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Tank unit
SANDVIK CTHS430:02
Signature
SANDVIK CTHS430:02
Tank unit
Copyright 2012 Sandvik SRP AB. All rights reserved. No parts of this document may be reproduced or copied in any form or by any means without written permission from Sandvik SRP AB. All data and information in this manual may be changed without further notice. Reservations for misprints. Document number: S 223.855.en Original instructions Issue: 20120827 Version: 01 Document type: Installation Manual (IM)
Sandvik Stationsplan, SE-233 81 Svedala, Sweden Tel: +46 (0)40 409000, Fax: +46 (0)40 409260 www.sandvik.com
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 ............................................................. 2.1.1 Warning signs ....................................................... 2.1.2 Risk levels.............................................................. 2.1.3 Prohibition signs..................................................... 2.1.4 Mandatory signs..................................................... 2.1.5 Personnel............................................................... 2.1.6 Personal protection ................................................ 2.2 General safety precautions................................................. 2.2.1 Machine safety guards........................................... 2.2.2 Machine access ..................................................... 2.2.3 Electrical safety...................................................... 2.2.4 Welding .................................................................. 2.2.5 Hydraulic system.................................................... 2.2.6 Lubrication system ................................................. 2.2.7 Lubricants and waste lubricants............................. 2.2.8 Diesel oil, white spirit and other cleaning agents ... 2.2.9 Lifting and moving loads ........................................ 2.3 Emissions ........................................................................... 14 14 15 15 15 16 17 18 19 19 20 20 21 22 23 23 24 24
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3. Installation preparations
3.1 General ............................................................................... 3.2 Installation preparations check list ...................................... 3.3 Placement ........................................................................... 3.3.1 Electrical installation............................................... 3.3.2 Remote control system .......................................... 3.3.3 Guard ..................................................................... 3.4 Operating in low temperatures............................................ 3.4.1 Measures for easier starting and running in cold climate ........................................................ 3.4.2 Low temperature problems symptoms and remedies ..................................... 3.4.3 Heater set - cold climate ........................................ 3.4.4 Diesel heating system ............................................ 3.4.5 Heating cables on oil lines ..................................... 3.4.6 Heating in the component section of the oil tank unit ................................................... 3.4.7 Synthetic oils .......................................................... 3.4.8 Mineral oil for the winter season ............................ 3.4.9 Blanking off the oil cooler radiator .......................... 3.4.10 Frequency converter .............................................. 3.4.11 Two-speed fan motor for oil cooler ......................... 3.4.12 Insulation of the oil tank ......................................... 3.4.13 Continuous running of the lubrication oil pump ...... 26 27 28 29 29 29 30 30 31 32 33 33 34 34 35 36 36 36 37 37
4. Transport handling
4.1 Goods data ......................................................................... 4.1.1 Contents ................................................................. 4.1.2 Loading and unloading goods signs....................... 4.2 Lifting equipment................................................................. 4.2.1 Overhead gantry or mobile crane........................... 4.2.2 Using a fork lift (only for goods on pallet) ............... 40 40 41 42 43 44
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IM Sandvik CTHS430:02 Tank unit 4.3 Unloading the goods........................................................... 4.3.1 Unpacking area...................................................... 4.3.2 Inspection of goods................................................ 4.4 Moving and Storage............................................................ 4.4.1 Moving ................................................................... 4.4.2 Storage................................................................... 4.5 Unpacking the goods .......................................................... 4.6 Disposal/return of packaging material ................................ 45 45 45 46 46 46 48 49
6. Electrical installation
6.1 General requirements ......................................................... 6.2 Overview............................................................................. 6.3 Motors and heating elements ............................................. 6.3.1 M2 Main lubrication pump................................... 6.3.2 M3 Oil cooler fan motor....................................... 6.3.3 M6 Hydroset pump.............................................. 6.3.4 E7 Oil heaters ..................................................... 6.3.5 M8 Overpressure fan .......................................... 6.4 Connection boxes ............................................................... 62 62 63 63 63 63 63 63 64
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1. Introduction
To ensure maximum safety, always read section 2. Safety precautions before carrying out any work on the equipment or making any adjustments.
1. Introduction
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1. Introduction
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.
V10
8 1 2 7
3
1 2 3 4 Machine type Serial number/PCR Local manufacturer number Mass (kg)
4
5 6 7 8
CE marking This equipment complies with the basic health, environment and safety regulations of the European Union and European Economic Area. Sandvik will not take responsibility for this compliance when customers modify any configuration of the oil tank unit.
