CTHS430-02 IM S223.855.en-01

Installation Manual
Doc. No. S 223.855.en
Tank unit
SANDVIK CTHS430:02
This document is valid for:
Serial No. / Machine No.
Signature
SANDVIK CTHS430:02
Tank unit
Copyright 2012 Sandvik SRP AB. All rights reserved. No parts of this document may be reproduced or copied in any form or by any means without written permission from Sandvik SRP AB. All data and information in this manual may be changed without further notice. Reservations for misprints. Document number: S 223.855.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
IM Sandvik CTHS430:02 Tank unit
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
5. Mechanical installation and connections

5.1 5.2 5.3 5.4 General requirements ......................................................... Foundation.......................................................................... Hydroset and lubrication systems....................................... Hoses and pipes General ................................................ 5.4.1 Oil tank unit ............................................................ 5.4.2 Air/oil cooler ........................................................... 5.4.3 Water/oil cooler (option) ......................................... 5.5 Overpressure system.......................................................... 5.6 Lubricants ........................................................................... 52 53 53 54 54 56 57 58 60
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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7. Final installation checks

7.1 Installation and connection checks ..................................... 7.1.1 Lubrication system and Hydroset checks............... 7.2 Electrical checks ................................................................. 7.2.1 Check the pressure switch PS2 ............................. 7.3 Safety checks...................................................................... 7.4 Start-up ............................................................................... 66 66 66 67 68 68
8. Preparations for commissioning

8.1 8.2 8.3 8.4 General ............................................................................... Presence and correctness checks ...................................... Supply value checks ........................................................... Function checks .................................................................. 8.4.1 Preparation............................................................. 8.5 Health and safety checks.................................................... 8.6 Documentation.................................................................... 70 70 70 71 71 71 71
9. Disassembly, storage and removal

9.1 Moving and storage ............................................................ 9.1.1 Short moves and short-term storage...................... 9.1.2 Long moves and long-term storage ....................... 9.1.3 Regular inspection during storage ......................... 9.2 Return to the manufacturer ................................................. 9.3 Disposal .............................................................................. 74 74 75 76 76 77
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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
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 00 Telefax +46 (0)40 40 92 60
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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
Order number Manufacturer Maximum operating speed Year of manufacture
CE marking This equipment complies with the basic health, environment and safety regulations of the European Union and European Economic Area. Sandvik will not take responsibility for this compliance when customers modify any configuration of the oil tank unit.
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1. Introduction
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 in section 2.1.5 Personnel. Feedback If you have comments on this manual or problems connected to the documentation, send an e-mail to: manuals.srp@sandvik.com
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1. Introduction
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 Manual for the tank unit. The pinionshaft lubrication is described in the Operators manual for 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.
1 2 3
Oil tank unit Overpressure fan Overpressure air regulator (option)
4 5
Air/oil cooler Water/oil cooler (option)
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1. Introduction
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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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2.1 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
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2.1.2 Risk levels

Throughout the manual, risk levels are indicated with DANGER, WARNING or CAUTION. The DANGER and WARNING levels are accompanied by a warning sign, see section 2.1.1 Warning signs.
Failure to observe information marked DANGER! can result in lifethreatening injuries! DANGER! Failure to observe information marked WARNING! can result in personal injury and/or serious damage to, or destruction of, equipment! WARNING! CAUTION! Failure to observe information marked CAUTION! can result in minor personal injury and/or damage to equipment!
2.1.3 Prohibition signs
Do not remove guards
2.1.4 Mandatory signs
Disconnect current
Read the manual
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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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2.1.6 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
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2.2 General safety precautions

Falling stones Clear the feed arrangement and the crusher thoroughly from process material before any maintenance work is carried out inside or below the crusher, to prevent stones from falling down.
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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2.2.1 Machine safety guards

Do not remove guards Make sure that all guards are in place and functioning, to prevent exposure to rotating parts. Only operate the equipment when all PROHIBITION! guards are mounted. Rotating parts Exposure to rotating parts (pumps, fans etc.) must be prevented by guards. Always attach the guards after maintenance work. WARNING! 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.
WARNING!
Make sure all defective guards are checked, repaired and replaced before starting the equipment.
2.2.2 Machine access

Every machine requires access for personnel who carry out inspections and/ or maintenance work. Suitable access platforms and guard rails must be installed. Walkways, stairs and ladders must be designed in accordance with applicable regulations. These parts are not included in the tank units standard specification. For advice, contact Sandvik SRP AB.
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2.2.3 Electrical safety

