QJ330-1107-english.pdf

operator’s manual

Doc. no. S 222.166 en

SANDVIK CJ211:01

This document is valid for:

Serial no. / Machine no.

Sign.

SANDVIK CJ211:01 © Copyright 2007 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 222.166 en Issue: 20070625 Version: 1

Sandvik SRP AB Stationsplan, SE-233 81 Svedala, Sweden Tel: +46 (0)40 409000, Fax: +46 (0)40 409260 www.sandvik.com

Table of contents

1. Introduction 1.1 Equipment information.......................................................... 6 1.1.1 Document information.............................................. 8 1.2 Operating principles of a jaw crusher ................................... 9 1.2.1 Description ............................................................. 10

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..................................................... 2.2 Personnel............................................................................ 2.2.1 Personal protection ................................................ 2.3 General safety precautions................................................. 2.3.1 Machine safety guards........................................... 2.3.2 Electrical safety...................................................... 2.3.3 Welding .................................................................. 2.3.4 Hydraulic systems.................................................. 2.3.5 Lifting and moving loads ........................................ 2.3.6 Feed and jams ....................................................... 2.4 Emissions ........................................................................... 2.4.1 Dust........................................................................ 2.4.2 Noise...................................................................... 2.4.3 Radioactivity...........................................................

14 14 14 14 14 15 16 16 17 18 18 19 19 20 21 21 21 21

3. Technical data 3.1 General data ....................................................................... 24 3.2 Processing data .................................................................. 24

4. Start up the jaw crusher 4.1 General ............................................................................... 26 4.1.1 Getting started ....................................................... 26 4.1.2 Running-in.............................................................. 27

CJ211:01

1 Sandvik SRP AB – Doc. no. S 222.166 en Ver. 1

Table of contents

5. Inspection and care 5.1 5.2 5.3 5.4

General ............................................................................... 30 Routine inspection and care ............................................... 31 Recommended tool box ...................................................... 32 Crushing chamber............................................................... 33 5.4.1 Jaw plates .............................................................. 33 5.4.2 Deflector plate ........................................................ 34 5.4.3 Clamping bar.......................................................... 34 5.4.4 Wear plate .............................................................. 35 5.4.5 Jaw shim plate ....................................................... 35 5.4.6 Support bar ............................................................ 35 5.4.7 Cheek plate ............................................................ 35 5.5 Setting adjustment system.................................................. 36 5.5.1 Toggle plate............................................................ 36 5.5.2 Toggle seat............................................................. 36 5.6 Setting measurement.......................................................... 37 5.6.1 Setting measuring gauge ....................................... 37 5.6.2 Gauge for CSS....................................................... 37 5.6.3 Measuring instructions ........................................... 38

6. Lubrication 6.1 General ............................................................................... 40 6.1.1 Manual lubrication .................................................. 40 6.1.2 Lubricant requirements........................................... 42

7. Crushing chamber 7.1 Exchanging clamping bars.................................................. 7.1.1 Removing clamping bar ......................................... 7.1.2 Installing clamping bar............................................ 7.2 Exchanging jaw plates ........................................................ 7.2.1 Removing jaw plate................................................ 7.2.2 Installing jaw plate .................................................. 7.3 Exchanging wear plates...................................................... 7.3.1 Removing wear plate ............................................. 7.3.2 Installing wear plate ............................................... 7.4 Exchanging support bars .................................................... 7.4.1 Removing support bar ............................................ 7.4.2 Installing support bar .............................................. 2

© Sandvik SRP AB – Doc. no. S 222.166 en Ver. 1

44 44 45 46 46 48 50 50 52 53 53 54

CJ211:01

Table of contents 7.5 Exchanging deflector plate ................................................. 7.5.1 Removing deflector plate ....................................... 7.5.2 Installing deflector plate ......................................... 7.6 Exchanging cheek plates.................................................... 7.6.1 Removing cheek plate ........................................... 7.6.2 Installing cheek plate ............................................. 7.7 Exchanging jaw shim plates ............................................... 7.7.1 Removing jaw shim plate ....................................... 7.7.2 Installing jaw shim plate .........................................

54 54 55 57 58 59 61 61 63

8. Setting adjustment system 8.1 8.2 8.3 8.4

General ............................................................................... Setting adjustment .............................................................. Pre-loading of retraction cylinder ........................................ Hand pump ......................................................................... 8.4.1 Setting the hydraulic pressure ............................... 8.4.2 Changing the discharge setting ............................. 8.5 Setting hydraulics (option) .................................................. 8.5.1 Setting the hydraulic pressure ............................... 8.5.2 Changing the discharge setting .............................

