CTHS430-02_IM_S223.855.en-01

8/12/2019 CTHS430-02_IM_S223.855.en-01

1/80

Installation Manual Doc. No. S 223.855.en

SANDVIK CTHS430:02

Tank unit

8/12/2019 CTHS430-02_IM_S223.855.en-01

2/80

8/12/2019 CTHS430-02_IM_S223.855.en-01

3/80

IM Sandvik CTHS430:02 Tank unit

3

2012 Sandvik SRP AB S 223.855.en-01

1. Introduction

1.1 Equipment information.......................................................... 8

1.1.1 Document information............................................ 10

1.2 Operating principles............................................................ 11

1.2.1 Lubrication system................................................. 11

1.2.2 Description............................................................. 11

2. Safety precautions

2.1 Hazard information ............................................................. 14

2.1.1 Warning signs ....................................................... 14

2.1.2 Risk levels.............................................................. 15

2.1.3 Prohibition signs..................................................... 15

2.1.4 Mandatory signs..................................................... 15

2.1.5 Personnel............................................................... 16

2.1.6 Personal protection ................................................ 17

2.2 General safety precautions................................................. 18

2.2.1 Machine safety guards........................................... 19

2.2.2 Machine access ..................................................... 19

2.2.3 Electrical safety...................................................... 20

2.2.4 Welding .................................................................. 20

2.2.5 Hydraulic system.................................................... 21

2.2.6 Lubrication system................................................. 22

2.2.7 Lubricants and waste lubricants............................. 23

2.2.8 Diesel oil, white spirit and other cleaning agents ... 23

2.2.9 Lifting and moving loads ........................................ 24

2.3 Emissions ........................................................................... 24

8/12/2019 CTHS430-02_IM_S223.855.en-01

4/80

4 2012 Sandvik SRP AB

S 223.855.en-01


3. Installation preparations

3.1 General ............................................................................... 26

3.2 Installation preparations check list ...................................... 27

3.3 Placement........................................................................... 28

3.3.1 Electrical installation............................................... 29

3.3.2 Remote control system .......................................... 29

3.3.3 Guard ..................................................................... 29

3.4 Operating in low temperatures............................................ 30

3.4.1 Measures for easier starting and runningin cold climate ........................................................ 30

3.4.2 Low temperature problems symptoms and remedies..................................... 31

3.4.3 Heater set - cold climate ........................................ 32

3.4.4 Diesel heating system............................................ 33

3.4.5 Heating cables on oil lines ..................................... 33

3.4.6 Heating in the component sectionof the oil tank unit ................................................... 34

3.4.7 Synthetic oils .......................................................... 34

3.4.8 Mineral oil for the winter season ............................ 35

3.4.9 Blanking off the oil cooler radiator .......................... 36

3.4.10 Frequency converter .............................................. 36

3.4.11 Two-speed fan motor for oil cooler......................... 36

3.4.12 Insulation of the oil tank ......................................... 37

3.4.13 Continuous running of the lubrication oil pump ...... 37

4. Transport handling

4.1 Goods data ......................................................................... 40

4.1.1 Contents................................................................. 40

4.1.2 Loading and unloading goods signs....................... 41

4.2 Lifting equipment................................................................. 424.2.1 Overhead gantry or mobile crane........................... 43

4.2.2 Using a fork lift (only for goods on pallet) ............... 44

8/12/2019 CTHS430-02_IM_S223.855.en-01

5/80


5


4.3 Unloading the goods........................................................... 45

4.3.1 Unpacking area...................................................... 45

4.3.2 Inspection of goods................................................ 45

4.4 Moving and Storage............................................................ 46

4.4.1 Moving ................................................................... 464.4.2 Storage................................................................... 46

4.5 Unpacking the goods.......................................................... 48

4.6 Disposal/return of packaging material ................................ 49

5. Mechanical installation and connections

5.1 General requirements......................................................... 52

5.2 Foundation.......................................................................... 53

5.3 Hydroset and lubrication systems....................................... 53

5.4 Hoses and pipes General ................................................ 54

5.4.1 Oil tank unit ............................................................ 54

5.4.2 Air/oil cooler ........................................................... 56

5.4.3 Water/oil cooler (option)......................................... 57

5.5 Overpressure system.......................................................... 58

5.6 Lubricants ........................................................................... 60

6. Electrical installation

6.1 General requirements......................................................... 62

6.2 Overview............................................................................. 62

6.3 Motors and heating elements ............................................. 63

6.3.1 M2 Main lubrication pump................................... 63

6.3.2 M3 Oil cooler fan motor....................................... 63

6.3.3 M6 Hydroset pump.............................................. 63

6.3.4 E7 Oil heaters ..................................................... 63

6.3.5 M8 Overpressure fan .......................................... 63

6.4 Connection boxes............................................................... 64

8/12/2019 CTHS430-02_IM_S223.855.en-01

6/80


S 223.855.en-01


7. Final installation checks

7.1 Installation and connection checks ..................................... 66

7.1.1 Lubrication system and Hydroset checks............... 66

7.2 Electrical checks ................................................................. 66

7.2.1 Check the pressure switch PS2 ............................. 67

7.3 Safety checks...................................................................... 68

7.4 Start-up ............................................................................... 68

8. Preparations for commissioning

8.1 General ............................................................................... 70

8.2 Presence and correctness checks ...................................... 70

8.3 Supply value checks ........................................................... 70

8.4 Function checks .................................................................. 71

8.4.1 Preparation............................................................. 71

8.5 Health and safety checks.................................................... 71

8.6 Documentation.................................................................... 71

9. Disassembly, storage and removal

9.1 Moving and storage ............................................................ 74

9.1.1 Short moves and short-term storage...................... 749.1.2 Long moves and long-term storage ....................... 75

9.1.3 Regular inspection during storage ......................... 76

9.2 Return to the manufacturer ................................................. 76

9.3 Disposal .............................................................................. 77

8/12/2019 CTHS430-02_IM_S223.855.en-01

7/80

7


1. IntroductionTo ensure maximum safety, always readsection 2. Safety precautionsbefore

carrying out any work on the equipment or making any adjustments.

8/12/2019 CTHS430-02_IM_S223.855.en-01

8/80


S 223.855.en-01

IM Sandvik CTHS430:02 Tank unit 1. Introduction

1.1 Equipment information

Purpose

The purpose of this Sandvik equipment is to be an oil tank component in a

crushing and screening unit or site within an aggregate or mining process.This crusher component has been exclusively designed for this application. It

is not the responsibility of Sandvik secure the design and usage for the

complete aggregate, mining, or recycling process. Sandvik will not accept

any liability for damage to equipment or injury to personnel caused by

unauthorized or improper use or modification of this equipment.

Manufacturer

This Sandvik equipment has been manufactured by:

Sandvik SRP AB

SE-233 81 Svedala

Sweden

www.sandvik.com

For maintenance

Contact the nearest Sandvik company, agent or representative, or contact the

factory directly:

Sandvik SRP AB

Service Department

SE-233 81 Svedala

Sweden

Telephone +46 (0)40 40 90 00Telefax +46 (0)40 40 92 60

8/12/2019 CTHS430-02_IM_S223.855.en-01

9/80


9


Identification

The figure below shows the location and an example of the tank units

identification plate. The identification plate contains data needed when

contacting Sandvik concerning this specific equipment.

CE markingThis equipment complies with the basic health, environment and safetyregulations of the European Union and European Economic Area.