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1. Introduction
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1. Introduction
1.2.2 Description
The following figure shows an overview of the oil tank units nomenclature and components.
1 2 3
4 5
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1. Introduction
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2. Safety precautions
To ensure maximum safety, always read this section carefully before operating, carrying out any work on the equipment or making any adjustments.
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2. Safety precautions
General danger
Dangerous voltage
Risk of crushing
Hanging load
Skid risk
Flying fragments
Rotating fan
Irritant
Hot surface
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2. Safety precautions
Disconnect current
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2. Safety precautions
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.
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2. Safety precautions
Ear protection
Safety helmet
Eye protection
Protective gloves
Safety boots
Mask or respirator
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2. Safety precautions
WARNING!
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.
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2. Safety precautions
WARNING!
Make sure all defective guards are checked, repaired and replaced before starting the equipment.
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2. Safety precautions
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. Risk of fire and explosion Due to the risk of leakage, open flames and hot surfaces (>200 C/ >390 F) must be kept at a safe distance from the tank unit and the lubrication pipe work.
DANGER!
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2. Safety precautions
WARNING! CAUTION!
WARNING! CAUTION!
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2. Safety precautions
WARNING!
WARNING! CAUTION!
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2. Safety precautions
WARNING!
WARNING!
WARNING!
CAUTION!
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2. Safety precautions
Make sure that the capacity of the lifting equipment (Working Load Limit, WLL) is adequate and that the lifting equipment is in good working order. If lifting tackle has to be made up by joining separate components, make sure that the joints are secure and have the same lifting capacity (Working Load Limit, WLL) as the rest of the tackle.
NOTE!
Always use lifting tackle certified in accordance with local conditions. Always engage the safety clips on lifting hooks to prevent the tackle from slipping off. Use ropes or poles to steady and maneuver loads. Never use hands or feet. Make sure that the route and the destination are free from obstacles before moving a suspended load. It must be possible to quickly and safely lower the load to the ground in case of an emergency. When depositing loads, keep the lifting equipment in place until it has been made sure that the load is stable.
2.3 Emissions
For emissions such as dust, noise and radioactivity in the tank units environment, see section 2. Safety precautions in the crushers manuals.
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3. Installation preparations
To ensure maximum safety, always read section 2. Safety precautions before carrying out any work on the equipment or making any adjustments.
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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 the Installation Manual Appendix and with any site-specific installation drawings. If the site does not meet the specifications, please contact Sandvik SRP AB for guidance and customizing.
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. 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 in section 3.2 Installation preparations check list as a guide and for documenting the installation procedure.
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3. Installation preparations
Type:
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3. Installation preparations
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.
4 2
1 Crusher 2 Oil tank unit 3 Overpressure fan or regulator for compressed air
4 Pinionshaft
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. See section 5.4.1 Oil tank unit and installation drawings in the Installation 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. See section 5.5 Overpressure system and installation drawings in the Installation Manual Appendix. (Continued)
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3. Installation preparations
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 the Installation 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.
3.3.3 Guard
The oil tank unit have two moving parts covered with guards, the pump P1 connected to the motor M2 and the fan connected to the motor M3 on the air/ oil cooler.
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3. Installation preparations
If it is difficult to start the crusher even when the appropriate recommendations have been followed, contact Sandvik for further assistance.
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3. Installation preparations
No Yes
Oil returns to the tank, but not in sufficient quantity. Wait 3.5 min. to drain the crusher and then make a new attempt to start up.
Stop the oil pump. Has oil run back through the oil line to the return oil flow switch?
Has oil overflowed over the dust collar? 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?
Install low temperature equipment in the tank. (Heating in component section and insulated tank bottom.) Does oil flow back to the tank?
During long periods with very low temperatures, the crusher should be heated during the night to avoid excessive cooling. Position a fan heater beneath the crusher and cover the feed opening. In addition, the lubrication oil pump should be run continuously.
The ambient air temperature is too low, which makes the oil cooler too effective. The oil is slowed down and blocks the passages in the radiator coil! Blank off the radiator completely or partially. Start with 50% blanked off.
Under very low temperatures the radiator coil can be thawed out with a fan heater.
Install heating cables on the oil lines. Does oil flow back to the tank?
Insulate the oil tank. Does oil flow back to the tank?