66 67 68 69 69 70 71 71 73

9. Troubleshooting 9.1 Faults and suggested corrective actions ............................ 76

10. Automatic lubricator (option) 10.1 General ............................................................................... 80 10.1.1 Automatic lubrication.............................................. 80 10.1.2 Lubricant requirements .......................................... 84

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Table of contents

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CJ211:01

1. Introduction To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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1. Introduction

1.1 Equipment information Purpose The purpose of this Sandvik equipment is to be a crusher component in a crushing and screening unit or site within an aggregate, recycling or mining process. It can also be configured as a stand-alone machine complete with motor, motor support, V-belts and pulley, and guards. The machine reduces the size of rocks, minerals, recycling material and similar materials. This crusher component has been exclusively designed for these applications. It is not the responsibility of Sandvik SRP AB to secure the design and usage for the complete aggregate, recycling or mining process. Sandvik SRP AB 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 Stationsplan SE-233 81 Svedala Sweden www.sandvik.com For maintenance Contact the nearest Sandvik SRP AB company, agent or representative, or the manufacturer directly: Sandvik SRP AB Service department SE-233 81 Svedala Sweden. Telephone +46 (0)40 409000 Telefax +46 (0)40 409260

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CJ211:01

1. Introduction Identification The figure below shows an example of the crusher’s identification plate. The identification plate contains data needed when contacting Sandvik SRP AB concerning this specific equipment. Enter the serial number of the associated machine in the intended field on the second page of this manual (the copyright page).

8 7

1 1 2 3 4 5 6 7 8

2

3

4

5

6

Machine type Part number Serial number Mass (kg) Order number Manufacturer Year of manufacture CE mark

CE marking This equipment complies with the basic health, environment and safety regulations of the European Union and European Economic Area. Sandvik SRP AB will not take responsibility for this compliance when a customer modifies the jaw crusher in any way.

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1. Introduction

1.1.1 Document information Purpose of this Operator’s manual The purpose of this Operator’s manual is to provide the operator with information on how to handle and operate 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 installation and operation of this equipment are: • •

Installation manual (IM) Wear parts catalog (WPC)

• Operator’s manual (OM) When ordering technical publications, always specify the language and quote the machine serial number. Technical publications related to maintenance of this equipment are: • Maintenance manual (MM) • Spare parts catalog (SPC) These publications are only available to trained maintenance personnel. Sandvik SRP AB can provide adequate training and authorize personnel. Read more about the document structure and accompanying work roles in section 2.2 Personnel. Number of pages This document contains a total of 86 pages. Feedback If you have comments on this Operator’s manual or problems connected to the jaw crusher’s documentation, send an e-mail to: [email protected]

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1. Introduction

1.2 Operating principles of a jaw crusher In a jaw crusher the process material is crushed between two rigid surfaces. The motion of the moving surface is independent of the load on the jaw crusher. The crushing action is achieved by the movement of the moving jaw (3), which together with the stationary jaw (4) and the cheek plates (2) form the crushing chamber. Individual pieces of the process material (e.g. rock or ore) are nipped, compressed and crushed between the two jaws. The quality and quantity of the produced process material is a product of the interaction between the jaw crusher and the process material. The geometry of the crushing chamber, the dynamics of the jaw crusher and the process material are the most important factors. The power from the motor is transferred through V-belts to one of the flywheels (1) that are mounted on the eccentric shaft (5). The rotation of the eccentric shaft and the movement of the toggle plate (6) cause an elliptical motion of the moving jaw. When the distance between the jaws decreases, the incoming process material will be subjected to a compressing stress and thereby crushed. When the moving jaw moves away from the stationary jaw, the process material is able to flow down through the chamber. The jaw plates must be regularly reversed or replaced as they are continuously worn. Read more in section 5. Inspection and care.

1 1 2 3 4 5 6

Flywheel Cheek plate Moving jaw Stationary jaw Eccentric shaft Toggle plate

5

2 3 4 6

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1. Introduction

1.2.1 Description The following figures show an overview of the jaw crusher’s nomenclature and components. Bottom view 1 Flywheel 2 Eccentric shaft (concealed) 3 Frame 4 Front frame end 5 Fastening for cheek plate 6 Foot 7 Hydraulic cylinder – wedge 8 Setting wedge (concealed) 9 Support bar 10 Retraction cylinder 11 Back frame end

1 2 3 4 5 6

7

8

9

10

11

Top view 12 13 14 15 16 17 18 19

10

Bearing housing Moving jaw Counterweight Deflector plate Clamping bar Cheek plate Jaw plate – moving Jaw plate – stationary

12 13

14 15 16 17 18 19


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1. Introduction Top view with drive and guards 20 21 22 23

Guard over V-belts and flywheel Motor Motor support Guard over free flywheel

20 21 22 23

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1. Introduction

This page is intentionally left blank

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2. Safety precautions To ensure maximum safety, always read this section carefully before doing any work on the equipment or making any adjustments.

