06.CH660-03 Installation Instructions S223.1048-02 en

Original instructions
S 223.1048 - 2 en-US
18/06/2015 13:08:06
Installation Instructions
CH660:03
This publication is copyright of Sandvik – © Sandvik 2014.
It must not be copied*, reproduced or otherwise made available in full or in part to any third party
without Sandvik's prior written consent.
All rights reserved.
* The maintenance checklists in the Maintenance Instructions and Operator's Instructions may be
copied solely for maintenance purposes of Sandvik equipment.
Document number: S 223.1048

Version: 2
Language: en-US
Issue: 18/06/2015
Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
WARNING!
IGNORING INSTRUCTIONS HAZARD
Lack of knowledge can lead to risky situations.
Read and understand the information in the manual. If anything is

unclear, please contact Sandvik. Keep this publication for future
reference.
Copyright © Sandvik
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Table of contents
1. Installation preparations
1.1. General preparations................................................................... 10
1.2. Machine access........................................................................... 10
1.3. Crusher capacity and performance..............................................10
1.4. Installation preparations checklist................................................ 11
1.5. Placement....................................................................................12
1.5.1. Height differentiation in the return line............................. 12
1.5.2. Maximum allowed pressure in pressure line.................... 13
1.6. Foundation...................................................................................14
1.6.1. Foundation loads..............................................................15
1.6.2. Natural frequencies.......................................................... 15
1.6.3. Movement of the crusher................................................. 15
1.6.4. Using an existing concrete foundation............................. 16
1.6.5. Using a steel supporting structure....................................16
1.7. Installation alternatives................................................................ 17
1.7.1. Installation packages........................................................18
1.7.2. Direct drive installation package...................................... 18
1.7.3. V-belt drive installation package.......................................18
1.7.4. Rubber dampers.............................................................. 19
1.7.5. Crusher mounting feet......................................................20
1.8. Crusher arrangement...................................................................21
1.8.1. Electrical installation - general......................................... 21
1.8.2. Remote control system (option)....................................... 21
1.9. Process material.......................................................................... 21
1.9.1. Dust protection................................................................. 21
1.9.2. Feed arrangement............................................................21
1.9.3. Feed arrangements for fine crushing............................... 23
1.9.4. Discharge arrangement....................................................24
1.9.5. Guards............................................................................. 25
1.9.6. Platforms and guard rails................................................. 25
1.10. Operating in low temperatures...................................................26
1.10.1. Measures for easier starting and running in cold climate
................................................................................................... 26
1.10.2. Low temperature problems - symptoms and remedies...
27
1.10.3. Heater set - cold climate................................................ 28
1.10.4. Diesel heating system.................................................... 29
1.10.5. Heating cables on oil line............................................... 29
1.10.6. Heating in the component section..................................30
1.10.7. Synthetic oils.................................................................. 30
1.10.8. Mineral oil for the winter season.................................... 31
1.10.9. Blanking off the oil cooler radiator..................................31
1.10.10. Frequency converter.................................................... 31
1.10.11. Two-speed fan motor for oil cooler............................... 31
1.10.12. Insulation of the oil tank............................................... 32
1.10.13. Continuous running of the lubrication oil pump............ 32
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Table of contents
2. Transport handling
2.1. Goods data.................................................................................. 34
2.1.1. Contents...........................................................................34
2.1.2. Loading and unloading goods signs.................................34
2.2. Lifting equipment......................................................................... 35
2.3. Overhead gantry or mobile crane................................................ 35
2.4. Fork lift......................................................................................... 36
2.5. Unpacking area............................................................................37
2.6. Inspection of goods......................................................................37
2.7. Moving and storage..................................................................... 37
2.7.1. Moving..............................................................................38
2.7.2. Storage of a non-assembled crusher............................... 38
2.7.3. Pre-delivery rust prevention treatment............................. 39
2.8. Unpacking the goods................................................................... 39
2.9. Disposal/return of packaging material......................................... 40
3. Mechanical installations and connections

3.1. General requirements.................................................................. 42
3.2. Crusher on a subframe with rubber dampers.............................. 42
3.3. Crusher on a concrete foundation – fixed installation..................45
3.4. Crusher with rubber dampers on a steel supporting structure.....45
3.5. Motor and direct drive.................................................................. 46
3.6. Motor and V-belt drive..................................................................46
3.7. Installing the feed hopper............................................................ 46
3.8. Overpressure system...................................................................47
3.8.1. Installing the overpressure system...................................48
3.9. Water/oil cooler temperature switch settings............................... 49
3.10. Platforms....................................................................................49
3.11. Lubricants.................................................................................. 49
3.12. Hydroset and lubrication systems..............................................50
3.13. Pipes and hoses - General........................................................ 50
3.13.1. Connections................................................................... 51
3.13.2. Oil tank unit.................................................................... 52
3.13.3. Air/oil cooler................................................................... 53
3.13.4. Water/oil cooler (option)................................................. 54
4. Electrical installations
4.1. General requirements – Electricians............................................58
4.2. The electrical system................................................................... 58
4.3. Motors, pumps, and heating elements.........................................58
4.3.1. M1 – Crusher motor......................................................... 58
4.3.2. M2 - Lubrication oil pump.................................................59
4.3.3. M3 - Oil cooler fan motor..................................................59
4.3.4. M6 - Hydroset pump.........................................................59
4.3.5. E7 - Oil heaters................................................................ 59
4.3.6. M8 - Overpressure fan..................................................... 60
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Table of contents
4.3.7. M9 - Pinionshaft oil pump.................................................60

4.4. TIMS (option)............................................................................... 60
4.4.1. TIMS installation (options)................................................60
4.4.1.1. General description TIMS.................................... 60
4.4.1.2. TIMS input........................................................... 61
4.4.1.3. TIMS input (external)........................................... 64
4.4.1.4. TIMS output for normal signals............................64
4.4.1.5. Alarms..................................................................66
4.4.1.6. TIMS output for fault signals................................ 67
4.4.1.7. TIMS programs.................................................... 68
4.4.1.8. Control logic TIMS............................................... 69
4.4.1.9. Communication....................................................71
4.4.2. L-boxes............................................................................ 72
4.4.2.1. L11 connection box.............................................. 72
4.4.2.2. L12 box - auxiliary motors starting.......................72
5. Final installation checks

5.1. Installation and connection checks.............................................. 76
5.2. Lubrication system and Hydroset checks.................................... 76
5.3. Electrical checks.......................................................................... 76
5.4. Checking the pressure drop indicators (PS2, PS3)..................... 76
5.5. Safety checks.............................................................................. 78
5.6. Start-up........................................................................................ 78
6. Preparations for commissioning

6.1. General........................................................................................ 80
6.2. General checks............................................................................80
6.3. Supply value checks.................................................................... 80
6.4. Function checks – Preparation.................................................... 80
6.5. Health and safety checks.............................................................81
6.6. Documentation.............................................................................81
7. Disassembly and removal

7.1. Moving the cone crusher............................................................. 84
7.1.1. Short moves and short-term storage................................84
7.1.2. Long moves and long-term storage................................. 85
7.1.3. Draining procedure...........................................................85
7.2. Storage of an assembled crusher................................................85
7.3. Regular inspection during storage............................................... 86
7.4. Return to the manufacturer..........................................................87
7.5. Disposal....................................................................................... 87
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Table of contents
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1.1. General preparations

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

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

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

• Choice of eccentric throw
• Feed size distribution and moisture
• Feed rate
• Discharge system design
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• Screening capacity
• Automation controls (options), both ASRi and main control system for
the crushing plant
The following factors are very likely to lower the capacity and
performance of a cone crusher:
• Adhesive or moist process material

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

Signature
Placement Site access checked for cone crusher
and oil tank unit dimensions?
Smallest area through which the cone
crusher components must pass?
(W × H) ____ x ____
Available service space? ____ x ____ x
(L × W × H) ____
Available lifting device on site? Type:
Length of oil hoses and pipes?
Length of V-belts (if applicable)?
Foundation Foundation constructed according to
drawings?
Electrical system All necessary cables arranged to the
crusher and the oil tank unit?
Cable lengths?
All necessary switchgear installed?
All necessary connections to plant control
system arranged?
Electrical power available?
Process material Process material tested by Sandvik?
Dust protection Dust protection complies with local
regulations?
Feed arrangement Feed arrangement designed correctly?
Discharge Discharge arrangement is ready to be
connected to outlet of the crusher?
Guards Need for additional guards?
Platforms and Comply with local regulations? Designed
guard rails so that they do not interfere with the
crusher’s or tank unit's function?
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1.5. Placement
Sandvik recommends:
• marking with paint the limits of service areas in the vicinity of the
crusher and the oil tank unit.
• fencing in the site to avoid damage and unauthorized operation, if
applicable.
Make sure that there is easy access to the crusher. A well planned
installation will result in better overall performance of the cone crusher,
easier service, and lower down-time.
NOTE! The oil tank unit can be installed on any side of the crusher. This is
important to decide before the foundation is designed. Refer to the
installation drawings in the Mechanical Drawings.
Place the tank unit as close to the cone crusher as possible.
Excessively long oil lines as well as many or sharp bends will increase
the flow friction and lower the performance.
Place the tank unit below the level of the cone crusher. Return oil must
run back to the oil tank unit and be pumped to the cone crusher.
Make sure that there is sufficient room to drain out all oil.
Make sure there is access to a lifting device meeting the requirements
stated in chapter Transport handling on page 33.
Consider additional clearance for the feed arrangement (for example
chute, feeder or other equipment).
Consider additional clearance for the discharge arrangement, see
section Discharge arrangement on page 24.
Consider the placement of the motor for a crusher with V-belts. There
are several possible installation arrangements for a crusher with V-belt
drive. If the optional Sandvik motor bracket is used, ensure that the
motor is correctly positioned and aligned.
1.5.1. Height differentiation in the return line

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

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

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

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

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

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

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

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

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

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

10 × 90° bends R=2×D 10 × 1.02 = + 10.2 psi
13 ft height difference 13 × 0.44 = + 5.72 psi
Pressure build-up in oil line = 76.19 psi
Crusher minimum oil pressure + 43.51 psi
Minimum required pump pressure 119.7 psi
The required pump pressure will be approximately 123 psi.
1.6. Foundation
The crusher equipment must have a stable, adequately dimensioned
foundation. A well designed and level foundation is of the utmost
importance for the successful operation of the crusher equipment. The
foundation can be either a cast concrete foundation or a steel
supporting structure.
The design and construction of the concrete foundation or steel
supporting structure must be undertaken by qualified and experienced
personnel
NOTE! The concrete foundation or steel supporting structure must be designed
and constructed in accordance with the applicable national and local
engineering regulations and building codes, etc.
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The foundation must be designed to accommodate the static and

dynamic loads generated by the crusher, with an adequate safety factor.
Refer to the Technical Specifications.
Anchor plates and foundation bolts must be sufficiently strong and must
be well anchored.
NOTE! Anchor plates and foundation bolts for casting into the concrete
foundation are not included in the delivery.
The foundation must be constructed to accurate dimensions. The
crusher's mounting points must be level, that is, max ±1 mm (±0.04")
deviation at load application points.
NOTE! It is important to decide on the placement of the drive motor and the oil
tank unit before the foundation is designed. The oil tank unit can be
installed on either side of the crusher. For a crusher with a V-belt drive it
is possible to install the motor on either side of the crusher. This is done
by changing the placement of the mounting feet on the crusher, see
section Crusher mounting feet on page 20.
For general information on placement, see section Placement on page
12. Contact Sandvik to discuss any questions about the way in which
you plan to install the crusher.
1.6.1. Foundation loads