CAUTION! Only personnel working according to European Standard EN 50110 or equivalent are permitted to perform electrical operations on the equipment. Dangerous voltage Personnel must regard all electrical equipment as live until it is proven dead by proper testing procedures. DANGER!
Make sure all broken or damaged electrical cables and connectors are checked, repaired and replaced before starting the equipment. Control cabinets must be lockable.
2.2.4 Welding
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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2.2.5 Hydraulic system

CAUTION! Only personnel certified in hydraulics are permitted to perform maintenance on the hydraulic system (except bleeding air from the Hydroset system). Oil pressure Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system. Never adjust pressure relief valves beyond the recommended values. Hot oil Hydraulic oil can become very hot during operation. Allow the oil to cool before working on the hydraulic system. WARNING! Hot surface Equipment and hoses/pipes containing hydraulic oil can have hot surfaces. Always wear protective gloves. WARNING! Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk. Make sure all defective hoses, valves or fittings are checked, repaired and replaced before starting the equipment.
WARNING! CAUTION!
WARNING! CAUTION!
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2.2.6 Lubrication system

When changing from mineral oil to synthetic oil, or if the oil has coked, the tank unit must be thoroughly cleaned. Contact Sandvik SRP AB for further instructions. Oil pressure Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system. Hot oil Lubrication oil can become very hot during operation. Allow the oil to cool before working on the lubrication system. WARNING! Hot surface Equipment and hoses/pipes containing lubrication oil can have hot surfaces. Always wear protective gloves. WARNING! Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk. Make sure all defective hoses, valves or fittings are checked, repaired and replaced before starting the equipment.
WARNING!
WARNING! CAUTION!
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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 as recommended in the MSDS and according to local regulations. Toxic substances Read the suppliers Material Safety Data Sheet (MSDS). Used and contaminated oil can be a health hazard. Use protective gloves and goggles. Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk.
WARNING!
WARNING!
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 to evaporate before pouring oil into the cleaned compartments. Health hazard Before you use a cleaning agent, read the suppliers Material Safety Data Sheet (MSDS) and follow the instructions carefully. Risk of serious injuries to eyes, skin, respiratory system etc. Use personal protection and other safety measures as recommended in the MSDS. Handle all cleaning agents and their waste with care and according to the suppliers Material Safety Data Sheet (MSDS) and local regulations. Collect the waste in suitable containers and dispose as recommended in the MSDS and according to local regulations.
WARNING!
CAUTION!
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2.2.9 Lifting and moving loads

CAUTION! Only personnel with adequate lifting training are permitted to perform lifting operations. Hanging load Never work or stand underneath a crane that is lifting material. Keep a safe distance to hanging loads. DANGER!
Make sure that the capacity of the lifting equipment (Working Load Limit, WLL) is adequate and that the lifting equipment is in good working order. If lifting tackle has to be made up by joining separate components, make sure that the joints are secure and have the same lifting capacity (Working Load Limit, WLL) as the rest of the tackle.
NOTE!
Always use lifting tackle certified in accordance with local conditions. Always engage the safety clips on lifting hooks to prevent the tackle from slipping off. Use ropes or poles to steady and maneuver loads. Never use hands or feet. Make sure that the route and the destination are free from obstacles before moving a suspended load. It must be possible to quickly and safely lower the load to the ground in case of an emergency. When depositing loads, keep the lifting equipment in place until it has been made sure that the load is stable.
2.3 Emissions
For emissions such as dust, noise and radioactivity in the tank units environment, see section 2. Safety precautions in the crushers manuals.
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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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3.2 Installation preparations check list

System Placement Checks 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? Length of oil hoses and pipes? Foundation (if needed) Electrical system Foundation constructed according to drawings? 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 Platforms and guard rails Need for additional guards? Comply with local regulations? Designed so they do not interfere with crushers or tank units function? Remarks Date/sign
Type:
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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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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.
3.3.1 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. See section 6. Electrical installation and the electrical drawings in the Installation 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 motor M2 and the fan connected to the motor M3 on the air/ oil cooler.
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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.
NOTE!
If it is difficult to start the crusher even when the appropriate recommendations have been followed, contact Sandvik for further assistance.
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 individual case. A combination of several methods may be necessary. Part numbers for ordering the modification kits are listed under the respective methods. Heating cables on oil lines Additional oil heaters Diesel heating system Heating in the component section of the oil tank unit Synthetic oils Mineral oil for the winter season Blanking off the oil cooler radiator Two-speed fan motor for oil cooler 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
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3.4.2 Low temperature problems symptoms and remedies