Sandvik will not take responsibility for this compliance when customers

modify any configuration of the oil tank unit.

6543

8

7

1

2

V10

1 Machine type

2 Serial number/PCR

3 Local manufacturer number

4 Mass (kg)

5 Order number

6 Manufacturer

7 Maximum operating speed

8 Year of manufacture

8/12/2019 CTHS430-02_IM_S223.855.en-01

10/80


S 223.855.en-01


1.1.1 Document information

Purpose of this Installation Manual

The purpose of this manual is to provide the installation personnel with

information on how to safely install this Sandvik equipment.

It is important to: keep the manual for the lifetime of the equipment

pass the manual on to any subsequent holder or user of the equipment.

Document Compliance

The instructions in this document are in accordance with the design and

construction of the equipment at the time it was delivered from the Sandvik

SRP AB manufacturing plant.

Technical Publications

Technical publications related to the installation of this equipment are:

IM - Installation Manual

IMA - Installation Manual Appendix

Technical publications related to the operation and maintenance of this

equipment are:

OMM - Operators and Maintenance Manual

SPC - Spare Parts Catalog

Read more about the document structure and accompanying work categories

insection 2.1.5 Personnel.

Feedback

If you have comments on this manual or problems connected to the

documentation, send an e-mail to: [email protected]

8/12/2019 CTHS430-02_IM_S223.855.en-01

11/80


11


1.2 Operating principles

1.2.1 Lubrication system

There are two separate lubrication systems the circulatory main lubrication

system and the pinionshaft oil bath lubrication. The main lubrication system

is described in Operators and Maintenance Manualfor the tank unit. The

pinionshaft lubrication is described in the Operators manualfor the crusher.

Setting adjustment

To control fragment size and to compensate for wear the crusher has a setting

control system, called the Hydroset system. It basically consists of a robust

hydraulic jack which supports the mainshaft and adjusts its position. Moving

the Hydroset piston up and down will change the discharge setting and the

size of the crushed material.

1.2.2 Description

The following figure shows an overview of the oil tank units nomenclature

and components.

123 4 5

1 Oil tank unit

2 Overpressure fan

3 Overpressure air regulator (option)

4 Air/oil cooler

5 Water/oil cooler (option)

8/12/2019 CTHS430-02_IM_S223.855.en-01

12/80


S 223.855.en-01


This page is intentionally left blank

8/12/2019 CTHS430-02_IM_S223.855.en-01

13/80

13


2. Safety precautionsTo ensure maximum safety, always read this section carefully before

operating, carrying out any work on the equipment or making anyadjustments.

8/12/2019 CTHS430-02_IM_S223.855.en-01

14/80


S 223.855.en-01

IM Sandvik CTHS430:02 Tank unit 2. Safety precautions

2.1 Hazard information

2.1.1 Warning signs

General danger Dangerous voltage Risk of crushing

Hanging load Skid risk Flying fragments

Rotating fan Irritant Hot surface

8/12/2019 CTHS430-02_IM_S223.855.en-01

15/80


15


2.1.2 Risk levels

Throughout the manual, risk levels are indicated with DANGER,

WARNING or CAUTION. The DANGER and WARNING levels

are accompanied by a warning sign, seesection 2.1.1 Warning signs.

CAUTION! Failure to observe information marked CAUTION! can result in minor

personal injury and/or damage to equipment!

2.1.3 Prohibition signs

2.1.4 Mandatory signs

DANGER!

Failure to observe information marked DANGER! can result in life-threatening injuries!

WARNING!

Failure to observe information marked WARNING! can result in

personal injury and/or serious damage to, or destruction of,

equipment!

Do not remove

guards

Disconnect current Read the manual

8/12/2019 CTHS430-02_IM_S223.855.en-01

16/80


S 223.855.en-01


2.1.5 Personnel

All work on the equipment must be carried out by trained personnel.

Trained means that the person in question has been given practical

instructions by Sandvik SRP AB personnel on how the various tasks

are carried out.

All expected work tasks on this production equipment have been defined by

Sandvik SRP AB as belonging to one of three categories:

Installation

Operation

Maintenance

Sandvik SRP AB provides technical documentation appropriate to the

categories:

Installation Manual and Installation Manual Appendix Operators and Maintenance Manual

Spare Parts Catalog

Adequate training can be provided, contact Sandvik SRP AB for further

information.

The technical documentation from Sandvik SRP AB only covers work on the

production equipment itself it does not cover work tasks associated with

other equipment or routines at the site.

It is the responsibility of the plant management to assign responsibility for:

The production equipment and the work area around the equipment

All personnel in the vicinity of the equipment

Compliance with national and local safety regulations

Checking that all safety devices are fully operational

Sandvik SRP AB declines all responsibility for injury or damage resulting

from non-compliance with the instructions in this manual.

8/12/2019 CTHS430-02_IM_S223.855.en-01

17/80


17


2.1.6 Personal protection

Sandvik SRP AB strongly recommends that personal protective equipment is

always worn when working in the vicinity of the equipment.

Sandvik SRP AB strongly recommends to use a safety harness when

working above, inside or under the equipment.

The Sandvik SRP AB recommendation for personal protective equipment

includes:

Ear protection Safety helmet Eye protection

Protective gloves Safety boots Mask or respirator

8/12/2019 CTHS430-02_IM_S223.855.en-01

18/80


S 223.855.en-01


2.2 General safety precautions

Always switch the power off and lock out the equipment (so that it cannot

inadvertently be switched on) before any maintenance work is started. Also

ensure that it is not possible for anyone else to switch the power on while

maintenance work is carried out.

Avoid staying on the equipment, unless necessary for maintenance work.

CAUTION! Sharp edges can appear on the equipment due to wear, please consider

sharp edges when handling worn parts. Remove any sharp edges.

WARNING!

Falling stones

Clear the feed arrangement and the crusher thoroughlyfrom process

material before any maintenance work is carried out inside or belowthe crusher, to prevent stones from falling down.

8/12/2019 CTHS430-02_IM_S223.855.en-01

19/80


19


2.2.1 Machine safety guards

Make sure all defective guards are checked, repaired and replaced before

starting the equipment.

2.2.2 Machine access

Every machine requires access for personnel who carry out inspections and/

or maintenance work. Suitable access platforms and guard rails must be

installed. Walkways, stairs and ladders must be designed in accordance with

applicable regulations.

These parts are not included in thetank units standard specification. For

advice, contact Sandvik SRP AB.

PROHIBITION!

Do not remove guardsMake sure that all guards are in place and functioning, to prevent

exposure to rotating parts. Only operate the equipment when all

guards are mounted.

WARNING!

Rotating partsExposure to rotating parts (pumps, fans etc.)must be prevented by

guards. Always attach the guards after maintenance work.

WARNING!

Flying fragments

Ejected fragments can fall down in the vicinity of the equipment.

Provide adequate guards and warning signs at appropriate places

around the danger zone.Sandvik SRP AB also recommends additional protection.

8/12/2019 CTHS430-02_IM_S223.855.en-01

20/80


S 223.855.en-01


2.2.3 Electrical safety

CAUTION! Only personnel working according to European Standard EN 50110 or

equivalent are permitted to perform electrical operations on theequipment.

Make sure all broken or damaged electrical cables and connectors are

checked, repaired and replaced before starting the equipment.

Control cabinets must be lockable.

2.2.4 Welding

CAUTION! Never weld the tank unit or parts attached to it.

DANGER!

Dangerous voltagePersonnel must regard all electrical equipment as live until it is proven

dead by proper testing procedures.