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2. Safety precautions

2.1 Hazard information 2.1.1 Warning signs

General danger

Dangerous voltage

Risk of crushing

Hanging load

Risk of crushing

Flying fragments

2.1.2 Risk levels Throughout the manual, level of risk is indicated as “DANGER”, “WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels are accompanied by a warning sign (see above). 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 damage to equipment!

2.1.3 Prohibition signs

Do not remove guards

2.1.4 Mandatory signs

Disconnect current before any work

14

Read the manual


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2.2 Personnel All work on the equipment is to be carried out only by trained or authorized personnel. – “Trained” means that the person in question has been given practical instruction by an authorized person on how the various tasks are to be carried out. – “Authorized” means that a person has undergone a theoretical and practical test of knowledge, organized by Sandvik SRP AB. He/she is therefore judged to have the knowledge and competence to carry out the tasks assigned to the appropriate role. All expected work tasks on this production equipment have been defined by Sandvik SRP AB as belonging to one of three categories – work roles – based on different competence profiles. These three work roles are: • Installation • Operation • Maintenance Sandvik SRP AB provides technical documentation appropriate to all three work roles: • Installation manual • Operator’s manual and Wear parts catalog • Maintenance manual and Spare parts catalog Sandvik SRP AB can provide adequate training for all three work roles and can carry out authorization of trained personnel. The technical documentation from Sandvik SRP AB covers only 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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2.2.1 Personal protection Sandvik SRP AB strongly recommends that personal protective equipment is always worn when working in the vicinity of the equipment. The Sandvik SRP AB recommendation for personal protective equipment includes:

Ear protection

Safety helmet

Eye protection

Protective gloves

Safety boots

Mask or breathing apparatus

2.3 General safety precautions

WARNING!

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

Always switch off power and lock out the equipment (secure it cannot 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 being done. Before maintenance work, place two wooden blocks between the moving jaw and the back frame end to prevent the moving jaw from falling back. Dangerous work Never stand inside the crushing chamber when heavy parts (e.g. jaw plates and cheek plates) are being lifted out or in. WARNING!

(Continued)

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2. Safety precautions Avoid remaining on the crusher, unless necessary for maintenance work. Risk of crushing Never remain on the crusher while crushing. Moving parts constitute a risk of crushing. WARNING! Ejection Never look into the crusher while crushing. Fragments and possibly harmful substances fed to the crusher may be ejected. WARNING!

2.3.1 Machine safety guards Do not remove guards Make sure that all guards are in place and functioning, to prevent exposure to flying fragments and rotating parts. Never operate the PROHIBITION! equipment unless guards are mounted. Rotating parts Exposure to rotating parts of the equipment shall be prevented by guards. Always attach guards after maintenance work. WARNING!

WARNING!

Flying fragments Fragments ejected upwardly may fall down in the vicinity of the crusher. Provide adequate guards and warning signs at appropriate places around the danger zone.

Upwardly ejected fragments may fall down in the vicinity of the crusher. Therefore Sandvik SRP AB recommends additional protection. Platforms with guard rails shall be installed around the crusher’s feed opening. Walkways, stairs and ladders must be designed in accordance with applicable regulations. (These parts are not included in the crusher’s standard specification). NOTE!

To prevent the ejection of large stones the feed hopper should be equipped with a pivoted stone guard. The stone guard must not be raised during crushing. Make sure all defective guards and dust sealing components are checked, repaired and replaced before starting the equipment.

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2.3.2 Electrical safety CAUTION!

Only electrical personnel working according to European Standard EN 50110 or similar are permitted to perform electrical operations on the crusher. 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.

2.3.3 Welding CAUTION!

Welding on the crusher is only permitted when and as described in the manual. For all other welding operations on the crusher local Sandvik service personnel must be consulted.

CAUTION!

Only welders qualified according to European Standard EN 287 or similar are permitted to perform welding operations on the crusher.

If welding an item to the crusher, ground must be attached to the item itself. If a crusher component is to be welded, ground should be attached as near to the welding area as possible.

WARNING!

18

Toxic gases Inhalation of welding fumes can be dangerous to health. Always follow instructions provided by the welding equipment supplier. Several parts of the crusher are made of manganese steel. Long-term exposure to manganese oxide can affect the nervous system.


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2.3.4 Hydraulic systems CAUTION!

Only personnel certified in hydraulics are permitted to perform operations on the hydraulic system.

WARNING!

Oil pressure Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system.

CAUTION!

Never adjust pressure relief valves beyond the recommended values. Oil temperature Hydraulic oil can get very hot in operation. Allow the oil to cool before working on the hydraulic system.

WARNING!

Make sure all defective hoses, valves or fittings are checked, repaired and replaced before starting the equipment.

WARNING!

Risk of crushing Never touch or alter hydraulic cylinders when the equipment is in operation. The hydraulic cylinders may suddenly change position. Always keep body parts away from hydraulic cylinders in operation.

2.3.5 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 from a hanging load.

WARNING!