Refer to the Mechanical Drawings for information on the static and
dynamic forces transmitted to the foundation via the crusher's mounting
points. The information about dynamic loads applies for the crusher's
maximum eccentric throw.
1.6.2. Natural frequencies

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

If the crusher is mounted on rubber dampers, it will oscillate horizontally
up to ± 15 mm (±0.6") during normal operation. During starting and
stopping the movement is greater – up to ± 50 mm (±2"). Make sure
that there is room for the crusher's movement all around.
If the crusher is mounted on rubber dampers, the sub-frame or motor
bracket, the motor and the drive assembly will move with the crusher.
Provide sufficient space all around the sub-frame or motor bracket, the
motor and the drive assembly.
The feed hopper is bolted to the crusher's topshell and thus moves with
the crusher. Do not attach any chute or conveyor to the feed hopper, as
this would subject the crusher and the other attachment points to
abnormal loads.
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Hoses and cables attached to the crusher and motor will also move.
Provide adequate space for this movement and protect hoses and
cables from falling stones and dust.
1.6.4. Using an existing concrete foundation

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

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

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

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

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

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

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

(see section Crusher with rubber dampers on a steel supporting
structure on page 45.
NOTE! If the crusher is mounted on rubber dampers it will gyrate
(see section Movement of the crusher on page 15). If the
motor is fixed to the foundation, there will be relative
movement between the crusher and the motor. This normally
means that a V-belt drive will be used in such a case. If so,
make sure that the center line of the motor's shaft is within
15° of the vertical plane through the center line of the
crusher's pinionshaft. Otherwise there is a major risk of
problems with the V-belt drive.
Sandvik recommends that the motor is mounted on a frame, similar to
the arrangement used in Sandvik's standard V-belt drive installation
package. See section V-belt drive installation package on page 18.
NOTE! As the motor is installed directly on the foundation, there is no machined
structure (sub-frame or motor bracket) between the motor and the
crusher. It is therefore important that the alignment of the motor is very
carefully checked.
Other installation arrangements are possible, to suit the individual
requirements of the plant in question. Please contact Sandvik to discuss
the way in which you intend to install your equipment.
1.7.1. Installation packages

The installation components supplied by Sandvik depend on what has
been ordered in each individual case. Sandvik offers two different
installation packages, one with a direct drive and one with a V-belt drive.
Drive alternatives vary depending on crusher model.
1.7.2. Direct drive installation package

The crusher is bolted to a sub-frame constructed of steel sections. The
motor is also mounted on the sub-frame. Between the motor and the
crusher there is a flexible coupling and a torque-limiting coupling. This
arrangement makes it easy to keep the motor, drive and crusher in the
correct alignment. Refer to the Mechanical Drawings and Motor and
direct drive on page 46 for more details of the direct drive installation.
The sub-frame is supported by rubber dampers, fixed on the foundation.
1.7.3. V-belt drive installation package

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

To reduce the stresses in the concrete foundation or steel supporting
structure, it is advisable to install the crusher on anti-vibration
compression mountings which absorb the vibrations generated when
the equipment is running.
Crushing hazard
If the crusher is mounted on rubber dampers, there is a risk
of crushing fingers etc. when the machine is running,
WARNING! especially when starting and stopping.
Make sure that there is room for the crusher's horizontal
movement. Information on this movement is given on the
installation drawing.
Following rubber dampers are used:
• Dampers (Type A) are used on the sub-frame beneath the crusher,

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

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

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

Make sure all local requirements are fulfilled, also the ones that are site
specific.
NOTE! The crusher must be installed in such a way that it can be operated as a
standalone unit during maintenance sessions. Secure that any power
shutdown related to crusher activity does not interfere with other site-
critical operations.
External cables, disconnecting switches and fuses must be ordered
before installation. See chapter Electrical installations on page 57 for
further information. Contact Sandvik for further information about the
cables, switches and fuses.
1.8.2. Remote control system (option)

At most sites a main control system is used to control the process. Has
the main control system been prepared for the addition of the
equipment?
1.9. Process material

Sandvik recommends the prior testing of the quality of the material that
is to be processed with the cone crusher. Process material wears the
cone crusher and the adjacent equipment in varying ways. Sandvik can
assist with such testing.
1.9.1. Dust protection

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

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

• The material is evenly distributed around the crushing chamber
• The material fed to the crusher is not segregated
However, it is important to design the infeed so that the construction is
removable to facilitate easy maintenance of the equipment. The cone
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crusher can be delivered with a feed hopper and without a distributor to

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

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

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

Fine crushing gives rise to the highest loads on the crusher. To obtain
correct feeding, always use a splitter for feed sizes up to 80 mm (3.1")
This part is not included in the normal scope of supply from Sandvik.
The splitter prevents segregation and also distributes the material
evenly around the crushing chamber.
For installation dimensions of the feed hopper, see the installation
drawing.
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NOTE! The topshell arms must be correctly oriented relative to the splitter and
the material must not be segmented to the sides.
The material must be led into the splitter through the area highlighted in
the drawing. This area can normally be adjusted. The duty of the splitter
is to split up the material stream into equal parts on either side of the
topshell spider arms.
Feed arrangements with EC or C crushing chamber

To prevent damage to the crusher and/or unnecessary wear on the
spider cap and arm liners, the feed to the crusher must be arranged so
that the material falls onto a “stone box” before it enters the crusher.
This reduces the drop height and speed of the material, particularly
important with EC or C crushing chambers that are fed with relatively
coarse material. The “stone box” contributes to a reduction of
segregation.
When processing coarse material, keep the level of material in the feed
hopper a little lower than normal to prevent bridging.
Contact Sandvik for advise on design of feed arrangements.
1.9.4. Discharge arrangement

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

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

the foundation forms two sides of the discharge
Crusher mounted on a concrete foundation or hopper. The two remaining sides and the hopper
steel supporting structure with discharge hole bottom are attached to anchor plates cast into
in floor. Openings are blanked off. the foundation.
1.9.5. Guards
All moving and rotating parts on the machine must be covered with
guards. The belt drive and coupling or direct drive coupling must be
equipped with guards. The oil tank unit has only one moving part, the
pump P1 of the pump motor M2.
Conveyors and feed arrangements always present a potential risk of
falling process material. Design overhead conveyors and feed
arrangement so that guards protect walkways and platforms from falling
process material.
1.9.6. Platforms and guard rails

All equipment need inspection and maintenance. It is important to
design suitable platforms for this purpose. The standard scope of supply
for a cone crusher from Sandvik does not include platforms and guard
rails.
A well-designed platform never relies on the cone crusher for support as
vibrations and movement of the crusher make it unsuitable. The floor of
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the platform should preferably be “solid” (instead of wire mesh) to avoid

the risk of falling tools or equipment accidentally falling and hitting
someone below. Use kicking boards and wire mesh on the sides under
the handrails for the same reason.
NOTE! Never use conveyors as walkways. Always design walkways along the
conveyors with guard rails, and ensure sufficient carrying capacity to
meet local rules and legislation. Take into account the build-up of stone
and dust, as well as the weight of tools and parts for service work. Make
sure overloading is not possible.
1.10. Operating in low temperatures

The cone crusher's oil tank unit needs special preparations for reliable
operation in low temperatures. The following section describes
recommended methods.
The accompanying flow chart Low temperature problems – symptoms
and remedies on page 27 can be used to determine which method to
use.
NOTE! If it is difficult to start the crusher even when the appropriate
recommendations have been followed, contact Sandvik for further
assistance.
1.10.1. Measures for easier starting and running in cold

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

• Additional oil heaters
• Diesel heating system
• Heating in the component section of the oil tank unit
• Synthetic oils
• Mineral oil for the winter season
• Blanking off the oil cooler radiator
• Two-speed fan motor for oil cooler
• Insulation of the oil tank
• Continuous running of the lubrication oil pump
A cone crusher that is fitted with “low temperature equipment” will
normally be equipped with:
• Additional oil heaters

• Insulated bottom in the component section of the oil tank unit
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1.10.2. Low temperature problems - symptoms and

remedies
1. Start the oil 2. Yes: Has 4. Yes: Start

pump. Does the crusher crushing when the
the “Crusher started and crusher has warmed
ready for start” continued to up.
signal appear run normally?
5. No: Does the 8. Yes: The ambient air
within 40 s?
crusher stop due to temperature is too low, which
interruptions in makes the oil cooler too
return oil flow? efficient. The oil is slowed down
and blocks the passage in the
radiator coil. Blank off the
radiator completely or partially.
Start with 50% blanked off.
Alternatively, fit a 2-speed
motor to the cooling fan.
3. No: Stop the 6. Yes: Oil returns to
oil pump. Has the tank, but not in
oil run back sufficient quantity.
through the oil Wait 3.5 min. to
line to the drain the crusher
return oil flow and then make a
switch? new attempt to start
up.
7. No: Has oil 9. Yes: During long periods with
overflowed the dust very low temperatures, the
collar? crusher should be heated
during the night to avoid
excessive cooling. Position a
fan heater beneath the crusher
and cover the feed opening. In
addition, the lubrication oil
pump should run continuously.
10. Yes: There is a blockage in
the return oil line. Clean out the
blockage. If necessary, install
heating cables on the return oil
line. Does the oil flow back to
the tank?
11. No: Install low temperature See
equipment in the tank (heating boxes
in the component section and 12 and
insulated tank bottom). Does 13 on
the oil flow back to the tank? next
page
Continued 12. Yes: Under very low

from last temperatures the radiator coil
page can be "thawed out" with a fan
heater.
Yes: See box 6.
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13. No: Change to synthetic 14. Yes: See box

oil (alternatively, use an ISO 6.
VG100 oil).
15. No: Install 16. Yes: See
Does the oil flow back to the
heating cables box 6.
tank?
on the oil lines.
17. No: 18. Yes: See box
Does the oil flow
Insulate the 6.
back to the
oil tank. Does
tank? 19. No:
the oil flow
Sometimes it
back to the
can be advisable
tank?
to run the
lubrication oil
pump
continuously to
minimize starting
problems.
1.10.3. Heater set - cold climate