Sometimes it can be advisable to run the lubrication oil pump continuously to minimize starting problems
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3. Installation preparations
1
1 Heater element - cold climate 2 Bottom plate insulated
Modification kit
Modification kit
452.5370-901
Description
Heaters and insulation for a cold climate
Voltage (V)
Rating (W)
Connection diagram
Position number
1 (2 ) 2 3 Heater element 265/460 240/415 220/400 22190 21785 21500 3.194.0191
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3. Installation preparations
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3. Installation preparations
Sandvik does not supply modification kits with fan heaters. Select a suitable fan heater from any supplier.
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)
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3. Installation preparations
The following synthetic oils are recommended by Sandvik for the lubricating system. Other brands can be used after consulting the supplier.
Brand
Mobil oil
Type
SHC XMP 150
Viscosity (cSt) at 40 C
150
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 Manual for 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.
Brand
Mobil oil
Type
SHC 626
Viscosity (cSt) at 40 C
68
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3. Installation preparations
Cooling fan
The fan starts at low speed Runs at low speed Runs at high speed Runs at high speed Runs at low speed The fan stops
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3. Installation preparations
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3. Installation preparations
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4. Transport handling
To ensure maximum safety, always read section 2. Safety precautions before carrying out any work on the equipment or making any adjustments.
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4. Transport handling
Mass kg (lbs)
400 (800) 150(330) 100 (220)
Measurements L W H mm (")
1350 950 900 (53.2 37.4 35.5) 1000 800 700 (40 27.6 23.6) 300 300 700 (20 11.9 27.6)
4.1.1 Contents
A Package Inventory List is attached to one of the packages in the delivery.
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.
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4. Transport handling
885.0260-00
885.0250-00
Center of gravity
NOTE!
Maximum load for both lifting eyes and lifting angles are shown in the installation drawings in the Installation Manual Appendix.
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4. Transport handling
overhead gantry mobile crane fork lift (use only for goods on pallet/platform)
Lifting with fork lift without a pallet or a platform may damage the goods. Equipment specifications Make sure that the lifting capacities of the equipment and tackle comply with the minimum values given in the following 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.
Equipment or tackle
Overhead gantry Mobile crane Lifting chains, cables, ropes or slings Fork lift (only for goods on pallet/platform)
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4. Transport handling
DANGER!
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 in section 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 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 twitches and jerks. k) Never use hands or feet to guide the load. Keep clear of the load.
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4. Transport handling
DANGER!
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.
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4. Transport handling
CTHS430
If damage has occurred during transport, report this immediately also to the Sandvik shipping department. The address is found on thePackage Inventory List.
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4. Transport handling
4.4.1 Moving
Hanging load Keep clear of hanging loads. See section 2. Safety precautions. Check the gross 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!
a) Attach the lifting equipment according to the instructions in section 4.2 Lifting equipment and the drawings in the Installation 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) f) g) h) i) Check that the transport platform has come loose from the oil tank unit. Move the load into position. Lower it gently to the floor. Leave enough room for access to all sides. Make sure that the component is firmly supported. Remove the lifting equipment.
4.4.2 Storage
Hanging load Keep clear of hanging loads. See section 2. Safety precautions. Check the gross 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. Sandvik recommends storing the oil tank unit indoors. Long-term exposure to moisture or very high or low temperatures may damage the tank.
WARNING!
CAUTION!
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4. Transport handling
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:
Characteristic
Minmax temperatures Max relative humidity
Value
540 C (41104 F) 80%
Notes
Non-condensing
c) Lift the components into position according to the instructions in section 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.
NOTE!
Before delivery from the factory, the oil tank unit is wrapped with rust preventative materials sufficient for approximately one year of storage.
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4. Transport handling
WARNING!
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 also section 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. See section 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.
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4. Transport handling
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4. Transport handling
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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 mounted horizontally 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.
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. For general information on placement, see section 3.3 Placement.
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Pipes are not supplied by Sandvik. 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. See section 5.4.1 Oil tank unit. For a description of hoses, pipes and connections on the tank unit and crusher, see the Installation Manual Appendix.
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!
a) Install the tank unit in a suitable location. See also section 3.3 Placement and section 4. Transport handling.
NOTE!
The tank unit must be placed below the level of the cone crusher. (Continued)
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5 10
b) Connect the oil lines to the tank unit, see the Installation Manual Appendix.
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/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.
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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 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. A by-pass valve CV4 is 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.
CV4
Air flow
NOTE!
Pipes and pipe fittings are not supplied by Sandvik. 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.
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See also the drawing in the Installation Manual Appendix. TS2 TS4
TS4 V
O
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.
NOTE!