DANGER!

Risk of fire and explosionDue to the risk of leakage, open flames and hot surfaces (>200 C/>390 F) must be kept at a safe distance from the tank unit and the

lubrication pipe work.

8/12/2019 CTHS430-02_IM_S223.855.en-01

21/80


21


2.2.5 Hydraulic system

CAUTION! Only personnel certified in hydraulics are permitted to perform

maintenance on the hydraulic system (except bleeding air from the

Hydroset system).

CAUTION! Never adjust pressure relief valves beyond the recommended values.

CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired

and replaced before starting the equipment.

WARNING!

Oil pressurePressurized oil is dangerous if released incorrectly. Relieve all

pressure before carrying out maintenance or repair work on the

hydraulic system.

WARNING!

Hot oil

Hydraulic oil can become very hot during operation. Allow the oil to

cool before working on the hydraulic system.

WARNING!

Hot surface

Equipment and hoses/pipes containing hydraulic oil can have hotsurfaces. Always wear protective gloves.

WARNING!

Skid risk

When filling, controlling or changing oil there is a risk of spillage thatcan cause a slippery surface. Always remove oil spillage and stains

to avoid skid risk.

8/12/2019 CTHS430-02_IM_S223.855.en-01

22/80


S 223.855.en-01


2.2.6 Lubrication system

When changing from mineral oil to synthetic oil, or if the oil has coked,

the tank unit must be thoroughly cleaned. Contact Sandvik SRP AB forfurther instructions.

CAUTION! Make sure all defective hoses, valves or fittings are checked, repairedand replaced before starting the equipment.

WARNING!

Oil pressure

Pressurized oil is dangerous if released incorrectly. Relieve allpressure before carrying out maintenance or repair work on the

hydraulic system.

WARNING!

Hot oilLubrication oil can become very hot during operation. Allow the oil to

cool before working on the lubrication system.

WARNING!

Hot surface

Equipment and hoses/pipes containing lubrication oil can have hotsurfaces. Always wear protective gloves.

WARNING!

Skid riskWhen filling, controlling or changing oil there is a risk of spillage that

can cause a slippery surface. Always remove oil spillage and stainsto avoid skid risk.

8/12/2019 CTHS430-02_IM_S223.855.en-01

23/80


23


2.2.7 Lubricants and waste lubricants

CAUTION! Handle all lubricants and waste lubricants with care and according to

the suppliers Material Safety Data Sheet (MSDS)and local regulations.

Collect waste lubricants in suitable containers and dispose asrecommended in the MSDSand according to local regulations.

2.2.8 Diesel oil, white spirit and other cleaning agents

It is recommended to clean the tank and the tank units parts with diesel oil.

Use white spirit only if it is necessary.

CAUTION! If white spirit is used for cleaning, wipe it off carefully and allow it toevaporate before pouring oil into the cleaned compartments.

CAUTION! Handle all cleaning agents and their waste with care and according tothe suppliers Material Safety Data Sheet (MSDS)and local regulations.

Collect the waste in suitable containers and dispose as recommendedin the MSDSand according to local regulations.

WARNING!

Toxic substances

Read the suppliers Material Safety Data Sheet (MSDS). Used and

contaminated oil can be a health hazard. Use protective gloves andgoggles.

WARNING!

Skid riskWhen filling, controlling or changing oil there is a risk of spillage thatcan cause a slippery surface. Always remove oil spillage and stains to

avoid skid risk.

WARNING!

Health hazardBefore you use a cleaning agent, read the suppliers Material Safety

Data Sheet (MSDS)and follow the instructions carefully. Risk ofserious injuries to eyes, skin, respiratory system etc. Use personalprotection and other safety measures as recommended in the MSDS.

8/12/2019 CTHS430-02_IM_S223.855.en-01

24/80


S 223.855.en-01


2.2.9 Lifting and moving loads

CAUTION! Only personnel with adequate lifting training are permitted to perform

lifting operations.

Make sure that the capacity of the lifting equipment (Working Load Limit,

WLL)is adequate and that the lifting equipment is in good working order.

If lifting tackle has to be made up by joining separate components, make sure

that the joints are secure and have the same lifting capacity (Working Load

Limit, WLL)as the rest of the tackle.

Always engage the safety clips on lifting hooks to prevent the tackle from

slipping off.

Use ropes or poles to steady and maneuver loads. Neveruse hands or feet.

Make sure that the route and the destination are free from obstacles before

moving a suspended load. It must be possible to quickly and safely lower the

load to the ground in case of an emergency.

When depositing loads, keep the lifting equipment in place until it has been

made sure that the load is stable.

2.3 Emissions

For emissions such as dust, noise and radioactivity in the tank units

environment, seesection 2. Safety precautions in the crushers manuals.

DANGER!

Hanging loadNever work or stand underneath a crane that is lifting material. Keep asafe distance to hanging loads.

NOTE! Always use lifting tackle certified in accordance with local conditions.

8/12/2019 CTHS430-02_IM_S223.855.en-01

25/80

25


3. Installation preparationsTo ensure maximum safety, always readsection 2. Safety precautionsbefore


8/12/2019 CTHS430-02_IM_S223.855.en-01

26/80


S 223.855.en-01

IM Sandvik CTHS430:02 Tank unit 3. Installation preparations

3.1 General

Check that the dimensions of the installation site and the positions of the

connections comply with the installation drawings in theInstallation Manual

Appendixand with any site-specific installation drawings. If the site does not

meet the specifications, please contact Sandvik SRPAB for guidance and

customizing.

Check that the oil tank unit meets the local legislation demands. In case of

doubt, please consult local authorities or local authorized personnel.

Prepare the installation site as much as possible by installing electricity and

water supply, foundation etc. before starting the main installation.Use the check list insection 3.2 Installation preparations check listas a

guide and for documenting the installation procedure.

NOTE! Make sure that the required service area at the site matches the requirements

in the installation drawings, and that the installation area is accessible for

spare and wear part delivery.

8/12/2019 CTHS430-02_IM_S223.855.en-01

27/80


27


3.2 Installation preparations check list

System Checks Remarks Date/sign

Placement Site access checked for oil tank unit

dimensions?

Smallest area that the oil tank unit

components must pass through?

(W H)

Available service area?

(L W H)

Available lifting device on site? Type:

Length of oil hoses and pipes?

Foundation

(if needed)

Foundation constructed according to

drawings?

Electrical system All necessary cables arranged to the

oil tank unit?Cable lengths?

All necessary switchgear installed?

All necessary connections to plant

control system arranged?

Electrical power available?

Guards Need for additional guards?

Platforms and

guard rails

Comply with local regulations?

Designed so they do not interfere with

crushers or tank units function?

8/12/2019 CTHS430-02_IM_S223.855.en-01

28/80


S 223.855.en-01


3.3 Placement

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 runback to the oil tank unit and be pumped to the cone crusher. Seesection

5.4.1 Oil tank unitand installation drawings in theInstallation Manual

Appendix.

Place the overpressure fan or air regulator for compressed air above the

connection to the pinionshaft housing. This to prevent oil from running into

the overpressure system. Seesection 5.5 Overpressure systemand

installation drawings in theInstallation Manual Appendix.

(Continued)

4

1 3

2

1 Crusher

2 Oil tank unit

3 Overpressure fan or regulator

for compressed air

4 Pinionshaft

8/12/2019 CTHS430-02_IM_S223.855.en-01

29/80


29


Place the oil tank unit so that it is easily accessible for operation, service and

maintenance but protected against damage and unauthorized access.