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.
The component section of the oil tank unit is normally open at the
bottom to provide good ventilation and cooling of the oil pumps. In a
cold climate it might be necessary to insulate the tank to keep the oil at
working temperature and prevent pressure drop.
1 2 3 1
1 Heater element - cold climate

2 Cable set - cold climate (concealed)
3 Insulation
Modification kit Description Voltage (V) Rating (W) Connection

diagram
452.5261 Heaters and insulation for
a cold climate
Position number
1 Insulation
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Modification kit Description Voltage (V) Rating (W) Connection

diagram
2 Heater element 400 2×1700 291.0054
(2 x) 460 2×2200
525 2×1700
575 2x2000
3 Cable set - cold climate
1.10.4. Diesel heating system

In plants without 24-hour electrical power, a timer-controlled diesel
heating system can be used. The system starts heating the oil up to
three hours before electrical power is available.
The tank unit is prepared for diesel heating.
The diesel heating system uses a 12 V DC supply.
Modification kit
452.5389
1.10.5. Heating cables on oil line

Refer to the installation drawings in Mechanical drawings.
At low temperatures, the oil in the lines between the tank unit and the
crusher can solidify and block the lines. This problem can be minimized
by insulating the oil lines and installing heating cables.
It is preferable to use a heating cable of the self-regulating type which
needs no thermostat. The heating cable should have a rating of 8-10 W/
mand 40 mm (1.6") insulation.
Install the heating cable on the underside of the oil line and use
insulating tape to keep the cable in place. If possible, increase the slope
of the return oil line before installing heating cables.
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If the oil lines are more than 50 mm (2") in diameter, or if the oil needs
to be heated to a temperature of 50 ºC (122 ºF) above the ambient
temperature, the heating cable can be led backwards and forwards on
the same line.
Heating cables are in many countries considered as high voltage
equipment and must therefore be installed by an authorized electrician.
The heating cable can be purchased from a local supplier who can
usually also install it. Heating cable is normally supplied for 230 V.
1.10.6. Heating in the component section

Extra heating in the tank unit can be provided by a standard fan heater
with a rating of about 600 W. The fan heater must have a thermostat
which prevents overheating.
Risk of equipment or property damage
NOTICE Position the fan heater so that oil cannot drip onto it.
Sandvik does not supply modification kits with fan heaters. Select a
suitable fan heater from any supplier.
1.10.7. Synthetic oils

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

• Easier starting at low temperature
• Lower energy consumption due to lower friction
• Wider temperature range
• No oxidation and “coking”
The synthetic oil shall meet the same requirements as for mineral oil.
For further information about lubricant requirements, refer to the
Technical specifications.
The following synthetic oils are recommended by Sandvik for the
lubricating system. Other brands can be used after consulting the
supplier.
Brand Type Minimum pour point Viscosity (cSt) at 40 °C

Mobil oil SHC XMP 150 -48 °C 150
The recommended synthetic oils can be mixed with mineral-based oils,

but should be diluted as little as possible.
NOTE! Empty the crusher and oil tank carefully before refilling with synthetic oil.
To reduce the risk of dilution of a synthetic lubricating oil, the Hydroset
oil should also be synthetic. A grade with a viscosity down to 30 cSt at
40 °C can be selected for the Hydroset system.
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NOTICE It must be possible to mix the lubricating and Hydroset oils
used in the crusher. Consult the oil supplier if in doubt.
The following synthetic oils are recommended by Sandvik for the

Hydroset system. Other brands can be used after consulting the
supplier.
Brand Type Minimum pour point Viscosity (cSt) at 40 °C

Mobil oil SHC 626 -51 °C 68
1.10.8. Mineral oil for the winter season

In ambient temperatures below 0 ºC, an ISO VG 100 oil can be used,
refer to section Lubrications systems in the Technical Specifications.
1.10.9. Blanking off the oil cooler radiator

If the cooling fan is started at a low ambient temperature, the pressure
drop across the cooler will cause the by-pass valve CV4 on the cooler
to open. The oil is then not sufficiently cooled, and can overheat.
The easiest way to avoid this is to blank off the radiator so that less air
passes through the radiator matrix. The degree of blanking depends on
the ambient temperature and must be determined by trial-and-error.
1.10.10. Frequency converter

Another way to reduce the air flow through the radiator is to use a
frequency converter for the oil cooling fan.
Frequency converters are not supplied by Sandvik.
1.10.11. Two-speed fan motor for oil cooler

Another way to reduce the air flow through the radiator is to use a two-
speed motor on the cooling fan. The speed of the cooling fan is
determined by the oil temperature in the return line.
Examples of switching points with ISO VG 150 oil:
Return oil temperature Cooling fan

Rising oil temperature 43 °C (109 °F) The fan starts at low speed
43–46 °C (109-115 °F) Runs at low speed
Over 46 °C (115 °F) Runs at high speed
Falling oil temperature Over 43 °C (109 °F) Runs at high speed
43–40 °C (109-104 °F) Runs at low speed
40 °C (104 °F) The fan stops
Two-speed motors are not supplied by Sandvik.
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1.10.12. Insulation of the oil tank

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

pump
Running the oil pump continuously while the cone crusher is stopped
will prevent the oil from solidifying in the lines and crusher.
Leave the oil tank heaters switched on. Cover the crusher’s feed
opening to prevent excessive cooling by cold air passing through the
crusher chamber.
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2.1. Goods data

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

L x W x H (")
Cone crusher No 26600 kg (58643 lbs) 2 850 mm (112.2") × 2 440 mm (96.1") × 3
430 mm (135.0")
Tool box etc. No 650 kg (1433 lbs) 1 170 mm (46.1") × 1 170 mm (46.1") × 920 mm
(36.3")
Feed hopper No 1400 kg (3087 lbs) 2 450 mm (96.5") × 2 200 mm (86.6") × 1
250 mm (49.2")
Feed hopper No N/A N/A
cone
ASRi Yes 60 kg (133 lbs) 800 mm (31.5") × 600 mm (23.6") × 620 mm
(24.4")
Frame Yes 1700 kg (3448 lbs) 2 800 mm (110.2") × 800 mm (31.5") × 450 mm
(17.7")
Motor Yes 1900 kg (4189 lbs) 1 750 mm (68.9") × 1 050 mm (41.3") × 1
400 mm (55.1")
Motor frame Yes 550 kg (1213 lbs) 2 800 mm (110.3") × 800 mm (31.5") × 900 mm
(35.4")
Tank
Part name Mass kg (lbs) Measurements

L x W x H (")
Tank unit 800 kg (1764 lbs) 1 870 mm (73.6") × 1 420 mm (55.9") × 1 360 mm (53.5")
Heat exchanger 235 kg (518 lbs) 1 170 mm (46.1") × 1 170 mm (46.1") × 920 mm (36.3")
2.1.1. Contents
A Package Inventory List is attached to one of the packages in the
delivery.
NOTE! If the equipment is collected from the factory, check before
transport that the equipment corresponds with the items in the
Package Inventory List.
If the equipment is delivered by Sandvik to a harbor or to the
site, check immediately after arrival that the equipment
corresponds with the items in the Package Inventory List, and
that the equipment is not damaged in any way.
2.1.2. Loading and unloading goods signs

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

Make sure that the lifting equipment and the lifting capacities of the
equipment and tackle comply with the value given in the table:
NOTE! The lifting capacity of a mobile crane varies with the lifting radius. Make
sure that the lifting capacity is sufficient at the appropriate lifting radius.
Recommended Equipment and tackle Nominal load to be lifted

Overhead gantry 26300 kg (57982 lbs)
Mobile crane
Lifting chains, cables, ropes or slings
Fork lift (only for goods on pallet/platform)
2.3. Overhead gantry or mobile crane

Suspended load hazard
Check the gross weight of the components to be
lifted. Incorrect lifting methods may result in serious
WARNING! injuries or even death.
Handle the component with care. Stand clear of
suspended loads.
The following instructions apply to this crusher equipment.

a) Make sure that the lifting chains, hooks and other equipment are in
a good state and attended to according to instructions from the
manufacturer.
b) Make sure that the lifting chains have the correct lengths for the
angle from the vertical at which they are to be used.
c) Make sure that the lifting equipment has a sufficient SWL (Safe
Working Load) for the weight to be lifted and the method of lifting
the crusher.
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d) Follow the applicable lifting standard for the equipment used.

e) Place the lifting equipment according to the symbols found in
section Loading and unloading goods signs on page 34.
f) Check that the load lies against the saddles of the hooks. Never
put load on the tip of a hook.
g) Slowly take up the slack in the lifting gear. Make sure that the
hooks are secure in the lifting eyes of the component. If necessary,
adjust the gear to distribute the load evenly.
h) Check that the chains/lifting gear can straighten out correctly.
Never lift with a twisted chain.
i) Make sure that the destination is clear and able to support the
weight before lifting.
j) Lift, move and lower the load carefully and calmly. Avoid sudden
movements.
k) Never try to use hands or feet to guide the load. Keep clear of the
load.
2.4. Fork lift

Check the gross weight of the components to be
lifted. Incorrect lifting methods may result in serious
Handle the component with care. Stand clear of
suspended loads.

Always use the lifting eyes mounted on the top of the
oil tank unit and a suitable lifting equipment when
WARNING! lifting the oil tank unit without pallet/platform. Handle
the oil tank unit with care. Stand clear of suspended
loads.
The oil tank unit must be placed on a pallet/platform when lifted with a
fork lift.
The following instructions apply to this crusher equipment.
a) Make sure that the forks are of the correct length and lifting
capacity for the crusher component on its transport platform.
b) Set the lifting forks to the correct width for lifting the load from the
side.
c) Make sure that the load is firmly attached to the transport platform.
d) If the transport platform of the component is fitted with fork tubes,
manoeuver the forks inside these to lift the component.
e) Make sure that the destination is clear and able to support the
weight before lifting.
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f) Lift and move the load carefully and calmly.

g) Lower the load gently to the floor.
2.5. Unpacking area

The required unpacking area for the different machine variants should
ideally have the approximate dimensions given below.
Installation area required L × W × H

4.8×18×4.4 m (15.7×59.1×14.4 ft)
Allow an extra space as specified below for installation of the oil tank.
Installation area required L × W × H

5×4.5×3 m (20×15×10 ft)
These dimensions allow about 1.0 m (3.3 ft) of free space around and
above the cone crusher parts.
2.6. Inspection of goods

Please inspect the outside of the packages before starting to unload.
Report any damage to the person responsible for the installation of the
crusher. If the damage is severe and prevents the parts from being
installed, submit a damage claim to the transport company directly
without delay. Document the damage with a camera.
NOTE! If any damage has occurred during transport to the installation site,
please also report this immediately to Sandvik’s shipping department.
The address can be found on the Package Inventory List.
2.7. Moving and storage