Use clean fresh water. If only contaminated water is available, contact Sandvik first! b) Set the temperature switch TS2 to the correct value. For further information about temperature switches, see the Operators and Maintenance Manual for the tank unit.
NOTE!
When a water/oil cooler is used, the temperature switches should be set at the values for Normal Operating Conditions regardless of the ambient temperature. For further information, 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:
Value on scale
1 2 3 4 5
Oil temperature
25 C (77 F) 32 C (90 F) 43 C (109 F) 57 C (135 F) 65 C (149 F)
c) Set the temperature switch TS4 to 3 on the scale to keep the oil at 43 C (109 F).
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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.
1 Hoses 2 Coupling to the air supplier FU5 Air filter PF Fan M8 Motor to fan FV6 Compressed air regulator FU6 Filter to air regulator P Coupling to the oil tank unit C Coupling to the pinionshaft housing
NOTE!
(Continued)
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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 the Installation Manual Appendix.
NOTE!
Air introduced into the crusher and the tank must be free from moisture and dust. 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 will damage the blower and result in malfunction of the cone crusher.
NOTE!
The regulator FV6 with filter FU6 must be mounted horizontally and if it is possible, they should be installed in a heated space.
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. b) Measure the hose length between the air suppliers coupling (2) and the T-connection C on the pinionshaft. Measure the hose length between the T-connection C on 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 Tconnection C on the pinionshaft housing. Use hose clamps. e) Connect the other hose (1) between the tank overpressure coupling P and the T-coupling C on the pinionshaft housing. Use hose clamps.
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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.
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6. Electrical installation
To ensure maximum safety, always read section 2. Safety precautions before carrying out any work on the equipment or making any adjustments.
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6. Electrical installation
6.2 Overview
Electrical drawings are included in the Installation Manual Appendix. The purpose of the electrical system is to power the cone crusher with its auxiliary 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.
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6. Electrical installation
The crusher drive motors M1 relay must be interlocked with the main lubrication pump motor M2, so it is only possible to run the crusher when the lubrication pump M2 is in operation.
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6. Electrical installation
ASRiCBT
L9
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1 2 3 4 5
Brand name and type of oil and grease are recorded. The oil tank unit is placed in relation to cone crusher according to instruction and is properly installed. The Hydroset and lubrication systems are correctly installed. Air/oil or water/oil (option) cooler is installed properly. Piping and hosing has been installed according to the recommendations in this manual.
1 2
All electric cables are correctly connected. All motors have the correct rotation direction.
(Continued)
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WARNING!
H10
PS2
Clip Pressure switch - main lubrication Filter unit - main lubrication Pressure drop warning lamp main lubrication
FU1
a) Locate the pressure switch PS2. b) Remove the clip (1) on top of the pressure switch. c) Remove the pressure switch PS2 by pulling it straight up from the oil filter assembly FU1. d) Turn the pressure switch PS2 upside 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 PS2 back to its normal position. e) Fit the clip (1) on top of the pressure switch PS2.
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7.4 Start-up
No. Checks Done
Prepare the oil tank unit for production. See the Operators and Maintenance Manual for further details.
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8.1 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 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.
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2 3
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.
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WARNING!
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 Manual for 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 MSDS and according to local regulations.
d) Drain the oil from the Hydroset system, but leave the oil in the pump. See the Operators and Maintenance Manual for 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)
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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:
Characteristic
Minmax temperatures Max relative humidity
Value
540 C (41104 F) 80%
Notes
Non-condensing
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.
j)
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9.3 Disposal
CAUTION!
If the oil tank unit is to be permanently disposed of, follow the sequence given below.
Risk of fire and explosion Due to the risk of leakage, open flames and hot surfaces (>200 C/ >390 F) must be kept at a safe distance from the tank unit and the lubrication pipe work.
DANGER!
WARNING!
Toxic gases When dismantling and scrapping the oil tank unit it can be necessary to cut the parts. This process can create toxic gases. Provide good ventilation and use breathing apparatus. Environmental hazard Disposed oil tank parts can leak toxic substances into the subsoil water and soil during long-term storage. Recycle or dispose all material and components in compliance with the Material Safety Data Sheet (MSDS) if any and/or local regulations.
WARNING!
a) Shut down and disconnect the oil tank unit according to the instructions in section 9.1 Moving and storage. (Continued)
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b) Disassemble the equipment as much 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 Lubrication and water hoses Electrical cables Electrical components Pumps and motors Oil filters Lubricants c) Recycle or dispose all material and components in compliance with suitable Material Safety Data Sheets (MSDS) and local regulations.
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