Make sure that the capacity of the lifting equipment is adequate and that the equipment itself is in good working order. If a lifting tackle has to be made up by joining separate components, make sure that the joints are secure and have the same lifting capacity 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 manoeuvre loads. Do not 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 lower the load to the floor quickly and safely in an emergency. When depositing loads, keep the lifting equipment in place until the stability of the load has been checked.

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2.3.6 Feed and jams CAUTION!

When the crushing chamber is empty, avoid feeding solitary large boulders into the upper part of the chamber. In unfavourable circumstances the moving jaw may be pushed forward and bring the toggle plate out of position.

CAUTION!

Never feed combustible process material into the crusher.

WARNING!

Flying fragments Never use wedges etc. to clear jams in the feed opening. Stones and fragments can be thrown out at high speed from the crushing chamber.

WARNING!

DANGER!

Explosives Never remove blocking boulders from the crusher by blasting. Blasting may cause personal injury and seriously damage bearings or other parts. Sandvik SRP AB takes no responsibility for injury to personnel or damage to the equipment when blasting is used. Risk of crushing Never stand inside the crusher when a blockage is removed. You might be pulled forcefully and suddenly downwards together with the material in the crushing chamber and be crushed.

If it is possible to change the direction of rotation of the jaw crusher’s flywheel for a while to clear a jam. Always return to the normal rotation direction when the jam has been cleared. In some cases it is also possible to increase the CSS (closed side setting) temporarily to clear a jam. CAUTION!

If a hydraulic hammer is installed, never use it to fracture stones in the crushing chamber. This may seriously damage bearings or other vital components.

However, Sandvik SRP AB recommends that a jam in the feed opening is cleared by using a hydraulic hammer. If a blockage occurs, use the hydraulic hammer to poke the stones to break the blockage. A hydraulic hammer can also be used to knock off corners and edges from slightly oversized stones so that they can enter the crushing chamber. Always follow local regulations when attempting to clear a jam.

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CJ211:01


2.4 Emissions 2.4.1 Dust Health hazard Crushing and processing material will create dust. Such dust can be more or less dangerous to the health. Use a breathing mask DANGER!

Sandvik SRP AB strongly recommends using additional equipment for dust suppression. Examples are dust extraction (vacuum) and dust encapsulation by water spray or foam. Such equipment is not included in the crusher’s standard specification. Sandvik SRP AB declines all responsibility for any health hazards caused by dust, generated when processing minerals in the crusher.

2.4.2 Noise Health hazard Crushing and processing material will create noise. Such noise can be more or less dangerous to the hearing. Use ear protection. WARNING!

2.4.3 Radioactivity

DANGER!

Health hazard Radon is a radioactive gas that occurs naturally in bedrock. Radon may cause lung cancer. Mineral type, ventilation and water are all factors that influence the contents of radon gases.

Sandvik SRP AB declines all responsibility for any health hazards caused by the release of radon or any other harmful substances when processing minerals in the crusher.

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3. Technical data

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3. Technical data

3.1 General data Characteristics

Data

Model

CJ211

Type

Jaw crusher

Application

Mineral processing, Recycling

Weight

14 300 kg

Length

2.39 m

Width

2.44 m

Height

2.18 m

Nominal speed

270 rpm

Motor power

90 kW

Moment of inertia

388 kg/m2

3.2 Processing data Characteristics

Data

Max. feed opening

1.10 × 0.70 m

CSS

min–maxa

Nominal capacity

40 to 200 mm 80 to 490 tonnes/h

a. Minimum CSS varies with the work index (hardness) of the processing material. Contact Sandvik for more information.

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CJ211:01

4. Start up the jaw crusher This section describes how to start up the jaw crusher when it’s installed in a crushing and screening unit. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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4. Start up the jaw crusher

4.1 General Each jaw crusher delivered by Sandvik has been assembled, test run and checked in our factory before shipping. The test run is carried out without load to discover any mechanical faults. This test is performed before the jaw crusher is installed on the crushing and screening unit.

4.1.1 Getting started NOTE!

Check that the jaw crusher’s CSS (closed side setting) is not smaller than the recommended value. The minimum CSS can be found in section 3. Technical data. Start the crusher and let it run for 2 hours without load. In the meantime check the following: – That the guards are in place. – That the direction of the crusher’s flywheels is correct (see figure). right

wrong

– That there is no unusual noise. – That the bearings do not overheat. (Continued)

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CJ211:01

4. Start up the jaw crusher During this period correct any faults that are discovered. Make sure everything is in order before starting to feed material carefully to the jaw crusher. Distribute the feed evenly across the width of the crusher’s feed opening. The size of the material must not be bigger than the feed opening, marked in the picture.

4.1.2 Running-in During the first month or 160 operating hours, check daily that old grease is forced out of the labyrinths seals. If not, grease the bearings (see section 6. Lubrication). Check the bearing temperatures regularly. Check the tightness of all threaded fasteners. Avoid overloading the jaw crusher.

