the washers, disc springs, sleeves and nuts. Measure dimension "T" before tightening the nuts. See Fig. 10.6.3.
Note !
When installing the concave ring, ensure that there is an even fit all around the topshell by tightening the bolts in diagonal rotation until the dimension T-4.5 mm is reached. This corresponds to 460° rotation of the nut.
When you have tightened the bolts, check with a feeler gauge that there is no play between the topshell or filler ring and the lower part of the concave ring. There are holes in the clamping ring to facilitate this check. When the concave ring has been properly installed, fill the space between the concave ring and the topshell or filler ring with plastic backing composition up to the level of the lifting holes in the mantle. See Section 19 – Backing with plastic composition. Check the tightness of clamping bolts after a short period of operation.
Figure 10.6.3 Concave ring clamping bolts and nuts
1800-Series Hydrocone crushers
S 223.370.01 en 19 (44)
10. Topshell assembly & concave ring
2003-06-10 H6800
10.7 Replacemant of concave ring - H6800 Hydrocone crusher The design of the H6800 Hydrocone is such that all concave rings - from EF to EC - can be fitted into a single topshell. This is made possible - despite the great difference in shape of the various concave rings - by using filler rings. See Section 10.8 - Filler ring. No filler ring is used with C, CX, EC and EF concave rings. These are mounted direct in the topshell with plastic backing. When the EF concave ring is used, a 4-piece wearing ring is installed. Its lugs are welded to the topshell. Use an A-dimension of 4 - 5mm. See Fig. 10.7.1. The concave ring is pulled into the topshell by a clamping ring with six clamping bolts. The concave ring has locating bosses which fit into recesses in the clamping ring, whilst the ring itself is positioned against the topshell by locating dowels. See Fig. 10.7.1. If lifting lugs are to be welded to the concave ring, make sure they are amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4.
1800-Series Hydrocone crushers
S 223.370.01 en 20 (44)
10. Topshell assembly & concave ring
2003-06-10 H6800
1. Locking ring 2. Shims 3. Concave ring 4. Filler ring 5. Clamping ring 6. Plank 7. Gap between clamping ring and topshell 8. Lifting hole/plastic backing level hole 9. Wearing plate (only with EF crushing chamber).
H6800
EF crushing chamber
Figure 10.7.1 H6800
1800-Series Hydrocone crushers
S 223.370.01 en 21 (44)
10. Topshell assembly & concave ring
2003-06-10 H6800
Removal When the topshell has been removed from the crusher, position it on planks so that the concave ring is unobstructed. See Fig. 10.7.2. Remove the bolts which hold the concave ring in the topshell. Make a note of the way the disc springs are arranged. See Fig. 10.7.3.
Note !
The screws in the top of the topshell hold the filler ring and should not be removed during a normal liner change.
Since the concave ring of an H6800 Hydrocone is backed with plastic composition, it may remain in the topshell and must then be driven out. Hit the top rim of the concave ring with a sledge hammer. If the concave ring does not come loose, two jacks can be positioned between the top rim of the concave ring and the topshell arms. See Fig. 10.7.2. Hit the concave ring around its top rim at the same time as the jacks are operated.
Figure 10.7.2
1800-Series Hydrocone crushers
S 223.370.01 en 22 (44)
10. Topshell assembly & concave ring
2003-06-10
H6800 If the concave ring does not come loose when these methods are used, it must be split with a cutting torch. Take great care to avoid damage to the topshell and filler ring.
Warning !!!
Use a breathing mask when cutting liners and plastic backing. Make sure that the work-place is well ventilated. We advise against using explosives to loosen the concave ring. This would entail risks of injury for personnel and damage to equipment. The cost of resultant damage can far outweigh any time-saving during liner replacement.
Inspection Lift up the topshell and inspect the contact surface in the topshell. If any ridges or depressions have been formed in the topshell by the machined contact surfaces of the concave ring, they must be ground off so that they do not prevent good contact between the new concave ring and the topshell. If there is serious wear or if the concave ring has worn deep grooves in the topshell, contact Sandvik Rock Processing for advice about the appropriate course of action. Check that the filler ring is securely installed in the topshell. If the filler ring has come loose it must be taken out for inspection of the contact surfaces and the retaining screws. See Section 10.8 - Filler ring. Reassembly In principle, the H6800 concave ring is installed in the following way: Place the clamping ring on planks with the six clamping bolts positioned in their holes. See Fig. 10.7.1. Position the concave ring with its six locating bosses in the appropriate recesses in the clamping ring. Check that the locating dowels are properly screwed into the lower edge of the topshell. Coat the topshell and filler ring surfaces which will be in contact with plastic backing with a thin layer of grease or silicon spray to facilitate removal and cleaning next time the liners are changed. To increase the life of the clamping ring (wear on the inside diameter), it can be rotated relative to the topshell (6x60°).
1800-Series Hydrocone crushers
S 223.370.01 en 23 (44)
10. Topshell assembly & concave ring
2003-06-10 H6800
Lower the topshell onto the clamping ring, using the locating dowels to ensure correct positioning. Check that the gap between the clamping ring and the topshell is even all round. See Fig. 10.7.1. Fit the washers, disc springs, sleeves and nuts. Measure dimension "T" before tightening the nuts. See Fig. 10.7.3.
Note !
When installing the concave ring, ensure that there is an even fit all around the topshell by tightening the bolts in diagonal rotation until the dimension T-4.5 mm is reached. This corresponds to 460° rotation of the nut.
When you have tightened the bolts, check with a feeler gauge that there is no play between the topshell or filler ring and the lower part of the concave ring. There are holes in the clamping ring to facilitate this check. When the concave ring has been properly installed, fill the space between the concave ring and the topshell or filler ring with plastic backing composition up to the level of the lifting holes in the mantle. See Section 19 - Backing with plastic composition. Check the tightness of clamping bolts after a short period of operation.
Figure 10.7.3 Concave ring clamping bolts and nuts
1800-Series Hydrocone crushers
S 223.370.01 en 24 (44)
10. Topshell assembly & concave ring
2003-06-10
10.8 Filler ring H2800 Hydrocone As explained previously, all concave rings can be fitted into the single topshell. The filler ring in the H2800 Hydrocone acts as a spacer with metal-to-metal contact against both the topshell and the concave ring. See Fig. 10.4.1. The filler ring of the H2800 is intended for EF, F, MF, M and C concave rings. The EC concave ring is mounted directly in the topshell without a filler ring. Removal If the intention is to change to an EC crushing chamber, the filler ring must be removed. Remove the screws which hold the locking ring and the filler ring in the topshell. The filler ring has a tapered seating in the topshell and jacks must be used to press it out. Position the jacks between the top edge of the filler ring and the topshell arms. Press out the filler ring. Use two jacks, each with a capacity of approx. 40 tons. If the filler ring still does not come free, it may be necessary to heat the topshell while the jacks are operated. Inspection Clean the filler ring. Inspect the contact surfaces of the filler ring and the topshell. If there are any ridges or depressions, they must be ground off before reassembly is started. Reassembly Lubricate the O-ring and position it in its groove in the outer surface of the filler ring. See Fig. 10.4.1. Raise the filler ring into position in the topshell. Install the locking ring (which pulls the filler ring up into position), coat the screws with grease and fit them. Tighten the bolts in diagonal rotation until they are tight. Check the tightness of the screws after a few days of operation. In some cases this will mean removing the cone plates in the feed hopper.
1800-Series Hydrocone crushers
S 223.370.01 en 25 (44)
10. Topshell assembly & concave ring
2003-06-10
H3800 Hydrocone As explained previously, all concave rings can be fitted into the single topshell. The filler ring in the H3800 Hydrocone acts as a spacer with metal-to-metal contact against both the topshell and the concave ring. See Fig. 10.5.1. Two types of filler ring are used. One (M) is intended for F, MF and M concave rings. The other (C) is intended for MC, C and EF concave rings. The EC concave ring is mounted directly in the topshell without a filler ring. Removal If the intention is to change to a coarser crushing chamber, the filler ring may need to be removed. Check in the spare parts list which filler ring is used with which concave ring. Remove the screws which hold the locking ring and the filler ring in the topshell. The filler ring has a tapered seating in the topshell and jacks must be used to press it out. Position the jacks between the top edge of the filler ring and the topshell arms. Press out the filler ring. Use two jacks, each with a capacity of approx. 40 tons. If the filler ring still does not come free, it may be necessary to heat the topshell while the jacks are operated. Inspection Clean the filler ring. Inspect the contact surfaces of the filler ring and the topshell. If there are any ridges or depressions, they must be ground off before reassembly is started. Reassembly Lubricate the O-ring and position it in its groove in the outer surface of the filler ring. See Fig. 10.5.1 Raise the filler ring into position in the topshell. Install the locking ring (which pulls the filler ring up into position), coat the screws with grease and fit them. Tighten the bolts in diagonal rotation until they are tight. Check the tightness of the screws after a few days of operation. In some cases this will mean removing the cone plates in the feed hopper.
1800-Series Hydrocone crushers
S 223.370.01 en 26 (44)
10. Topshell assembly & concave ring
2003-06-10
H4800 Hydrocone The filler ring in the H4800 reduces the volume of the space between the topshell and the concave ring. Two types of filler ring are used, the MF and the MC. The MF filler ring is backed with plastic composition in its upper part and has metallic contact with the topshell in the lower part. The MC filler ring has full-height metallic contact and is not backed against the topshell. The filler ring provides an even gap to the concave ring, intended for filling with plastic backing composition. See Fig. 10.6.1. The MF filler ring is intended for F and MF concave rings whilst the MC filler ring is intended for M, MC and EF concave rings. The C and EC concave rings are installed directly in the topshell - without a filler ring - and are backed with plastic composition. Removal If the intention is to change to a coarser crushing chamber, the filler ring may need to be removed. Check in the spare parts list which filler ring is used with which concave ring.
Note !
If a filler ring which is backed with plastic composition comes loose during operation, it must be removed, inspected, reinstalled and backed with plastic composition again. If a solid filler ring comes loose during crushing, it should be removed and its contact surfaces inspected before it is refitted.
Remove the screws which hold the filler ring in the topshell. The filler ring has a tapered seating in the topshell and jacks must be used to press it out. Position the jacks between the top edge of the filler ring and the topshell arms. Press out the filler ring and at the same time use a sledge hammer to hit around the top edge and the inside of the filler ring. Use two jacks, each with a capacity of approx. 40 tons. If the filler ring still does not come free, it may be necessary to heat the topshell while the jacks are operated. Inspection Clean the filler ring. Inspect the contact surfaces of the filler ring and the topshell. If there are any ridges or depressions, they must be ground off before reassembly is started.
1800-Series Hydrocone crushers
S 223.370.01 en 27 (44)
10. Topshell assembly & concave ring
2003-06-10
Reassembly Press a little grease into each threaded hole in the filler ring. When the bolts have been threaded all the way into the filler ring, the holes must be completely filled with grease to prevent corrosion and the accumulation of dirt. This will make it easier to remove the filler ring next time.
Note !
Never grease those surfaces on the topshell and filler ring which are affected by plastic backing.
Pull the filler ring up into position in the topshell by tightening the six screws in diagonal rotation – with the washers and shims in position - until they are tight. See Fig. 10.6.1. When an MF filler ring has been properly seated, back it with plastic composition. See Section 19 – Backing with plastic composition. Check the tightness of the screws after a few days of operation. In some cases this will mean removing the cone plates in the feed hopper. H6800 Hydrocone The filler ring in the H6800 reduces the volume of the space between the topshell and the concave ring. Two types of filler ring are used, the (MF) and the (MC). The lower part of the filler ring has metallic contact with the topshell, whilst the upper part is backed with plastic composition. The filler ring provides an even gap to the concave ring, intended for filling with plastic backing composition. See Fig. 10.7.1. The (MF) filler ring is intended for F and MF concave rings, whilst the (MC) filler ring is intended for M and MC concave rings. The C, CX, EC and EF concave rings are installed directly in the topshell - without a filler ring - and are backed with plastic composition.
1800-Series Hydrocone crushers
S 223.370.01 en 28 (44)
10. Topshell assembly & concave ring
2003-06-10
Removal If the intention is to change to a coarser crushing chamber, the filler ring may need to be removed. Check in the spare parts list which filler ring is used with which concave ring.
Note !
If the filler ring comes loose during operation, it must be removed, inspected, reinstalled and backed with plastic composition.
Remove the screws which hold the filler ring in the topshell. The filler ring has a tapered seating in the topshell and jacks must be used to press it out. Position the jacks between the top edge of the filler ring and the topshell arms. Press out the filler ring and at the same time use a sledgehammer to hit around the top edge and inside surface of the filler ring. Use two jacks, each with a capacity of approx. 40 tons. If the filler ring still does not come free, it may be necessary to heat the topshell while the jacks are operated. Inspection Clean the filler ring. Inspect the contact surfaces of the filler ring and the topshell. If there are any ridges or depressions, they must be ground off before reassembly is started. Reassembly Press a little grease into each threaded hole in the filler ring.
Note !
Never grease those surfaces on the topshell and filler ring which are affected by plastic backing.
Pull the filler ring up into position in the topshell by tightening the six screws in diagonal rotation until they are tight. See Fig. 10.7.1. When the filler ring has been properly seated, back it with plastic composition. See Section 19 – Backing with plastic composition. Check the tightness of the screws after a few days of operation. In some cases this will mean removing the cone plates in the feed hopper.
1800-Series Hydrocone crushers
S 223.370.01 en 29 (44)
10. Topshell assembly & concave ring
2003-06-10 S2800
10.9
Replacement of concaves and lower concave ring S2800 Hydrocone crusher
The S2800 Hydrocone crusher has a crushing chamber which is formed on the outside by an upper row of concaves and a lower concave ring. If only the lower concave ring is to be changed, see Section 10.13. If lifting lugs are to be welded to the concaves or lower concave ring, make sure they are amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4. Removal All of the concaves are chamfered on the rear edges to make removal easier. See Fig. 10.9.1. Remove the concaves with wedges. It may be necessary to resort to a cutting torch to remove the concaves, depending on how worn they are. Do not stand inside the crusher when removing the concaves! Do not use explosives to loosen concaves.
Warning !!!
When cutting plastic-backed concaves with a torch, ensure that the work-place is well ventilated and use a breathing mask. If the topshell is upside down when the concaves are being removed, protect the spider bushing so that it will not be damaged by falling concaves. Protect the machined surfaces of the topshell. Block up the feed hopper attachment flange. See Fig.10.13.1.
Caution !!
1. 2.
Area which may need to be burnt off. Chamfer Figure 10.9.1 Concaves
1800-Series Hydrocone crushers
S 223.370.01 en 30 (44)
10. Topshell assembly & concave ring
2003-06-10 S2800
To make removal of the first concave easier, the edges of the adjacent concaves can be burnt off, as shown Fig. 10.9.1. The lower concave ring has recesses on the back to make removal with wedges easier. Split the lower concave ring at the three marking notches and use wedges in the recesses to press out the smallest segment first. See Fig. 10.9.2. When cutting with a torch, ensure that the work-place is well ventilated and use a breathing mask.
Warning !!!
1. 2.
Recesses for wedges Marking notch Figure 10.9.2 Concave ring
Inspection Carefully clean out all plastic backing from the inside of the topshell. If there are deep depressions, they must be filled in by welding and the topshell must be remachined. Ledges, recesses and grooves in the topshell must be completely free from remnants of plastic backing to ensure satisfactory bonding when the new lower concave ring is backed.
1800-Series Hydrocone crushers
S 223.370.01 en 31 (44)
10. Topshell assembly & concave ring
2003-06-10 S2800
Reassembly
1. 2. 3. 4.
Lower concave ring Topshell Sealing compound Plate
Figure 10.9.3 Place the topshell and lower concave ring on a smooth surface (e.g. a piece of plate), well sealed with unbroken strings of sealing compound. See Fig. 10.9.3.
Note !
Never grease the surfaces of the topshell and lower concave ring which will come into contact with plastic backing.
Adjust the position of the lower concave ring so that there is an even gap to the topshell all around. See Fig. 10.9.3. Position the concaves in the topshell with even gaps (6-8 mm) between each one. Lock the concaves in place by driving wooden wedges between the concaves and a support ring. See Fig. 10.11.4. Seal the gaps between adjacent concaves to a depth of 10-15 mm from the crushing surface. Use a cement mortar which does not shrink, for example with an additive such as Sika-3 or similar. Oakum can also be used but in this case the gaps should be given additional sealing with plastic composition or hot asphalt. Pour the thoroughly mixed plastic composition through the cut-outs in the top edges of the concaves so that the space behind the concaves is filled to the top. See Section 19 – Backing with plastic composition.
1800-Series Hydrocone crushers
S 223.370.01 en 32 (44)
10. Topshell assembly & concave ring
2003-06-10 S3800
10.10 Replacement of concaves and lower concave ring S3800 Hydrocone crusher The S3800 Hydrocone crusher has a crushing chamber which is formed on the outside by an upper row of concaves and a lower concave ring. If only the lower concave ring is to be changed, see Section 10.13. If lifting lugs are to be welded to the concaves or lower concave ring, make sure they are amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4. Removal All of the concaves are chamfered on the rear edges to make removal easier. See Fig. 10.10.1. Remove the concaves with wedges. It may be necessary to resort to a cutting torch to remove the concaves, depending on how worn they are. Do not stand inside the crusher when removing the concaves! Do not use explosives to loosen concaves.
Warning !!!
When cutting plastic-backed concaves, ensure that the workplace is well ventilated and use a breathing mask. If the topshell is upside down when the concaves are being removed, protect the spider bushing so that it will not be damaged by falling concaves. Protect the machined surfaces of the topshell. Block up the feed hopper attachment flange. See Fig. 10.13.1.
Caution !!
1. 2.
Area which may need to be burnt off Chamfer Figure 10.10.1 Concaves
1800-Series Hydrocone crushers
S 223.370.01 en 33 (44)
10. Topshell assembly & concave ring
2003-06-10 S3800
To make removal of the first concave easier, the edges of the adjacent concaves can be burnt off, as shown in Fig. 10.10.1. The lower concave ring has recesses on the outside to make removal with wedges easier. Split the lower concave ring at the three grooves (directly beneath the marking notches) and use wedges in the recesses to press out the smallest segment first. See Fig. 10.10.2.
Warning !!!
When cutting with a torch, ensure that the work-place is well ventilated and use a breathing mask.
1. 2.
Recesses for wedges Marking notch
Figure 10.10.2 Concave ring Inspection Carefully clean out all plastic backing from the inside of the topshell. If there are deep depressions, they must be filled in by welding and the topshell must be remachined. Ledges, recesses and grooves in the topshell must be completely free from remnants of plastic backing to ensure satisfactory bonding when the new lower concave ring is backed.
1800-Series Hydrocone crushers
S 223.370.01 en 34 (44)
10. Topshell assembly & concave ring
2003-06-10 S3800
Reassembly
1. 2. 3. 4.
Lower concave ring Topshell Sealing compound Plate
Figure 10.10.3 Place the topshell and lower concave ring on a smooth surface (e.g. a piece of plate), well sealed with unbroken strings of sealing compound. See Fig. 10.10.3.
Note !
Never grease the surfaces of the topshell, lower concave ring and concaves which will come into contact with plastic backing.