Make sure that there is sufficient room to drain out all oil.

Make sure that all requirements for the service area are met as shown in the

installation drawings in theInstallation Manual Appendix. If possible, mark

the limits of the service area with paint. Note the dimensions of the actual

service area in the check list.

Make sure that there is access to a lifting device meeting the requirements in

section 4. Transport handling. Note the available type of lifting device in the

check list.

3.3.1 Electrical installation

Make sure that all local and site-specific requirements for electrical

installations are fulfilled.

External cables, disconnecting switches and fuses must be ordered before

installation. Seesection 6. Electrical installationand the electrical drawings

in theInstallation Manual Appendix.

Contact Sandvik for further information about cables, switches and fuses.

3.3.2 Remote control system

At most sites a main control system is used to control the process. Make sure

that the control system is prepared for the addition of the tank.

3.3.3 Guard

The oil tank unit have two moving parts covered with guards, the pump P1

connected to the motorM2 and the fan connected to the motorM3 on the air/

oil cooler.

8/12/2019 CTHS430-02_IM_S223.855.en-01

30/80


S 223.855.en-01


3.4 Operating in low temperatures

The following section describes recommended methods for reliable

operation in low temperature.

The accompanying flow chart (section 3.4.2 Low temperature problems symptoms and remedies) can be used to determine which method to use.

3.4.1 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 individualcase. 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 or a frequency converter

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

NOTE! If it is difficult to start the crusher even when the appropriate

recommendations have been followed, contact Sandvik for further

assistance.

8/12/2019 CTHS430-02_IM_S223.855.en-01

31/80


31


3.4.2 Low temperature problems

symptoms and remedies

Start

Oil returns to the tank, butnot in sufficient quantity.Wait 3.5 min. to drain thecrusher and then make anew attempt to start up.

Start the oil pump. Doesthe Crusher ready forstart signal appear within40 s?

There is a blockage in thereturn oil line. Clean out theblockage. If necessary,install heating cables on thereturn oil line. Does the oilflow back to the tank?

Has the crusher startedand continued to runnormally?

Start crushing when thecrusher has warmed up.

Stop the oil pump. Has oilrun back through the oil lineto the return oil flow switch?

Does the crusher stopdue to interruptions inreturn oil flow?

The ambient air tempera-ture is too low, whichmakes the oil cooler tooeffective. The oil isslowed down and blocksthe passages in the radi-ator coil!Blank off the radiator

completely or partially.Start with 50% blankedoff.

Alternatively, installa frequency converter ora two-speed motor to thecooling fan.

Has oil overflowed over thedust collar?

During long periods withvery low temperatures,the crusher should beheated during the nightto avoid excessivecooling. Position a fanheater beneath thecrusher and cover thefeed opening. In addition,the lubrication oil pumpshould be run continu-ously.

Under very low tempera-

tures the radiator coilcan be thawed out witha fan heater.

Install low temperatureequipment in the tank.(Heating in componentsection and insulated tankbottom.) Does oil flow backto the tank?

Change to synthetic oil.Does oil flow back to thetank?

Install heating cables on theoil lines. Does oil flow backto the tank?

Insulate the oil tank. Doesoil flow back to the tank?

Sometimes it can be advis-able to run the lubrication oilpump continuously to mini-mize starting problems

No

Yes

Alternatively, use an ISOVG 100 oil.

8/12/2019 CTHS430-02_IM_S223.855.en-01

32/80


S 223.855.en-01


3.4.3 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.

Modification kit

Modification kit Description Voltage (V) Rating (W) Connection

diagram

452.5370-901 Heaters and insulationfor a cold climate

Position number

1(2 )

Heater element 265/460240/415220/400

221902178521500

3.194.0191

2 Insulation3 Cable set - cold climate

1

132

1 Heater element - cold climate

2 Bottom plate insulated

3 Cable set - cold climate (not visible)

8/12/2019 CTHS430-02_IM_S223.855.en-01

33/80


33


3.4.4 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.

3.4.5 Heating cables on oil lines

See installation drawings in theInstallation Manual Appendix.

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 byinsulating 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 810 W/m and

40 mm (1.6") insulation.

Install the heating cable on the underside of the oil line and use insulating

tape to keep the cable in place. If possible, increase the slope of the return oil

line before installing heating cables.

If the oil lines are >50 mm (2") in diameter, or if the oil need be heated to a

temperature 50 C (122 F) above the ambient temperature, the heating cablecan 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.

Modification kit

452.5388-901

8/12/2019 CTHS430-02_IM_S223.855.en-01

34/80


S 223.855.en-01


3.4.6 Heating in the component section of the oil tank

unit

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.

CAUTION! 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.

3.4.7 Synthetic oils

Synthetic oils will allow for trouble-free starting at about 10C 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. See the

text and the table for mineral oil in the Operators and Maintenance Manual

for the oil tank unit.

(Continued)

Skid risk

When filling, controlling or changing oil there is a risk of spillage thatcan cause a slippery surface. Always remove oil spillage and stains

to avoid skid risk.

8/12/2019 CTHS430-02_IM_S223.855.en-01

35/80


35


The following synthetic oils are recommended by Sandvik for the lubricating

system. Other brands can be used after consulting the supplier.

The recommended synthetic oils can be mixed with mineral-based oils, but

should be diluted as little as possible. Empty the crusher and oil tank

carefully before refilling with synthetic oil. For further information, see the

Operators and Maintenance Manualfor the tank unit.

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.

CAUTION! 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.

3.4.8 Mineral oil for the winter season

In ambient temperatures below 0 C (32 F), an ISO VG 100 oil can be used.

CAUTION! Handle all oil and waste oil with care and according to the suppliersMaterial Safety Data Sheet (MSDS)and local regulations. Collect the

waste in suitable containers and dispose as recommended in the MSDSand according to local regulations.

Brand Type Minimum pour point Viscosity (cSt) at 40 C

Mobil oil SHC XMP 150 -48 C 150

Brand Type Minimum pour point Viscosity (cSt) at 40 C

Mobil oil SHC 626 -51 C 68

8/12/2019 CTHS430-02_IM_S223.855.en-01

36/80


S 223.855.en-01


3.4.9 Blanking off the oil cooler radiator

If the cooling fan on the air/oil cooler is started at low ambient temperature,

the pressure drop across the cooler will cause the by-pass valve CV4on the

cooler to open. The oil is then not cooled at all and can overheat.

The easiest way to avoid this is to blank off the radiator so that less air passesthrough the radiator matrix. The degree of blanking depends on the ambient

temperature and must be determined by trial-and-error.

3.4.10 Frequency converter

To reduce the air flow through the radiator, a frequency converter for the oil

cooling fan can be used.

For further information about the frequency converter, please contact

Sandvik

3.4.11 Two-speed fan motor for oil coolerAnother 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

4346 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

4340 C (109-104 F) Runs at low speed

40 C (104 F) The fan stops

8/12/2019 CTHS430-02_IM_S223.855.en-01

37/80


37


3.4.12 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 materialis 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.

3.4.13 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 crushers feed opening to

prevent excessive cooling by cold air passing through the crusher chamber.