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4. Start up the jaw crusher


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5. Inspection and care This section describes the routine inspection and care instructions for the jaw crusher. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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5. Inspection and care

5.1 General To ensure optimum performance, the jaw crusher needs to be evenly fed. The size of the material must not be bigger than the feed opening, marked in the picture.

Avoid overloading the crusher. Overloading can be caused by: – – – –

30

Unfavourable wear pattern on the jaw plates (cavities or “ski slopes”) Excessive jaw plate wear or jaw plate “arching” Too small discharge setting Excessive fines content in the feed material


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5.2 Routine inspection and care NOTE!

Every jaw crusher must be subjected to regular systematic checks. This will result in fewer and smaller repairs, less downtime and thus lower overall running costs. A new machine must be inspected often during the initial operating period. The intervals between inspections can then be increased until a suitable frequency is found. Keep a written log including the crusher’s operating conditions, important data and details of adjustments made and any repairs carried out. Since crushers operate under widely differing conditions, it is impossible to recommend an inspection and care schedule applicable to all crushers. However, regular inspections are necessary. The following table describes an example:

Interval

Action

Remarks

See section

Daily

Check bearing temperatures.

Perform checks when the jaw crusher is running. External bearing housing temperature should not exceed 70°C.

–

Check tightness of threaded fasteners holding the jaw plates.

Tighten if necessary.

–

Check wear on the jaw plates and cheek plates.

Excessive wear can result in reduced capacity.

5.4

40 operating hours

80 operating hours

Check that all grease hoses are properly connected. Grease the bearings.

Lubricate when the jaw crusher is running empty and is at normal operating temperature.

6.1

Check exit of old grease.

Adjust quantity if necessary.

6.1, 10.1

Check the grease level in the lubricator’s reservoir.

Refill if necessary.

10.1

Check tightness of all threaded fasteners.

Tighten if necessary. Replace damaged bolts.

–

Check the toggle plate and the toggle seats for wear or damage. Check the guide plate fasteners.

After a long period out of operation

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6.1, 10.1

5.5 Replace damaged bolts.

Lubricate the bearings before starting up.


– 6.1, 10.1

31


5.3 Recommended tool box The following is a list of recommended tools for use during maintenance work described in this manual.

32

Tool

Included in tool kit

Used for

Gauge for CSS

Yes

Setting measurement

Lifting tool

Yes

Jaw plates / Cheek plates

Slugging wrench 46 mm

Yes

Jaw plates / Clamping bars

Combination wrench 46 mm

Yes

Jaw plates / Clamping bars


Yes

Support bars


No

Cheek plates


No

Deflector plate

Crow bar

No

Jaw plates

Props, 2 pcs

No

Jaw plates

Grease gun with hose

No

Bearings

Hammer with nylon head

No

Cheek plates

Lifting tackle and chain

No

–

Mobile crane

No

–

Protective gloves

No

–


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5.4 Crushing chamber NOTE!

See section 7. Crushing chamber for information about how maintenance is carried out. To ensure optimum performance and cost effective production it’s important to frequently inspect the following parts and to replace them before they are completely worn out.

5.4.1 Jaw plates The wear pattern and the adjustment of the jaw plates have a great effect on the crusher’s capacity. Crushers can be fitted with jaw plates with different patterns and profiles to suit different crushing duties. Jaw plates often get worn more at one end or a spot close to one end. Therefore, their life can be extended by reversing them (turning them upsidedown). Nip angle α

If the jaw plates are worn down at the bottom end and then reversed, there is a risk that the nip angle becomes too large in the upper part of the crushing chamber. This can create a reduced grip on the material with a consequent decreased capacity. Sandvik recommends to exchange the jaw plates if this occurs. Several factors affect the wear of the jaw plates (3300-1), so it’s impossible to generalize when and how to reverse or exchange them. Check the wear pattern regularly and make a judgement of when to reverse or exchange the jaw plates. In general, if the jaw plates are frequently reversed, the wear will be more uniform and will have less effect on the nip angle. A simple rule is: – If the tooth height of a part of the jaw plate is 30 % reduced (70 % remaining) it is time to reverse for the first time (teeth are measured from base to top). – If a part of the jaw plate is worn down almost in level with the original tooth base it is time to reverse for the second time. – After the jaw plate is worn down in level with the tooth base and reversing won’t help, it is time to exchange the jaw plate. NOTE!

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Often it is advantageous to replace the jaw plate (3300-1) before it is completely worn out.