Adjust the position of the lower concave ring so that there is an even gap to the topshell all around. See Fig. 10.10.3. Position the concaves in the topshell with even gaps between each one. There must also be 6-8 mm gaps between the concaves and the top of the lower concave ring. Lock the concaves in place by driving wooden wedges between the concaves and a support ring. See Fig. 10.11.4. Seal the gaps between adjacent concaves to a depth of 10-15 mm from the crushing surface. Use a cement mortar which does not shrink, for example with an additive such as Sika-3 or similar. Oakum can also be used but in this case the gaps should be given additional sealing with plastic composition or hot asphalt. Pour the thoroughly mixed plastic composition through the cut-outs in the top edges of the concaves so that the space behind the concaves is filled to the top. See Section 19 – Backing with plastic composition.
1800-Series Hydrocone crushers
S 223.370.01 en 35 (44)
10. Topshell assembly & concave ring
2003-06-10 S4800
10.11 Replacement of concaves and lower concave ring S4800 Hydrocone crusher The S4800 Hydrocone crusher has a crushing chamber which is formed on the outside by an upper row of concaves and a lower concave ring. If only the lower concave ring is to be changed, see Section 10.13. If lifting lugs are to be welded to the concaves or lower concave ring, make sure they are amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4. Removal All of the concaves are chamfered on the rear edges to make removal easier. See Fig. 10.11.1. Remove the concaves with wedges. It may be necessary to resort to a cutting torch to remove the concaves, depending on how worn they are. Do not stand inside the crusher when removing the concaves! Do not use explosives to loosen concaves.
Warning !!!
When cutting plastic-backed concaves, ensure that the work place is well ventilated and use a breathing mask. If the topshell is upside down when the concaves are being removed, protect the spider bushing so that it will not be damaged by falling concaves. Protect the machined surfaces of the topshell. Block up the feed hopper attachment flange. See Fig. 10.13.1.
Caution !!
1. 2.
Area which may need to be burnt off Chamfer Figure 10.11.1
1800-Series Hydrocone crushers
S 223.370.01 en 36 (44)
10. Topshell assembly & concave ring
2003-06-10 S4800
To make removal of the first concave easier, the edges of the adjacent concaves can be burnt off, as shown in Fig. 10.11.1. The lower ring has recesses on the outside to make removal with wedges easier. Split the lower ring at the grooves (directly beneath the marking notches) and use wedges in the recesses to press out the segment. See Fig. 10.11.2. When cutting with a torch, ensure that the work-place is well ventilated and use a breathing mask.
Warning !!!
1. 2. 3.
Recesses for wedges Marking notch and groove for cutting Groove Figure 10.11.2 Concave ring
Inspection Carefully clean out all plastic backing from the inside of the topshell. If there are ridges or deep depressions, they must be filled in by welding and the topshell must be remachined. Ledges, recesses and grooves in the topshell must be completely free from remnants of plastic backing to ensure satisfactory bonding when the new lower ring is backed.
1800-Series Hydrocone crushers
S 223.370.01 en 37 (44)
10. Topshell assembly & concave ring
2003-06-10 S4800
Reassembly
1. 2. 3. 4.
Lower concave ring Topshell Sealing compound Plate
Figure 10.11.3 Place the topshell and lower concave ring on a smooth surface (e.g. a piece of plate), well sealed with unbroken strings of sealing compound. See Fig. 10.11.3.
Note !
Never grease the surfaces of the topshell, lower concave ring and concaves which will come into contact with plastic backing.
Position the lower concave ring so that the grooves on the outside come beneath the spider arms - as shown in Fig. 10.11.2 - in order to prevent undesirable wearing through into the grooves. Adjust the position of the lower concave ring so that there is an even gap to the topshell all around. See Fig. 10.11.3. Position the concaves in the topshell with even gaps between each one. There must also be 6-8 mm gaps between the concaves and the top of the lower concave ring. Lock the concaves in place by driving wooden wedges between the concaves and a support ring. See Fig. 10.11.4.
1800-Series Hydrocone crushers
S 223.370.01 en 38 (44)
10. Topshell assembly & concave ring
2003-06-10 S4800
Seal the gaps between adjacent concaves to a depth of 10-15 mm from the crushing surface. Use a cement mortar which does not shrink, for example with an additive such as Sika-3 or similar. Oakum can also be used but in this case the gaps should be given additional sealing with plastic composition or hot asphalt. Pour the thoroughly mixed plastic composition through the cut-outs in the top edges of the concaves so that the space behind the concaves is filled to the top. See Section 19 – Backing with plastic composition.
1. 2.
Support ring Wooden wedge
Figure 10.11.4 Reassembly of concaves
1800-Series Hydrocone crushers
S 223.370.01 en 39 (44)
10. Topshell assembly & concave ring
2003-06-10 S6800
10.12 Replacement of upper and lower concave rings S6800 Hydrocone crusher The S6800 Hydrocone crusher has a crushing chamber which is formed on the outside by an upper concave ring and a lower concave ring. In contrast to other 1800-Series S-type crushers, the S6800 has a 2-piece upper shell. See Fig. 10.12.1. If only the lower concave ring is to be changed, see Section 10.13. If lifting lugs are to be welded to the upper and lower concave rings, make sure they are amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4.
1. 2.
Spider Topshell Figure 10.12.1 S6800
Removal Remove the complete upper shell (i.e. topshell and spider) from the crusher. Before removing the upper and lower concave rings, take off the spider from the topshell. Remove the nuts from the bolts which clamp the spider to the topshell. There are four press screws in the topshell flange to facilitate splitting the joint.
1800-Series Hydrocone crushers
S 223.370.01 en 40 (44)
10. Topshell assembly & concave ring
2003-06-10 S6800
The spider can then be lifted off the topshell with the spider arm liners and rim liners still in place.
Caution !!
Protect the machined surfaces of the spider and the topshell. Support them with planks.
The topshell can now be turned upside down so that the lower concave ring can be removed and then, if necessary, the upper concave ring as well. Both upper and lower concave rings have grooves on the outside to make removal easier. Split the lower concave ring at the grooves and press out the smaller segment first, with wedges. See Fig. 10.12.2. When the lower concave ring has been removed you can determine the positions of the grooves in the upper concave ring. Split the upper ring at the grooves and press out the segment with wedges.
Warning !!!
1. 2. 3.
When cutting with a torch, ensure that the work-place is well ventilated and use a breathing mask. Do not stand inside the crusher when removing the segments! Do not use explosives to loosen the segments.
Recesses for wedges Marking notch and groove for cutting Groove Figure 10.12.2 Concave ring
1800-Series Hydrocone crushers
S 223.370.01 en 41 (44)
10. Topshell assembly & concave ring
2003-06-10 S6800
Inspection Carefully clean out all plastic backing from the inside of the topshell. If there are ridges or deep depressions, they must be filled in by welding and the topshell must be remachined. Ledges, recesses and grooves in the topshell must be completely free from remnants of plastic backing to ensure satisfactory bonding when the new concave rings are backed. Reassembly
1. 2. 3. 4.
Lower concave ring Topshell Sealing compound Plate
Figure 10.12.3 Place the topshell and lower concave ring on a smooth surface (e.g. a piece of plate), well sealed with unbroken strings of sealing compound. See Fig. 10.12.3. The lower concave ring can be lowered into the topshell from above.
Note !
Never grease the surfaces of the topshell and crushing rings which will come into contact with plastic backing.
Position the upper and lower concave rings so that the grooves on the outside come beneath the spider arms - as shown in Fig. 10.12.2 - in order to prevent undesirable wearing through into the grooves. Adjust the position of the upper and lower concave rings so that there is an even gap to the topshell all around. See Fig. 10.13.1. There must be a gap of 6-8 mm between the upper concave ring and the lower concave ring.
1800-Series Hydrocone crushers
S 223.370.01 en 42 (44)
10. Topshell assembly & concave ring
2003-06-10
Seal the gap between the upper and lower concave rings to a depth of 10-15 mm from the crushing surface. Use a cement mortar which does not shrink, for example with an additive such as Sika-3 or similar. Oakum can also be used but in this case the gap should be given additional sealing with plastic composition or hot asphalt. Pour the thoroughly mixed plastic composition through the cut-outs in the top edge of the upper concave ring so that the space behind the concave rings is filled to the top of the upper ring. See Section 19 – Backing with plastic composition.
10.13 Replacement of lower concave ring only – S-type Hydrocones If only the lower concave ring is to be replaced, this is most conveniently done with the topshell turned upside down. Protect the machined surfaces of the topshell. Block up beneath the feed hopper attachment flange, see Fig. 10.13.1. If lifting lugs are to be welded to the lower concave ring, make sure they are amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4.
Note !
Never grease the surfaces of the topshell and concave ring which will come into contact with plastic backing.
Lift the lower concave ring into the topshell and make sure that there is an even gap all around inside the topshell and between the lower concave ring and the upper concave ring or the upper row of concaves. Seal the gaps between the lower concave ring and the upper concave ring or the concaves. Pour in the plastic backing between the lower concave ring and the topshell. See Section 19 – Backing with plastic composition. If the topshell must be turned right way up and installed before the plastic backing has set, follow the sequence described below: Fit four plate segments with screws in the bottom edge of the topshell to lock the lower concave ring in place. See Fig. 10.13.1. Carefully seal the gap. Carefully turn the topshell upright and place it on the bottomshell. Final installation of the bolts which clamp the topshell to the bottomshell should be delayed until the plastic backing has set.
Note !
1. 2.
1800-Series Hydrocone crushers
S 223.370.01 en 43 (44)
10. Topshell assembly & concave ring
2003-06-10
If a new lower concave ring is installed together with a worn upper concave ring or worn concaves, the transition area must be inspected to ensure that there is no "shelf" in the crushing chamber. If there is such a "shelf", and it protudes more than 8-10 mm (S2800, S3800) or 10-12 mm (S4800, S6800), chamfer it or remove it with a cutting torch.
Plate segment Chamfer or remove this shelf
Figure 10.13.1 Replacement of lower concave ring only
1800-Series Hydrocone crushers
S 223.370.01 en 44 (44)
10. Topshell assembly & concave ring
2003-06-10
10.14 Crushing hard but less abrasive material Special precautions must be taken when replacing concaves on a crusher which crushes hard but less abrasive material. A hard material which is not abrasive will peen the concaves faster than they wear. See Fig. 10.14.1. A.
If special precautions are not taken, the gaps between concaves can disappear completely and this can lead to cracks in the topshell.
B.
Check the gaps between concaves every day. When they decrease below 3 mm, burn off the edges of the concaves. This also applies for the gap between the lower concave ring and the upper concaves (concave ring). Use a carbon arc cutter if possible.
Figure 10.14.1
1800-Series Hydrocone crushers
S 223.394.00 en 1 (5)
11. Spider bearing
2001-11-15
11. Spider bearing
Contents
Page
11.1
Spider bearing - checking play
2
11.2
Replacement of spider bushing and seal
3
11.1
1800-Series Hydrocone crushers
S 223.394.00 en 2 (5)
11. Spider bearing
2001-11-15
Spider bearing – checking play
The spider bearing has an important function in the crusher since it is the pivot point for the gyratory movement of the mainshaft. 1800-Series crushers have an hourglass-shaped bushing with a tapered outer surface. See Fig. 11.1.1.
1. 2. 3. 4. 5. 6.
Circulation hole O-ring Air vent Lubricant pipe Spider bearing seal Pivot point
Figure 11.1.1 Spider bearing – checking play Table 11.1.2 Permitted max. play and distance to pivot point Crusher H2800 S2800 H3800 S3800 H4800 S4800 H6800 S6800
S (mm) 1.6 2.1 1.9 2.5 2.1 2.9 2.4 3.2
S (ins.) 0.063 0.083 0.075 0.100 0.083 0.115 0.095 0.126
L (mm) 75 75 103 103 165 165 165 165
L (ins.) 3.0 3.0 4.0 4.0 6.5 6.5 6.5 6.5
1800-Series Hydrocone crushers
S 223.394.00 en 3 (5)
11. Spider bearing
2001-11-15
The maximum permissible play in the spider bearing ("S" in Fig. 11.1.1) must be checked each time the liners are changed or at least twice per year. See Table 11.1.2. If the play "S" is found to be near the maximum permissible, and it is decided to keep running with the old bushing, the lubricant must be checked and topped up more frequently than normal. Check the grease level through the plug in the spider cap and keep an eye open for leakage down over the mainshaft sleeve. See also Sections 9.5 and 12.6. When the play "S" is being measured, the mainshaft must be pushed in the direction in which it is inclined and the measurement should then be made on the opposite side with a feeler gauge. Measure on a level with the pivot point – see Dimension L in Fig. 11.1.1. Feeler gauges are included in the tool kit supplied with the crusher. If the maximum play has been exceeded, the spider bushing and/or the mainshaft sleeve must be replaced. When the bearing is dismantled, the old components can be measured and compared with the measurements obtained from new components so that it can be determined which item is most worn and whether acceptable play can be obtained if just one item is replaced. For information on inspecting the surface finish of the mainshaft sleeve, see Section 12.6 – Mainshaft sleeve. If the play considerably exceeds the maximum allowable value, the mainshaft has been given an abnormal inclination during crushing and has thus worn the eccentric bushing at an incorrect angle.
Caution !!
11.2
If a new spider bushing and a new mainshaft sleeve are fitted, the shaft will be returned to its correct inclination. This will result in line contact between the eccentric bushing and the mainshaft. The excessive pressure will be too great for the eccentric bushing and the result can be a seizure. The eccentric bushing must therefore be changed as well when an extremely worn spider bushing is replaced.
Replacement of spider bushing and seal
The spider bushing and seal can be changed without removing the topshell. However, it is recommended that a change is carried out in connection with liner replacement since accessibility is better and it is easier to clean the components when the topshell has been removed. It can in some cases also be a good idea to change the spider bearing seal each time the liners are changed.
1800-Series Hydrocone crushers
S 223.394.00 en 4 (5)
11. Spider bearing
2001-11-15
Removal Remove the screws which hold the spider cap and lift it off the topshell. Remove the screws which retain the spider bushing and press it up out of the spider by running the same screws into the threaded holes in the top flange of the bushing. Tighten the screws all around with gradually increasing torque. See Fig. 11.2.2. The spider bearing seal comes out with the bushing and can then be changed. Inspection Clean and inspect the seating for the O-ring between the spider cap and the topshell. Clean and inspect the seatings in the topshell for the spider bushing and the seal. Check that the lubrication and air vent passages in the topshell are unobstructed and that grease can reach the bushing. Check also that the air vent is clean. Clean out the circulation holes in the spider bushing and make sure that they are not blocked. Reassembly When refitting the seal ring, snap it onto the locating groove at the bottom of the spider bushing and make sure that the sealing lip points upwards. See Fig. 11.2.1. When the bushing has been placed in the topshell, the gap between the flange of the bushing and the topshell is approx. 3 mm. Tighten the screws all round, gradually increasing the torque. See Fig. 11.2.2. The flange on the spider bushing should be flush against the topshell. Tighten the screws to the torque given in Table 2.8.1. Fill the spider bearing with grease up to the top edge of the bushing. See Section 9.5 – Spider bearing lubrication. Position the O-ring on its seat on the spider cap, as shown in Fig. 11.1.1. Grease the O-ring thoroughly first. Fit the spider cap and tighten the screws. If the spider bushing and spider bearing seal are changed without the topshell being removed from the crusher, it is important to properly oil the outer diameter and sealing lip of the seal. This is in order to reduce the risk of the seal not seating properly. It is also important that the space between the spider and the mainshaft sleeve has been properly cleaned out.
Caution !!
Make sure that the inner surface of the spider bushing is liberally coated with grease before the bushing is lowered down over the mainshaft sleeve.
1800-Series Hydrocone crushers
S 223.394.00 en 5 (5)
11. Spider bearing
2001-11-15
1 2.
Spider bushing Spider bearing seal
Figure 11.2.1 Reassembly of spider bearing seal
Figure 11.2.2 Tightening of spider bushing screws
1800-Series Hydrocone crushers
S 223.371.00 en 1 (13)
12. Mainshaft assembly & mantle
2002-12-15
12. Mainshaft assembly & mantle
Contents
Page
12.1
Mainshaft - Nomenclature
2
12.2
General
3
12.3
Head nut
3
12.4
Inner head nut
5
12.5
Mantle
6
12.6
Mainshaft sleeve
8
12.7
Mainshaft
9
12.8
Headcentre
11
12.9
Dust seal ring
12
12.10 Scraper
13
1800-Series Hydrocone crushers
S 223.371.00 en 2 (13)
12. Mainshaft assembly & mantle
2002-12-15
12.1 Mainshaft - Nomenclature 1. 2. 3. 4. 5.
Head nut Inner head nut Mantle Mainshaft sleeve Mainshaft
6. 7. 8. 9. 10.
H-type Hydrocone
Headcentre Dust seal ring Scraper Mainshaft step Circlip
S-type Hydrocone
Figure 12.1.1
1800-Series Hydrocone crushers
S 223.371.00 en 3 (13)
12. Mainshaft assembly & mantle
2002-12-15
12.2 General When the topshell assembly is removed, the mainshaft assembly remains in the bottomshell. At this stage it is wise to carry out various inspection and maintenance procedures - for example, change the mantle and check the play between dust collar and dust seal ring.
Note !
Even if the mantle is changed with the mainshaft in position in the crusher, the shaft must always be lifted so that the step bearing can be inspected. See Section 13 - Bottomshell assembly.
Inspect - and if necessary, clean out - the recess for the dust seal ring between the headcentre and the retaining ring.
12.3 Head nut Removal
Caution !!
Burn off the ring between the mantle and head nut and then unscrew the nut. NOTE! The H6800 and S6800 have a left-hand thread on the head nut whilst the other crushers have a right-hand thread. When burning off the ring, take care to keep the flame away from the mainshaft. The weld between the mantle and the burning ring is made with a stainless electrode. Since it is difficult to cut stainless material with a cutting torch, it is advisable to grind off the weld first. This procedure also minimizes the heat input to the head nut and thus reduces the risk that heat is transferred to the inner head nut, destroying the adhesion of the locking fluid to the mainshaft.
Warning !!!
When using a cutting torch, make sure that there is good ventilation and use a breathing mask.
Inspection Carefully clean the threads on the inner head nut and the head nut with a wire brush and lubricate the threads with molybdenum disulphide paste or an equivalent. Inspect the surface of the mainshaft below the threads. Polish any damaged areas until a smooth surface is obtained. To check the fit of the headcentre, measure the distance from the top of the headcentre to the top of the shaft. Compare this measured value with the larger of the two dimensions stamped on the top of the shaft. See Section 12.8.
1800-Series Hydrocone crushers
S 223.371.00 en 4 (13)
12. Mainshaft assembly & mantle
2002-12-15
Refitting Screw on the nut and tighten it hard by hitting the lugs with a sledge hammer. Weld the ring to the nut and the mantle. See Fig. 12.3.1 and the adjacent table. Begin welding between the ring and the nut. Use 80 mm (3 ins.) long welds with 130 mm (5 ins.) gaps. Align the welds to the mantle with the gaps between welds to the nut. To prevent fine material from entering the opening between the burning ring ends, these can be welded up using an OK 48.00 electrode. Avoid welding immediately below the lugs on the head nut. A weld in this area makes it more difficult to remove the head hut. In some cases it may be necessary to weld all the way around the ring, for example when moist material is crushed. The electrode used to weld between the burning ring and the mantle must meet the requirements of DIN 8556: E 18 8 Mn B 20+110, with the following approximate analysis in the weld.
%
C
Mn
Cr
Ni
0.1
6
18
8.5
An example of a suitable electrode is ESAB's OK Selectrode 67.45. For the weld between the ring and the head nut, use an ESAB OK 48.00 electrode, or an equivalent.