Important notes
If the crusher components must be stored before installation, make sure
that the storage area meets the requirements given in section Storage
of a non-assembled crusher on page 38.
If installation starts immediately, check whether it is possible to move
the crusher components to the installation site/unit. Unpacking and
installation can be performed together.
When moving the crusher components to the installation site/unit,
deposit them so that they can be lifted out and positioned without being
turned around.
Wait until installation can start before unpacking the crusher
components.
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2.7.1. Moving
a) Lift the crusher component only enough to clear the floor and as
instructed above, see section Lifting equipment on page 35
A cone crusher weighs up to
26300 kg (57982 lbs)
WARNING! Handle the cone crusher with care. Stand clear
of suspended loads.
b) Make sure that the load remains stable on the lifting equipment.
c) Move the crusher component to the assembly destination.
d) Lower the crusher component gently to the floor. Leave enough
room for access to all sides.
e) Make sure that the crusher components are firmly supported.
f) Remove the lifting equipment.
g) Remove any screws holding the transport platform to the crusher
component.
2.7.2. Storage of a non-assembled crusher

Risk of damage to equipment
Sandvik recommends storing the crusher
NOTICE components indoors. Exposure to moisture or too
high or too low temperatures may damage the cone
crusher if it is stored for a longer time.
NOTE! For an assembled crusher see section Storage of an assembled

crusher on page 85.
a) Make sure that the storage area is sufficient for access.
b) Make sure that the indoor storage environment meets the
conditions given in the table below.
Characteristic Value Notes

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

is uneven, place blocks or plates under the crusher components to
provide steady support.
d) Make sure that the crusher component is stable and remove the
lifting equipment.
e) Inspect the rust prevention treatment and touch-up or repeat the
treatment if necessary.
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f) Fasten the lifting eye bolt on the top end of the mainshaft. Lift the
mainshaft assembly out of its transport frame and put it down on
wooden blocks placed beneath the lifting eye and the lower edge
of the mantle. Avoid contact with the bearing surfaces on the two
ends of the mainshaft.
g) Inspect the stored components regularly and check that the rust
prevention film is intact and that the components have not been
damaged.
h) Cover the crusher components with tarpaulins if they are stored
outdoors.
NOTE! Store seals and gaskets in a dark, dust-free, dry place.
Keep them in their packaging until they are required. Never
tie seals with steel wire or hang them on nails or pins
during storage. Rubber components must be stored free
from any stresses in order to avoid cracking and
deformation.
2.7.3. Pre-delivery rust prevention treatment

Before delivery from the factory, the crusher and oil tank unit are treated
with rust preventatives sufficient for approximately 30 days of transport
and storage. The internal bearing surfaces of the crusher are covered
with oil and then sealed off from the outside environment. In special
cases, additional rust prevention treatment can be specified in the order.
2.8. Unpacking the goods

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

from the equipment delivery.
c) Inspect the crusher components for damage.
d) Inspect the crusher’s accessories for damage.
e) Open the boxes containing smaller components and inspect these
for damage.
f) Open the tool box and locate the Package Inventory List for the
contents.
g) Check the contents of the tool box.
h) Check that the data on the identification plate corresponds with the
data given in the Package Inventory List.
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i) Store the additional spare and wear parts in the allocated

depository.
j) If needed, send a transport damage report to Sandvik
NOTE! If possible, document any damage with a camera.
2.9. Disposal/return of packaging material

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

connections
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3.1. General requirements

Contact Sandvik to discuss any questions you may have regarding your
installation plan for the crusher equipment.
Personnel
Only qualified installation personnel are authorized to install the crusher
equipment. Refer to Personnel in the Safety and environmental
instructions
The installation area
a) Clear the installation site. If necessary, clean the ground before
starting the installation.
b) Make sure that there is sufficient room to move safely around the
installation. If any adjacent machines on the site cannot be stopped,
take measures to prevent accidental contact.
c) Make sure that lighting is adequate and arrange additional portable
lights if necessary.
Lifting equipment, tools and materials
Packing
Leave wrapping and ties on the parts until they are ready for use.
Leave the plastic plugs in the oil hose connections until they are ready
to be connected, but make sure to remove them before connecting the
hoses.
Installation sequence
The sequence that should be followed when the equipment is to be
installed is determined by the relevant installation alternative.
In these Installation instructions, detailed assembly sequence
instructions are given for the two installation alternatives that are
described above, that is, the Sandvik standard direct drive installation
package or standard V-belt drive installation package.
3.2. Crusher on a subframe with rubber

dampers
See installation drawings in the Mechanical drawings
452.4448 for direct drive
452.4447 for V-belt drive
Preparatory checks
Check that the foundation matches the dimensions given on the
installation drawing, refer to Mechanical Drawings.
Make sure that anchor plates are provided in the correct positions – and
at the correct levels – for the two larger (Type A) rubber dampers
beneath the sub-frame (below the crusher) and the four smaller rubber
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dampers (Type B) beneath the motor end of the sub-frame. See the
installation drawing for more details.
The maximum deviation is ±1 mm (±0.04") at each load application
point. If the deviation is >1 mm (>0.04"), use shims to level.
Installation sequence
a) Carefully clean any dust and oil from the area where the crusher is
to be installed.
b) Place the six rubber dampers on the foundation, see section
Rubber dampers on page 19. Make sure that the upper and lower
fixing plates (4), (8), and (9,) are attached.
c) Turn the rubber dampers to the positions shown on the installation
drawing.
d) Tack weld the six lower fixing plates (4), (8) to the anchor plates on
the foundation.
e) Lower the sub-frame into position on the rubber dampers.
f) Spot weld the six upper fixing plates (9) to the sub-frame.
g) Remove the screws and washers (2), (3), (6) and (7) and then lift
the sub-frame away from the foundation.
h) Remove the six rubber dampers (1), (5).
i) Turn the sub-frame over and weld all around the six upper fixing
plates (9).
j) Weld all around the six lower fixing plates (4), (8) to the anchor
plates in the foundation.
k) Put the six rubber dampers back into position on top of the lower
fixing plates (4), (8) and fit the lower screws (2), (6) and the
washers (3), (7).
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l) Reinstall the sub-frame and fit the upper screws (2), (6) and
washers (3), (7).
11, 12
A1 14
2, 3
15
A2
B 6, 7,10
7, 16
Type A1 Fitted to crusher mounting foot

Type A2 Fitted to sub-frame
2 Screw
3 Washer
9 Upper fixing plate
11 Washer
12 Locking nut
14 Crusher mounting foot
15 Sub-frame
Type B Fitted to sub-frame or motor bracket

6 Screw
7 Washer
10 Locking nut
16 Screw
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m) Lower the bottomshell onto the sub-frame.
V-belt Direct drive
NOTE! Make sure that the pinionshaft is pointing in the correct

direction.
n) Tighten the screws at the connection points between the
bottomshell and the sub-frame.
Tightening torque:
2 800 Nm (2 065 ft lbs)
For information about the installation of the motor and the direct
drive or V-belt drive, see section Motor and direct drive on page
46 or Motor and V-belt drive on page 46.
3.3. Crusher on a concrete foundation –

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

supporting structure
Refer to the corresponding installation drawing in the Mechanical
drawings.
Assuming that rubber dampers are used, the installation of a crusher on
a steel supporting structure follows – in principle – the sequence
described for installation on a concrete foundation, although it must be
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tailored to the design of the structure in question. You should therefore

draw up a new installation sequence, using the directions given in the
relevant parts of the instructions above for the installation of a crusher
on a new concrete foundation.
See section Crusher with V-belt/direct drive and rubber dampers, on a
concrete foundation on page 42.
3.5. Motor and direct drive

Install direct drive motor
Refer to the Maintenance instructions section Installing the direct drive
motor for further information.
Safeset coupling
Refer to the Maintenance instructions section Safeset coupling for
further information.
Flexible coupling
Refer to the Maintenance instructions section Assembly procedure for
flexible coupling for further information.
Speed monitor for direct drive
Refer to the Maintenance instructions section Speed monitor for direct
drive for further information.
Drive guard
Refer to the Maintenance instructions section Drive guard for further
information.
3.6. Motor and V-belt drive

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

Install the feed hopper according to the illustration. The process
material (arrow) must enter aligned with the spider arm.
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a) Arrange the lifting equipment.

b) Put lifting hooks to the lifting eyes (1).
c) Carefully lift the feed hopper (2) onto the rim of the topshell.
A feed hopper weighs up to 2200 kg (4851 lbs).
Incorrect lifting methods can result in serious
Handle the feed hopper with care. Stand clear of
suspended loads.
d) Install the screws, washers and lock nuts (3, 4, 5) to attach it to the
topshell.
3, 4, 5
1 Lifting eye
2 Feed hopper (lower)
3 Screw
4 Washers
5 Lock nut
3.8. Overpressure system

The cone crusher and the oil tank unit are equipped with a common
overpressure system to exclude dust from the equipment. A correctly
functioning overpressure system is important for the performance of the
crusher.
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For further information refer to the Installation Instructions and the

Mechanical Drawings.
3.8.1. Installing the overpressure system

For installation drawings, refer to the Mechanical Drawings.
NOTE! Hoses, pipes and pipe fittings are not supplied by Sandvik.
Minimum and maximum length of hoses 2-15 m (7-50 ft)

Minimum and maximum pressure 600-1000 Pa (0.087-0.0145 psi)
Minimum blower capacity 0.3 m3 (793 US gall./min)
The length of the hoses depends on the position of the air supplier and
the tank.
a) Install the overpressure system:
• Install the overpressure system (overpressure fan or regulator
for compressed air) or at least 0.5 m (20") above the tank and
the pinionshaft to prevent oil from running into them.
• The overpressure fan can be mounted horizontally or
vertically. When the fan motor is connected, check that the
direction of rotation is the same as shown by the arrow on the
fan housing. If the rotation isn’t correct, the output of the fan
will be insufficient.
• The regulator FV6 with filter unit FU6 must be mounted
horizontally and if possible, installed in a heated space.
It is important to install the fan in a dust free
NOTICE environment. Dust will damage the blower and
result in malfunction of the equipment
b) Measure the hose length between the air supplier’s coupling (2)
and the T-connection C on the pinionshaft.
c) Cut the appropriate length from the hose coil supplied with the oil
tank unit.
d) Connect one hose (1) between the air supplier’s coupling (2) and
the T-connection C on the pinionshaft housing. Use hose clamps.
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1 C C
FU6
FV6 2 1 C
1 Hoses
2 Coupling to the air supplier
C Coupling to the pinionshaft housing
FU6 Filter to air regulator
FV6 Compressed air regulator
3.9. Water/oil cooler temperature switch

settings
RISK OF EQUIPMENT OR PROPERTY DAMAGE
Incorrect settings can damage the equipment.
If a water/oil cooler is used, set the temperature switches
NOTICE L1-TS1, L1-TS2 and TS3 to the values given for “normal
operating conditions”, whatever the ambient air temperature
is. Refer to the Technical specifications.
3.10. Platforms
Sandvik recommends installing platforms so they are located at least
50 mm (2") away from the crusher to avoid contact. Allowance must be
made for this. When the crusher is mounted on rubber compression
mountings there is a risk of pinching between the oscillating parts of the
crusher and the stationary structure. During normal operation the
crusher will oscillate horizontally up to ±15 mm (±0.6"). During starting
and stopping the movement is greater, up to ±50 mm (±2").
See section Platforms and guard rails on page 25 for further
information.
3.11. Lubricants
Fill the required amounts of oil into the tanks.
For further information, refer to the Technical specifications.
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Keep some extra oil within easy reach. It may be necessary to add
some oil after start-up due to the length of the hoses.
3.12. Hydroset and lubrication systems