8/12/2019 CTHS430-02_IM_S223.855.en-01

38/80


S 223.855.en-01



8/12/2019 CTHS430-02_IM_S223.855.en-01

39/80

39


4. Transport handlingTo ensure maximum safety, always readsection 2. Safety precautionsbefore


8/12/2019 CTHS430-02_IM_S223.855.en-01

40/80


S 223.855.en-01

IM Sandvik CTHS430:02 Tank unit 4. Transport handling

4.1 Goods data

The oil tank unit is delivered as a complete assembled unit. Auxiliary and

optional equipment is delivered in separate packages.

Some basic measurements are given in the table below to indicate the spacerequired by the equipment during transportation. The number of packages

delivered may vary depending on the oil tank variant and equipment.

4.1.1 Contents

A Package Inventory List is attached to one of the packages in the delivery.

Part name Mass

kg (lbs)

Measurements L W H

mm (")

Tank unit 400 (800) 1350 950 900 (53.2 37.4 35.5)

Air/oil cooler 150(330) 1000 800 700 (40 27.6 23.6)

Water/oil cooler (option) 100 (220) 300 300 700 (20 11.9 27.6)

NOTE! If the tank is collected from the factory, check before transport that the

equipment corresponds with the items in the Package Inventory List.

If the tank is delivered by Sandvik either to a harbour or to the work site,

check immediately after arrival that the equipment corresponds with the

items in the Package Inventory List.

8/12/2019 CTHS430-02_IM_S223.855.en-01

41/80


41


4.1.2 Loading and unloading goods signs

Make sure that the handling personnel understand and follow the mandatory

and warning symbols used on the packages.

Use the forks here Overhead lifting point

Center of gravity Lifting point for chain

NOTE! Maximum load for both lifting eyes and lifting angles are shown in the

installation drawings in the Installation Manual Appendix.

885.0260-00

885.0250-00

8/12/2019 CTHS430-02_IM_S223.855.en-01

42/80


S 223.855.en-01


4.2 Lifting equipment

Different types of lifting equipment

The following types of equipment can be used to lift and move the goods:

overhead gantry

mobile crane

fork lift (use only for goods on pallet/platform)

Equipment specifications

Make sure that the lifting capacities of the equipment and tackle comply with

the minimum values given in the following table.

NOTE! Lifting with fork lift without a pallet or a platform may damage the goods.

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.

Equipment or tackle Lifting capacity

kg (lbs)

Overhead gantry 500 (1200)

Mobile crane 500 (1200)

Lifting chains, cables, ropes or slings 500 (1200)

Fork lift (only for goods on pallet/platform) 500 (1200)

8/12/2019 CTHS430-02_IM_S223.855.en-01

43/80


43


4.2.1 Overhead gantry or mobile crane

The following instructions apply to this oil tank unit.

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 in which they are to be used.

c) Make sure that the lifting equipment has a sufficient WLL (Working

Load Limit) for the weight to be lifted and for the method of lifting.

d) Follow the applicable lifting standard for the equipment used.

e) Place the lifting equipment according to the symbols found insection

4.1.2 Loading and unloading goods signs

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 chains. Make sure that the hooks

are secure in the lifting eyes of the component. If necessary, adjust the

chains to distribute the load evenly.

h) Check that the chains can straighten out correctly. Never lift with atwisted 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 twitches and

jerks.

k) Never use hands or feet to guide the load. Keep clear of the load.

DANGER!

Hanging load

Keep clear of hanging loads. Seesection 2. Safety precautions.Check the gross weight of the components to be lifted and make sure

the WLL (Working Load Limit) of the lifting equipment is sufficient forthe weight to be lifted.

8/12/2019 CTHS430-02_IM_S223.855.en-01

44/80


S 223.855.en-01


4.2.2 Using a fork lift (only for goods on pallet)

The following instructions apply to this oil tank unit.

CAUTION! Always use the lifting eyes mounted on the top of the oil tank unit and

a suitable lifting sling or similar when lifting the oil tank unit withoutpallet/platform, see the installation drawings in the Installation Manual

Appendix.

The oil tank unit must be placed on a pallet/platform when lifted with a fork

lift.

a) Make sure that the forks are of the correct length and lifting capacity for

the oil tank unit on its transport pallet/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 pallet/

platform.

d) If the transport platform of the component is fitted with fork tubes,

manoeuvre the forks inside these to lift the component.

e) Make sure that the destination is clear and able to support the weight

before lifting.

f) Lift and move the load carefully and calmly.

g) Lower the load gently to the floor.

DANGER!

Hanging load

Keep clear of hanging loads. Seesection 2. Safety precautions.Check the gross weight of the components to be lifted and make sure

the WLL (Working Load Limit) of the lifting equipment is sufficient forthe weight to be lifted.

8/12/2019 CTHS430-02_IM_S223.855.en-01

45/80


45


4.3 Unloading the goods

4.3.1 Unpacking area

The unpacking area should have approximately 1.5 m (5 ft) of free space

around and above the tank.

4.3.2 Inspection of goods

Inspect the outside and wrapping of the packages before unloading. Report

any damage immediately to the person responsible for the installation.

If the damage is severe enough to prevent installation, submit a damage

claim to the transport company without delay. If possible, document thedamage with a camera.

Minimum recommended unpacking area L W H

CTHS430 3 2.5 2.5 m (10 8.2 8.2 ft)

NOTE! If damage has occurred during transport, report this immediately also to the

Sandvik shipping department. The address is found on thePackage

Inventory List.

8/12/2019 CTHS430-02_IM_S223.855.en-01

46/80


S 223.855.en-01


4.4 Moving and Storage

Important notes

If the oil tank must be stored before installation, make sure that the storage

area meets the requirements insection 4.4.2 Storage.If possible, place the oil tank unit at the installation site before unpacking.

Do not unpack the components until immediately before starting installation.

Position the packages on the installation site so that the oil tank unit can be

lifted out and installed without being turned around.

When lifting, follow the instructions insection 4.2 Lifting equipment.

4.4.1 Moving

a) Attach the lifting equipment according to the instructions insection

4.2 Lifting equipmentand the drawings in theInstallation Manual

Appendix.

b) Remove any screws holding the transport platform to the component.

c) Lift the component only enough to clear the floor.d) Make sure that the component remains stable on the lifting equipment.

e) Check that the transport platform has come loose from the oil tank unit.

f) Move the load into position.

g) Lower it gently to the floor. Leave enough room for access to all sides.

h) Make sure that the component is firmly supported.

i) Remove the lifting equipment.

4.4.2 Storage

CAUTION! Sandvik recommends storing the oil tank unit indoors. Long-term

exposure to moisture or very high or low temperatures may damage thetank.

WARNING!

Hanging loadKeep clear of hanging loads. Seesection 2. Safety precautions.Check the gross weight of the components to be lifted and make surethat the WLL (Working Load Limit) of the lifting equipment is sufficient

for the weight to be lifted.

WARNING!

Hanging load

Keep clear of hanging loads. Seesection 2. Safety precautions.Check the gross weight of the components to be lifted and make surethat the WLL (Working Load Limit) of the lifting equipment is sufficient


8/12/2019 CTHS430-02_IM_S223.855.en-01

47/80


47


a) Prepare a storage area large enough to store the components with at least

1.5 m (5 ft) of free space around and above for access and ventilation.

b) Make sure that the storage area environment meets the conditions in the

table below:

c) Lift the components into position according to the instructions insection

4.4.1 Moving. If the ground/floor is uneven, place blocks or plates under

the components to provide a steady support.

d) Make sure that the components are stable before removing the lifting

equipment.

Characteristic Value Notes

Minmax temperatures 540 C (41104 F)

Max relative humidity 80% Non-condensing

NOTE! Before delivery from the factory, the oil tank unit is wrapped with rust

preventative materials sufficient for approximately one year of storage.