Caution !!
Always earth close to the welding area. Always connect the earth to the mainshaft nut/mantle.
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1. 2. 3. 4. 5.
Mainshaft sleeve Inner head nut Head nut Burning ring Mantle
Crusher
Weld size (a-dimension)
H2800 S2800
5-6 mm (0.20-0.25 ins.)
H3800 S3800 H4800 S4800
6-7 mm (0.25-0.30 ins.)
H6800 S6800 Figure 12.3.1 Head nut
12.4 Inner head nut The inner head nut need only be removed if its outer threads are damaged. The H6800 and S6800 have a lefthand thread. Removal Chisel or grind a groove in the inner head nut and split it with a wedge.
Caution !!
Do not chisel or grind so deep that the mainshaft threads are damaged.
Refitting Clean the threads of the mainshaft and inner head nut with a degreasing fluid. Check that the inner head nut can be run down to the end of the thread. Remove the inner head nut again and apply Loctite 270 or an equivalent to the mainshaft threads. Screw on the inner head nut until it tightens against the radius on the mainshaft. See Fig. 12.3.1.
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12.5 Mantle Removal When the head nut has been removed, lift the mantle off the headcentre with the help of hooks under the bottom edge or by welding on two lifting lugs. If lifting lugs are welded to the mantle, they must be amply dimensioned and must be welded with an electrode suitable for manganese. See Sections 12.3 and 2.9.4.
Caution !!
Always earth close to the welded area. Always connect the earth to the mainshaft nut/mantle.
If the mantle is backed with plastic composition, removal may be difficult (applies to H4800, H6800, S3800, S4800 and S6800). If the mantle cannot be lifted off, hit it around its bottom edge with a sledge hammer whilst it is being lifted and - if necessary - heat the mantle.
Caution !!
The plastic composition decomposes at a temperature of approx. 160°C (320°F). Make sure that the working area is well ventilated. Take care to avoid damaging the mainshaft's bearing surfaces and threads with the mantle.
Inspection Manganese flow in the mantle can give rise to a gap between the headcentre and the mantle, allowing these components to move relative to each other. This causes wear on the lower part of the contact surface on the headcentre. If this occurs, the fit must be restored by grinding and polishing. If wear is severe, contact Sandvik Rock Processing for advice about what measures to take. Refitting a mantle which is a metal-to-metal fit (H2800, S2800 and H3800) Thoroughly clean the headcentre and mantle before reassembling. Position the mantle on the headcentre and fit the head nut, as described in Section 12.3. Before welding, check with a feeler gauge that the bottom of the mantle is in contact with the headcentre all around its periphery. NOTE! Plastic backing is not required on these crushers. Refitting a plastic-backed mantle (H4800, H6800, S3800, S4800 and S6800) Thoroughly clean the headcentre and mantle before reassembling. To simplify future mantle removal, cover the outer surface of the headcentre with a thin coat of grease or silicon spray.
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Position the mantle on the headcentre and tighten the head nut so that the bottom edge of the mantle lies against the headcentre. Check with a feeler gauge around the bottom of the mantle. Remove the head nut. Coat the outer threads of the inner head nut with some kind of lubricating paste to protect against splashing when the plastic is poured in. Pour in wellmixed plastic composition until the level shown in Fig. 12.5.1 and Table 12.5.2 is reached. See Section 19 - Backing with plastic composition. Do not allow the level of plastic composition to rise above the shoulder on the headcentre. Refit the head nut and tighten it as soon as the plastic composition has been poured in.
Note !
H-type Hydrocone with EF-mantle
H-type Hydrocone
S-type Hydrocone
Figure 12.5.1 Backing the mantle with plastic composition For dimension ”P”, see Table 12.5.2.
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Table 12.5.2 Crusher S3800 H4800 H4800-EF S4800 H6800 H6800-EF S6800
"P" mm 300 130 270 295 180 280 360
"P" ins. 11.8 5.1 10.6 11.6 7.1 11.0 14.2
12.6 Mainshaft sleeve The top end of the mainshaft is fitted with a protective sleeve, which can be replaced if the bearing surface becomes worn or damaged. Wear on the bearing surface of the mainshaft sleeve can take the form of a regular pattern. The lip of the spider bearing seal can also cause similar wear. This does not usually necessitate replacement of the sleeve, as long as the maximum play does not exceed the figure given in Section 11.1 - Spider bearing – checking play. The lower part of the mainshaft sleeve is exposed to wear from the feed material. Each time the topshell is removed (e.g. for manganese replacement), remove any burrs or ridges with emery paper. See also Section 9.5. Removal
Caution !!
When the mainshaft sleeve is to be removed, grind a longitudinal groove in it so that it can be split with a wedge. Be very careful when grinding to avoid damaging the mainshaft. Another method is to shock heat the sleeve and pull it off at the same time.
Inspection Inspect the machined surfaces on the mainshaft. Polish away any irregularities or rust, and clean thoroughly. Fitting The mainshaft sleeve has a shrink fit on the mainshaft. Before assembly, check that all surfaces are clean and smooth. Heat the mainshaft sleeve to about 150°C (302°F). NOTE! Do not overheat the sleeve.
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This can be done in an oil bath or if that is not available, by heating with an L.P.G. torch on the inside of the sleeve. If a torch is used, heat the sleeve in two stages. Heat the sleeve to 150°C (302°F) and allow the heat to distribute itself evenly throughout the sleeve for about 5 minutes. Check the temperature and - if necessary - reheat the sleeve to the correct temperature. Drop the sleeve onto the mainshaft until it comes down against the shoulder.
12.7 Mainshaft Removal For further examination of the mainshaft, it must be lifted out of the bottomshell. Before this is done, carefully clean the mainshaft, the flange and arms of the bottomshell and also around the dust seal ring retainer, to prevent dirt entering the bearings when the shaft is lifted out. When the shaft has been lifted out it is important to cover over the dust collar to prevent dirt entering the oil and the bearings. Caution !!
It is possible that when the mainshaft is lifted out, the step washer sticks to the mainshaft step and comes up with the shaft. Check that it is in the correct position in the crusher and is not upside down.
When the mainshaft is lifted out, the inner seal ring normally remains inside the dust collar. See Section 13.3 - Inner seal ring. When the mainshaft is lifted out of the eccentric bushing, the play between the mainshaft and the eccentric bushing can be measured. Use micrometers to measure the mainshaft and eccentric bushing. See Table 12.7.1. Table 12.7.1 Shaft diameter H2800 Crusher S2800 Nominal shaft 240 dia. (mm) Nominal shaft 9.45 dia. (ins.)
H3800 S3800
H4800 S4800
H6800 S6800
280
340
400
11.02
13.39
15.75
After fitting a remachined mainshaft, the play must not exceed the value given in Table 12.7.2. If the bearing surfaces are evenly worn, a larger play is permissible, as long as neither part is going to be repaired. In other words, a larger play is permissible between components which have worn against each other. If the eccentric bushing is changed, the spider bearing must also be checked. See Section 11.1. As soon as the mainshaft has been raised, place a piece of clean paper over the dust collar to prevent dirt entering the inside of the crusher and thus causing damage. If there is an abnormal amount of dirt on the inside of the dust collar, see Section 18.9.
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Table 12.7.2. Play between mainshaft and eccentric bushing Hydrocone
H2800 S2800
H3800 S3800
H4800 S4800
H6800 S6800
Play in mm
1.5
1.7
1.8
1.9
Play in inches
0.060
0.067
0.071
0.075
Inspection Inspect the lower bearing surface of the mainshaft. If it has a dull appearance, this is a sign of contaminated oil. A bright surface usually indicates clean oil. Inspect also the step bearing components. See Section 13.5 - Step bearing. Inspect the dust seal ring. See Section 12.9 - Dust seal ring. Refitting
Note !
Before refitting the mainshaft, align the step washer so that its centre is midway between the centreline of the Hydroset cylinder and the extended centreline of the eccentric bushing bore. In addition, make sure that the spherical surface is facing upwards.
Fix the inner seal ring on the mainshaft by placing it askew. When the shaft has entered the eccentric bushing, the ring can be released from the shaft by a light blow and will fall down onto the dust collar.
Note !
Caution !!
Re-install the mainshaft in the bottomshell and take great care when lowering it into the eccentric bushing. The bearing surfaces on the mainshaft and the mainshaft step must not be damaged by impact or by falling against the bottomshell. The dust seal ring may otherwise be damaged when the shaft is lowered. To reduce the risk of injury to personnel and of damage to components, use the inspection holes in the bottomshell to check that the dust seal ring is properly centred and slides correctly down over the dust collar. It will be easier to move the dust seal ring to the correct position if the shaft is rotated when the ring is to go over the dust collar. When the dust seal ring nears the dust collar, great care must be taken to ensure that the seal ring glides correctly over the dust collar. When the dust seal ring has come onto the dust collar the rotation of the mainshaft should be stopped to prevent dislocation of the step washer.
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12.8 Headcentre Note !
Before making repairs on the headcentre, contact Sandvik Rock Processing.
The headcentre is shrunk onto the mainshaft at the factory. To establish that the shrink fit is still sound, check the displacement of the headcentre by measuring dimension "B" from the top of the headcentre to the top of the shaft. See Fig. 12.8.1. The measured dimension "B" must correspond to the larger of the dimensions stamped into the top end of the shaft (the smaller dimension indicates the position of the headcentre before shrinking). In addition, check the fit at the larger end of the headcentre and mainshaft. There must be no play. If dimension "B" does not correspond to the stamped dimension, or if there are other signs that the headcentre has come loose, contact Sandvik Rock Processing.
Figure 12.8.1 Headcentre displacement
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12.9 Dust seal ring The dust seal ring, which is supported beneath the headcentre, is free to move and is an easy sliding fit on the dust collar. It is the most important seal for the crusher's oil system. The dust seal consists of the dust seal ring and a retaining ring. The retaining ring is secured in the headcentre by screws. See Fig. 12.9.2. Removal To remove the dust seal ring, lift the mainshaft out of the crusher and lay it on wooden blocks. Remove the screws and then put four screws back into the threaded holes in the retaining ring. Tighten these four screws to press out the retaining ring from the headcentre. Support the retaining ring so that it cannot fall down and damage the mainshaft. Inspection Inspect the machined surfaces on the retaining ring and polish away any scratches and rust which could otherwise damage the dust seal ring. The fit between the retaining ring and the headcentre must be very tight. There must be no movement between these two components. Check that the dust seal ring slides easily on the dust collar under its own weight. If this is not the case, the hole in the dust seal ring may have been deformed during transport or storage. Adjust the ring so that it can easily be moved up and down on the dust collar.
Note !
The play between the dust seal ring and the dust collar must not exceed the value given in Table 12.9.1. Refitting Tighten the retaining ring screws. When reassembling, check that the dust seal ring can move freely between the headcentre and the retaining ring. Table 12.9.1. Maximum permissible play between dust seal ring and dust collar. Crusher H/S
Play (mm)
Play (ins.)
2800
1.3
0.051
3800
1.3
0.051
4800
1.5
0.060
6800
1.8
0.071
1. 2. 3. 4. 5.
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Dust seal ring Retaining ring Retaining plate Rubber scraper Dust collar
Figure 12.9.2. Dust seal ring
12.10 Scraper To prevent the accumulation of dust and material etc. on the outside of the dust collar, the crusher has a scraper mounted on the underside of the retaining ring. See Fig. 12.9.2. The scraper consists of a rupper flap and a retaining plate which is bolted to the bottom of the dust seal ring retaining ring. The purpose of the scraper is to ensure that there is always room for the downward movement of the mainshaft assembly, e.g. if tramp iron enters the crusher. Check the condition of the scraper at regular intervals through the inspection openings in the bottomshell.
Warning !!!
Never open the inspection covers when the machine is crushing. Never put a hand inside when the crusher is running.
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13. Bottomshell assembly
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13. Bottomshell assembly
Contents
Page
13.1
Bottomshell assembly - nomenclature
2
13.2
General
3
13.3
Inner seal ring
3
13.4
Locating bar
4
13.5
Step bearing
5
13.6
Eccentric bushing
7
13.7
Dust collar
10
13.8
Eccentric assembly
11
13.9
Gear carrier and counterweight
13
13.10
Eccentric gear
14
13.11
Wearing plate
14
13.12
Bottomshell bushing
15
13.13
Hydroset piston
17
13.14
Hydroset cylinder
18
13.15
Chevron packing
19
13.16
Hydroset cylinder bushing
22
13.17
Preparation for automatic setting regulation
23
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13.1 Bottomshell assembly - nomenclature 1. 2. 3. 4. 5. 6. 7. 8. 9.
Inner seal ring Locating bar Step bearing (mainshaft step/step washer/ piston wearing plate Eccentric bushing Dust collar Eccentric assembly Gear carrier and counterweight Eccentric gear Wearing plate
Figure 13.1.1
10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Bottomshell bushing Hydroset piston Hydroset cylinder Chevron packing Hydroset cylinder bushing Seating ring Lubrication oil outlet Lubrication oil inlet Hydroset connection Key Retaining ring
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13.2 General The bottomshell and the Hydroset cylinder can be regarded as a single unit since the Hydroset cylinder need not normally be removed. Almost all service work can be carried out from above when the topshell and mainshaft have been removed.
Warning !!!
On the outside of the bottomshell are two inspection holes through which the dust seal ring and dust collar can be inspected and checks can be made on liner condition and oil leakage. Do not open the covers while the machine is crushing. Do not put a hand inside while the crusher is running. Use amply dimensioned lifting equipment, strops etc. Take great care to avoid damaging bearing surfaces and components.
Before any work is carried out inside the crusher, drain out the oil by breaking the oil inlet line at a suitable point.
13.3 Inner seal ring The inner seal ring is intended to prevent dust entering the bearings and to prevent oil from the eccentric bushing splashing over the dust collar. See Fig. 13.1.1. Removal When the mainshaft has been lifted out, the inner seal ring remains in the dust collar. Inspection Clean the inner seal ring and make sure that the drain holes in the dust collar are free from obstructions. Check that the ring rests horizontally on the seating ring which, in turn, should lie flat in the dust collar. See Fig. 13.4.1 H2800 and S2800 crushers have no seating ring - the inner seal ring rests on the dust collar itself. The play between the inner seal ring and the shaft must not exceed 2.5 mm (0.10 ins.). Refitting Place the inner seal ring on the mainshaft and keep it in place by hanging it askew. When the lower part of the shaft has entered the eccentric bushing, free the inner seal ring with a light blow so that it drops down into position in the dust collar.
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13. Bottomshell assembly
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13.4 Locating bar The locating bar, which is attached by screws to the underside of the dust collar, acts as a stop for the gear carrier to prevent upward movement caused by forces in the bevel gears. Inspection Measure the clearance "S" between the locating bar and the gear carrier with a feeler gauge when the inner seal ring and the bushing retaining ring have been removed. This clearance is the same for all ”1800-series” crushers. Normally it is 0.2 mm (0.008 ins.), whilst the maximum permissible clearance is 0.4 mm (0.016 ins.). See Fig. 13.4.1. The clearance is adjusted by removing or adding shims (T) between the locating bar and the dust collar. When the gear backlash is adjusted, the locating bar clearance should be checked. Refitting When refitting the locating bar, tighten the screws to the value given in Section 2.8.5.
1. 2. 3. 4. 5. 6. 7.
Inner seal ring Seating ring Bushing retaining ring Dust collar Shim Locating bar Gear carrier
Figure 13.4.1 Locating bar
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13.5 Step bearing We recommend that you inspect the step bearing components in conjunction with liner changes and renew the bearing components at intervals which are based on experience. If wear on the step bearing components is severe, see Section 18 Fault tracing.
Note !
Removal The step bearing components can be lifted up through the eccentric bushing with the help of the special lifting hook included in the toolkit supplied with the crusher. See Fig. 13.5.1. Take care to avoid damaging or scratching the eccentric bushing. The mainshaft step is retained on the bottom of the mainshaft by a circlip. Since the step bearing components are normally covered in oil they may stick together and to the top of the Hydroset piston. For this reason, lift carefully and check that no sticking occurs.
Note !
1. 2. 3. 4.
Mainshaft step Lifting hook Step washer Piston wearing plate
Figure 13.5.1 H&S 2800/3800/4800/6800 Hydrocones
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The piston wearing plate rests on the Hydroset piston and is located by a recess in the middle of the piston. An offset dowel prevents rotation on the piston. The step washer lies loose on the piston wearing plate and comes out with the latter when it is removed. Inspection The mainshaft step and the piston wearing plate are made of a bronze with a high lead content, and this can sometimes lead to a temporary blackening of the rubbing surfaces. The step washer is made of steel and thus does not normally need replacement each time the mainshaft step and piston wearing plate are changed. If the step washer is to be used again it must be checked against the mainshaft step and the piston wearing plate. The maximum play between the step bearing components is 0.05 mm (0.002 ins.). Continual trouble with the step bearing indicates that the crusher is overloaded or that the oil is contaminated. The step bearing components should be removed from the crusher at regular intervals for inspection of the oil grooves. The mainshaft step and the piston wearing plate have oil grooves in the rubbing surfaces which lie against the step washer. If the grooves have sharp edges against the bearing surfaces, chamfer them off 1-2 mm (0.04-0.08 ins.) with a belt grinder, for example. See Fig. 13.5.4. When the total thickness of the step bearing (dimension H) is reduced to below the value given in Table 13.5.2, the mainshaft step and the piston wearing plate must be replaced. This corresponds approximately to the depth of the oil grooves. Table 13.5.2. Thickness of step bearing Crusher
Dim. "H" (mm)
Dim. "H" (ins.)
New
Worn
New
Worn
H2800 S2800
73
63
2.87
2.48
H3800 S3800
85
73
3.35
2.87
H4800 S4800
110
95
4.33
3.74
H6800 S6800
125
108
4.92
4.25
Figure 13.5.3
1. 2.
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Chamfers Oil groove
Figure 13.5.4 Oil grooves Assembly Clean and degrease the rubbing surfaces. Coat the bearing surfaces with a thin layer of molybdenum disulphide grease. Do not use too thick a coat and keep the grease out of the oil grooves to avoid obstructing oil circulation. Make sure that the dowels in the Hydroset piston and the mainshaft enter the corresponding holes in the piston wearing plate and the mainshaft step but do not "bottom" in the holes. The step washer must be turned so that its flat surface lies against the piston wearing plate. Place the mainshaft step and the retaining circlip on the bottom end of the mainshaft. Check that the mainshaft step can move slightly on the end of the mainshaft. The step bearing components can also be changed from below if the Hydroset cylinder cover and the Hydroset piston are removed. See Fig. 13.15.3 and read the adjacent text.
13.6 Eccentric bushing The eccentric bushing is part of the eccentric assembly and it is held in place by a retaining ring and a key. See Fig. 13.1.1. The eccentric throw of the crusher is altered by rotating the bushing in the bore of the eccentric or by changing the eccentric bushing.
Note !
The throw (in mm) is stamped into the top edge of the bushing near the relevant keyway together with the letter H for an H-type or letter S for a S-type. (e.g. H-32 or S-32). An arrow stamped into the top of the eccentric bushing key way indicates which eccentric throw has been set. An eccentric bushing intended for a S-type cannot be used in an H-type crusher, or vice-versa.
For details of the play between the mainshaft and the eccentric bushing, see Section 12.7 Mainshaft.