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

NOTE! Pipes are not supplied by Sandvik.
Route all pipes and hoses to and from the crusher along the same path.
All pipes and hoses to and from the crusher must be carefully sealed
and tightened to avoid leakage and prevent the pipes and hoses to
come loose from the connections.
The inclination of return lines is critical. Refer to Oil tank unit on page
52.
For a description of hoses, pipes and connections on the tank unit and
crusher, refer to the installation drawing in Mechanical drawings.
NOTE! When starting the pumps the first time, make sure that there are
no leakages. If there are leakages, use a suitable sealing
compound.
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3.13.1. Connections
P L N Q
J V 1
U
U
V
O U
Connections and Description Note

drainage
1 Earth terminal Earth connection
J Water to cooler Water/oil cooler (option)
L Oil from crusher (main and Main lubrication tank
pinionshaft)
N Oil to and from crusher Hydroset tank
O Water from cooler Water/oil cooler (option)
P Overpressure air From T-connection on pinionshaft
housing to tank
Q Oil from tank to crusher To pinionshaft housing
U Oil from tank to cooler (main) Air/oil cooler and water/oil cooler
(option)
V Oil from cooler to crusher (main) Air/oil cooler and water/oil cooler
(option)
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3.13.2. Oil tank unit

a) Install the tank unit in a suitable location, see section Placement on
page 12.
1 1
1 Lifting lug

An oil tank unit without cooler weighs up to
685 kg (1511 lbs)
WARNING! Handle the oil tank unit with care. Stand clear of
suspended loads.
b) Connect the oil lines to the tank unit, refer to the installation
drawings in Mechanical Drawings.
NOTE! The connections are already fitted to the crusher. Pipes
and pipe fittings are not supplied by Sandvik.
• Make sure that there are no kinks in the return oil hoses and
pipes.
• Avoid pipe elbows. Use large-radius pipe bends instead to
reduce resistance in the piping.
• Run the piping so that it is protected from falling stones.
• Make sure that the piping is securely supported to avoid
vibration.
• Make sure that the piping is free from burrs, metal shavings
and dirt before it is connected to the crusher and tank unit.
• Use normal oil piping and hoses for lubrication oil lines.
c) Inspect and clean the lubrication oil tank.
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d) Connect the Hydroset oil line to the oil tank unit with high-pressure
piping or hoses with minimum pressure rating 8 MPa (1160 psi).
• Make sure that there are no kinks in the oil hoses/pipes.
• If pipes are used, avoid pipe elbows. Use large-radius pipe
bends instead to reduce resistance in the piping.
• Run the piping so that it is protected from falling stones.
• Make sure that the piping is securely supported to avoid
vibration.
• Make sure that the piping is free from burrs, metal shavings
and dirt before it is connected to the crusher and tank unit.
e) Inspect and clean the Hydroset tank.
3.13.3. Air/oil cooler

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

NOTICE The air must pass through the cooler's matrix.
1 Air flow direction
The cooler and the piping must be shielded from direct sunlight.
The air/oil cooler can be installed directly on the oil tank unit or in a
suitable place close to it. Piping and hoses can be used to connect to
the oil tank unit. Hoses must always be fitted to the cooler.
If the ambient air contains a lot of dust, it is advisable to lead fresh air to
the cooler through a duct from a dust-free place. The duct must be
correctly dimensioned so that air flow is not restricted, and it must not
be rigidly connected to the air/oil cooler.
To reduce the amount of dust which settles in the radiator matrix, the
air/oil cooler is best placed so that the fan blows towards the crusher.
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The by-pass valve (CV4) is fitted on the air/oil cooler. It decreases the
pressure drop over the cooler if the crusher is started at low
temperatures.
NOTE! Pipes and pipe fittings are not supplied by Sandvik.

a) Install the air/oil cooler on or close to the oil tank unit.
b) Connect the hoses to the cooler.
c) Connect piping or hoses to the tank unit.
CV4
CV4 By-pass valve
3.13.4. Water/oil cooler (option)

Refer to the installation drawing in the Mechanical drawings.
NOTE! Pipes, water pump and pipe fittings are not supplied by Sandvik.
a) Connect water piping or hoses to the cooler. This must be
arranged at the site to suit local conditions.
Risk of property or equipment damage
NOTICE Use clean fresh water. If only contaminated
water is available, contact Sandvik first.
b) Set the temperature switches TS1, TS2 and TS3 to the correct
value, see the Technical specifications.
The supply of cooling water is controlled by thermostat
valve TS4.The values on its scale correspond to the following oil
temperatures:
Risk of property or equipment damage
Incorrect settings can damage the equipment.
If a water/oil cooler is used, set the temperature
NOTICE switches TS1, TS2 and TS3 to the values given
for “normal operating conditions”, whatever the
ambient air temperature is. Refer to the
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c) Set the thermostat valve TS4 to “3” on the scale to keep the oil at
43 °C (109 °F).
Value on scale Oil temperature

1 25 °C (77 °F)
2 32 °C (90 °F)
3 43 °C (109 °F)
4 57 °C (135 °F)
5 65 °C (149 °F)
TS2 TS4 TS4
J V
O U
J Water in
O Water out
U Oil from tank
V Oil to crusher
TS2 Temperature switch - return oil
TS4 Thermostat valve
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4.1. General requirements – Electricians

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

The purpose of the electrical system is to power the crusher with its
auxiliary systems and to control the aspects of the operation of the
crusher that are not controlled by the ASRi (option). See the ASRi
documentation for further information on the ASRi installation.
The crusher must be interlocked with the surrounding equipment.
Complete electrical drawings are collected in Electrical documentation
for the crusher and for the tank unit. External cables, disconnecting
switches and fuses must be ordered before installation. Contact
Sandvik for further information about cables, switches and fuses.
Connections for pump motors and other equipment are routed through
the connection box CB9 (LC10 for TIMS, option) on the oil tank unit.
The air/oil cooler fan and over pressure air fan motors are connected
directly.
4.3. Motors, pumps, and heating elements

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

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

• Electronic soft starter
NOTE! The crusher drive motor’s (M1) relay must be interlocked with the
lubrication oil pump motor M2, so that it is only possible to run the
crusher when the lubrication pump M2 is in operation.
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4.3.2. M2 - Lubrication oil pump

Risk of equipment or property damage.
The crusher drive motor’s (M1) relay must be interlocked with
NOTICE the lubrication oil M2, so that it is only possible to run the
crusher when the lubrication pumpM2 is in operation.
TIMS (option)
Risk of equipment or property damage.
The M2 relay must be interlocked so that it is only possible to
NOTICE run the lubrication oil pump when the “Lubrication oil pump
ready for start” signal from the TIMS is present.
4.3.3. M3 - Oil cooler fan motor

Every crusher has an air/oil cooler or water/oil (option) cooler in the
lubrication system. The temperature is controlled by the temperature
switch TS2. For further information about the temperature switches,
refer to the Technical specifications.
With a water/oil cooler it can be convenient to open/close the cooling
water supply with a magnetic valve.
TIMS (option)
The cooling fan motor is controlled by the temperature sensors TT1 and
TT4 that generates the “Cooling fan on/off” signals from the TIMS.
If a water/oil heat exchanger is used, it can be convenient to open/close
the cooling water supply with a solenoid valve controlled by the
temperature transmitter TT5 that generates the “Cooling fan on/off”
signals.
NOTE! When the air/oil or water/oil cooler is in operation, the “Cooling fan in
operation” signal must be sent to the TIMS.
4.3.4. M6 - Hydroset pump

Starting and control equipment for the Hydroset pump is normally
delivered by Sandvik included in the ASRi system. The delivered
electrical cabinet L3 contains a fuse, a relay and a motor protection for
operation of the Hydroset pump.
Refer to the ASRi manuals.
4.3.5. E7 - Oil heaters

The temperature switch TS3 controls the heaters.
TIMS (options)
The lubrication oil heaters must be controlled by the temperature
sensor TS3 that generates the “Oil heating on/off” signals from the
TIMS.
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4.3.6. M8 - Overpressure fan

TIMS (option)
The overpressure fan motor must be controlled by the pressure
transmitter PT1that sends the “Over pressure fan on/off” signals to the
TIMS.
4.3.7. M9 - Pinionshaft oil pump

The pinionshaft oil pump (M9) must be interlocked with the
NOTICE lubrication oil pump (M2) so that it is only possible to run the
pinionshaft oil pump (M9) when the lubrication oil pump (M2)
is running.
TIMS (option)
The pinionshaft lubrication oil pump motor is controlled by the pressure
transmitter PT3 that sends the “Lubrication oil pump pinionshaft on/off”
signals to the TIMS.
NOTE! When the pinionshaft lubrication pump is in operation, the “Pinionshaft
lubrication oil pump in operation” signal must be sent to the TIMS.
4.4. TIMS (option)

The overall control logic for the oil tank unit is provided by the Tank
Instrumentation Monitoring System (TIMS), see section TIMS
installation (options) on page 60. Connections to the TIMS are made
to the connection box LC10 mounted on the oil tank unit.
To provide galvanic separation between the TIMS and the customer’s
electrical system, the relay box LC10.2 must be used. This relay box is
supplied with the TIMS.
Alternative to relay box LC10.2
Use a bus communication between the TIMS system and the customer
overview control system.
4.4.1. TIMS installation (options)

4.4.1.1. General description TIMS
The Tank Instrumentation Monitoring System, TIMS, is an option that
provides the control logic necessary for the proper operation of the
lubrication and overpressure air systems.
TIMS can be connected to the plant control system via hard-wired
digital inputs and outputs or via Profinet. It receives input signals from
sensors and transmitters in the lubrication and overpressure air
systems. The system monitors the values, compares them with set-
points in the TIMS program, and sends the appropriate output signals to
the plant control system.
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The functions monitored by TIMS are:
• Inlet and return oil temperatures (main lubrication)

• Inlet and return oil flows (main lubrication)
• Lubrication oil pressure (main lubrication)
• Lubrication oil pressure (pinionshaft lubrication)
• Differential pressure across filter (main lubrication)
• Differential pressure across filter (pinionshaft lubrication)
• Oil level in tank (main lubrication)
• Pressure in over pressure dust sealing system (crusher)
• Temperature of oil in tank (main lubrication)
• Temperature close to spider bushing (crusher)
• Temperature of oil at cooler outlet
The TIMS outputs are used to control the oil heaters, the lubrication oil
pump, the over pressure fans, the pinionshaft lubrication oil pump, the
air/oil or water/oil cooler, and to give a signal permitting operation of the
crusher drive motor.
The TIMS unit is built into an encapsulated box LC10 mounted on the
outside of the oil tank unit. The plant control system can be connected
to LC10 or LC10.2, refer to the Mechanical Drawings.
There are three other connection boxes:
• LC9, to which the various power cables are connected to the motors
inside the oil tank unit.
• ASR-CBT, to which all connections in the tank unit for the ASRi
system are made.
• LC10.2, which contains relays for galvanic separation between the
TIMS system and the customer’s electrical system.
PT1 is connected to the TIMS, but the two relays for the level
transmitter LT2 and the speed switch SS1 shall be connected directly to
the customer’s control system.
For further information, refer to the connection and circuit diagrams in
the Mechanical drawings.
4.4.1.2. TIMS input
Temperature sensor TT1
Type: PT100 transducer

Location: In the return oil entry box in the lubrication oil tank
Measuring function: Temperature of the lubrication oil returning from the crusher
Control function 1: Protective thermostat. If the main lubrication return oil temperature rises
above the maximum permissible value, the drive motor will stop.
Control function 2: Oil cooling thermostat. Controls either the cooling fan (air/oil cooler) or the
cooling water magnetic valve (water/oil cooler).
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Location: On the inner wall of the lubrication oil tank, near the bottom
Measuring function: Temperature of oil in the lubrication oil tank
Control function : Controls the contactor for the oil heaters.