8/12/2019 CTHS430-02_IM_S223.855.en-01

48/80


S 223.855.en-01


4.5 Unpacking the goods

a) Remove any loose boxes and packages before unpacking the main

components.

b) Unpack and check each item against the Package Inventory List.

c) Check the unpacked components and accessories for damage. In case of

damage, send a transport damage report to Sandvik.

See alsosection 4.3.2 Inspection of goods.

d) Open the crushers tool box and take out the documentation.

e) Locate the Package Inventory List.

f) Check that the data on the oil tank unit identification plate corresponds

with the Package Inventory List. Seesection 1.1 Equipment

information.

g) Move spare and wear parts to the spare part store.

h) Dispose of the packaging material according to the instructions in

section 4.6 Disposal/return of packaging material.

WARNING!

Hanging load

Keep clear of hanging loads. Seesection 2. Safety precautions.

Check the gross weight of the components to be lifted and make surethat the WLL (Working Load Limit) of the lifting equipment is sufficient


8/12/2019 CTHS430-02_IM_S223.855.en-01

49/80


49


4.6 Disposal/return of packaging material

The packaging material includes all pallets, crates, wrapping, boxes and

other protective material that are not part of the equipment. Packaging is

normally not returned to the manufacturer. Check if there is a special agreement for the return of the packaging to

the manufacturer.

If the packaging must be returned, prepare an area to store pallets,

transport racks and any other returnable packaging.

Check if there is a special arrangement for recycling packaging material.

If the packaging is not to be returned or recycled, check with the local

authorities how to separate and dispose of packaging material.

Dispose of pollutant waste (bubble wrapping, plastic bags, expanded

polystyrene, etc.) in accordance with local regulations.

8/12/2019 CTHS430-02_IM_S223.855.en-01

50/80


S 223.855.en-01



8/12/2019 CTHS430-02_IM_S223.855.en-01

51/80

51


5. Mechanical installation and

connectionsTo ensure maximum safety, always readsection 2. Safety precautionsbefore


8/12/2019 CTHS430-02_IM_S223.855.en-01

52/80


S 223.855.en-01

IM Sandvik CTHS430:02 Tank unit 5. Mechanical installation and connections

5.1 General requirements

Personnel

Only qualified installation personnel are authorized to install the oil tank

unit. Seesection 2. Safety precautionsfor a definition of installationpersonnel.

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, for further information, see theInstallation Manual

Appendix.

If any adjacent machines on the site cannot be stopped, take measures to

prevent accidental contact.

c) Make sure that lighting on the installation site is adequate. Use

additional portable lights if necessary.

Lifting equipment, tools and materials

The equipment used for lifting and moving the components can also be used

for unpacking and installing the oil tank unit.

Seesection 4.2 Lifting equipment.

Packing

Leave wrapping and ties on the parts until they are ready for use.

Leave the plastic plugs in the oil line openings until they are ready to be

connected, but do not forgetto remove them before connecting the pipes.

8/12/2019 CTHS430-02_IM_S223.855.en-01

53/80


53


5.2 Foundation

The oil tank unit might need an adequately dimensioned foundation. Sandvik

recommends a steel supporting structure or a concrete foundation.

A steel supporting structure or a transportable frame must be mountedhorizontally and rest on a firm ground. If the oil tank unit is not sufficiently

stable the supporting structure will vibrate and be subjected to stresses.

For general information on placement, seesection 3.3 Placement.

5.3 Hydroset and lubrication systems

Oil is supplied to the crusher through two lines one two-way line from the

Hydroset cylinder and one to the main lubrication system.

The pinionshaft is lubricated in an oil bath in the pinionshaft housing.

The oil returns to the oil tank unit through two lines the Hydroset two-way

line and the main lubrication return oil line.

For general information on placement, seesection 3.3 Placement.

NOTE! The oil tank unit can be installed on either side of the crusher. This is

important to decide before the foundation is designed.

For further information, see the Installation Manual Appendix.

8/12/2019 CTHS430-02_IM_S223.855.en-01

54/80


S 223.855.en-01


5.4 Hoses and pipes General

Route all pipes and/or hoses to and from the crusher along the same path.

All pipes and/or hoses to and from the crusher must be carefully sealed and

tightened to avoid leakage and prevent the pipes/hoses to come loose from

the connections.

The inclination of return lines is critical. Seesection 5.4.1 Oil tank unit.

For a description of hoses, pipes and connections on the tank unit and

crusher, see theInstallation Manual Appendix.

5.4.1 Oil tank unit

a) Install the tank unit in a suitable location.

See alsosection 3.3 Placementandsection 4. Transport handling.

(Continued)

NOTE! Pipes are not supplied by Sandvik.

NOTE! When starting the pumps the first time, make sure there are no leakages.

If there are leakages, use a suitable compound to seal.

WARNING!

Hanging load

Keep clear of hanging loads. Seesection 2. Safety precautions.The oil tank unit without cooler weighs approx. 310 kg (700 lbs).

Make sure that the WLL (Working Load Limit) of the lifting equipmentis sufficient for the load.

NOTE! The tank unit must be placed below the level of the cone crusher.

L

L Return oil hose

8/12/2019 CTHS430-02_IM_S223.855.en-01

55/80


55


b) Connect the oil lines to the tank unit, see theInstallation Manual

Appendix.

Make sure that there are no kinks in the return oil hoses/pipes.

Avoid pipe elbows. Use large-radius pipe bends instead to reduce

resistance in the piping.

Run the piping so that it is protected against 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 water piping and hoses for lubrication oil lines.

c) Inspect and clean the lubrication oil tank.

Hydroset connections

a) Connect the Hydroset oil line to the oil tank unit with high-pressure

piping or hoses.

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 against 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.

b) Inspect and clean the Hydroset tank.

Distance tank crusher Inclination of return oil hose

< 3 m (10 ft) 5

> 3 m (10 ft) 10

NOTE! The connections are already fitted to the crusher. Pipes and pipe fittings are

not supplied by Sandvik.

8/12/2019 CTHS430-02_IM_S223.855.en-01

56/80


S 223.855.en-01


5.4.2 Air/oil cooler

For further information, see theInstallation Manual Appendix.

CAUTION! If the crusher is installed at high altitude and/or extremely high or low

ambient air temperature, a special cooling system is required.

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 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/oilcooler is best placed so that the fan blows towards the crusher.

A by-pass valve CV4is fitted on the air/oil cooler. Its duty is to limit the

pressure over the pump and coolers if the crusher is started at low

temperatures.

a) Install the air/oil cooler on or close to the tank unit.

b) Connect the hoses to the cooler.

c) Connect piping or hoses to the tank unit.

NOTE! The cooler and the piping must be shielded from direct sunlight.

NOTE! Pipes and pipe fittings are not supplied by Sandvik.

CV4

Air flow

CV4 By- pass valve

8/12/2019 CTHS430-02_IM_S223.855.en-01

57/80


57


5.4.3 Water/oil cooler (option)

See also the drawing in theInstallation Manual Appendix.

a) Connect water piping or hoses to the cooler. This must be arranged at the

site to suit local conditions.

b) Set the temperature switch TS2to the correct value.

For further information about temperature switches, see the Operators and

Maintenance Manual for the tank unit.

The supply of cooling water is controlled by temperature switch TS4.