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Removal Lift out the mainshaft. Lift out the inner seal ring and the seating ring, (if fitted). Remove the eccentric bushing retaining ring from the top of the eccentric. See Fig. 13.4.1. In the case of an H4800, H6800, S4800 or S6800, this ring is in two parts, of which only the part locking the eccentric bushing need be removed. The bushing can then be withdrawn from the eccentric with the help of the special lifting tool in the toolkit supplied with the crusher (in principle as when lifting the bottomshell bushing - see Fig. 13.12.1). If the bushing is a tight fit, the whole eccentric assembly must be removed. See Section 13.8. The bushing can then be driven out from the eccentric with a wooden block and a hammer. Protect the bearing surface on the upper side of the gear carrier from damage. If the bushing cannot be driven out in this way, it must be pressed out with a hydraulic jack, as shown in Fig. 13.6.1.
1. 4.
Eccentric Plate
2. 5.
Wooden blocks Eccentric bushing
3.
Figure 13.6.1 Eccentric bushing
Reaction beam
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If the mainshaft and mantle have rotated at the same speed as the eccentric during operation. it is probable that the eccentric bushing has seized on the mainshaft. In this case the mainshaft cannot be lifted out in the normal way. The dust collar must be freed so that the mainshaft and eccentric assembly can be lifted out. Try to take out the screws which clamp the eccentric bushing retaining ring to the top of the eccentric. If this proves to be impossible, try to push the eccentric downwards. If this cannot be done, the dust collar must be destroyed. The eccentric can then be removed from the shaft and bushing. Inspection Before fitting a new bushing, inspect the bore of the eccentric. It must be smooth and must not be oval or conical. Any ovality or conicity must be corrected by scraping or grinding the bore of the eccentric with a belt grinder. The maximum permissible play between the eccentric bushing and the eccentric is 0.22 mm (0.009 ins.) for H & S 2800, 3800 and 4800 crushers and 0.25 mm (0.010 ins.) for H & S 6800 crushers. If a serious seizure occurs between the mainshaft and the eccentric bushing, the resultant high temperature can lead to so-called heat cracks (reminiscent of fish scales) on the bearing surface of the mainshaft. These heat cracks are narrow vertical lines – 3-5 mm (0.125-0.2 ins.) long – which can be difficult to discover. If they are not dealt with, there is a major risk of a new failure. Contact Sandvik Rock Processing for information on suitable corrective measures. Refitting Make sure that the key is in place in the correct keyway in the bushing before it is installed in the eccentric. Coat the outer surface of the eccentric bushing with oil. Under certain circumstances the bushing can become distorted. In such a case it may be necessary to press the bushing into place. Never hit the bronze bushing. The top edge of the eccentric bushing must not lie above the top of the eccentric. Measure the bore of the bushing to check that it is round and straight. Fit the eccentric bushing retaining ring which locks the eccentric bushing in the eccentric. Tighten the screws to the correct torque, (see Section 2.8) and lock them with a locking fluid (see Section 2.8.7)
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13.7 Dust collar It is not normally necessary to remove the dust collar unless the eccentric assembly is to be taken out. Removal If the dust collar is to be removed, great care must be taken to avoid damage to the underlying gasket. Use the full-length threaded screws to press the dust collar off the bottomshell. Caution !!
To avoid upsetting the dust collar, use a four-part lifting sling in eyebolts, (Item 3 in Fig. 13.7.1).
Inspection If the dust collar has worked loose and turned so that the fit against the bottomshell has been destroyed, contact Sandvik Rock Processing. Check that the outer surface of the dust collar has not been worn or damaged in such a way that dust can penetrate between the dust collar and the dust seal ring. Refitting When the dust collar is to be refitted, make sure that the holes in the gasket line up with the corresponding holes in the bottomshell. Make sure that the locating dowel in the bottomshell lines up with the corresponding hole in the dust collar so that the locating block is positioned above the pinion.
1. 2. 3.
Dust collar Gasket Lifting eyes (4x) Figure 13.7.1 Dust collar
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13.8 Eccentric assembly The eccentric assembly consists of the eccentric, the gear carrier and counterweight, the eccentric bushing and the eccentric gear. The assembly is supported by the wearing plate which is mounted on the bottomshell. See Fig. 13.1.1. Removal
Note !
Remove the dust collar and then screw three lifting eyes into the threaded holes in the top of the gear carrier. Lift the eccentric assembly about 10 mm. Check with a screwdriver through the hole in the gear carrier that the wearing plate remains in place in the bottomshell. See Fig. 13.8.1 The eccentric assembly can then be lifted out. Take great care to avoid damaging the bottomshell bushing. Older crushers have no threaded holes in the top of the gear carrier. In such a case, first remove the eccentric bushing retaining ring and then raise the eccentric unit with the help of four lifting holes in the top of the eccentric.
1.
Checking hole in gear carrier
Figure 13.8.1 Eccentric assembly
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If the eccentric has seized in the bottomshell bushing, it will be impossible to rotate the crusher pulley. The bottomshell bushing and the wearing plate will then follow with the eccentric assembly when it is lifted out. The bottomshell bushing - which has already been seriously damaged on its bearing surface - must in some cases be split in order to remove it. Inspection Examine the eccentric to see if the wearing surfaces are scratched or have been subjected to heavy wear or excessive temperature. Examine also the wearing plate, see Section 13.11 below. Inspect the inner surface of the eccentric bushing as well. Look especially for wear, scratches or dark spots which can indicate that the bushing has been subjected to high temperatures. If a serious seizure occurs between the eccentric and the bottomshell bushing, the resultant high temperature can lead to so-called heat cracks (reminiscent of fish scales) on the bearing surface of the eccentric. These heat cracks are narrow vertical lines – 3-5 mm (0.0125-0.2 ins.) long – which can be difficult to discover. If they are not dealt with, there is a major risk of a new failure. Contact Sandvik Rock Processing for information on suitable corrective measures. Refitting
Note !
Coat the outer surface of the eccentric with oil. Take great care when the eccentric is being lowered into the bottomshell bushing to avoid damage to the latter. Just before the eccentric reaches its final position, rotate the crusher pulley slightly in both directions while lowering the eccentric carefully. This will ensure that the eccentric gear and the pinion mesh correctly.
1800-Series Hydrocone crushers
S 223.372.00 en 13 (23)
13. Bottomshell assembly
2001-11-15
13.9 Gear carrier and counterweight Removal The gear carrier is an interference fit on the eccentric and must therefore be pressed off. See Fig. 13.9.1.
1. 4.
Gear carrier Wooden blocks
2. 5.
Eccentric Reaction beam
3. 6.
Key Plate
Figure 13.9.1 Inspection Examine the bearing surfaces for signs of damage. Refitting Heat the gear carrier to a temperature about 50°C (90°F) above the temperature of the eccentric and mount it on the eccentric. Make sure that the key is correctly installed and that the gear carrier butts correctly against the shoulder on the eccentric when the components have cooled down.
1800-Series Hydrocone crushers
S 223.372.00 en 14 (23)
13. Bottomshell assembly
2001-11-15
13.10 Eccentric gear Removal Three threaded holes are provided in the gear carrier. Use press screws in these holes to remove the gear. Inspection Examine the tooth "footprint" and look for signs of wear. See Section 15 - Bevel gears. Refitting Pull the gear onto the carrier with the attachment screws until it lies flush against the seating on the carrier. It is important that these screws are correctly tightened since there is no key in the assembly. Tighten the screws to the correct torque. See Section 2.8 (2.8.6).
13.11 Wearing plate The wearing plate upon which the eccentric assembly is supported is designed so that it absorbs the rotating moment from the bottomshell bushing. The wearing plate is locked to the bottomshell by dowels. See Fig. 13.12.1. Inspection Examine the protrusions which lock the bottomshell bushing and grind off any minor deformation so that good contact is obtained in the cut-outs at the top of the bushing. The wearing plate must be replaced if the correct play cannot be maintained when the gear backlash is adjusted. It must however be replaced when it has been worn to the minimum thickness shown in Table 13.11.1. Table 13.11.1 Wearing plate Crusher
Min. wearing plate thickness (mm)
Min. wearing plate thickness (ins.)
H2800 S2800
18
0.71
H3800 S3800
23
0.91
H4800 S4800
25
0.98
H6800 S6800
23
0.91
1800-Series Hydrocone crushers
S 223.372.00 en 15 (23)
13. Bottomshell assembly
2001-11-15
13.12 Bottomshell bushing Removal The fit between the bushing and the bottomshell is such that the bushing can normally be lifted out easily. The bushing expands due to friction heat and there must therefore be enough room for this. The bushing must be pulled from its seating with the help of a special lifting tool which is positioned beneath the bottom edge of the bushing. This lifting tool is included in the toolkit supplied with the crusher. This tool is not intended for lifting the bushing out from the crusher. Use the lifting eyes supplied. Note! The lifting eyes are not designed to pull the bushing from its seating. See Fig. 13.12.1.
1. 2.
Wearing plate Dowel
3. 4.
Bottomshell bushing Lifting tool
Figure 13.12.1 Bottomshell assembly
5.
Lifting eye
1800-Series Hydrocone crushers
S 223.372.00 en 16 (23)
13. Bottomshell assembly
2001-11-15
Inspection The play between the eccentric and the bottomshell bushing is found by measuring the diameters with suitable micrometers. See Table 13.12.2. Table 13.12.2 Crusher
Bottomshell bushing Nominal bore dia.(mm)
Bottomshell bushing Nominal bore dia.(ins.)
H2800 S2800
350
13.78
H3800 S3800
420
16.54
H4800 S4800
510
20.08
H6800 S6800
600
23.62
If the eccentric is remachined, the maximum play must not exceed the value given in Table 13.12.3. Table 13.12.3 Max. permissible play between eccentric and bottomshell bushing Crusher
Max. play (mm)
Max. play (ins.)
H2800 S2800
1.3
0.051
H3800 S3800
1.5
0.060
H4800 S4800
1.7
0.067
H6800 S6800
1.9
0.075
If the bearing surfaces have worn evenly, a larger play is permissible as long as neither component is to be replaced. Before fitting a new bushing, inspect the hole in the bottomshell. It must be smooth and must not be oval or conical. If the new bushing cannot be installed with a light push fit, it must not be forced into place. Any ovality or conicity caused by hot running must be corrected by scraping or grinding with a belt grinder in the bore of the bottomshell. The maximum permissible play between the bottomshell and the bottomshell bushing is 0.22 mm (0.009 ins.) for the H & S 2800, 3800 and 4800, 0.25 mm (0.010 ins.) for the H & S 6800. If the bore of the bottomshell is round, a slightly oval bushing can be carefully pressed down into place.
1800-Series Hydrocone crushers
S 223.372.00 en 17 (23)
13. Bottomshell assembly
2001-11-15
Refitting Since the lugs on the wearing plate are fixed in relation to the bottomshell, the bottomshell bushing must be rotated to a position where its cut-outs match the wearing plate protrusions. The flange around the top of the bushing must butt against the top of the bottomshell hub.
13.13 Hydroset piston At the bottom of the piston is the chevron packing, held in place by a clamping ring. In the upper part of the piston there is an oil groove fed with oil by narrow oil channels on the outside of the piston. This provides lubrication for the upper part of the piston and prevents dirt falling down between the piston and the Hydroset bushing. The lubrication oil enters the crusher through the wall of the Hydroset cylinder and flows through the Hydroset piston and up through the step bearing. Removal The Hydroset piston can be removed from above or below.
Note !
Before taking out the piston, disconnect the lubricating oil supply line and raise the piston far enough to allow all of the oil inside the piston to drain out. When this has been done, lower the piston to its lowest position and disconnect the Hydroset line.
The piston can be lifted out with the help of the two lifting eyes included in the toolkit supplied with the crusher. If the piston is to be removed downwards, follow the directions given in Section 13.15 - Chevron packing. Inspection Clean the piston and, if necessary, change the chevron packing. Inspect the outer surface of the piston. Inspect also the bore of the Hydroset cylinder bushing, as described below in Section 13.16 - Hydroset cylinder bushing.
1800-Series Hydrocone crushers
S 223.372.00 en 18 (23)
13. Bottomshell assembly
2001-11-15
Refitting Coat the rubbing surfaces of the piston and Hydroset cylinder bushing with molybdenum disulphide before refitting the piston. Carefully lubricate the sealing lips of the chevron packing. Take care to avoid damaging the sealing lips of the chevron packing when the piston is lowered into the Hydroset cylinder and into the Hydroset cylinder bushing. If a new chevron packing has been fitted it may be difficult to push the piston down into the bushing. If this is the case, install the step bearing components and use the mainshaft as a weight to press the piston carefully down into the bushing.
Note !
The position sensor must be removed before the piston is fitted from above as the position sensor can otherwise be damaged.
13.14 Hydroset cylinder The bottomshell and Hydroset cylinder are separate units. There is normally no reason to remove the Hydroset cylinder from the bottomshell. The joint between the Hydroset cylinder and the bottomshell is sealed with an O-ring and unless severe leakage occurs it very seldom needs changing. See Fig. 13.1.1. Regarding the tightening of the screws, see Section 2.8 (2.8.3). If the Hydroset cylinder is to be taken off, use the lowering rods in the toolkit supplied with the crusher.
1800-Series Hydrocone crushers
S 223.372.00 en 19 (23)
13. Bottomshell assembly
2001-11-15
13.15 Chevron packing If only the chevron packing is to be changed, the job can most conveniently be done from below. See Fig. 13.15.1. Removal Disconnect the lubricating oil supply line and raise the Hydroset piston far enough to allow the oil inside the piston to drain out.
Caution !!
If the mainshaft has not been removed, lower it to the bottom of its travel and then raise it slightly. Block up with timber beneath the headcentre, on top of the arms in the bottomshell, and lower the mainshaft onto the blocks. Make sure that the shaft rests securely on the blocks. The mainshaft must not rest on the dust collar inside the headcentre or on the dust seal ring. This is prevented by the blocking-up, which also eliminates the risk of oil remaining under pressure when the Hydroset line is disconnected.
Disconnect the Hydroset line and drain out the oil. Use the lowering rods and piston retainer which are included in the toolkit supplied with the crusher to lower the Hydroset cylinder cover. When the groove - about 90 mm (3.5 ins.) from the bottom of the piston - becomes visible, fit the piston retainer, as shown in Fig. 13.15.1. Use one of the screws which clamps the Hydroset cylinder cover to the Hydroset cylinder. Make sure that the piston retainer is correctly aligned and is securely engaged in the circumferential groove on the piston. When the piston retainer is in position, lower the Hydroset cylinder cover so far that there is room to take out the screws which hold the chevron packing clamp plate.
Note !
Place two of the lowering rods so that there is room between them for removal of the piston if this proves necessary. The piston has a boss which enters a recess in the Hydroset cylinder cover when the piston is in its lowest position. See Fig. 13.1.1. For this reason it is necessary - if the piston is to be taken out - to lower in stages and use timber blocks.
Inspection Examine the chevron packing for damage. Remember that it must withstand a pressure of up to 20 MPa (2900 psi). If damage is found on the surface which seals against the cylinder bushing, the piston must be removed so that the bushing can be examined.
1800-Series Hydrocone crushers
S 223.372.00 en 20 (23)
13. Bottomshell assembly
2001-11-15
Refitting Oil each ring of the packing and oil also the piston and the cylinder bushing. Fit the packing on the piston as shown in Fig. 13.15.2. The sealing lips must point downwards. Make sure that the clamp plate is pulled up tight against the piston so that the packing is compressed slightly. Since the chevron packing is designed for the dimensions of its seating, it will be correctly clamped first when it (and the piston) have been installed in the Hydroset cylinder bushing. A. B.
Removal upwards Removal downwards, using the piston retainer (3).
1. 4. 7.
Lifting eye Chevron packing Hydroset cylinder cover
2. 5. 8.
O-ring Packing clamping plate Lowering rod
3. 6.
Figure 13.15.1 Removal of Hydroset piston
Piston retainer O-ring
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13. Bottomshell assembly
2001-11-15
Assemble the various components in the crusher in the reverse of the order of removal. Take great care to avoid damaging the sealing lips when inserting the packing into the Hydroset cylinder bushing.
Note !
Always renew the O-ring between the Hydroset cylinder and the cylinder cover.
Tighten the cover plate screws to the correct torque. See Section 2.8 (2.8.4).
1.
Chevron packing
Figure 13.15.2 Chevron packing If the piston is removed completely, inspect the step bearing components and if necessary replace them. See Fig. 13.5.4. The bore of the Hydroset cylinder bushing can also be inspected.
1. 3. 5.
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13. Bottomshell assembly
2001-11-15
Mainshaft step Locking screw Washer
2. 4. 6.
Hydroset cylinder bushing Lowering rod O-ring
Figure 13.15.3 Removal of mainshaft step
13.16 Hydroset cylinder bushing The Hydroset cylinder bushing is a short bushing in the lower section of the Hydroset cylinder, where the chevron packing seals. The Hydroset cylinder bushing is locked in position by a small screw and washer beneath the bottom edge of the Hydroset cylinder. This screw also locates the Hydroset cylinder cover so that the Hydroset line always lies beneath one of the bottomshell arms. The Hydroset cylinder bushing provides a sealing surface in the lower part of the Hydroset cylinder. Together with the Hydroset piston, the chevron packing and the Hydroset cylinder cover it functions as a hydraulic cylinder. In the upper part of the Hydroset cylinder there is no bushing. The top of the Hydroset piston is located by the inner surface of the cylinder. See Fig. 13.1.1.
1800-Series Hydrocone crushers
S 223.372.00 en 23 (23)
13. Bottomshell assembly
2001-11-15
Removal When the Hydroset piston has been removed - as shown in Fig. 13.15.1 - the bushing can also be removed with the help of the lowering rods and the Hydroset cylinder cover. Inspection Inspect the inner surface for scratches or unevenness. There must be no damage on the bushing. Scratches or unevenness can easily allow oil to leak past the chevron packing and thus allow the setting (CSS) to increase. Inspect also the upper part of the Hydroset cylinder - above the bushing - which acts as a locating surface for the piston. Polish away any scratches or unevenness in this area. Assembly Fit the O-ring and prepare the contact faces of the Hydroset cylinder and the bushing with molybdenum disulphide. Press the bushing into the cylinder and lock it in position with the screw at the bottom of the bushing. Fit the step bearing components, the piston, the O-rings and the Hydroset cylinder cover, as described in Section 13.15 above.
Note !
Always renew the O-rings on the Hydroset cylinder cover and between the Hydroset cylinder bushing and the Hydroset cylinder.
13.17 Preparation for Automatic Setting Regulation If no automatic setting regulation system is fitted to the crusher, the holes required for the installation of ASR components are plugged. No extra measures need be taken during normal removal or refitting of the Hydroset cylinder assembly components. If the crusher is fitted with ASR, information about the installation and maintenance of the regulation components fitted to the crusher is given in a separate instruction manual. Regarding tightening torques for the mainshaft position sensor and the adapter, see Section 2.8.
1800-Series Hydrocone crushers
S 223.373.00 en 1 (9)
14. Pinionshaft assembly
2001-11-15
14. Pinionshaft assembly
Contents
Page
14.1
Lubrication
2
14.2
Removal of complete pinionshaft assembly
2
14.3
Removal of pinionshaft
4
14.4
Refitting pinionshaft
8
14.5
Refitting complete pinionshaft assembly
9
1800-Series Hydrocone crushers
S 223.373.00 en 2 (9)
14. Pinionshaft assembly
2001-11-15
14.1 Lubrication The pinionshaft assembly forms a complete unit with separate lubrication. The H2800, H3800, S2800 and S3800 have oil-bath lubrication. The oil level is checked and topped up with the help of a level tube and a filler plug. The H4800, H6800, S4800 and S6800 have a circulatory lubrication system. The circulatory system is designed so that a constant flow of oil is pumped from the tank unit to the pinionshaft housing. A level tube maintains a constant level in the pinionshaft housing whilst excess oil runs back to the tank through the main return hose. For more information, see Section 6 - Lubrication system and Section 9.4 - Pinionshaft lubrication.