Location: In the main lubrication oil line to the crusher, after the air/oil or the water/oil
cooler
Measuring function: Temperature of the main lubrication oil to the crusher (after cooling)
Control function : Controls that the Oil cooling system functions correctly

Location: In the spider hub on the cone crusher
Measuring Temperature in the spider bearing
function:
Control Protective thermostat.
function : If the temperature rises above limit value 1 (60 °C/140 °F), a B-alarm is initiated.
The B-alarm can be reset if the temperature is below 55 °C/131 °F. If the
temperature continues to rise and reaches limit value 2 (65 °C/149 °F)), an A-
alarm is initiated and the crusher’s drive motor will stop. The A-alarm can be
reset if the temperature is below 60 °C/140 °F.
Oil flow monitor FT4
Type: Digital transducer

Location: In the main lubrication oil line to the crusher, before the air/oil or water/oil
cooler
Measuring Flow rate of the main lubrication oil to the crusher
function:
Control function : Stops the crusher drive motor if the main lubrication oil flow rate drops below
minimum value 60 l/min (2.12 ft³/min).
Oil flow rate Transducer signal

10-250 l/min (0.35–8.83 ft³/min) 4-20 mA
Pressure transducer PT2
Type: Analog pressure transducer

Location: In the oil tank unit, between the lubrication oil pump M2 and the main oil filter
unit FU1
Measuring Main lubrication oil pressure, ahead of the main filter unit FU1
function:
Control function 1: Stops the lubrication oil pump motor M2 if the oil pressure rises above 1.5
MPa (218 psi).
Control function 2: If the oil pressure difference between PT2 and PT4 exceeds 0.22 MPa (36
psi), a B-alarm is initiated and the “Filter blocked FU1/M2” LED is lit.
Oil pressure Transducer signal

0–1.6 MPa (0–232 psi) 4-20 mA
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Location: In the oil tank unit, between the pinionshaft lubrication oil pump M9 and the
filter unit FU2
Measuring Pinionshaft lubrication oil pressure, ahead of the lubrication filter unit FU2
function:
Control function If the oil pressure is below 0.19 MPa (28 psi) for at least 1 minute, a B-alarm
1: is initiated. If the pressure is still below the limit after 1 hour, an A-alarm is
initiated and the drive motor is stopped.
Control function If the pressure exceeds 0.45 MPa (65 psi), a B-alarm is initiated and the
2: “Filter blocked FU2/M9” LED is lit.

0–1.6 MPa (0–232 psi) 4-20 mA

Location: In the main lubrication oil line, on the outlet side of the main filter unit FU1
Measuring Main lubrication oil pressure between the main oil filter unitFU1 and the air/oil
function: or the water/oil cooler
Control If the oil pressure difference between PT2 and PT4 exceeds 0.22 MPa (36
function : psi), a B-alarm is initiated and the “Filter blocked FU1/M2” LED is lit.

0–1.6 MPa (0–232 psi) 4-20 mA
Level sensor LT1
Type: Analog level transducer

Location: In the lubrication oil tank
Measuring function: Oil level in the main lubrication oil tank
Control function : If the oil level drops below the minimum value 320 mm (12.6"), a B-alarm is
initiated.
Relative level Transducer signal

35–790 mm (1.4–31.1") 4-20 mA
Overpressure transmitter PT1

Location: In the LC11 electrical cabinet
Measuring Measures the pressure in the overpressure air line to the crusher. A tube
function: connects the pressure transmitter to the air line.
Control function : If the air pressure drops below the minimum value 0.3 kPa (0.04 psi), a B-
alarm is initiated.
Air pressure Transducer signal

0–1.6 kPa (0–0.23 psi) 4-20 mA
Return oil flow switch FS1
Type: Mechanical sensor (NO/NC)

Location: In the return oil entry box on the oil tank unit
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Measuring Detects the main lubrication oil return flow

function:
Control function 1: If the main lubrication return oil return flow drops below the minimum value,
an A-alarm is initiated and the crusher’s drive motor is shut down.
Control function 2: To prevent switch contacts from welding, the signal “Lubrication pump ready
for start” is only permitted when the switch is closed (NC).
Pressure drop indicator PS3
Type: Pressure guard

Location: On the pinionshaft lubrication oil filter unit
Measuring function: Differential pressure across the pinionshaft lubrication oil filter
Control function : If the pressure exceeds 0.22 MPa (36 psi), a B-alarm is initiated and the
“Filter blocked FU2/M9” LED is lit.
Reset push button S1
Type: Push button switch

Location: On the side of the TIMS box LC10
Control function : Resets alarms initiated by TIMS
Program selector S2
Type: Rotary switch

Location: On the DIN rail inside the TIMS box LC10
Control function: Used to select the temperature settings for different operating conditions and
oil viscosity
Program 0: Normal operating conditions
Program 1: Operation at high temperatures
Program 2: Operation at low temperatures
Program 3: Special settings
See sectionTIMS programs on page 68 for further information.

4.4.1.3. TIMS input (external)
Power supply inputs:
• 100/120–220/240 VAC 50/60 Hz

• Neutral
• Ground (earth)
Signal inputs from the plant control system:
• Crusher drive motor running

• Lubrication oil pump running
• Pinionshaft lubrication oil pump running
• Oil cooling system activated
4.4.1.4. TIMS output for normal signals
The circuit diagram for TIMS shows all TIMS output signals. Refer to the
circuit diagram in the Mechanical drawings. The circuit diagram
indicates which signals that must be used in the plant’s control system
and which that are optional.
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NOTE! Sandvik strongly recommends that the two optional output signals that
indicates that an A-alarm or a B-alarm has been initiated must be
connected to the plant’s control system.
Crusher operation permitted

NOTICE This output signal must be connected as a condition for
operation of the crusher.
Signal category: Condition for operation

Output signal: PNP transistor output and indication on TIMS alarm panel
Function: Indicates that the instruments and safety devices in the tank permit operation of
the crusher's drive motor M1.
Lubrication oil pump M2 ready for start

NOTICE This output signal must be connected as a condition for
starting the lubrication oil pump.
Signal category: Condition for operation

Output signal: PNP transistor output
Function: Indicates that the instruments and safety devices in the oil tank unit permit
operation of the lubrication oil pump M2.
Oil cooling fan M3 ON
Signal category: Run command

Function: Start/stop signal for the cooling fan. Must be connected to the cooling fan
contactor.
Oil heaters E7.2 and E7.3 (E7.1 and E7.4) ON
Signal Run command

category:
Function: On/off signal for the oil heaters in the lubrication oil tank. Must be connected to
the oil heater's contactor .
Triggered by temperature transmitter TT3.
The run command is not initiated if the oil level in the tank is below
250 mm (10").
For information about the operating conditions for the thermostat, refer to the
Technical Specifications.
Overpressure fan M8 ON

Function: On/off signal for the overpressure fan motor. Must be connected to the
overpressure fan motor contactor.
The overpressure fan will start when the “Crusher operation permitted” signal is
given, and will stop 3 minutes after the crusher has stopped.
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Pinionshaft lubrication oil pump M9 ON

Function: Start/stop signal for the pinionshaft lubrication oil pump. The pump will start at
the same time as the crusher’s drive motor and stop 30 seconds after the
crusher's drive motor has stopped.
4.4.1.5. Alarms
Any fault discovered by TIMS is designated as an A-alarm or a B-alarm.
A-alarm
An A-alarm is a serious fault which shall stop the crusher’s drive motor.
When an A-alarm has been indicated it is necessary to go out to the oil
tank unit and investigate the fault. When the fault has been corrected,
the operator must press the RESET ALARM push button on the TIMS
box before the crusher can be restarted.
The signals “Low flow in the return oil line”FS1, and “Low
NOTICE flow in the main oil supply to the crusher” FT4 are very
serious alarms which must stop the crusher drive motor
immediately.
All other A-alarms should first stop the material feed by cancelling the
signal “Material feed to the crusher permitted” about 1 minute before the
crusher drive motor is stopped.
The A-alarms are:
• FS1 - Low flow in the return oil line

• FT4 - Low flow rate in the main oil supply line to the crusher
• PT3 - Low pressure (lubrication oil – pinionshaft)
• TT1 - High temperature in the return oil line
• TT1 - High temperature (limit value 2) in spider bearing
B-alarm
A B-alarm is less serious and does not shut down the crusher’s drive
motor. However, it indicates that a fault has occurred which should be
corrected as soon as possible. The operator must press the RESET
ALARM push button to cancel the alarm. If nothing has been done to
correct the fault, a new B-alarm is registered almost immediately, so it is
recommended to correct the fault right away.
To avoid damage to the equipment it is recommended to stop the
material feed to the crusher when a B-alarm is activated. Cancel the
signal “Material feed to the crusher permitted” approximately 1 minute
before the crusher drive motor is stopped.
The B-alarms are:
• TT1 - Low oil level in the main tank

• FU1/M2 - Filter blocked
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• FU2/M9 - Filter blocked

• PT1 - Low overpressure
• TT5 - High temperature (limit value 1) in the spider bearing
LED indicators on TIMS box
H1 Crusher - Ready for operation