The values on its scale correspond to the following oil temperatures:

c) Set the temperature switch TS4to 3 on the scale to keep the oil at

43 C (109 F).

NOTE! Pipes, water pump and pipe fittings are not supplied by Sandvik.

NOTE! Use clean fresh water. If only contaminated water is available, contact

Sandvik first!

NOTE! When a water/oil cooler is used, the temperature switches should be set atthe values for Normal Operating Conditions regardless of the ambient

temperature. For further information, see the Operators and Maintenance

Manual for the tank unit.

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

J

O

V

U

TS4 TS4J Water in

O Water out

U Oil from tank

V Oil to crusher

TS2 Temperature

switch- return oil

TS4 Temperature switch

AVTA 25

8/12/2019 CTHS430-02_IM_S223.855.en-01

58/80


S 223.855.en-01


5.5 Overpressure system

The cone crusher and the tank unit are equipped with a common

overpressure system to prevent dust from entering the cone crusher or the oil

tank and contaminating the oil. A correctly functioning overpressure system

is important for the performance of the crusher.

(Continued)

Minimum and maximum length of hoses 215 m (750 ft)

Minimum and maximum pressure 6001000 Pa (0.0870.145psi)

Minimum blower capacity at 600 Pa0.3 m

3

/min (793 US gall./min)

NOTE! Hoses, pipes and pipe fittings are not supplied by Sandvik.

C C

C

PF

M8

FU5

1

1

2

2

1

1

P

P

C

C

FV6FU6

P

1 Hoses

2 Coupling to the air supplier

FU5Air filter

PF Fan

M8 Motor to fan

FV6Compressed air regulator

FU6Filter to air regulator

P Coupling to the oil tank unit

C Coupling to the pinionshaft housing

8/12/2019 CTHS430-02_IM_S223.855.en-01

59/80


59


Normally the system consists of two hoses and an air supplier. The air

supplier is a fan or a regulator with filter connected to a compressed air

system.

The hoses are joined in a T-connector on the pinionshaft housing. The length

of the hoses depends on the position of the air supplier and the tank.

For detailed drawings, see theInstallation Manual Appendix.

a) Install the fan or the regulator with filter

The 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 isnt

correct, the output of the fan will be insufficient.

CAUTION! It is important to install the fan in a dust free environment. Dust willdamage the blower and result in malfunction of the cone crusher.

The regulator FV6with filter FU6must be mounted horizontally and if

it is possible, they should be installed in a heated space.

b) Measure the hose length between the air suppliers coupling (2) and the

T-connection Con the pinionshaft.

Measure the hose length between the T-connection Con the pinionshaft

and the tank overpressure coupling P.

c) Cut the appropriate lengths from the hose coil supplied with the oil tank

unit.

d) Connect one hose (1) between the air suppliers coupling (2) and the T-

connection C on the pinionshaft housing. Use hose clamps.

e) Connect the other hose (1) between the tank overpressure coupling P and

the T-coupling Con the pinionshaft housing. Use hose clamps.

NOTE! Air introduced into the crusher and the tank must be free from moisture and

dust.

NOTE! Install the fan or the regulator at least 0.5 m (20") above the tank and the

pinionshaft to prevent oil from running into them.

8/12/2019 CTHS430-02_IM_S223.855.en-01

60/80


S 223.855.en-01


5.6 Lubricants

Fill the required amount of oil into the tanks.

For further information about lubricants and lubrication, see the Operators

and Maintenance Manual.

Keep some extra oil within easy reach. It may be necessary to add some after

start-up due to the length of the hoses.

8/12/2019 CTHS430-02_IM_S223.855.en-01

61/80

61


6. Electrical installationTo ensure maximum safety, always readsection 2. Safety precautionsbefore


8/12/2019 CTHS430-02_IM_S223.855.en-01

62/80


S 223.855.en-01

IM Sandvik CTHS430:02 Tank unit 6. Electrical installation

6.1 General requirements

Electricians

Electricians should be certified according to local regulations and have

experience of similar types of installations, proven skills in reading andworking 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 further information, seesection 2. Safety precautions.

6.2 Overview

Electrical drawings are included in theInstallation Manual Appendix.

The purpose of the electrical system is to power the cone crusher with itsauxiliary systems and to control the operation.

If in any doubt about the connection, testing and operation of the electrical

equipment, please contact Sandvik SRP AB.

Connections for pump motors and other equipment are routed through

connection box L9 on the oil tank unit. The air/oil cooler fan and

overpressure air fan motors are connected directly.

8/12/2019 CTHS430-02_IM_S223.855.en-01

63/80


63


6.3 Motors and heating elements

Starting equipment for the oil tank pumps/motors 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.

6.3.1 M2 Main lubrication pump

The power supply to the motor must incorporate the necessary fuse, relay

and motor protector, all installed in an electrical cabinet. Starting and

stopping can be made possible either by buttons or via software.

6.3.2 M3 Oil cooler fan motor

Every crusher has an air/oil or water/oil (option) cooler in the lubrication

system. The temperature is controlled by a temperature switch TS2. The

power supply to each air/oil cooler motor must incorporate the necessary

fuse, relay and motor protection built into an appropriate switch gear cabinet.

With a water/oil cooler it can be convenient to open/close the cooling water

supply with a magnetic valve.

For further information about temperature switches, see the Operators and

Maintenance Manualfor the tank unit.

6.3.3 M6 Hydroset pump

Starting and control equipment for the Hydroset pump is normally delivered

by Sandvik. The delivered electrical cabinet L3contains fuses, relays and

motor protection for operation of the Hydroset pump.

6.3.4 E7 Oil heaters

The power supply to the oil heaters must incorporate the necessary fuse,

relay and motor protection built into an appropriate switch gear cabinet.

The temperature is controlled by a temperature switch TS3.

6.3.5 M8 Overpressure fan

The power supply to the overpressure fan must incorporate the necessary

fuse, relay and motor protection built into an appropriate switch gear cabinet.

NOTE! The crusher drive motorsM1 relaymust be interlocked with the main

lubrication pump motorM2, so it is only possible to run the crusher when

the lubrication pumpM2is in operation.

8/12/2019 CTHS430-02_IM_S223.855.en-01

64/80


S 223.855.en-01


6.4 Connection boxes

L9

ASRi-

CBT

L9 Connection box, motor power ASRi-CBT ASRi connection box

8/12/2019 CTHS430-02_IM_S223.855.en-01

65/80

65


7. Final installation checksTo ensure maximum safety, always readsection 2. Safety precautionsbefore


8/12/2019 CTHS430-02_IM_S223.855.en-01

66/80


S 223.855.en-01

IM Sandvik CTHS430:02 Tank unit 7. Final installation checks

7.1 Installation and connection checks

Seesection 5. Mechanical installation and connectionsfor further details on

the following checks.

7.1.1 Lubrication system and Hydroset checks

7.2 Electrical checks

Seesection 5. Mechanical installation and connectionsfor further details on

the following checks.

(Continued)

No. Checks Done

1 Brand name and type of oil and grease are recorded.

2 The oil tank unit is placed in relation to 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.

No. Checks Done

1 All electric cables are correctly connected.

2 All motors have the correct rotation direction.

8/12/2019 CTHS430-02_IM_S223.855.en-01

67/80


67


7.2.1 Check the pressure switch PS2

The pressure switch PS2is of normally open (NO) type. This means that if

the pressure switch malfunction it 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 switch PS2.

b) Remove the clip (1) on top of the pressure switch.

c) Remove the pressure switch PS2by pulling it straight up from the oil

filter assembly FU1.

d) Turn the pressure switch PS2upside down and position the pressure

switch back on the tube. The pressure drop warning lamp H10 on the

front panel will light up if the pressure switch works.Turn the pressure

switch PS2back to its normal position.

e) Fit the clip (1) on top of the pressure switch PS2.