14.2 Removal of complete pinionshaft assembly Check the gear backlash. See Section 15. Measure the distance between the flange of the pinionshaft housing and the bottomshell with a feeler gauge. There is a recess in the edge of the gasket to facilitate this measurement. Write down the resulting dimension as this information will be useful if the gasket is damaged when the pinionshaft assembly is withdrawn from the crusher. Check the axial play in the bearings by pulling the crusher pulley outwards. Abnormally large play can be an indication that a bearing replacement is necessary. Use a dial gauge for this check. Remove the magnetic plug or level tube in the bottom of the pinionshaft housing and drain out the oil. Check to see if there is metal swarf or similar on the magnetic plug. If this is the case, the pinionshaft bearings have probably been damaged. Remove one of the mesh adjustment screws and the screws which retain the pinionshaft assembly in the bottomshell. See Fig. 15.3.3. Place a sling around the end of the pinionshaft housing and lift until the sling is tight. Pull the pinionshaft housing out from the bottomshell. Place the pinionshaft assembly on a pair of trestles.
1800-Series Hydrocone crushers
S 223.373.00 en 3 (9)
14. Pinionshaft assembly
2001-11-15
01. Fille r tube: H2800, H3800, S2800, S3800 Oil inlet: H4800, H6800, S4800, S6800 02.
Level tube/oil outlet: H4800, H6800, S4800, S6800
03.
Magnetic plug: H4800, H6800, S4800, S6800
04.
Level tube: H2800, H3800, S2800, S3800
Figure 14.2.1 Pinionshaft lubrication connections
1800-Series Hydrocone crushers
S 223.373.00 en 4 (9)
14. Pinionshaft assembly
2001-11-15
14.3 Removal of pinionshaft Warning !!!
4800 crushers have seal rings made of fluorinated rubber. If they have been exposed to extreme heat (burnt), they must be treated in the same way as corrosive acid.
Remove the screws between the crusher pulley and the tapered bushing. Put screws in the threaded holes in the crusher pulley and tighten them so that the pulley comes loose. Remove the pulley, the retaining washer, the tapered bushing and the key. Remove the pinion in the following way: Take off the locking ring. Mount a robust extractor as shown in Figs. 14.3.2 and 14.3.3. If the pinion cannot be removed with just the extractor, heat the pinion while the extractor is tightened. Take great care when the pinion heats up and comes loose. Caution !!
An H3800, H4800, H6800, S3800, S4800 or S6800 has a special bearing cover with a lip for an extractor. See Fig. 14.3.3. In the case of an H2800 or S2800, pull off the pinion in the manner shown in Fig. 14.3.2. Protect the teeth with a plate beneath the larger end of the pinion. Before the pinionshaft, bearings and spacers can be taken out from the pinionshaft housing, the level tube (Fig. 14.2.1) must be removed, as described on page 7. When this has been done, the pinionshaft - with bearings and spacers - can be removed. See Fig. 14.3.1. Carefully heat the spacers and remove them - and the bearings - from the shaft.
Caution !!
Great care must be taken and cleanliness is vital when work is carried out on the bearings. Never let bearing components lie unprotected.
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S 223.373.00 en 5 (9)
14. Pinionshaft assembly
2001-11-15
H2800, H3800, H4800, H6800, S2800, S3800, S4800 and S6800
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
12. 13. 14. 15. 16. 17.
Spacer O-ring Inner bearing Pinionshaft Outer bearing Key Key Locking ring Pinion Bearing cover Level tube (H2800, H3800, S2800, S3800) Pinionshaft housing Bearing cover Tapered bushing Retaining washer Crusher pulley Seal ring
Figure 14.3.1
1800-Series Hydrocone crushers
S 223.373.00 en 6 (9)
14. Pinionshaft assembly
2001-11-15
Figure 14.3.2 Removal of pinion (H2800 and S2800)
Figure 14.3.3 Removal of pinion (H/S3800, H/S4800 and H/S6800) Remove the key. Make sure there are no burrs on the end of the pinionshaft. Take out the screws and remove the two bearing covers.
1800-Series Hydrocone crushers
S 223.373.00 en 7 (9)
14. Pinionshaft assembly
2001-11-15
Removal of level tube H2800, H3800, S2800 and S3800 The level tube is screwed into the bottom of the pinionshaft housing near the outer bearing. See Fig. 14.2.1 - item 04. Unscrew the filler tube with the level plug and TREDO seal ring. H4800, H6800, S4800 and S6800 The level tube is located near the inner bearing and is removed as described below: Pull out the short discharge tube and take out the level tube. The level tube has a threaded hole at the bottom for an M8 extractor screw. The level tube must be taken out before the shaft can be pulled out in the direction of the arrow. See Fig. 14.3.4.
01. 02. 03.
O-ring Steel wire Hole for removal
04. Discharge tube 05. O-rings 06. Extractor screw
Figure 14.3.4 Level tube
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S 223.373.00 en 8 (9)
14. Pinionshaft assembly
2001-11-15
14.4 Refitting pinionshaft Caution !!
The work must be carried out indoors, in a clean environment. When heating bearings and components which are to be shrunk into place, use an oil bath or an oven. Open flame must be treated with great care since there is an obvious risk of overheating or localized heating.
Heat the bearings and spacers to max. 100°C (212°F).
Caution !!
When heating bearing components, check the temperature with a thermometer, or other equipment recommended by the bearing manufacturer.
Fit the components in the reverse of the removal sequence. Remember to fit new O-rings between the spacers and the shaft (and also on the inner level tube of an H4800, H6800, S4800 or S6800). To avoid damage to the O-rings when they are being fitted onto the pinionshaft, remove all sharp edges from keyways and locking ring grooves. Oil the surfaces over which the O-ring is to be fitted. Place the O-ring in the recess in the spacer. Make sure that it is not squashed or damaged. The spring-loaded lips of the inner and outer seals must point towards the pinion. Lock the bearing cover screws with a locking fluid. See Section 2.8 (2.8.7). Heat the pinion to 130°C (266°F) and mount it, with the key, on the pinionshaft. Mount the crusher pulley on the shaft. Tighten the central washer's retaining screw hard before pulling the pulley up onto the tapered bushing.
1800-Series Hydrocone crushers
S 223.373.00 en 9 (9)
14. Pinionshaft assembly
2001-11-15
14.5 Refitting complete pinionshaft assembly If a new pinionshaft housing is to be fitted, or if the pinionshaft, gears or inner spacer have been changed, you must check the gear backlash and the tooth bearing footprint, as described in Section 15. Refitting is the reverse of the removal sequence. Fit a gasket of the correct thickness between the pinionshaft flange and the bottomshell (as measured previously during removal, see Sections 14.2 and 15.2, Table 15.2.2). Push the pinionshaft assembly into the bottomshell. When it nears its correct position, slowly turn the shaft backwards and forwards so that the pinion meshes correctly with the eccentric gear. Put the retaining screws back into position in the bottomshell. Install the mesh adjustment screw(s). Tighten the screws which retain the pinionshaft assembly in the bottomshell. Check the backlash in the gears. See Section 15. Fit the oil inlet line and the other components of the circulatory lubrication system (if applicable). Fill the pinionshaft housing with oil up to the correct level. See Section 5.1 - Paragraph 8.
1800-Series Hydrocone crushers
S 223.374.00 en 1 (9)
15. Bevel gears
2001-11-15
15. Bevel gears
Contents
Page
15.1
General
2
15.2
Installing a complete pinionshaft assembly
2
15.3
Gear backlash
3
15.4
Tooth bearing "Footprint"
7
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15. Bevel gears
2001-11-15
15.1 General 1800-Series Hydrocone crushers have spiral bevel gears. Under normal conditions, this type of gear transmission is reliable and requires very little maintenance. The gear and pinion are manufactured and marked as a matched set. For this reason, do not use a gear from one set with a pinion from another set.
15.2 Installing a complete pinionshaft assembly If the gear and pinion, pinionshaft housing etc. are to be replaced, or when a check was not made on the thickness of the gasket between the pinionshaft housing flange and the bottomshell during removal, the tooth bearing "footprint" and the backlash must be adjusted. The thickness of the gasket can be calculated in accordance with the principle shown in Fig. 15.2.1.
1.
Wedge
Figure 15.2.1. Installing a complete pinionshaft assembly Use a rod-type micrometer to measure dimension "A". Position the pinionshaft assembly upright, resting on the crusher pulley. To compensate for the axial play in the bearings, drive in a wooden wedge between the crusher pulley and the outer bearing cover. Then measure the distance between the contact face of the pinionshaft flange (which seats against the bottomshell) and the machined surface on the small end of the pinion. See Fig. 15.2.1. Dimension "B" is stamped into the small end of the pinion. Dimension "C" is stamped into the machined outer surface of the bottomshell.
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15. Bevel gears
2001-11-15
The gasket thickness can then be calculated with the formula: A + B - C = Gasket thickness. Note that the calculated gasket thickness applies for compressed gaskets. See Table 15.2.2. Table 15.2.2 Gasket thickness uncompressed (mm)
Gasket thickness compressed (mm)
Gasket thickness uncompressed (ins.)
Gasket thickness compressed (ins.)
0.5
approx. 0.3
0.020
approx. 0.012
0.8
approx. 0.5
0.030
approx. 0.020
1.5
approx. 0.9
0.059
approx. 0.035
Fit gaskets of the correct thickness, as determined by the calculation. Slide in the pinionshaft assembly and rotate the shaft slowly backwards and forwards as the pinion comes into mesh with the eccentric gear. Tighten the screws which clamp the pinionshaft housing to the bottomshell. Check and - if necessary - adjust the backlash and the tooth bearing "footprint". When a new eccentric gear and pinion set is installed, the correct "toothprint" will be obtained with the gasket thickness calculation described above.
15.3 Gear backlash Table 15.3.2 gives the correct backlash for the bevel gears. These values are theoretically calculated for reference during manufacture and installation of the gears. Practical experience has shown that the nominal gear backlash can be exceeded - due to the geometry of the installation - but the values given should be considered as a guide when judging the condition of the gear and pinion. If problems are encountered, contact Sandvik Rock Processing for advice. Correct backlash and tooth bearing "footprint" are essential if the gears are to operate properly. Inspection Since there is a certain amount of play between the eccentric and the bottomshell bushing, the backlash in the gears will vary in accordance with the position of the eccentric. To correctly determine the backlash it is therefore necessary to make four measurements, turning the pinion and rotating the eccentric gear through 90° between each measurement. The average of these measurements is then taken as the actual backlash. 90° rotation of the eccentric corresponds to slightly less than one revolution of the crusher pulley.
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15. Bevel gears
2001-11-15
Note !
Due to the play in the pinionshaft bearings it is important that the pulley and shaft are pulled outwards when the gear backlash is measured. In addition, the screws that hold the pinionshaft housing flange must be tight.
Since the backlash cannot be measured directly between the pinion and the eccentric gear, the movement of the crusher pulley is measured and the backlash is calculated from this measurement. A dial gauge should be used for these measurements. If a dial gauge is not available, a set square can be used. In this case, scribe marks are made on the pulley and the distance between the marks is measured. See Fig. 15.3.1.
1. Set square 2. Dial gauge
Figure 15.3.1. Measuring backlash. The following formula is used to check the backlash: Crusher pulley movement on = outer dia.
Play in gears Crusher pulley on pitch line x outer dia. Pinion pitch circle dia.
Example: The H2800 Hydrocone has a crusher pulley with 385 mm o.d. What movement should be measurable on the outer dia. of the crusher pulley? See Table 15.3.2 for the correct backlash and then use the formula as shown below. Maximum movement = on crusher pulley outer dia.
0.51 x 385 170
=
Max. = 1.16 mm
Minimum movement = on crusher pulley outer dia.
0.41 x 385 170
=
Min. = 0.93 mm
The standard crusher pulley diameters and the corresponding movements with correct gear backlash are shown in Table 15.3.2.
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15. Bevel gears
2001-11-15
Table 15.3.2 Hydrocone crushers Crusher
H2800 S2800
170 (6.7)
0.41 - 0.51 (0.016 - 0.020)
385 (15)
Movement on outer dia. of pulley with correct play mm (ins.) 0.93 - 1.16 (0.037 - 0.046)
H3800 S3800
180 (7.1)
0.60 - 0.80 (0.024 - 0.031)
385 (15)
1.28 - 1.71 (0.050 - 0.067)
H4800 S4800
192 (7.6)
0.80 - 1.00 (0.031 - 0.039)
385 (15)
1.60 - 2.00 (0.063 - 0.079)
H6800
255 (10.0) 255 (10.0)
0.89 - 1.14 (0.035 - 0.045) 0.089 - 1.14 (0.035 - 0.045)
510 (20) 640 (25)
1.78 - 2.28 (0.070 - 0.090) 2.23 - 2.86 (0.088 - 0.113)
S6800
Pinion pitch circle dia. mm (ins.)
Backlash on pitch circle dia. mm (ins.)
Crusher pulley outer dia. mm (ins.)
Adjustment Since the pinionshaft housing is eccentrically mounted, the backlash in the gears can be adjusted by rotating the pinionshaft housing. See Fig. 15.3.3. First slacken off the screws which retain the pinionshaft assembly. Release the gasket from the flange on the pinionshaft housing. The gear backlash can then be adjusted as follows: - Increase gear backlash by moving the adjusting lug downwards (=clockwise). - Reduce gear backlash by moving the adjusting lug upwards (= anti-clockwise).
1800-Series Hydrocone crushers
S 223.374.00 en 6 (9)
15. Bevel gears
2001-11-15
Decrease
Increase
Figure 15.3.3 Adjustment of backlash When the correct backlash has been obtained, tighten the retaining screws and lock the adjusting screws. Check the backlash one more time. If the pinionshaft assembly is to be removed and the backlash is correct, take out only one of the adjusting screws.
Note !
Use a feeler gauge to measure the thickness of the gasket between the pinionshaft housing's flange and the bottomshell before the attachment screws are loosened. There is a cut-out in the edge of the gasket to facilitate measurement. New gaskets may be needed. See Table 15.2.2.
1800-Series Hydrocone crushers
S 223.374.00 en 7 (9)
15. Bevel gears
2001-11-15
15.4 Tooth bearing "Footprint" The gear installation is correct only when the correct "footprint" and the correct backlash have been obtained. Checking the "footprint" Spiral bevel gears are manufactured for operation with a certain tooth bearing "footprint". To check the "footprint", apply Molykote Spray Rapid or marking blue to the teeth of the pinion. Rotate/drive the crusher pulley in the correct direction so that the "footprints" show up clearly. Ideal "footprints" are shown in Fig. 15.4.1 (H2800, H3800, H4800, S2800, S3800, S4800) and Fig. 15.4.4 (H6800, S6800). The ideal "footprint" is obtained when the contact mark is slightly high on the pinion and slightly low on the eccentric gear. Under light load, the length of the "footprint" is usually half the length of the teeth. Normally, the "footprint" moves towards the "heel" (larger end) of the tooth under heavy load. For this reason, the gears are adjusted so that the "footprint" lies nearer the "toe" (small end). Adjustment If the tooth bearing "footprint" differs from the ideal picture (shown in Fig. 15.4.1 and 15.4.4), the gear tooth meshing can be adjusted by using gaskets of different thicknesses between the flange of the pinionshaft housing and the bottomshell. - If the "footprint" is at the larger end of the pinion (near the outside of the gear), move the pinion outwards from the centre of the eccentric gear. To accomplish this, increase the thickness of the gasket between the pinionshaft housing and the bottomshell. See Fig. 15.4.2 (H2800, H3800, H4800, S2800, S3800 and S4800) and Fig. 15.4.5 (H6800 and S6800). -
If the "footprint" is at the smaller end of the pinion, (towards the inside of the gear) move the pinion inwards towards the centre of the eccentric gear. This is accomplished by reducing the gasket thickness. See Fig. 15.4.3 (H2800, H3800, H4800, S2800, S3800 and S4800) and Fig. 15.4.6 (H6800 and S6800).
1800-Series Hydrocone crushers
S 223.374.00 en 8 (9)
15. Bevel gears
2001-11-15
H2800, H3800, H4800, S2800, S3800 and S4800 Hydrocones 1. 2. 3. 4. 5.
Pinion "Footprint" "Heel" Eccentric gear "Toe"
Figure 15.4.1
Figure 15.4.2
Figure 15.4.3
1800-Series Hydrocone crushers
S 223.374.00 en 9 (9)
15. Bevel gears
2001-11-15
H6800 and S6800 Hydrocones 1. 2. 3. 4. 5.
Pinion "Footprint" "Heel" Eccentric gear "Toe"
Figure 15.4.4
Figure 15.4.5
Figure 15.4.6
1800-Series Hydrocone crushers
S 223.389.00 en 1 (4)
16. Drive arrangement
2001-11-15
16. Drive arrangement
Contents 16. Drive arrangement
Page 2
Direction of rotation
2
Speed monitor
3
Belt tensioning
3
1800-Series Hydrocone crushers
S 223.389.00 en 2 (4)
16. Drive arrangement
2001-11-15
16. Drive arrangement Warning !!!
Fixed guarding must be installed around the moving parts of the crusher's drive system. Since the crusher has a V-belt drive, it must be possible to check the tension in the belts. The guarding must be designed so that it complies with the applicable safety guarding regulations.
A V-belt drive is used as standard on H/S2800, 3800, 4800 and 6800 Hydrocone crushers and a crusher pulley is fitted as standard. Before the V-belts are fitted, the motor must be aligned so that the motor shaft and the crusher's pinionshaft are parallel and the V-belts run at right-angles to the shafts. The angle between the crusher's vertical centreline and the line joining the pulley centres must not exceed 30° (preferably not more than 20-25°). See Fig. This applies for a crusher supported on rubber compression mountings.
If the crusher is mounted rigidly, or if the motor and crusher are mounted on the same frame, the motor can be placed where desired. Direction of rotation
Caution !!
The crusher's V-belt pulley must rotate in the direction indicated by the arrow on the bottomshell. See Fig. 16.1. This is necessary for the self-tightening action of the head nut.
H2800, S2800 H3800, S3800 H4800, S4800
H6800, S6800
Figure 16.1
1800-Series Hydrocone crushers
S 223.389.00 en 3 (4)
16. Drive arrangement
2001-11-15
Speed monitor To partially overcome the problems caused by slipping or broken V-belts, a speed monitor should be fitted. It should be connected in such a way that the feed to the crusher is stopped if the pinionshaft speed drops. Belt tensioning During the first few days of operation, the belt tension must be checked frequently since new belts stretch. If the belts are not tensioned sufficiently, slipping can occur and belt life will be reduced considerably. The belt tension can be checked with a spring balance or a special instrument, a Tensiometer or its equivalent. See Fig. 16.2. The belt tension can be determined with the help of the deflection load. See Table 16.3.
l = deflection W = belt span F = deflecting load Figure 16.2 Belt tension
1800-Series Hydrocone crushers
S 223.389.00 en 4 (4)
16. Drive arrangement
2001-11-15
Table 16.3 Recommended deflection load (F) F kp/belt (lbf/belt) Belt profile
Normal
Max. (newly fitted belts)
SPC
7 (15.4)
12.0 (26.5)
8V
9 (19.8)
14.0 (30.9)
1.