Start
Start the oil pump. Does the Crusher ready for start signal appear within 40 s? Has the crusher started and continued to run normally? Start crushing when the crusher has warmed up.
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?
Does the crusher stop due to interruptions in return oil flow?
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.
Alternatively, install a frequency converter or a two-speed motor to the cooling fan.
Change to synthetic oil. Does oil flow back to the tank?
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?
Alternatively, use an ISO VG 100 oil.
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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3.4.3 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.
1
1 Heater element - cold climate 2 Bottom plate insulated
3 Cable set - cold climate (not visible)
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
Insulation Cable set - cold climate
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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.
Modification kit
452.5388-901
3.4.5 Heating cables on oil lines

See installation drawings in the Installation 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 by insulating the oil lines and installing heating cables. It is preferable to use a heating cable of the self-regulating type which needs no thermostat. The heating cable should have a rating of 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 cable can be led backwards and forwards on the same line. Heating cables are in many countries considered as high voltage equipment and must therefore be installed by an authorized electrician. The heating cable can be purchased from a local supplier who can usually also install it. Heating cable is normally supplied for 230 V.
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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

Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk.
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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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
Minimum pour point

-48 C
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
Minimum pour point

-51 C
Viscosity (cSt) at 40 C
68
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 suppliers Material Safety Data Sheet (MSDS) and local regulations. Collect the waste in suitable containers and dispose as recommended in the MSDS and according to local regulations.
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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 CV4 on 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 passes through 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 cooler

Another way to reduce the air flow through the radiator is to use a two-speed motor on the cooling fan. The speed of the cooling fan is determined by the oil temperature in the return line. Examples of switching points with ISO VG 150 oil:
Return oil temperature
Rising oil temperature 43 C (109 F) 4346 C (109-115 F) Over 46 C (115 F) Falling oil temperature Over 43 C (109 F) 4340 C (109-104 F) 40 C (104 F)
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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3.4.12 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 material is PAROC Pro Slab 35, 50 mm (2") thick. The insulation material must be protected from moisture, as it will otherwise lose its insulating properties. Insulation kits are not supplied by Sandvik.
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.
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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 space required by the equipment during transportation. The number of packages delivered may vary depending on the oil tank variant and equipment.
Part name
Tank unit Air/oil cooler Water/oil cooler (option)
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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4.1.2 Loading and unloading goods signs

Make sure that the handling personnel understand and follow the mandatory and warning symbols used on the packages.
885.0260-00
Use the forks here
Overhead lifting point
885.0250-00
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.
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4.2 Lifting equipment

Different types of lifting equipment The following types of equipment can be used to lift and move the goods:
NOTE!
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)
Lifting capacity kg (lbs)

500 (1200) 500 (1200) 500 (1200) 500 (1200)
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4.2.1 Overhead gantry or mobile crane

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 the WLL (Working Load Limit) of the lifting equipment is sufficient for the weight to be lifted.
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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4.2.2 Using a fork lift (only for goods on pallet)

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 the WLL (Working Load Limit) of the lifting equipment is sufficient for the weight to be lifted.
DANGER!
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 without pallet/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.
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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.
Minimum recommended unpacking area L W H
CTHS430
3 2.5 2.5 m (10 8.2 8.2 ft)
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 the damage with a camera.
NOTE!
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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4.4 Moving and Storage

Important notes If the oil tank must be stored before installation, make sure that the storage area meets the requirements in section 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 in section 4.2 Lifting equipment.
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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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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4.5 Unpacking the goods

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) 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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4.6 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.
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5.1 General requirements

Personnel Only qualified installation personnel are authorized to install the oil tank unit. See section 2. Safety precautions for a definition of installation personnel. 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 the Installation 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. See section 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 forget to remove them before connecting the pipes.
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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.
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, see section 3.3 Placement.
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5.4 Hoses and pipes General

NOTE!
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.
5.4.1 Oil tank unit

Hanging load Keep clear of hanging loads. See section 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 equipment is sufficient for the load.
WARNING!
a) Install the tank unit in a suitable location. See also section 3.3 Placement and section 4. Transport handling.
L Return oil hose
NOTE!
The tank unit must be placed below the level of the cone crusher. (Continued)
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Distance tank crusher
Inclination of return oil hose
< 3 m (10 ft) > 3 m (10 ft)
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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5.4.2 Air/oil cooler

For further information, see the Installation Manual Appendix.
CAUTION! NOTE! If the crusher is installed at high altitude and/or extremely high or low ambient air temperature, a special cooling system is required.
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
CV4 By- pass valve
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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5.4.3 Water/oil cooler (option)

J Water in O Water out U Oil from tank V Oil to crusher TS2 Temperature switch- return oil TS4 Temperature switch AVTA 25
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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5.5 Overpressure system