33


Capacity

3500-0

Worn out

Jaw plate change 3500-0 3400-0 3300-1 3100-0 3200-0

Wear

3400-0 3300-1

3100-0

Deflector plate (moving jaw only) Clamping bar Jaw plate Wear plate Support bar

3200-0

5.4.2 Deflector plate The deflector plate (3500-0) is fitted on the upper part of the moving jaw to protect the jaw from large rocks. Since this part is exposed to high pressure and heavy wear it is replaceable. The deflector plate (3500-0) is hollow. If it becomes curved in, or a hole is worn in, it needs to be replaced.

5.4.3 Clamping bar The clamping bar (3400-0) is fitted above the jaw plate (3300-1) to lock it to the jaw. This part is exposed to high pressure and heavy wear so it is replaceable. When a clamping bar (3400-0) is no longer straight or in full contact with the jaw plate it needs to be replaced.

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5.4.4 Wear plate A replaceable wear plate (3100-0) is sandwiched between the jaw plate (3300-1) and the jaw. It protects the jaws from arching under heavy loads. When a new jaw plate (3300-1) is no longer in contact with the whole surface of the wear plate (3100-0) it is necessary to replace the wear plate.

5.4.5 Jaw shim plate A replaceable jaw shim plate can instead of a wear plate be sandwiched between the jaw plate and the jaw. The jaw shim plate does not only protect the jaw from arching under heavy loads, but is also used to decrease the nip angle or minimum CSS.

5.4.6 Support bar The support bar (3200-0) supports the bottom edge of a jaw plate (3300-1). Since this part is exposed to high pressure and heavy wear, it is replaceable.

5.4.7 Cheek plate The sides of the crushing chamber are protected with cheek plates on the left side (1103-0) and right side (1104-0). Since these are exposed to high pressure and heavy wear (especially in the lower part of the crushing chamber), they are replaceable. Exchange a cheek plate when there is an obvious cavity in it (especially in the lower part).

1104-0 1104-0 1103-0

Cheek plate, right side Cheek plate, left side (concealed)

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1103-0


35


5.5 Setting adjustment system NOTE!

Maintenance for these parts must be carried out only by trained or authorized personnel, but the inspection can be performed by the operator. Worn components should be replaced in good time to avoid damaging the toggle plate or toggle seats, with a consequent need for expensive repairs. Sandvik recommends exchanging the toggle plate (5006-0) and the toggle seats (5004-0), (5005-0) at the same time.

5.5.1 Toggle plate The toggle plate (5006-0) is a part of the setting adjustment system. It forms a link between the moving jaw (3000-0) and the setting arrangement (1). The toggle plate is exposed to high pressure and heavy wear and is replaceable. If the minimum discharge setting cannot be reached, this could be an indication that the toggle plate is worn down. Check it and if necessary replace the toggle plate with a new one. Stress can create cracks or bend the toggle plate. If the toggle plate shows signs of cracks or is bent it is necessary to replace it with a new one.

5.5.2 Toggle seat The toggle plate (5006-0) is located by a toggle seat (5004-0), (5005-0) at each end. The toggle seats are hardened. But since they are exposed to high pressure and heavy wear, they are replaceable. If the toggle seats lose their shape it is necessary to replace them with new ones.

3000-0 5005-0 5006-0 5003-0 5004-0 1

Jaw (moving) Toggle seat, lower Toggle plate Toggle seat holder Toggle seat, upper Setting arrangement

1 5003-0 5004-0

3000-0

36

5005-0


5006-0

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5.6 Setting measurement 5.6.1 Setting measuring gauge The discharge setting is the closest distance between the jaw plates at the bottom of the crushing chamber. The distance varies with the crushing movement of the moving jaw – the smallest distance along this movement is called the CSS (closed side setting). It’s unlikely that the crusher stops when this distance is as small as possible, so the CSS must be measured on a running crusher.

Discharge setting

A gauge for CSS, consisting of a rod with discs, is supplied with the crusher. The diameter of the smallest disc, that is in contact with both the stationary and moving jaw plate when and where the distance is as small as possible, gives an appreciation of the CSS. The disc simulates the section of a spherical or ellipsoid stone.

Measuring tool

5.6.2 Gauge for CSS Characteristics

Data

Number of rubber discs

8

Diameter

45 to 135 mm

The measuring tool is composed of a set of rubber discs with different diameters, one rod with threaded ends, nuts, fixing washer and a nylon line for gauge lifting. When the rod is suspended by the line, it will maintain the mounted disc in a horizontal position.

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37

5.6.3 Measuring instructions NOTE!

Recommended tools Gauge for CSS Measuring tape

NOTE!

38

Run the jaw crusher empty. Clean the feeder from process material, before measuring begins. a) Make an assumption of the diameter of disc to use. Mount it on the rod. b) Lower the measuring tool by the line along the stationary jaw plate. The disc should be in contact with two crests. • If the measuring tool passes the bottom end of the jaw plates, the disc is too small, but if the measuring tool is stopped before it reaches the bottom end, the disc is too big. • When the correct disc is mounted, it is in a horizontal position touching two stationary jaw plate crests and barely touching one moving jaw crest at the bottom end of the jaw plates. This means that the disc diameter is equal to the CSS. • If a specific CSS is required, use the corresponding disc diameter and adjust the setting arrangement to obtain the required setting. Read more in section 8. Setting adjustment system. The crusher has accessories to help to adjust the CSS to a minimum. Simply by replacing the wear plates behind the jaw plates with thicker jaw shim plates (and exchanging the support bars) the minimum CSS can be decreased.