H2 A-alarm - Crusher stopped
H3 B-alarm - Divergence
H4 FS1 - Low flow (main and pinionshaft lubrication) return oil
H5 FT4 - Low flow (main lubrication) lubrication oil
H6 PT3 - Low pressure - lubrication oil (pinionshaft lubrication)
H7 TT1 - High temperature - return oil (main lubrication)
H8 TT5 - High temperature - spider bearing (limit value 1 or 2)
H9 LT1 - Low oil level in tank - (main lubrication)
H10 FU1/M2 - Filter blocked (main lubrication)
H11 FU2/M9 - Filter blocked (pinionshaft lubrication)
H12 PT1 - Low overpressure
4.4.1.6. TIMS output for fault signals

Fault: A-alarm
Signal category: Alarm

Output signal: PNP transistor output and indication on the TIMS alarm panel with a red LED.
Function: A serious fault has occurred and caused the crusher to shut down. A LED on
the TIMS alarm panel indicates the cause of the alarm.
Fault: B-alarm
Signal Alarm
category:
Output signal: PNP transistor output and indication on the TIMS alarm panel with a yellow
LED.
Function: A less serious fault or operational interruption has occurred. The crusher
continues to run, but the cause of the fault should be corrected as quickly as
possible. A LED on the TIMS alarm panel indicates the cause of the alarm.
Fault: Low return oil flow, main lubrication FS1
Signal category: A-alarm

Output signal: PNP transistor output and indication on the TIMS alarm panel.
Function: Continuous signal = Main lubrication oil return flow is below the minimum
permitted value.
Flashing signal = FS1 activated with the lubrication oil pump not running.
Indicates fault in FS1
Fault: Low oil flow to crusher, main lubrication FT4

Function: Continuous signal = Main lubrication oil flow to crusher is below the minimum
permitted value.
Flashing signal = FT4 activated but the lubrication oil pump M2 is not running.
Indicates fault in FT4.
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Fault: Low pressure, pinionshaft lubrication PT3

Function: Lubrication oil pressure to the pinionshaft housing is below the minimum value
Fault: High oil temperature, return oil chamber TT1

Function: The temperature of the main lubrication return oil is above the maximum value.
Refer to the Technical Specifications.
Fault: High temperature in spider bearing TT5
Signal category: A-alarm or B-alarm

Function: The temperature in the crusher spider bearing has exceeded the limit value 1
(B-alarm) or 2 (A-alarm).
See section TIMS input on page 61.
Fault: Low oil level in tank, main lubrication LT1
Signal category: B-alarm

Function: The oil level is low in the main lubrication oil tank.
Fault: Filter blocked FU1/M2

Function: Excessive pressure drop across the main lubrication oil filter FU1
(PT2 and PT4).
Fault: Filter blocked FU2/M9

Function: The pinionshaft lubrication oil filter FU2 is blocked (PS3).
Fault: Low overpressure at crusher PT1

Function: The pressure in the overpressure air supply to the crusher is too low. The
probable cause is that the air filter is blocked.
4.4.1.7. TIMS programs

TIMS can store a maximum of four programs. The only difference
between these programs is for the oil temperatures at which various
control signals are given.
Three of the programs that cover the operating conditions are described
in the Technical specifications:
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Program 0 Normal operating conditions

Program 1 Operation at high temperatures
Program 2 Operation at low temperatures
Program 3 is only included if the operating conditions of the crusher

cannot be covered by any of the three standard programs. If the crusher
is supplied with program 3 already programmed, the temperature set
points are shown in a table. For further information about the TIMS
(option) temperature settings, refer to the Technical specifications.
If it appears that it is necessary to change from one program to another,
this can be done by moving the program selector switch S2 inside the
TIMS connection box LC10. The number visible on this switch indicates
the selected program.
NOTE! Contact Sandvik for more information before changing the program.
Installation of custom programs and modification of existing programs
can be done on-site by a specialist from Sandvik.
4.4.1.8. Control logic TIMS
As explained in section General description TIMS on page 60, the TIMS
monitors the instruments and safety devices in the oil tank unit and
provides the control logic necessary for correct operation of the various
ancillary systems. The TIMS outputs must be used by the plant’s control
system to start and stop the various motors, etc. A description of how
the TIMS and the plant’s control system work together is given below.
In the explanation below, the following symbols are used:
• (IN/to TIMS) = Signal from plant control system to TIMS input

• (OUT/from TIMS) = Signal from TIMS output to plant control system
Starting the crusher
• TIMS checks that the flow switch FS1 and the flow monitor FT4 are
functioning correctly. If all is well, a signal is sent to start the oil pump:
(OUT/from TIMS “Lubrication oil pump ON” M2)
• The plant control system must be configured to start the oil pump and
send a confirmation signal back from the contactor:
(IN/to TIMS “Lubrication oil pump in operation”)
• Oil is pumped to the crusher and the TIMS makes the following
checks:
- Oil returns to the tank - FS1
- Oil temperature not too high - TT1
- Oil flow to the crusher sufficient - FT4
- No A-alarm initiated
• If the correct signals are obtained from the instruments, a
corresponding signal is sent to the plant control system:
(OUT/from TIMS “Crusher ready for operation”)
NOTE! The “Crusher ready for operation” signal is an absolute
condition for the operation of the crusher’s drive motor.
• If this signal is not present – i.e. there is some fault in the circulatory
oil system – the crusher’s drive motor must not be allowed to run.
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• If the “Crusher ready for operation” signal is not given, the LEDs on
the TIMS box LC10 indicates which monitor that is not ready
FS1 and/or FT4.
• When the “Crusher ready for operation” signal is given, TIMS sends a
start command for the overpressure fan:
(OUT/from TIMS “Overpressure fan ON”)
The plant control system now starts the overpressure fan M8.
• The crusher drive motor can now be started by the plant control
system. When the contactor closes, a confirmation signal must be
sent back from the contactor:
(IN/to TIMS “Crusher in operation”)
• The TIMS then generates a command signal to start the pinionshaft
lubrication pump:
(OUT/from TIMS “Pinionshaft lubrication pump ON”)
• The plant control system must start the pinionshaft lubrication pump
and send a confirmation signal back from the contactor:
(IN/to TIMS “Pinionshaft lubrication pump in operation”)
• If no confirmation signal is received back from the contactor by the
TIMS within 1 minute, an alarm signal is generated by TIMS:
(OUT/from TIMS “Low pressure lubrication oil (Pinionshaft)”)
During operation
• During operation, the flow of oil to and from the crusher is constantly
monitored. If the signal from any of the sensors FS1, TT1, FT4 or TT5
goes outside the permitted limits, an A-alarm is generated. The
“Crusher ready for operation” signal immediately disappears and the
crusher’s drive motor must stop. The TIMS alarm panel indicates
which sensor has initiated the alarm.
• When the crusher is operating the main lubrication return oil
temperature will rise, and when the temperature exceeds the limit
value the oil must be cooled. A command signal is generated so that
the plant control system can start the air/oil or water/oil cooler:
(OUT/from TIMS “Cooling fan ON”)
When the return oil temperature drops below the limit value, the air/oil
or water/oil cooler must be stopped. For further information about the
temperature settings for the air/oil and water/oil coolers, refer to the
• To reduce contaminating dust in the lubrication oil there is an
overpressure blower, either a fan or with compressed air with a
regulator, which introduce air at a slight overpressure into the crusher
and the oil tank. The air pressure at the inlet to the crusher is
monitored by a pressure transmitter PT1. If the pressure drops below
the limit value, a B-alarm is generated:
(OUT/from TIMS “B-alarm”)
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Normal stop of the crusher

• When the crusher is to be stopped, the feed to the crusher must be
stopped first.
NOTE! With an A-alarm, the crusher drive motor may be stopped
immediately, see section Alarms on page 66.
• After the feed has been stopped, the crusher must continue running
for a few minutes to allow all material to pass through the crusher.
This time delay depends on the layout of the plant. If in doubt, please
contact Sandvik.
• When the time delay has elapsed, the crusher’s drive motor can be
stopped. The confirmation signal from the contactor (IN/to TIMS
“Crusher in operation”) disappears.
• The pinionshaft lubrication oil pump must be stopped at the same
time as the crusher’s drive motor.
• After the crusher's drive motor has stopped, there must be a delay of
two minutes before the command signal for the main lubrication oil
pump (OUT/from TIMS “Lubrication oil pump ON”) disappears. This is
to ensure that the crusher’s bearings continue to be properly
lubricated while the crusher is slowing down.
• After the crusher’s drive motor has stopped, there is a delay of three
minutes before the command signal for the overpressure fan (OUT/
from TIMS “Overpressure fan ON”) disappears. This is in order to
allow all dust to disappear from the crushing chamber before the
crusher has come to a complete stop.
• If the oil cooling fan is in operation when the crusher's drive motor is
stopped, it will be stopped by TIMS at the same time as the main
lubrication oil pump is stopped.
Crusher drive and pinionshaft oil pump

Feed to crusher stopped stopped Lubrication oil pump stopped Overpressure fan stopped
X 0 1 2 3
All material passes

through crusher
4.4.1.9. Communication
TIMS communicates with the plant’s control system via a number of 24
V digital inputs and outputs. Some of these inputs and outputs are
essential for the operation of the system, while others are optional.
In some plants it is desired to integrate the TIMS more completely into
the plant control system. For this reason, the TIMS incorporates a
communication port. The standard communication protocol is Siemens
Profinet. Other communication protocols are available on request.
Contact Sandvik for more information.
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The communication protocol can be used either as status indication

together with the relay box LC10.2 or as a complete communication
between the TIMS and the plant’s control system. In this case there is
no need for the relay box LC10.2.
Refer to the electrical drawings in the Mechanical drawings.
4.4.2. L-boxes
4.4.2.1. L11 connection box
The L11 connection box collects signals from the crusher speed sensor
and the crusher overpressure sensor to the speed sensor SS1 and the
pressure transmitter PT1 inside the L11 box.
For L11 connection box drawings and circuit diagram, refer to the
Mechanical drawings.
NOTE! The L11 connection box should not be placed further than15 m from the
oil tank unit.
4.4.2.2. L12 box - auxiliary motors starting
Refer to the electrical drawings in the Mechanical drawings.
Sandvik offers the control cabinet L12 as an option to simplify the
electrical connection to the starting equipment of the crusher’s auxiliary
motors.
The control cabinet L12 has the protection classification IP65 and
complies with the EN 60439-1 and EN 60204-1 standards.
The control cabinet L12 includes:
• Main switch 100 A
• Starting equipment relays and motor protection for main lubrication
oil pump, cooler fan, oil heaters, overpressure fan and pinionshaft
lubrication oil pump
• Starting equipment for Hydroset pump
• Transformer for auxiliary supply 400/230 V/24 VDC
• Terminal blocks for electric motors
• Terminal blocks for connecting TIMS to LC10.2 relay box
• Terminal blocks for connecting external emergency stop
• Possibility to integrate the ASRi communication unit, normally
placed in the ASRi-L3 box. In that case the ASRi-L3 box will not be
used
• Connection of the ASRi-L1 push button box for manual adjustment
of the CSS
Signals and control units on the L12 control panel:
• Tripped motor protection
• Start and stop of the lubrication oil pump
• Crusher operation permitted
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• Start and stop of the crusher’s main motor