Measure the belt span (W) in meters, as shown in Fig. 16.2.
2.
Multiply the span by 1.5, to give the belt deflection (1) in cm.
3.
Set the top side of the lower O-ring to the correct deflection in cm on the meter's lower scale.
4.
Push the upper O-ring up against the lower edge of the outer sleeve.
5.
Press the meter against the belt in the middle of the span and press sufficiently hard to bring the top side of the lower O-ring level with the belt alongside.
6.
Remove the meter and read off the load (F) in kp (lbf) at the top side of the upper Oring. The correct load is obtained from Table 16.3, which is also reproduced on the meter.
7.
If the load is too low or too high on all of the belts, tighten or slacken them.
1800-Series Hydrocone crushers
S 223.368.00 en 1 (5)
17. Routine maintenance
2001-11-15
17. Routine maintenance
Contents
Page
17.1
General
2
17.2
Daily inspection
2
17.3
Weekly inspection
4
17.4
Yearly inspection
5
17.5
Checking manganese wear
5
17.6
Checks to be made before the topshell is removed
5
1800-Series Hydrocone crushers
S 223.368.00 en 2 (5)
17. Routine maintenance
2001-11-15
17.1 General Every crusher - and its extra equipment (such as an over-pressure dust sealing system) must be subjected to regular, systematic checks. This will result in fewer and smaller repairs, less downtime and thus lower overall running costs. Since crushers operate under widely differing conditions, it is impossible to recommend an inspection and maintenance schedule applicable to all crushers. However, some kind of regular inspection is necessary, for example in accordance with the schedule given below.
Note !
A new machine should first be inspected after a fairly short time of operation. The intervals between inspections can then be increased until a suitable frequency is found.
A written record must be kept. The crusher's operating conditions and loads, important instrument readings, adjustments carried out and any repairs made should be noted down. An example of such a record sheet is attached (S 223.405 en). For tightening torques for threaded fasteners, see Section 2.8 - Tightening threaded fasteners.
17.2 Daily inspection 1.
Before starting the crusher
Check the oil level in the lubrication tank. Check the oil level in the Hydroset tank. Check that the shut-off valves between the tanks and pumps are fully open. Check that no material has built up on the bottomshell arms. 2.
After starting the lubrication pump
Check that lubricating oil returns to the tank and that the oil is clean. Check that the oil lines do not leak.
3.
1800-Series Hydrocone crushers
S 223.368.00 en 3 (5)
17. Routine maintenance
2001-11-15
After starting the crusher
Check that the pinionshaft lubrication circuit is operating correctly (applies to H4800, H6800, S4800 and S6800 crushers). Check the setting. Check that material has not jammed in the feed hopper or distributor and blocked the feed opening. 4.
While crushing
Listen for abnormal noises in the crusher. Listen for abnormal noises in the lubrication pump(s). Check the return oil temperature. Check the drive motor current or power consumption. Check the Hydroset pressure. Check the temperature of the pinionshaft housing. Check that the Hydroset pressure gauge damping is correct. See Section 8.10 - Damping valve for pressure gauge. Check the lubricating oil pressure at normal working temperature. Check that no oil leakage has occurred. Check that no bolts have come loose. 5.
After stopping the crusher
Check that the oil heaters are connected. Check the distance between the head nut and the underside of the spider (i.e. the A-dimension). Check that there is no increase or change in the contamination on the return oil strainer, e.g. an abnormal amount of metal particles.
1800-Series Hydrocone crushers
S 223.368.00 en 4 (5)
17. Routine maintenance
2001-11-15
17.3 Weekly inspection Check all the items listed under "Daily inspection". In addition: Inspect the oil filter (check to see if the red button in the differential pressure sensor assembly protrudes – see Fig. 6.10.1 – Item 15), the dirt trap and the oil tank. Change or clean if necessary. Inspect the manganese for wear and damage. Measure the setting at 4 points around the crushing chamber to check for uneven wear. Check the dust seal ring for wear. Check the oil pump(s) for abnormal noise and wear. Check the tightness of all bolts. Retighten if necessary. See Section 2.8. Check the V-belts for wear and tension. Check the play between the mainshaft sleeve and the spider bushing. Check the backlash in the pinion and eccentric gear. Check the grease level in the spider bearing. Check the oil level in the pinionshaft housing or check that the pinionshaft lubrication system operates correctly. Check the cooler matrix of the air/oil heat exchanger. Blow clear if necessary. Check the condition of the scraper which rotates above the dust collar. This can be done through the inspection holes in the bottomshell. Check - using feeler gauges - between the headcentre and the mantle and between the topshell and the concave ring.
1800-Series Hydrocone crushers
S 223.368.00 en 5 (5)
17. Routine maintenance
2001-11-15
17.4 Yearly inspection Check all the items listed under "Daily inspection" and "Weekly inspection". In addition: Dismantle the crusher and inspect the following: The topshell and bottomshell for wear. The spider bearing for wear. The spider bearing grease seal for wear. The tapered contact faces of the topshell and bottomshell. The mainshaft sleeve for wear and pitting. The lower bearing surface on the mainshaft. The inner seal ring for wear. The play between the locating bar and the gear carrier. The eccentric bushing for wear and scratches. The eccentric for wear and scratches. The wearing plate for wear. The bottomshell bushing for wear and scratches. The thickness of the step bearing assembly. Check for wear and scratches. The bevel gears for wear. The Hydroset cylinder bushing for wear and scratches. The chevron packing for wear.
17.5 Checking manganese wear See Section 10.1 - Evaluation of liner wear.
17.6 Checks to be made before the topshell is removed See Section 10.2 - Checks prior to removal.
Symbols to be marked in the squares: X = no remarks O = adjustment carried out. The figures refer to the numbers on the next page.
All bolts for tightness. Retighten if necessary
V-belts for wear and tension
Gear backlash (record)
Dust seal for wear
Setting simultaneously at 4 points (record)
Crushing liners for wear and possible damage
Grease level in spider bearing
Play between mainshaft sleeve and spider bushing (record)
Oil pump(s) for abnormal noise and wear
WEEKLY INSPECTION: As daily inspection. In addition check: Oil filter (red button), dirt trap and oil tank. Change/clean if necessary
Distance between head nut and spider bushing (A-dimension) (record)
Oil level in pinionshaft housing
Oil strainer
That the oil heaters are connected
After stopping crusher check:
The feed arrangement
Hydroset pressure (record the pressure)
Drive motor current / power (record)
That no oil leakage has occurred That no bolts have loosened
Oil pressure(s) at normal running temperature (record the pressure(s) )
Return oil temperature
Whether abnormal noises can be heard from the crusher
Whether abnormal noises can be heard from the oil pump(s)
During crushing check:
Setting (if ASR is fitted, check also calibration)
After starting crusher check:
That the oil lines do not leak
That oil flows back into the tank
After starting lubricating oil pump check:
Oil level in Hydroset oil tank
Oil level in lubricating tank
DAILY INSPECTION: Before starting crusher check:
INSPECTION PROCEDURE
Week No.
Week No. Week No.
S M Tu W Th F Sa S M Tu W Th F Sa S M Tu W Th F Sa S M Tu W Th F Sa t t t t
Week No.
INSPECTION RECORD SHEET FOR HYDROCONE CRUSHERS S 223.405 en 1 (2) 2001-11-15
INSPECTION RECORD SHEET FOR HYDROCONE CRUSHERS
No. 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Remarks
S 223.405 en 2 (2) 2001-11-15 Cost
Sign.
1800-Series Hydrocone crushers
S 223.369.00 en 1 (11)
18. Fault tracing
2001-11-15
18. Fault tracing
Contents
Page
18.1
General
2
18.2
Crusher stops
3
18.3
Crusher will not hold a constant setting
4
18.4
Oil temperature too high
5
18.5
Crusher cannot be started
6
18.6
Points to watch regarding pinionshaft assembly
7
18.7
Abnormal noise in crusher
8
18.8
Crusher's capacity drops
9
18.9
Increasing bearing component wear (contaminated lubricant)
10
18.10
Bearing failure inside crusher
11
1800-Series Hydrocone crushers
S 223.369.00 en 2 (11)
18. Fault tracing
2001-11-15
18.1 General The symptoms and corrective measures described in this section on fault tracing do not cover all conceivable problems. Fault tracing diagrams must rather be considered as suggestions for carrying out systematic checks on basic functions. To correctly interpret the fault symptoms covered by the diagrams, start at the "fault" field and check through the "cause" fields. Follow the arrows to the "corrective action" alternatives. When correcting identified faults, consult the appropriate section of the instruction manual for more detailed information and explanations.
18.2 Fault Crusher stops
1800-Series Hydrocone crushers
S 223.369.00 en 3 (11)
18. Fault tracing
2001-11-15
Crusher stops Cause Pinionshaft oil pump not running.
Oil too hot. Protective thermostat TG1 activated.
Corrective action Pinionshaft oil pump is interlocked with crusher drive motor. Check electric circuits and drive motor starter.
Check operation of cooling system. Check control thermostat (TG2). Check fan motor and starter. Check radiator matrix. Clean inside and outside.
Bearing failure. Crusher seized.
Check operation of protective thermostat (TG1).
Low oil pump capacity.
Clean dirt trap. If necessary, change filter(s).
V-belts slipping
Tramp metal or blockage in crushing chamber.
Check that 0.7 MPa (102 psi) safety valve does not leak oil.
Strip down crusher to inspect and replace componenets.
Check pump capacity. If necessary, change pump.
Check operation of return oil flow switch.
Check oil lines.
Check that oil does not overflow over dust collar.
Check belt tension and adjust as necessary.
Restart crusher.
Clear out crushing chamber.
Reset drive motor overload protector.
Check condition of liners.
Check operation of feed system.
Inspect return oil strainer.
1800-Series Hydrocone crushers
S 223.369.00 en 4 (11)
18. Fault tracing
2001-11-15
18.3 Crusher will not hold a constant setting Fault
Cause
Corrective action
Crusher will not hold a constant setting
Oil leak in Hydroset system
Check oil lines
Seal or replace the relevant components No
Safety valve leaks
Check if setting increase has raised oil level in Hyrdoset tank
Do pressure peaks occur?
Yes
Change safety valve.
Modify feed arrangement. Choke feed! No segregation.
Control valve leaks
Check if setting increase has raised oil tank level in Hydroset tank.
Clean or replace control valve.
Chevron packing leaks
Check if oil level has risen in lubrication oil tank.
Replace chevron packing. Inspect Hydroset cylinder bushing – replace if necessary.
Air in Hydroset system
Setting increases during crushing but returns to normal when idling.
Bleed air from system.
Check accumulator gas pressure. Replace gas bladder or complete accumulator if necessary.
Accumulator gas pressure too low
Accumulator bladder damaged.
Check if mainshaft "climbs" to metal-tometal position when crusher is idling. Inspect Hydroset oil. Nitrogen in oil gives milky white colour.
Replace gas bladder or complete accumulator.
Bleed air from system.
18.4 Fault Oil temperature too high
1800-Series Hydrocone crushers
S 223.369.00 en 5 (11)
18. Fault tracing
2001-11-15
Oil temperature too high Cause
Corrective action
Protective thermostat (TG1) activated
Check operation of cooling fan. Check fan motor and starter.
Oil cooler running continuously.
Check cooling control thermostat (TG2). Inspect radiator matrix – clean inside and outside. Check that thermostatic valve on cooler operates correctly (if fitted) Check that pressure relief valve ("by-pass") closes.
For more information, see Section 22: Operating in low temperatures.
Clean dirt trap. If necessary, change oil filter(s). Low oil flow rate.
Inspect oil lines. Check pump capacity. If necessary change pump.
Wrong oil viscosity.
Change to oil with correct viscosity, as described in Section 6: Lubrication system, to provide correct operation conditions.
Incipient bearing failure.
If measures described above do not result in a drop in temperature:
Strip down crusher for mechanical inspection. Check return oil strainer.
18.5 Fault Crusher cannot be started.
1800-Series Hydrocone crushers
S 223.369.00 en 6 (11)
18. Fault tracing
2001-11-15
Crusher cannot be started Cause
Corrective action
Oil pump not running.
Check electric circuits and starter of pump motor.
Check that oil does not overflow over dust collar. Low oil pump capacity. No "Crusher ready for start" signal.
Clean dirt trap. If necessary, change filter(s). Check pump capacity. If necessary, change pump.
Oil pump running but no "Crusher ready for start" signal is obtained.
Check oil lines.
Check pinionshaft oil pump (which is interlocked with crusher drive motor).
Check operation of return oil flow switch.
TG1 cuts out crusher drive motor. Check operation of thermostat. Check pinionshaft oil pump motor protector and the other electrical circuits.
Oil pump running and "Crusher ready for start" signal is obtained.
Check crusher drive motor's starting equipment and the other electrical circuits.
Oil does not return to the tank (in cold weather).
Start the oil pump. Let it run approx. 30 seconds. Bridge over return oil switch so that "Crusher ready for start" signal is obtained. Start crusher. Let it run approx. 20 seconds. Remove bridge over return oil switch after approx. 40 seconds. Crusher will continue to run if sufficient oil is returning to the tank. If not, return oil switch will cut out crusher drive motor again. Repeat the sequence again after a couple of minutes.
For more information, see Section 22: Operating in low temperatures.
18.6 Fault
1800-Series Hydrocone crushers
S 223.369.00 en 7 (11)
18. Fault tracing
2001-11-15
Point to watch regarding pinionshaft assembly Cause
Points to watch regarding pinionshaft assembly.
Corrective action
Check oil level. Fill to correct level.
High temperature inside and outside pinionshaft housing.
Check that pinionshaft oil pump is running and oil reaches pinionshaft housing.
Oil leaking from outer bearing cover.
Outer seal or spacer worn or O-ring damaged.
Abnormal noise from pinionshaft assembly.
Incipient bearing failure.
Vibration in crusher or pinionshaft housing.
Check V-belt pulleys. Clean off any collected dust.
Large axial bearing play.
Indicates heavy wear on rollers and races. Check frequently for increasing noise or rising temperature in pinionshaft assembly.
If the oil level keeps dropping, this can indicate a damaged inner seal. Recheck oil level.
Stop the crusher. Remove the pinionshaft assembly for inspection and, if necessary, replace bearing components.
Change oil in the pinionshaft housing (oil bath lubrication) or change oil in the tank (circulatory lubrication).
Check V-belt tension. Are V-belts flapping?
Schedule removal and bearing replacement for a convenient time.
18.7 Fault Abnormal noise in crusher.
1800-Series Hydrocone crushers
S 223.369.00 en 8 (11)
18. Fault tracing
2001-11-15
Abnormal noise in crusher Cause
Corrective action
Incorrectly fitted bevel gears.
Incorrect gear meshing or insufficient backlash can cause noise from gears. Remove pinionshaft assembly. Measure correct gasket thickness. Adjust backlash.
Heavy wear on eccentric wearing plate.
Wear on eccentric wearing plate leads to reduced backlash. Insufficient backlash can cause noise from gears. Strip down crusher and replace eccentric wearing plate. Readjust backlash.
Crushing liner(s) loose.
Check and tighten concave ring bolts.
Check if there is play between mantle and headcenter.
"Grating" step bearing.
Reduce crusher’s operating load. Extend running-in period.
Inspect return oil strainer. Check for liner ovality.
Packing in crushing chamber or liners "metal to metal".
Check operating conditions and CSS. Check for liner ovality.
Increase CSS.
Check with a feeler gauge if there is a play between the flanges. Tighten bolts.
If there is still movement between topshell and bottomshell flanges, the tapered joint needs remachining. Contact Sandvik Rock Processing.
Movement between flanges of topshell and bottomshell.
18.8 Fault Crusher's capacity drops.
1800-Series Hydrocone crushers
S 223.369.00 en 9 (11)
18. Fault tracing
2001-11-15
Crusher's capacity drops Cause
Corrective action
"Ski-slope" formed on liners.
Check the feed arrangement. Make sure the crusher is choke fed.
Check the top size separation ahead of the crusher. Is there a large proportion of material smaller than the CSS?
Extremely large play in spider bearing.
Check the play in the spider bushing. See Section 11 – Spider bearing.
If there is exceptionally large play in the spider bushing, check the condition of the eccentric bushing.
V-belts slipping.
Check the V-belt tension – tighten if necessary.
Change V-belts. Inspect the grooves of the crusher pulleys.
Feed material has been changed.
Altered material composition, fraction length and material hardness can lead to changes in capacity.
Bridging in the feed opening.
Check the material level in the feed hopper. If possible, limit the top size of the feed or change crushing chamber.
18.9 Fault Increasing bearing component wear.
1800-Series Hydrocone crushers
S 223.369.00 en 10 (11)
18. Fault tracing
2001-11-15
Increasing bearing component wear Cause
Corrective action
Contaminated oil.
Check the oil condition regularly during the first year of operation.
Change oil regularly according to results of oil condition monitoring.
Oil filter blocked.
Replace filter elements.
Dust seal ring worn or damaged.
Check play between dust collar and dust seal ring.
Over-pressure dust sealing system is not working.
Inspect entire over-pressure dust sealing system and check operation. See Section 21.
Replace dust seal ring if play exceeds the values given in Table 12.9.1.
18.10 Fault Bearing failure inside crusher.
1800-Series Hydrocone crushers
S 223.369.00 en 11 (11)
18. Fault tracing
2001-11-15
Bearing failure inside crusher Symptom
Cause
Corrective action
Mainshaft assembly rotates very fast or at same speed as eccentric.
Seizure or incipient seizure between mainshaft and eccentric bushing.
Stop the crusher. Strip down to inspect the bearing components.
Pinionshaft cannot be turned.
Seizure between eccentric and bottomshell bushing.
If possible, take out screws holding dust collar. Remove mainshaft assembly and complete eccentric assembly.
Bearing failure in pinionshaft assembly.
Increased amount of swarf on return oil strainer.
Seizure in step bearing or in bronze bushings.
Needle-like particles on return oil strainer.
Seizure or wear on gears.
Tin or lead shavings on return oil strainer.
High temperature or localized overheating and seizure in bushings or step bearing.
Remove step bearing components. De-burr edges of oil grooves, polish bearing surfaces of bushings or step bearing components. Inspect bearing surfaces of bushings.
See corrective actions listed for "oil temperature too high" – (18.4).
Hydrocone crushers
S 223.375.00 en 1 (3)
19. Backing with plastic composition
2001-11-15
19. Backing with plastic composition
Contents
Page
19.1
General
2
19.2
Backing procedure
2
19.3
Hygienic aspects
3
19.4
Protective measures
3
Hydrocone crushers
S 223.375.00 en 2 (3)
19. Backing with plastic composition
2001-11-15
19.1 General To back concaves, crushing rings, mantles and concave rings in Hydrocone crushers, use a plastic composition which meets the requirements set by Sandvik Rock Processing. Two important requirements - after complete hardening and at 20°C (68°F) - are: Compressive strength at least 110 MPa (15950 psi) Shrinkage less than 0.01%. The backing material used by Sandvik Rock Processing is of the epoxy type and handling procedures are described below. Sandvik Rock Processing urge the user to follow the safety rules and handling directions mentioned in this instruction manual and provided by the manufacturer of the plastic backing composition.