Minimum and maximum length of hoses Minimum and maximum pressure Minimum blower capacity at 600 Pa
215 m (750 ft) 6001000 Pa (0.0870.145psi) 0.3 m3/min (793 US gall./min)
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.
FU5 PF M8 2 1 2 FU6 FV6 1 C C C C C 1 P P
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!
Hoses, pipes and pipe fittings are not supplied by Sandvik.
(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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6.1 General requirements

Electricians Electricians should be certified according to local regulations and have experience of similar types of installations, proven skills in reading and working from drawings and cable lists, and knowledge of local safety regulations regarding power and automation circuits. Work with electrical equipment must be performed only by skilled or instructed technicians. For further information, see section 2. Safety precautions.
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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6.3 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.
NOTE!
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.
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 Manual for 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 L3 contains 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.
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6.4 Connection boxes
ASRiCBT
L9
L9 Connection box, motor power
ASRi-CBT ASRi connection box
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7.1 Installation and connection checks

See section 5. Mechanical installation and connections for further details on the following checks.
7.1.1 Lubrication system and Hydroset checks

No. Checks Done
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.
7.2 Electrical checks

See section 5. Mechanical installation and connections for further details on the following checks.
No. Checks Done
1 2
All electric cables are correctly connected. All motors have the correct rotation direction.
(Continued)
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7.2.1 Check the pressure switch PS2

The pressure switch PS2 is 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.
Hot oil Lubrication oil can become very hot during operation. Allow the oil to cool before working on the lubrication system. Always wear protective gloves.
WARNING!
H10
PS2
1 PS2 FU1 H10
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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7.3 Safety checks

No. Checks Done
All threaded fasteners have been tightened to the correct torque.
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.
8.2 Presence and correctness checks

No. 1 2 3 Checks The data on the oil tank unit identification plate corresponds with the machine specification document. The ordered wear and spare parts have been delivered and deposited in the spare part store. 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) Sufficient process material is available for commissioning purposes. Done
8.3 Supply value checks

No. 1 Checks Hydroset and lubrication systems: - Systems have been thoroughly cleaned - Lubricants of the correct types are available Electrical power supply: - Voltage - Max voltage fluctuation within limits - Frequency - Fuse rating Done
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8.4 Function checks

8.4.1 Preparation
Start the oil tank unit according to the Operators and Maintenance Manual.
No. 1 2 4 5 6 Checks No unusual noises which could indicate misaligned parts or faults. Hydroset pressure within limits, see the Operators and Maintenance Manual, Technical Data Oil heating elements operate correctly. Overpressure dust exclusion system functions correctly Return lubrication oil temperature within limits for the chosen oil. Done
8.5 Health and safety checks

No. 1 Checks The oil tank unit stops when an Emergency stop button (if applicable) is pressed. Test must be made with the cone crusher running. The oil tank unit stops after a short delay when the Stop button for the cone crusher is pressed. All necessary guards are in place. Done
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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To ensure maximum safety, always read section 2. Safety precautions before carrying out any work on the equipment or making any adjustments. 78
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9.1 Moving and storage

9.1.1 Short moves and short-term storage
Hanging load Keep clear of hanging loads. See section 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. Risk of electrocution High voltage. Disconnect electrical power before disassembling the oil tank unit. WARNING! CAUTION! Sandvik recommends storing of the oil tank unit indoors. Long-term exposure to moisture or very high or low temperatures may damage the oil tank unit.
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)
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 in section 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.
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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.
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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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S 223.855.en-01
77
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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CTHS430-02 IM S223.855.en-01

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Installation Manual

Doc. No. S 223.855.en

This document is valid for:

Serial No. / Machine No.

IM Sandvik CTHS430:02 Tank unit

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

2012 Sandvik SRP AB

5. Mechanical installation and connections

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

7. Final installation checks

8. Preparations for commissioning

9. Disassembly, storage and removal

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

IM Sandvik CTHS430:02 Tank unit

1.1 Equipment information

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

Order number Manufacturer Maximum operating speed Year of manufacture

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

1.1.1 Document information

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

1.2 Operating principles

Oil tank unit Overpressure fan Overpressure air regulator (option)

Air/oil cooler Water/oil cooler (option)

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

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2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

IM Sandvik CTHS430:02 Tank unit

2.1 Hazard information

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

2.1.2 Risk levels

2.1.3 Prohibition signs

Do not remove guards

2.1.4 Mandatory signs

Read the manual

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

2.1.6 Personal protection

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

2.2 General safety precautions

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

2.2.1 Machine safety guards

2.2.2 Machine access

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

2.2.3 Electrical safety

2012 Sandvik SRP AB

IM Sandvik CTHS430:02 Tank unit

2.2.5 Hydraulic system

2012 Sandvik SRP AB