WARNING!

Hot oilLubrication oil can become very hot during operation. Allow the oil to

cool before working on the lubrication system.Always wear protective gloves.

PS2H10

FU1

1

1 Clip

PS2 Pressure switch - main lubrication

FU1 Filter unit - main lubrication

H10 Pressure drop warning lamp -

main lubrication

8/12/2019 CTHS430-02_IM_S223.855.en-01

68/80


S 223.855.en-01


7.3 Safety checks

7.4 Start-up

No. Checks Done

1 All threaded fasteners have been tightened to the correct torque.

No. Checks Done

1 Prepare the oil tank unit for production.

See the Operators and Maintenance Manualfor further details.

8/12/2019 CTHS430-02_IM_S223.855.en-01

69/80

69


8. Preparations for

commissioningTo ensure maximum safety, always readsection 2. Safety precautionsbefore


8/12/2019 CTHS430-02_IM_S223.855.en-01

70/80


S 223.855.en-01

IM Sandvik CTHS430:02 Tank unit 8. Preparations for commissioning

8.1 General

Perform the following checks even if an actual commissioning test is not

required.

8.2 Presence and correctness checks

8.3 Supply value checks

NOTE! Commissioning covers only the functioning of the individual machine.A line performance test is still required to check the functioning of the oil

tank unit as part of a complete production line. Contact the local service

organization about arrangements for a line performance test.

No. Checks Done

1 The data on the oil tank unit identification plate corresponds with

the machine specification document.2 The ordered wear and spare parts have been delivered and

deposited in the spare part store.

3 All the documents correspond to the specific oil tank unit:

- Operators and Maintenance Manual (OMM)

- Installation drawings (IMA)

- Spare part catalog (SPC)

- Factory acceptance test report (if relevant)

- Machine specification document (if relevant)

- Machine deviation report (if relevant)

4 Sufficient process material is available for commissioning

purposes.

No. Checks Done

1 Hydroset and lubrication systems:

- Systems have been thoroughly cleaned

- Lubricants of the correct types are available

2 Electrical power supply:

- Voltage

- Max voltage fluctuation within limits- Frequency

- Fuse rating

8/12/2019 CTHS430-02_IM_S223.855.en-01

71/80


71


8.4 Function checks

8.4.1 Preparation

Start the oil tank unit according to the Operators and Maintenance Manual.

8.5 Health and safety checks

8.6 Documentation

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.

No. Checks Done

1 No unusual noises which could indicate misaligned parts or faults.

2 Hydroset pressure within limits,

see the Operators and Maintenance Manual, Technical Data

4 Oil heating elements operate correctly.

5 Overpressure dust exclusion system functions correctly

6 Return lubrication oil temperature within limits for the chosen oil.

No. Checks Done

1 The oil tank unit stops when an Emergency stopbutton (if appli-

cable) is pressed. Test must be made with the cone crusher run-

ning.

2 The oil tank unit stops after a short delay when theStopbutton for

the cone crusher is pressed.

3 All necessary guards are in place.

8/12/2019 CTHS430-02_IM_S223.855.en-01

72/80


S 223.855.en-01



8/12/2019 CTHS430-02_IM_S223.855.en-01

73/80

73


9. Disassembly, storage and

removalTo ensure maximum safety, always readsection 2. Safety precautionsbefore


78

8/12/2019 CTHS430-02_IM_S223.855.en-01

74/80


S 223.855.en-01

IM Sandvik CTHS430:02 Tank unit 9. Disassembly, storage and removal

9.1 Moving and storage

9.1.1 Short moves and short-term storage

CAUTION! Sandvik recommends storing of the oil tank unit indoors. Long-termexposure to moisture or very high or low temperatures may damage

the oil tank unit.

If the oil tank unit is to be taken out of operation and moved into storage,

carry out the following steps:

a) Shut off the cone crusher, see the Operators and Maintenance Manual

for the crusher.

b) Shut off and disconnect the electrical power, the compressed air supplies

and the cooling water if a water/oil cooler is used.

c) Drain the oil from the main lubricating system but leave the oil in the

pump.

See the Operators and Maintenance Manualfor the oil tank unit.

CAUTION! Handle all lubricants and waste lubricants with care and according to

the suppliers Material Safety Data Sheet (MSDS)and local regulations.Collect waste lubricants in suitable containers and dispose as

recommended in the MSDSand according to local regulations.

d) Drain the oil from the Hydroset system, but leave the oil in the pump.See the Operators and Maintenance Manualfor the oil tank unit

e) If a water/oil cooler is used (option): Drain the water circuit at the lowest

point. Make sure that no water remains in the water/oil cooler.

(Continued)

WARNING!

Hanging loadKeep clear of hanging loads. Seesection 2. Safety precautions.Check the weight of the components to be lifted and make sure that the

WLL (Working Load Limit) of the lifting equipment is sufficient for the

weight to be lifted.

WARNING!

Risk of electrocutionHigh voltage. Disconnect electrical power before disassembling the oil

tank unit.

8/12/2019 CTHS430-02_IM_S223.855.en-01

75/80


75


f) Plug or protect any open connections on the oil tank unit.

g) Check that the doors to the cabinet are closed and locked with the

handle.

h) Check that the main lubrication tank cover and the Hydroset tank cover

are fit to the tank, closed and the locking handles are fastened.

i) Prepare a storage area large enough to store the components with at least

1.5 m (5 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:

j) Disassemble the oil tank unit to the extent necessary for the planned

transport/storage. For further information on how to disassemble, see the

Operators and Maintenance Manual for the tank unit.

k) Move the oil tank unit to the storage area according to the instructions in

section 4.4 Moving and Storage.

l) Cover the oil tank unit with suitable covering if stored outdoors.

9.1.2 Long moves and long-term storage

If the oil tank unit is to be moved into storage for more than 30 days, the

following steps should be carried out.

a) Carry out the steps insection 9.1.1 Short moves and short-term storage.

b) Wrap any loose components in bubble wrap or other suitable wrapping

to prevent damage.

c) Pack the equipment using suitable packing, crates and transport

platforms. Use the original packing, crates and transport platforms if

possible. Make sure that all parts are adequately protected.

d) If there is no oil left in the pumps, fill with oil to keep all surfaces inside

lubricated.

Characteristic Value Notes

Minmax temperatures 540 C (41104 F)

Max relative humidity 80% Non-condensing

8/12/2019 CTHS430-02_IM_S223.855.en-01

76/80


S 223.855.en-01


9.1.3 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.

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.

9.2 Return to the manufacturer

a) Prepare the equipment for transport according to the instructions in

section 9.1 Moving and storage.

b) Contact the local service organization for further instructions on

arranging transport.

8/12/2019 CTHS430-02_IM_S223.855.en-01

77/80


77


9.3 Disposal

CAUTION! If the oil tank unit is to be permanently disposed of, follow the sequence givenbelow.

a) Shut down and disconnect the oil tank unit according to the instructions

insection 9.1 Moving and storage.

(Continued)

DANGER!

Risk of fire and explosion

Due to the risk of leakage, open

CTHS430-02_IM_S223.855.en-01

Documents

Transcript of CTHS430-02_IM_S223.855.en-01