19.2 Backing procedure Mixing The plastic used to back liners is a 2-component epoxy-based composition with no solvent. The two components - the resin (component A) and the hardener (component B) - are mixed immediately before use. First, thoroughly stir component A (which may have formed a sediment) so that it is homogeneous and easy to pour. Add the hardener (component B) and then quickly and carefully mix the two components with a low-speed electric drill fitted with a mixing attachment. Make sure that no air bubbles are formed. To make mixing simpler, the two components have different colours. This makes is easy to see when complete mixing has been achieved. Use the composition immediately after mixing. Pouring The setting time varies between 7 and 24 hours, depending on the ambient temperature. When backing is carried out in cold weather the cans must be heated to approx.25°C (77°F) since the plastic will otherwise be too viscous. Do not heat the plastic composition with an open flame as this can damage the material. The components which are to be backed can be heated to 40-50°C (104-122°F), which will reduce the setting time. If the components are very cold the plastic will not set. In warm weather the cans must be protected from direct sunlight or else the composition may set too rapidly. In such conditions, keep the cans in the shade.
Hydrocone crushers
S 223.375.00 en 3 (3)
19. Backing with plastic composition
2001-11-15
Storage Unopened cans can be stored in a cool, dry place for about 12 months from the date of manufacture. If the cans are stored at a temperature below 0°C (32°F) the plastic will crystallize after a time. Heating to 60-70°C (140-158°F) for approx. 2 hours will restore the plastic to its original consistency.
19.3 Hygienic aspects Safe handling of epoxy resins and hardeners - in common with most other chemicals requires the observation of certain hygienic rules. Epoxy plastic which has set is physiologically harmless. Epoxy resin and hardener, however, can with some people cause skin irritation and allergic contact eczema. By carefully following the recommendations described in Section 19.4 below, these effects can be avoided.
19.4 Protective measures Good ventilation must be provided for the room where the plastic composition is mixed and in other affected work-places. The room where the plastic composition is mixed must be kept clean so that any spill is not spread around. Soap, water and paper towels must be available at the working place. Protect hands with P.V.C. gloves. A protective ointment should be rubbed into unprotected skin which can come into contact with epoxy products. Protective ointment can also be rubbed into the hands and wrists before the P.V.C. gloves are put on. Use protective goggles. If any splashes reach the eyes, wash them immediately with water. If irritation persists contact a doctor. If epoxy resin or hardener has come into contact with the skin, wash the affected area immediately with soap and water. Do not use a solvent. Establish whether there are any applicable National standards covering the handling and use of epoxy products. If so, follow the prescribed procedures. When removing plastic-backed components with the help of an oxy-acetylene torch or a carbon-arc cutter - as always when using a torch - take safety precautions. Work of this kind requires the use of a mask with an air filter.
S 966.001.00 en
Korrobond 65 Plastic backing material
Plastic backing material
S 966.001.00 en 1 (5)
Korrobond 65
2001-11-15
Korrobond 65 plastic backing composition
Contents
Page
1.
General
2
2.
Storage
2
3.
Handling
2
4.
Scrap
3
5.
Common misapprehensions
3
6.
Korrobond 65, label (component A)
4
7.
Korrobond 65, label (component B)
5
Encl.: Data sheet D 966.001 en Material Safety Data Sheets for Component A and Component B
1.
Plastic backing material
S 966.001.00 en 2 (5)
Korrobond 65
2001-11-15
General
Sandvik Rock Processing’s plastic backing composition – now with further reduced affect on the environment! Sandvik Rock Processing’s Korrobond 65 plastic backing composition – which is used for the installation of mantles, concaves, concave rings and filler rings – has been the subject of improvement and modification over a long period and is now the least environmentally hazardous backing composition on the market. As part of this modification process the blue pigment previously used in the hardener has been changed to a more environmentally friendly black pigment. • Epoxy resins have been available for 50 years and are used in many applications. The backing of wearing liners in crushers is only a small part of the field of use of epoxy resins. • Epoxy plastic composition has extremely good adhesion to steel and concrete. • Epoxy plastic composition has three times higher compressive strength and twenty times higher tensile strength than concrete. • Korrobond 65 is an epoxy-based backing material. • Korrobond 65 does not contain the environmentally toxic nonylphenol, which is commonly used as an additive in other epoxy-based backing materials. • Korrobond 65 has been developed to provide the correct characteristics for its application and development continues. As an example, ingredients are replaced – step by step – by others, to provide unchanged technical characteristics whilst at the same time reducing the environmental impact of the unhardened product on our environment.
2.
Storage
Korrobond 65 must be stored – in the original containers – in a cool place. The shelf-life is one year from the manufacturing date shown on the container.
3.
Handling
A common misapprehension is that a ”space suit” is needed when Korrobond 65 is mixed and poured. What is needed is a pair of overalls, plus gloves and protective glasses. Avoid bringing the mixed backing composition or the unmixed components into contact with bare skin and ensure that there is good ventilation – especially when mixing. When hardened Korrobond is burnt or ground, dangerous fumes are generated and the grinding dust can contain unhardened particles. For this reason, a breathing mask with an A2P3 filter must be used and contact with bare skin must be avoided. See also the relevant sections in our Information Manuals regarding Backing with plastic composition.
4.
Plastic backing material
S 966.001.00 en 3 (5)
Korrobond 65
2001-11-15
Scrap
Hardened Korrobond 65 does not present any significant environmental risk and can be recycled as a fill material. The hardened product can also be dumped. Unhardened Korrobond 65 must be treated as environmentally dangerous refuse and must be handled in accordance with the applicable local regulations.
5.
Common misapprehensions
Inflammable?
Wrong! Korrobond 65 can be burnt but it is not inflammable – neither as unhardened components nor as the fully hardened product.
Toxic?
Wrong! Korrobond 65 is not toxic. However, unhardened product can cause allergic reactions if sensitive skin frequently comes into contact with it.
Contains isocyanates?
Wrong! Unlike polyurethane-based backing composition, Korrobond 65 does not contain isocyanates.
Contains solvents?
Wrong! Unlike polyester-based backing composition, Korroband 65 does not contain styrene or other solvents.
Dangerous goods?
Partly wrong! Korrobond 65 component A (unhardened plastic composition) can be transported by road, sea and air without requiring special packaging. Korroband 65 component B (hardener) can be transported ”in limited quantities” by road and sea and – as “dangerous goods” – by air. This means special regulations concerning the number of cans per package, packing and marking. See also Data Sheet D 966.001 en with information on transport requirements.
Plastic backing material
S 966.001.00 en 4 (5)
Korrobond 65
2001-11-15
(Actual label size 200x140 mm)
Plastic backing material
S 966.001.00 en 5 (5)
Korrobond 65
2001-11-15
(Actual label size 155x60 mm)
Data sheet
D 966.001.00 en 1 (4)
Korrobond 65
2001-11-15
Korrobond 65 Korrobond 65 is a 2-component epoxy-based backing material for the installation of mantles, concaves, concave rings and filler rings in cone and gyratory crushers. Korrobond 65 Component A consists of a liquid epoxy resin with specially selected additives as listed in the accompanying “Material Safety Data Sheet – Component A”. (Epoxy products have been available for about 50 years and form the most versatile group of technologically advanced polymer materials. No other material has better adhesion to steel.) Korrobond 65 Component B acts as a hardener and consists of aliphatic amines, as described in the accompanying “Material Safety Data Sheet – Component B”. (The ambient temperature has a major affect on the speed at which the chemical reaction takes place. As soon as Korrobond 65 has hardened properly, its properties reach their final values.)
How much is needed? When the mantle and concave ring or concaves are to be changed at the same time in one of our crushers, the total quantity of plastic backing required lies in the range 100-500 kg, depending on the size and type of crusher and the crushing chamber fitted. The quantity of Korrobond 65 required for a liner change can be shipped by any normal form of transport, as long as the applicable transport regulations are followed. (See pages three and four.) From a weight and volume viewpoint it is Component A which forms the major part of a shipment and can set the limit for what can be shipped, for example when express delivery is necessary by air freight.
Handling the unhardened product Component A:
Epoxy resin is slightly to moderately irritating for skin, eyes and mucous membranes. The stickiness of the product can extend the time during which it is in contact with the skin. The product is mildly sensitizing (allergenic). The product is very viscous so the risk of inhalation is thus very low.
Data sheet
D 966.001.00 en 2 (4)
Korrobond 65
2001-11-15
Component B:
Aliphatic amines are strongly alkaline and are thus irritating and corrosive. The product can cause damage to skin, eyes and mucous membranes. The product can cause sensitization when inhaled.
Close fitting clothing, protective plastic gloves and protective glasses or a face mask must be used. Avoid exposing bare skin. When mixing the product, make sure that there is good ventilation and use an adjustable fume extractor.
Working with the hardened product Cutting:
Korrobond 65 contains approx. 25% of organic material. When it is burnt, various residual products are formed, depending on the air supply and the combustion temperature. Remnants of unhardened material can be encountered. Fumes from such material are dangerous and must be avoided.
Grinding:
Grinding dust can contain particles of unhardened material. These present the same risk of sensitization as when the unhardened material is handled.
Always use protective glasses and a fresh-air mask. Avoid exposing bare skin when grinding is carried out.
Handling scrapped product Unhardened product must be treated as environmentally dangerous refuse. The two Components A and B must be handled separately, in accordance with the applicable national laws and regulations. Fully hardened material constitutes an insignificant environmental hazard. The product can be disposed of in accordance with local regulations or can be recycled by fragmentation.
Environmental impact Component A:
Epoxy resins are not easily decomposed by biological action. The product can be accumulated biologically. The product is slightly toxic to aquatic organisms.
Component B:
Aliphatic amines are not easily decomposed by biological action. The product is not expected to cause biological accumulation due to a low log Pow value.
Data sheet
D 966.001.00 en 3 (4)
Korrobond 65
2001-11-15
Transporting the product Korrobond Component A is regarded as material which does not require special packing and quantities. Component A is delivered in 9.3 kg plate cans (approved by the UN), packed in boxes or shrink-wrapped, stacked on pallets. The cans are marked with a label, as shown by the sample on page 4 of Manual S 966.001 en. Korrobond 65 Component B is regarded as dangerous goods but in accordance with the applicable regulations for road and sea transport it can be sent ”in limited quantities” – i.e. as non-hazardous goods (from a documentation viewpoint) – under the conditions described below. In the case of air freight, the maximum “limited quantity” is 0.5 lit, which is less than one can and is therefore not a viable alternative for us. Component B is delivered in 0.7 kg cans (approved by the UN), marked with a label. (See example on page 5 of Manual S 966.001 en.) For Korrobond 65 Component B (hardener) the following regulations apply:
Road transport:
Packed in boxes containing max. 16 cans (11.2 liters). No limit on number of boxes per package. No limit on number of packages per shipment/order. Each box must be marked on two opposite sides with ¯. The designation UN 2735 must be written in the diamonds.
(Applies for Europe in accordance with ADR and the Baltic Treaty, with the exception of Ireland and the United Kingdom.)
Sea transport:
Packed in boxes containing max. 37 cans (29.6 kg). One (1) box per package. No limit on number of packages per shipment/order. The box/package must be marked with the text “Amines, Corrosive Liquid No. UN2735” or “Dangerous Goods in limited quantities, Class 8”. The text “Limited Quantity” must be written on the Bill of Lading.
(Applies internationally in accordance with the IMDG code.)
Air freight (passenger aircraft): Packed in boxes containing max. 7 cans (4.9 liters). One (1) box per package. No limit on number of packages per shipment/order.
Data sheet
D 966.001.00 en 4 (4)
Korrobond 65
2001-11-15
Air freight (cargo aircraft): Packed in boxes containing max. 85 cans (59.5 liters). One (1) box per package. No limit on number of packages per shipment/order.
In addition, the following applies for both passenger and cargo aircraft: Packaging alternatives • • •
Corrugated cardboard 4G Plywood 4D Timber 4C1 or 4C2.
Marking The box/package must be marked with: • The text “Polyamines, Corrosive Liquid No. UN2735”. • The name and address of the sender and the recipient. • The warning sticker “Corrosive”. • “This way up” stickers on two opposite sides. • The handling sticker “CAO”, placed alongside the warning stickers (only for transport in cargo aircraft).
Documentation DGD – “Declaration for Dangerous Goods” – must be produced in two copies and must contain the following information: • • •
Number and type of packages (e.g. “One box, fibreboard, 4G”). Gross weight of each package. The text “Polyamines, Corrosive Liquid, Class 8, No. UN 2735, PG III”.
The DGD must be signed by the sender. The declaration can never be signed by a shipping agent, operator or handling agent. The AWB (Air Way Bill) must be produced by the shipping agent.
(Applies internationally according to DGR.)
1800-Series Hydrocone crushers
S 223.408.00 en 1 (4)
21. Over-pressure dust sealing
2001-11-15
21. Over-pressure dust sealing
Contents
Page
21.1
General
2
21.2
Dust sealing principles
2
21.3
Regulator kit for compressed air
4
21.4
Blower kit
4
21.1
1800-Series Hydrocone crushers
S 223.408.00 en 2 (4)
21. Over-pressure dust sealing
2001-11-15
General
The crusher should be connected to a low-pressure air supply. This is because a slight underpressure can occur inside the crusher when aerated lubricating oil runs back to the tank. The resultant under-pressure will draw dust into the crusher and a film of dust will collect on the inside of the dust collar, at the top. See Fig. 21.2.1. The lubricating oil will transport dirt and dust around the lubrication system. This will result in rapid blockage of the filter cartridges, accelerated step bearing component wear and sedimentation in the oil tank. Of course, other components inside the crusher will also be subjected to unnecessarily heavy wear.
21.2
Dust sealing principles
The condition of the dust seal ring is of decisive importance for the function of the seal against the dust collar. A worn or oval dust seal ring gives a large gap to the dust collar and increases the possibility of dust and dirt entering the crusher. See Fig. 21.2.1. Dust
Figure 21.2.1
1800-Series Hydrocone crushers
S 223.408.00 en 3 (4)
21. Over-pressure dust sealing
2001-11-15
Measures to prevent dust entering the crusher are taken in two steps – by equalizing the pressures within the crusher and the tank unit and by creating an over-pressure inside the crusher. Pressure equalization between the crusher and the tank unit can be accomplished with a simple hose connection. A plastic hose is fitted to the T-piece mounted on the crusher, just above the pinionshaft housing. See Fig. 21.2.2.
Tank
Figure 21.2.2 The other end of the plastic hose is connected to the sleeve welded to the end wall of the tank, above the oil level. See Fig. 21.2.2.
Note!
It is important that the inspection covers on the tank unit are air tight. Adjust or replace the sealing strips as necessary.
An over-pressure is created inside the crusher either with the help of a regulator kit for compressed air or by a blower kit. See Section 21.3 and 21.4 respectively. The over-pressure prevents dust-laden air entering the crusher. The air introduced into the crusher must be free from water and dust. When the crusher is operating, the pressure at the point of entry into the crusher must be 600-1000 Pa. The over-pressure air is introduced through the same T-piece on the crusher as is used for the pressure equalization hose to the tank.
21.3
1800-Series Hydrocone crushers
S 223.408.00 en 4 (4)
21. Over-pressure dust sealing
2001-11-15
Regulator kit for compressed air
The regulator kit includes two pressure gauge connections – one for installation adjacent to the crusher and one for mounting next to the regulator. When the equipment is first installed, fit the pressure gauge to the connection adjacent to the crusher. Adjust the regulator to give the correct pressure at the entry to the crusher. Move the pressure gauge to the connection at the regulator. Read off the pressure and note it down. This pressure can then be used as a reference for future regulator adjustment. If possible, install the regulator and air filter in a heated place.
21.4
Blower kit
If compressed air is not available, a blower can be used. The capacity at 600 Pa (60 mm w.g.) must be at least 0.3m3/min (79 cu.ft./min.). Install the blower in a dust-free place. Install the blower at a level of at least 200 mm (8 ins.) above the inlet on the crusher (See Fig. 21.4.1). This is to prevent foamed oil running out to the blower if the blower stops while the crusher is running. When connecting up the blower motor, check that the direction of motion corresponds to the arrow on the blower housing. If the direction of rotation is incorrect, the output of the blower will be insufficient. The blower has an air filter with a replaceable paper element. Inspect the filter element at regular intervals and change it as necessary.
Level difference Min. 200 mm
1. 2.
Pressure gauge (0-1000 Pa) 3. 3/4" BSP T-piece 4.
3/8" BSP plug 5. 3/4" BSP sleeve 6.
Figur 21.4.1
T-piece Pressure equalization hose to tank
22.
1800-Series Hydrocone crushers
S 223.410.00 en 1 (11)
22. Operating in low temperatures
2001-11-15
Operating in low temperatures
Contents
Page
22.1
General
2
22.2
Insulation of the bottom of the component section of the oil tank unit
4
22.3
Installation of additional oil heaters
4
22.4
Diesel heating system
5
22.5
Heating cables on oil lines
5
22.6
Heater in the component section of the oil tank unit
6
22.7
Synthetic oils
6
22.8
Mineral oil for the winter season
7
22.9
A thermostatic valve to by-pass the oil cooler
7
22.10
Blanking off the oil cooler radiator
9
22.11
2-speed fan motor for oil cooler
9
22.12
Modified return oil flow switch interlock
9
22.13
Insulation of the oil tank
10
22.14
Continuous running of the lubrication oil pump
11
22.15
A heater in the Hydroset tank
11
Attached: Drg. No. 3.194.0190 en 3.194.0191 en 3.190.3592 en 3.190.3590 en
Circuit diagram – modified return oil flow switch interlock Circuit diagram – additional heaters Circuit diagram – heating cables Circuit diagram – heater for Hydroset oil
22.1
1800-Series Hydrocone crushers
S 223.410.00 en 2 (11)
22. Operating in low temperatures
2001-11-15
General
In cold weather there can be problems with starting and running the crusher since the lubricating oil becomes more viscous. There are a number of measures which can be taken to heat the oil, to conserve heat in the oil tank, to facilitate flow in the oil lines and through components, etc. These measures are described in the following sections (see Contents List on page 1). The measures which are to be taken must be judged in each individual case. Products which can be ordered from Sandvik Rock Processing: • • • • • •
Insulation of the bottom of the component section of the oil tank unit Installation of additional oil heaters Diesel heating system A thermostatic valve to ”by-pass” the oil cooler 2-speed fan motor for oil cooler A heater in the Hydroset oil tank
Other measures: • • • • • • • • •
Heating cables on the oil lines Extra heat in the component section of the tank unit Oil with lower viscosity Synthetic oils Mineral oil for the winter season Modified return oil flow switch interlock Insulation of the oil tank Continuous running of the lubrication oil pump Blanking off the oil cooler radiator
A crusher fitted with ”low temperature equipment” will normally be equipped with: • An insulated bottom in the component section of the oil tank unit • Extra heating elements • Modified oil monitor interlocks
1800-Series Hydrocone crushers
S 223.410.00 en 3 (11)
22. Operating in low temperatures
2001-11-15
Low Temperature problems- Symptoms and Remedies
Start
Oil returns to the tank but not in sufficient quantity. Wait 3-5 min. to drain the crusher and then make a new attempt to start up. yes There is a blockage in the return oil line. Clean out the blockage. If necessary, install heating cables in the return oil line. Does oil flow back to the tank?