CJ211:01

6. Lubrication This section describes how to lubricate the jaw crusher and gives information about the lubricants to be used. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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39

6. Lubrication

6.1 General NOTE!

CAUTION!

NOTE!

If the jaw crusher is equipped with the optional automatic lubricator, this chapter is replaced by section 10. Automatic lubricator (option). Always use lubricants which fulfil the requirements. The use of wrong lubricants may damage bearings and block lubricating passages. See section 6.1.2 Lubricant requirements.

Never mix different brands or types of grease. A bad mixture may cause precipitation and lose its lubricating characteristics. Consult your lubricant supplier. The grease has in addition a sealing effect in the labyrinth seals which prevents dust and other harmful substances entering the bearings. Sandvik therefore recommends frequent lubrication and larger grease quantities than are normally required to lubricate roller bearings.

NOTE! CAUTION!

To prevent contaminants entering the bearings, always clean the greasing nipple and the grease gun nozzle before lubrication is performed. Never use contaminated lubricants.

The handling of lubricants is associated with fire and health risks. Always follow your supplier’s instructions and safety regulations.

6.1.1 Manual lubrication Add at least the following quantity after every 40 hours of operation: Description

Qty.

Remarks

Grease amount distibuted over 4 roller bearings

1.04 kg

2.29 lb.

Risk of crushing Always connect the lubricator nozzle to the greasing nipple while the crusher is standing still. WARNING!

The jaw crusher must be at normal operating temperature before lubrication is performed to facilitate the exit of grease. NOTE!

In low temperatures (below 0°C), always run the jaw crusher empty for a while before greasing the bearings. (Continued)

40


CJ211:01

6. Lubrication Sandvik recommends running the jaw crusher empty while lubricating, so that the new grease is evenly distributed throughout the bearings. To prevent dirt and water entering the bearings, always ensure that the old grease is forced out of the labyrinth seals (see figure below), while pumping fresh grease into the greasing nipple.

Check that all hoses are properly connected before greasing. Use the greasing nipple (2) to lubricate the roller bearings. A lubrication distributor (1) distributes the grease evenly to the bearings.

1

1 Lubrication distributor 2 Greasing nipple

2

NOTE!

Run the jaw crusher for a while after lubrication to spread the grease. When operation begins, the bearing temperature usually rises slightly above the normal level. If the temperature rise is moderate and the temperature quickly returns to normal there is no danger to the bearings.

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41

6. Lubrication

6.1.2 Lubricant requirements The grease must contain anti-rust and EP additives and fulfil the following minimum requirements: Property

Test method

Requirements

NLGI value

DIN 51 818

2 or 3

Drop point

DIN ISO 2176

≥ 180

Base oil viscosity at 40°C in mm2/s (cSt)

≥ 170


≥ 100

Mechanical stability

SKF V2F 1000 rpm

Approved

Corrosion resistance

DIN 51 802 SKF Emcor

Approved

Temperature range Speed range

–30°C to +110°C Must lubricate effectively throughout the bearing’s entire operating speed range

Viscosity index

at least 80

Examples of lubricants, which according to their manufacturer fulfil Sandvik’s requirements: Aral Aralub HLP 2 BP Energrease LS-EP 2 ESSO Beacon EP 2 N Mobil Mobilgrease HP 222

Molub-Alloy Tribol 4020/220-2 Shell Ariax Li X 2 Statoil UniWay Li X 62 Texaco Hytex EP 2

For other types of grease, consult your lubricant supplier.

42


CJ211:01

7. Crushing chamber This section describes the maintenance needed for the crushing chamber of the jaw crusher. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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43

7. Crushing chamber

7.1 Exchanging clamping bars The following wear parts are required: Description

NOTE!

Cat. no.

Qty.

Remarks

Clamping bar

1210-0

1

stationary jaw, weight 37 kg

Screw M6S M30×280/300

1211-0

3

stationary jaw

Self-locking nut M6MN M30

1211-1

3

stationary jaw

Washer D95/35×10

1211-5

6

stationary jaw

Flexible washer

1211-6

3

stationary jaw

Clamping bar

3400-0

1

moving jaw, weight 37 kg

Screw M6S M30×780

3401-0

3

moving jaw


3401-1

3

moving jaw

Washer D95/35×10

3401-5

6

moving jaw

Flexible washer

3401-6

3

moving jaw

These instructions are valid for both moving and stationary jaw. The pictures describe the moving jaw.