• Disconnection of oil heaters
• Indication of A- and B-alarms
The L12 control cabinet does not include:
• Starting equipment for the crusher’s main motor
• Supply cable
• Cables to relay and connection boxes on the oil tanks
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5.1. Installation and connection checks

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

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

checks
No. Checks Done

1 Brand name and type of oil and grease are recorded.
2 The oil tank unit is placed in relation to the cone crusher according to instruction
and is properly installed.
3 The Hydroset and lubrication systems are correctly installed.
4 Air/oil or water/oil (option) cooler is installed properly.
5 Piping and hosing has been installed according to the recommendations in this
manual.
5.3. Electrical checks

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

1 All electric cables are correctly connected.
2 Make sure that the rotation directions of the motors are correct
3 Check the PS2 sensor (see below)
4 ASRi is installed properly (option)
5.4. Checking the pressure drop indicators

(PS2, PS3)
The pressure drop indicators are of normally open (NO) type. This
means that if the indicators malfunctions they will not indicate the need
for oil filter exchange. Perform this check with the power on but pumps
and crusher off.
a) Locate the pressure drop indicator PS2.
b) Remove the clip (1) on top of the indicator.
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c) Remove the indicator PS2 by pulling it straight up from the oil filter
unit FU1.
d) Turn the indicator PS2 upside down and position the indicator back
on the tube. The pressure drop warning lamp H10 on the front
panel will light up if the indicator works.
e) Turn the indicator PS2 back to its normal position.
f) Fit the clip on top of the indicator PS2.
g) Locate the pressure drop indicator PS3 on the filter unit FU2.
h) Do the same check from 2) to 6) on PS3. The warning lamp H11
on the front panel will light up if the indicator works.
PS3 1 L10 M2 H10 H11 PS2 1
FU2 FU1
1 Clip
PS3 Pressure drop indicator - pinionshaft lubrication
FU2 Filter unit - pinionshaft lubrication
H11 Pressure drop warning lamp - pinionshaft lubrication
PS2 Pressure drop indicator - main lubrication
FU1 Filter unit - main lubrication
H10 Pressure drop warning lamp - main lubrication
TIMS (option)
The pressure drop indicator PS2 is replaced by the pressure
transducers PT2 and PT4 before and after the filter unit FU1. No check
is needed, a B-alarm is initiated and the “FU1/M2 - Filter blocked” LED
will light up.
The pressure drop indicator PS3 for the filter unit FU2 on the pinionshaft
lubrication system should be checked the same way as in the
description for the tank unit without TIMS (see above). A B-alarm is also
initiated and the “FU2/M9 - Filter blocked” LED will light up.
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PS3 1 L10 PT2 PT4

E E
E-E
FU2
1 Clip
PS3 Pressure drop indicator - pinionshaft lubrication
FU2 Filter unit - pinionshaft lubrication
L10 TIMS box
FU1 Filter unit - main lubrication
PT2 Pressure transducer before FU1
PT4 Pressure transducer after FU1
5.5. Safety checks
No. Checks Done

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

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

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

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

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

1 There are no unusual noises which could indicate misaligned parts or faults
2 There is no contact between oscillating crusher and stationary structure.
3 The hydroset pressure is within limits (see Technical specifications).
4 Oil heating elements operate correctly.
5 Over-pressure dust exclusion system functions correctly
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No. Checks Done

6 Return lubrication oil temperature is within limits for the chosen oil.
6.5. Health and safety checks
No. Checks Done

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

The storage is considered short-term if it is shorter than 30 days.
Preparation for moving
a) Shut off utilities connected to the cone crusher:
• Electrical power
• Process material
Risk of electrocution
Follow the safety precautions when
disassembling the parts to avoid high voltage
DANGER! electrocution.
b) Disconnect the following connections:

• Electrical power
• ASRi (option)
c) Plug or protect all open connections.
d) Check that the doors to the cabinet are closed and locked with the
handle.
e) Check that the main lubrication tank cover as well as the Hydroset
tank cover are fit to the tank, closed and that all nuts are tightened.
f) Disassemble the crusher and the oil tank unit to the extent
necessary for the planned transport/storage. See section Draining
procedure on page 85 and refer to the Maintenance Instructions
for information on how to disassemble.
g) Prepare a storage area large enough to store the components with
at least 1 m (3.3 ft) of free space around and above them for
access and ventilation. Make sure that the storage area
environment meets the conditions in the table below:
Characteristic Value Notes

Min. - max. temperatures 5–40 °C (41–104 °F)
Max. relative humidity 80% Non-condensing
h) Move the cone crusher and the oil tank unit to the new position
according to section Moving and storage on page 37.
i) Level the cone crusher and the oil tank unit roughly.
Risk of property damage
NOTICE Protect the sensitive machined parts' surfaces.
Treat them with anti rust agent.
j) Cover the cone crusher and the oil tank unit with suitable
protective covering.
84 S 223.1048 - 2 en-US 18/06/2015 13:08:06
k) Store the cone crusher and the oil tank unit according to section
Storage of a non-assembled crusher on page 38.
7.1.2. Long moves and long-term storage

The storage is considered long-term if it is for more than 30 days.
a) Perform the instructions a) to i) listed in section Short moves and
short-term storage on page 84.
b) Wrap all loose components in bubble wrap or other suitable
wrapping to prevent damage.
c) Pack the equipment in suitable packing, crates and transport
platforms. Use original packing, crates and transport platforms if
possible. Make sure that all parts are adequately protected.
d) Fix small boxes to each other to prevent them from moving during
transport.
e) If there is no oil left in the pumps, fill with oil to keep all surfaces
inside lubricated.
f) Perform the instructions j) to k) listed in section Short moves and
short-term storage on page 84.
7.1.3. Draining procedure

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

If an assembled crusher is taken out of operation for a period of more
than 30 days, carry out the following:
a) Plug the oil return line so that the oil cannot run out from the
crusher.
b) Close the valve(s) between the tank and the pump to prevent oil
running back from the crusher through the pump.
S 223.1048 - 2 en-US 18/06/2015 13:08:06 85
c) Use the crusher's oil system to fill the bottomshell with lubricating
oil until a little oil overflows over the dust collar (1).
1 Oil level = top of dust collar
d) Plug the over-pressure air connections.

e) Fill the pinionshaft housing with oil and plug the inlet and outlet
holes.
f) Fill the spider bushing with grease to prevent condensation on
bearing surfaces.
g) NOTE! Before putting the crusher into operation, check that the
ventilation hole and the breather are not blocked with
grease.
Coat the exposed part of the mainshaft sleeve (between the spider
and the head nut – see arrows) with grease. Make sure that this
area is protected from contamination.
h) If the lubrication and Hydroset oil tank unit is stored separately

from the crusher, fill the pumps with oil.
i) Rotate the crusher pulley/drive shaft by hand through at least four
revolutions every 14th day.
7.3. Regular inspection during storage

The following checks should be carried out regularly during the storage
period:
• Inspect the oil tank unit for damage and make sure that it is
protected from rust and contamination.
86 S 223.1048 - 2 en-US 18/06/2015 13:08:06
• If the oil tank unit has not been in operation before being stored,
check that the rust prevention packing is undamaged, and renew it
if necessary.
7.4. Return to the manufacturer

a) Prepare the equipment for transport, see section Draining
procedure on page 85.
b) Contact the local service organization for further instructions on
arranging transport.
7.5. Disposal
If the cone crusher is to be permanently disposed of, follow the
sequence below.
a) Drain the cone crusher, see section Draining procedure on page
85.
b) Perform the steps a) to g) listed in section Short moves and short-
term storage on page 84.
c) Disassemble the equipment as far as possible and separate the
following parts and material:
• Stainless steel
• Cast steel (frame etc.
• Cast manganese steel (mantle, concave ring, etc.)
• Bronze (bushings and bearing components)
• Rubber
• Nylon and other plastics
• Electrical cables
• Electrical components
• Pumps and motors
• Oil filters
• Lubricants
Toxic gas hazard
Fumes are toxic.
When dismantling and scrapping the crusher it
WARNING! can be necessary to cut certain parts. This
process can create toxic gases.
Always work with a respirator approved by the
respirator manufacturer for the job you are
doing.
Make sure the area is well ventilated.
S 223.1048 - 2 en-US 18/06/2015 13:08:06 87
d) Recycle or dispose of all material and components in compliance

with local regulations.
Environmental hazard
Long-term storage of disposed crusher parts
can leach heavy metals and other potentially
WARNING! hazardous substances into subsoil water and
soil.
Sandvik recommends recycling all material and
components in compliance with local
regulations.
88 S 223.1048 - 2 en-US 18/06/2015 13:08:06

06.CH660-03 Installation Instructions S223.1048-02 en

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What are the steps for preparing a cone crusher for storage?

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What safety precautions should be taken when disassembling and scrapping a cone crusher?

What safety precautions should be taken when disassembling and scrapping a cone crusher?

Original instructions

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Document number: S 223.1048

Lack of knowledge can lead to risky situations.

Read and understand the information in the manual. If anything is

3. Mechanical installations and connections

4.3.7. M9 - Pinionshaft oil pump.................................................60

5. Final installation checks

6. Preparations for commissioning

7. Disassembly and removal

This page is intentionally left blank

1.1. General preparations

1.2. Machine access

1.3. Crusher capacity and performance

• Choice of crushing chamber

• Adhesive or moist process material

1.4. Installation preparations checklist

System Check Remark Date/

1.5.1. Height differentiation in the return line

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

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

Example ISO units:

15 meters DN 100 piping 15 × 130 = 1950 mm

The crusher should be placed 4 m above the tank.

49 ft 4" piping 49 × 1.56 = 76.44"

The crusher should be placed 12 ft above the tank.

1.5.2. Maximum allowed pressure in pressure line

15 meters DN 38 piping 15 × 27.9 = 418.5 kPa

The required pump pressure will be approximately 850 kPa.

49 ft 1.5" piping 49 × 1.23 = 60.27 psi

The required pump pressure will be approximately 123 psi.

The foundation must be designed to accommodate the static and

1.6.1. Foundation loads

1.6.2. Natural frequencies

1.6.3. Movement of the crusher

1.6.4. Using an existing concrete foundation

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

1.6.5. Using a steel supporting structure

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

1.7. Installation alternatives

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

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

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

1.7.1. Installation packages

1.7.2. Direct drive installation package

1.7.3. V-belt drive installation package

1.7.4. Rubber dampers

Following rubber dampers are used:

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

Type A Fitted to sub-frame

Type B Fitted to sub-frame or motor bracket

4 Rubber compression mounting

1.7.5. Crusher mounting feet

1.8. Crusher arrangement

1.8.1. Electrical installation - general