Start the oil pump. Does the “crusher ready for start” signal appear within 40 seconds? no yes
yes
yes
yes
yes
Install a by-pass around the oil cooler with a thermostatic valve. Does oil flow back to the tank? no Install low temperature equipment in the tank. (Additional heaters, insulated tank bottom, time delay for oil monitor interlocks.) Does oil flow back to the tank? no Change to a synthetic oil. Does oil flow back to the tank? no Install heating cables on the oil lines. Does oil flow back to the tank? no
yes
Insulate the oil tank. Does oil flow back to the tank? no Sometimes it can be advisable to run the lubrication oil pump continuously to minimize starting problems.
Has the crusher started and continued to run normally? no Does the crusher stop due to interruptions in the return oil flow?
Stop the oil pump. Has oil run back through the return line to the return oil flow switch? no Has oil overflowed over the dust collar? no
yes
yes
yes
yes
During long periods with very low temperatures, the crusher should be heated during the night to avoid excessive cooling. Position a fan heater beneath the crusher and cover the feed opening. In addition, the lubrication oil pump can be run continuously. Under very low temperatures the radiator core can be “thawed out” with a fan heater.
Alt. use an ISO VG 100 oil.
yes
yes
Start crushing when the crusher has warmed up. The ambient air temperature is too low, which makes the oil cooler too effective. The oil is slowed down and blocks the passages in the radiator core! Blank off the radiator completely or partially. Start with 50% blanked off. Alt. – fit a 2-speed motor to the cooling fan.
22.2
1800-Series Hydrocone crushers
S 223.410.00 en 4 (11)
22. Operating in low temperatures
2001-11-15
Insulation of the bottom of the component section of the oil tank unit
Normally, the component section of the oil tank unit is completely open at the bottom. This is because – under most conditions – a bottom plate is unnecessary. In fact, it is usually desirable to provide good ventilation in this area so that the lubrication and Hydroset oil pump motors are properly cooled. During the winter, however, it can be desirable to keep filters and dirt traps etc. warm to reduce pressure drop in the lubrication system. Bottom plates are available for the oil tank units of H/S 2800, H/S3800, H/S 4800 and H/S 6800 crushers: Crusher
Modification kit
Tank drawing No.
H/S2800
442.6965-00
1.442.8911
H/S3800
442.6965-00
1.442.8911
H/S4800
442.9014-00
1.442.9017
H/S6800
442.9014-00
1.442.8946
22.3
Installation of additional oil heaters
In order to heat the oil to the correct temperature, it can be necessary to install extra heaters. Installation is easiest if this equipment is ordered together with a new crusher, but extra heaters can also be fitted in the tanks of older crushers. Modification kits can be ordered under the part numbers given below: H/S2800/3800 Crusher
Modification kit
Tank drawing No.
Voltage (V)
Rating (W)
Connection diagram
H/S2800
2 off 984.0607-00
1.442.8911
265/460 240/415 220/380
2x1640 2x1340 2x1125
3.194.0191
H/S3800
2 off 984.0607-00
1.442.8911
265/460 240/415 220/380
2x1640 2x1340 2x1125
3.194.0191
H/S4800
2 off 984.0605-00
1.442.9017
265/460 240/415 220/380
2x2190 2x1785 2x1500
3.194.0191
H/S6800
2 off 984.0605-00
1.442.8946
265/460 240/415 220/380
2x2190 2x1785 2x1500
3.194.0191
22.4
1800-Series Hydrocone crushers
S 223.410.00 en 5 (11)
22. Operating in low temperatures
2001-11-15
Diesel heating system
In plants where there is no electric power during the night – e.g. transportable plants with dieselgenerators – the installation of a diesel heating system can be a useful addition. With the help of a battery and a timer, the system goes into operation and starts to heat oil up to three hours before the electrical supply is available. A diesel heating system can of course be used together with electrical heating. Tank units for an H/S 2800, 3800, 4800 or 6800 crusher are prepared for diesel heating. The diesel heating system uses a 12 V DC supply. Diesel heating systems can be ordered under the part numbers given below. See also Section 24 – Optional extra equipment, S 223.411 en. Crusher
Modification kit
Tank drawing No.
H/S2800
442.9993-00
1.442.8911
H/S3800
442.9993-00
1.442.8911
H/S4800
442.9993-90
1.442.9017
H/S6800
442.9993-90
1.442.8946
22.5
Heating cables on oil lines
At low temperatures, the oil in the lines between the tank unit and the crusher can solidify and form a “plug” which interferes with the flow of oil during starting. This problem can be minimized by insulating the oil lines and installing heating cables. Before heating cables are installed, the slope of the return oil line should be increased, if it is possible. The heating cable should have a rating of 8-10 W/m and 40 mm thick insulation should be used. Install the heating cable on the underside of the oil line and use insulating tape to keep the cable in place. In the case of oil lines larger than 50 mm in diameter and when it is desired to heat the oil to a temperature 50ºC above the ambient temperature, the heating cable can be led backwards and forwards on the same line. Heating cables are in many countries considered as high voltage equipment and must therefore be installed by an authorized electrician, in compliance with the relevant regulations.
1800-Series Hydrocone crushers
S 223.410.00 en 6 (11)
22. Operating in low temperatures
2001-11-15
Heating cable is normally supplied for 230 V. It is usually most convenient to purchase the heating cable from a local supplier who can also install it. It is preferable to use a heating cable of the self-regulating type which needs no thermostat. The cable should be connected as shown in the enclosed diagram 3.190.3592.
22.6
Heater in the component section of the oil tank unit
To make it easier to start a crusher it can sometimes be advisable to provide additional heat in the component section of the oil tank unit. This heat is intended to keep oil in filters, dirt traps, valves, pumps, pipes etc. easy-flowing. Extra heat can conveniently be provided by a fan heater with a rating of about 600 W and equipped with a thermostat which prevents overheating. If maximum benefit is to be obtained from the extra heat, it is advisable also to insulate the bottom of the component section of the unit oil tank. (See Section 22.2). Since the manufacturers are always changing the fan heater models available, Sandvik Rock Processing has not prepared any modification kits with fan heaters. It is easiest for the crusher owner to select the heater which he finds most suitable. Position the fan heater so that no oil can drip onto it.
22.7
Synthetic oils
These oils are in all respects superior to mineral-based oils. The characteristics of synthetic oils can in general be described as: • Longer life, thanks to high stability which gives lower cost for oil changes. • Easier starting at low temperatures. • Lower energy consumption due to lower friction. • Wider temperature range. • Elimination of the risk of dangerous oxidation and ”coking”. In the case of a Hydrocone crusher, it could be said that if starting difficulties are experienced with mineral-based oil at -10ºC, for instance, the use of suitable synthetic oil will mean that the temperature can drop about 10ºC – i.e. to about -20ºC – before similar difficulties are experienced. The following synthetic oils can be recommended. Other brands can also be used but the selection of a suitable type must be discussed with the supplier. Supplier
Type
Min. pour point °C
Viscosity (cSt) at 40°C
Mobil oil
SHC 629
- 48
142
Nynäs
Mereta 150
- 42
150
1800-Series Hydrocone crushers
S 223.410.00 en 7 (11)
22. Operating in low temperatures
2001-11-15
The oils mentioned here can be mixed with mineral-based lubricating oils but the crusher and oil tank should be carefully emptied so that the synthetic oil is diluted as little as possible. If a change is made to synthetic lubricating oil it is also advisable to change over to a synthetic Hydroset oil. This is in order to reduce the dilution which can occur in the lubricating oil if there is any leakage past the Hydroset packing. In addition, a synthetic oil will give smoother operation than a mineral oil in valves and pipes. The oil normally used in the Hydroset system is a grade with viscosity 68 cSt at 40°C but when synthetic oil is used, a grade with a viscosity down to 30 cSt at 40°C can be selected. The following synthetic oils can be used in the Hydroset system: Supplier
Type
Min. pour point °C
Viscosity (cSt) at 40°C
Mobil oil
SHC 626
- 52
66
Mobil oil
SHC 624
- 57
31
Nynäs
Mereta 68
- 45
68
Nynäs
Mereta 32
- 54
32
Other brands can be used but the selection of a suitable type must be discussed with the supplier. Whatever the type selected, it must be possible to mix the lubricating and Hydroset oils used in the crusher.
22.8
Mineral oil for the winter season
In low ambient temperatures – below 0ºC – an ISO VG 100 oil can be used (See SA 3067, 110-AB). It is vital that thermostats TG1 and TG2 are set in accordance with the recommendations given in Section 6.14 “Operation in low temperatures” with an ISO VG 100 oil.
22.9
A thermostatic valve to by-pass the oil cooler
Operation of the thermostatic valve When a crusher is started up with cold oil, the largest single cause of pressure drop is the air/oil heat exchanger. This pressure drop can be minimized with the help of a thermostatic valve. See Fig. 22.9.2. The thermostatic valve is mounted on the oil cooler and operates in such way that as long as the oil temperature is below 35ºC, the oil goes from port 1 to port 2 inside the valve, and port 3 is closed. From port 2, the oil flows through an external line to the cooler’s outlet manifold. It passes
1800-Series Hydrocone crushers
S 223.410.00 en 8 (11)
22. Operating in low temperatures
2001-11-15
through the manifold and flows to the crusher. When it passes through the cooler’s outlet manifold, the oil gives up some of its heat energy to the cooler which is thus warmed up. This results in a lower pressure drop across the cooler when the thermostatic valve gives free passage from port 1 to port 3, as described below. When the oil temperature rises above 35ºC, the thermostatic valve starts to allow some of the oil to go to the cooler through port 3. At an oil temperature of 45ºC the ”by-pass” line (port 2) is completely closed off and all of the oil goes through the cooler. Thermostat and mounting kit Table 22.9.1 Crusher
Cooler
Mounting kit
Part No.
Designation
Part. No.
H/S2800/3800
910.0101-00
995011 A0
442.9845-00
H/S4800
910.0102-00
994303 A3
442.9844-00
H/S6800
910.0103-00
995012 A0
442.9842-00
The thermostatic valve is mounted on the cooler as shown in fig. 22.9.2.
Inlet manifold
Outlet manifold
From oil tank
To crusher via tank Figure 22.9.2
1800-Series Hydrocone crushers
S 223.410.00 en 9 (11)
22. Operating in low temperatures
2001-11-15
22.10 Blanking off the oil cooler radiator When the oil temperature rises so high that the cooling fan starts, it can happen that the cooling is too effective. The pressure drop across the cooler rises so high that the pressure relief valve ahead of the cooler opens. If this happens, the oil is not cooled at all – it can be too hot even though the ambient temperature is low. The easiest way to avoid stoppages of this kind is to blank off the radiator so that a smaller mass of air is passed through the radiator core. The degree of blanking must be determined by trial-and-error in each individual case. At present no blanking kit is available.
22.11 2-speed fan motor for oil cooler Compared to the method described in Section 22.10 above, a more sophisticated way of reducing the air flow through the radiator is to use a 2-speed motor on the cooling fan. The fan starts at low speed at a certain temperature. If this provides sufficient cooling - i.e. the oil temperature does not rise further - the fan continues to run at low speed as long as cooling is required. If, on the other hand, the oil temperature rises further, the fan switches to high speed at a pre-set temperature. Table 22.11.1 gives examples of suitable switching points if an ISO VG 150 oil is used.
Rising oil temperature
Falling oil temperature
Return oil temperature
Cooling fan
43°C
The fan starts at low speed
43-46°C
Runs at low speed
Over 46°C
Runs at high speed
Over 43°C
Runs at high speed
43-40°C
Runs at low speed
40°C
The fan stops
For more information, contact Sandvik Rock Processing.
22.12 Modified return oil flow switch interlock When the crusher is to be started it can sometimes be useful to by-pass the return oil flow switch interlock for a short period during the starting phase. The crusher motor can then be started without the return oil flow switch interlock giving a “crusher ready for start” signal. With the crusher in motion the oil is effectively heated by friction so that it becomes easier for the oil to pass through the bearings and other restricted passages. This results in higher oil flow through the crusher.
1800-Series Hydrocone crushers
S 223.410.00 en 10 (11)
22. Operating in low temperatures
2001-11-15
Technically this is arranged in such a way that the lubrication oil pump is started and run for a pre-set time, for example 20 seconds. When this time has elapsed, a new time period is started. During this second period, the ”crusher ready for start” signal is given and the return oil flow switch interlock is by-passed. This second period can also be around 20 seconds, for example, and during this time the crusher motor can be started. If oil reaches the return oil flow switch before this second period has expired, the crusher will continue to run. If oil has not reached the return oil switch within this time, the crusher motor will stop. A new start attempt should not be made until the oil which has been pumped into the crusher has run back to the tank. If a new start attempt is made prematurely, there is a risk that the crusher becomes over-filled with oil. Oil will overflow over the dust collar inside the crusher and drop down onto the discharge conveyor. The components needed for this interlock by-pass can be obtained from Sandvik Rock Processing. It is usually most convenient if a local electrician installs the components although Sandvik Rock Processing can of course do the job if required. Crusher
Connection diagram
H/S2800/3800
3.194.0190
H/S4800/6800
3.194.0190
22.13 Insulation of the oil tank In order to heat the oil to the correct temperature during the winter, it can be advisable to insulate the tank. This means that it will be easier to start the crusher after a cold night since the oil temperature is higher than it would be if the tank were not insulated. When the ambient temperature rises (i.e. when the winter gives way to spring) it may be necessary to remove the insulation if the cooling capacity of the system is insufficient. Sandvik Rock Processing does not have standard off-the-shell insulation kits. Insulation can easily be installed by the plant personnel. A suitable material is Rockwool 1330-00, 50 mm thick. The insulation material must be protected from moisture, as it will otherwise lose its insulating properties.
1800-Series Hydrocone crushers
S 223.410.00 en 11 (11)
22. Operating in low temperatures
2001-11-15
22.14 Continuous running of the lubrication oil pump During cold weather it may be difficult to start the crusher since oil has solidified in the oil lines and in the crusher itself. This can be avoided or minimized if the oil pump is allowed to run continuously during the time when the crusher is standing still. The heaters in the oil tank must be switched on and the crusher’s feed opening must be covered over to avoid excessive cooling by cold air passing freely through the crushing chamber. If this is allowed to happen, the heating power installed in the tank will probably be insufficient.
22.15 A heater in the Hydroset tank In our combined lubrication and Hydroset oil tank units, the Hydroset oil has no heating element but is instead heated indirectly by the lubricating oil. Under extreme conditions it can be desirable to install a heating element in the Hydroset oil tank section as well. Crusher
Modification kit
Voltage (V)
Rating (W)
Connection diagram
H/S2800/3800
442.8462-00
220/380
225
3.190.3590
H/S4800/6800
442.8463-00
220/380
670
3.190.3590
Since there is not much space in the component section of the oil tank, the heating element in these modification kits has had to be positioned on the back of the tank unit. This means that space is required behind the tank (approx. 200 mm). The thermostat, which is mounted in the element itself, is set at 25ºC. This is a sufficiently high temperature for the oil to pass easily through the control valve etc. In addition, this reduces the time the element is switched on and reduces “coking”.
1800-Series Hydrocone crushers
S 223.366.00 en 1 (1)
24. Extra equipment
2001-11-15
24. Extra equipment To simplify and improve the operation of our cone and gyratory crushers when they are used under special conditions, we have developed a range of optional extra equipment. This equipment is described in a number of Instruction Manuals / Spare Parts Lists / Drawings, as described below. These publications can be ordered from Sandvik Rock Processing.
1.
Diesel heating system
S 223.411 en
2.
Level monitor(s) in feed hopper Type Telco (for one level) Type Telco, Triple (for three levels)
4.190.3874 3.194.0104
The design of the equipment and its availability can vary between different crusher models. To order any of this equipment, contact Sandvik Rock Processing.
Försäkran om överensstämmelse Declaration of Conformity
S 058.039.01
1 (1)
2002-08-20
Försäkran om överensstämmelse Declaration of Conformity Konformitätserklärung Certificat de conformité
Declaración de conformidad Assicurazione di conformità Verklaring van overeenstemming Forsikring om overensstemmelse
Forsikring om overensstemmelse Atestado de concordância Yhdenmukaisuusvakuutus
Kross typ: Crusher type: Brecher Typ: Type de concasseur:
Tipo de triturador: Tipo di frantumatrice: Breker, type: Knuseværkstype:
Knuse-type: Tipo de trituradora: Murskain tyyppi:
Hydrocone
S2800:1 H2800:1
S3800:1 H3800:1
S4800:1, S4800:2 H4800:1, H4800:2
S6800:1 H6800:1
(sv) Vi försäkrar att produkten som omfattas av denna försäkran är i överensstämmelse med följande direktiv och harmoniserade standarder:
(es) Garantizamos que el producto objeto de esta declaración cumple las disposiciones de las directivas y normas armonizadas siguientes:
(no)
Vi forsikrer at produktet som omfattes av denne forsikring er i overensstemmelse med følgende direktiver og harmoniserende standarder:
(en) We declare that the product to which this declaration relates is in conformity with the following standards and normative documents:
(it)
(pt)
Para os devidos efeitos, declaramos que o produto abrangido por este atestado está de acordo com as directivas e padrões harmonizados seguintes:
(de) Wir bescheinigen, dass das Produkt, auf das sich diese Erklärung bezieht, mit folgenden Direktiven und harmonisierenden Normen übereinstimmt:
(nl) Wij garanderen dat het product waarvoor deze verklaring geldt in overeenstemming is met de volgende richtlijnen en geharmoniseerde normen:
(fi)
Vakuutamme että kone, jota tämä vakuutus koskee, on yhdenmukainen seuraavien normien ja ohjeellisten asiakirjojen kanssa:
(fr)
(da) Vi forsikrer hermed, at dette produkt, som omfattes af denne forsikring, er i overensstemmelse med følgende direktiver og harmoniserede standarder:
Nous garantissons que le produit faisant l’objet du présent certificat est conforme à la directive suivante et aux normes qui lui sont relatives:
Assicuriamo che il prodotto contemplato da questa assicurazione è conforme alle direttive seguenti e alle norme armonizzate.
93/68/EEC
Direktivet om CE-märkning Directive on CE-marking Direktive hinsichtlich CE-Kennzeichnung Directive sur le marquage CE
Directiva de certificación CE Direttiva sui contrassegni CE Richtlijn voor CE-merk Direktivet om CE-mærkning
Direktivet om CE-merking Directiva sobre a gravação de CE CE-merkinnän direktiivi
98/37/EG
Maskindirektivet Machinery Directive Maschinendirektive Directive sur les machines
Directiva sobre maquinaria Direttiva per le macchine Machinerichtlijn Maskindirektivet
Maskindirektivet Directiva sobre máquinas Konedirektiivi
89/336/EEC EN 50081-2 EN 50082-2 EN 60439-1-am11
EMC-direktivet EMC Directive EMC-Direktive Directive EMC
Directiva EMC Direttiva EMC EMC-richtlijn EMC-direktivet
EMC-direktivet Directiva EMC EMC direktiivi
73/23/EEC EN 60439-1 EN 60204-1
Lågspänningsdirektivet Low-voltage Directive Niederspannungsdirektive Directive sur les basses tensiones
Directiva sobre baja tensión Direttiva per la bassa tensione Richtlijn voor laagspanningsinstallaties Lavspændingsdirektivet
Lavspenningsdirektivet Directiva sobre baixa tensão Pienjännite direktiivi
Anders Nilsson Konstruktionschef Engineering Manager Konstruktionsleiter Directeur de la construction
Director de diseño Direttore tecnico Chef constructie Konstruktionschef
Konstruksjonsjef O chefe de construção Suunnittelupäällikkö
Sandvik SRP AB SE-233 81 SVEDALA, Sweden
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