7.1.1 Removing clamping bar a) Empty the feeder and the crushing chamber from processing material.

WARNING!

WARNING!

NOTE!

Recommended tools 46 mm Slugging wrench 46 mm Combination wrench Props

44

Risk of crushing Be aware of the weight of the jaw plate, see section 7.2 Exchanging jaw plates. Make sure the moving jaw is reclined so that the jaw plate will not fall forwards when removing the clamping bar. Risk of crushing Be aware of the weight of the deflector plate, see section 7.5 Exchanging deflector plate. After removing the clamping bar, make sure the deflector plate is properly fastened before doing any more work in the crushing chamber.

Put two props between the jaws to prevent the jaw plates below the clamping bars from falling out. b) Use a slugging wrench and combination wrench to loosen the nuts (3401-1) that hold the clamping bar (3400-0). c) Remove the nuts (3401-1), washers (3401-5) and flexible washers (3401-6). d) Knock out the screws (3401-0) and clamping bar (3400-0).


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7. Crushing chamber

3500-0 3400-0 3401-0 3401-5 3401-6 3401-1

Deflector plate Clamping bar Screw Washer Flexible washer Self-locking nut

3500-0 3400-0 3401-0 3401-5 3401-6 3401-5 3401-1

7.1.2 Installing clamping bar NOTE!

If it is planned to exchange more parts in the crushing chamber, please proceed to the instructions for those parts before installing the new clamping bar. a) Clean the slot where the clamping bar fits. b) Push in the clamping bar (3400-0) with the screws (3401-0). c) Place the washers (3401-5), flexible washers (3401-6) and nuts (3401-1) on the screws (3401-0). d) Use a slugging wrench and combination wrench to tighten the nuts (3401-1). The flexible washers (3401-6) must be 10 mm compressed when installation is complete.

NOTE!

The clamping bar must not touch the jaw at the bottom of the slot where it is fitted. Preferably, a new clamping bar should have at least 10 mm play for wear. e) Remove the props from the crushing chamber.

NOTE!

CJ211:01

Check compression of the flexible washers after 2 and 4 operating hours and then according to section 5.2 Routine inspection and care. Tighten nuts if necessary.


45

7. Crushing chamber

7.2 Exchanging jaw plates The following wear parts are required:

WARNING!

Description

Cat. no.

Qty.

Remarks

Jaw plate

1208-1

1


Jaw plate

3300-1

1


Risk of crushing Never weld external lifting eyes to the jaw plates. Always use the referred lifting cavity on the jaw plate and the lifting tool provided with the jaw crusher. Read section 2. Safety precautions for further information.

NOTE!


NOTE!

Remove the clamping bar before removing a jaw plate. See section 7.1.1 Removing clamping bar.

7.2.1 Removing jaw plate a) Remove the props between the jaws.

WARNING!

Recommended tools Crow bar Lifting tackle and chain Mobile crane Lifting tool

NOTE!

Risk of crushing Be aware of the weight of the jaw plate, see table above. Make sure the moving jaw is reclined so that the jaw plate will not fall forwards while releasing the jaw plate or uncovering the lifting cavity. Never stand in the crushing chamber while releasing the jaw plate or uncovering the lifting cavity.

b) Release the jaw plate (3300-1) from the jaw by applying a crow bar to the upper edge of the jaw plate. Bend carefully. c) Position the hook of a mobile crane vertically above the crushing chamber. Make sure the crane is able to move longitudinally with respect to the jaw crusher. d) Apply a crow bar between the jaw plate (3300-1) and the deflector plate (moving jaw) (3500-0) or front frame end (stationary jaw) to uncover the lifting cavity (1). (Continued)

46


CJ211:01

7. Crushing chamber e) Remove any sponge rubber strip or rags from the lifting cavity (1). f) Hang the lifting tool (2) (provided with the crusher) on the hook of the mobile crane and attach the hook of the lifting tool to the lifting cavity (1).

WARNING! NOTE!

Risk of crushing If the jaw plate is worn down too far, the lifting cavity can be worn away or deformed. Sandvik strongly recommends exchanging the jaw plates before this occurs.

It can be necessary to reinforce a worn away or deformed lifting cavity by welding on a plate. The electrode used for welding on the jaw plate must comply with DIN 8555 E8-200 ckZ, for example ESAB’s OK Selectrode 67.45. g) Take up the slack in the lifting tackle.

DANGER!

Hanging load Be aware of the weight of the jaw plate, see table above. Handle the jaw plate with care. The tackle should now be tight but not lifting the jaw plate. Keep clear of hanging loads, see section 2. Safety precautions.

h) Carefully lift the jaw plate (3300-1) out of the crushing chamber. Risk of crushing If the wear plate is attached to the jaw plate when the jaw plate is lifted out it can come off while lifting. Keep clear of hanging loads. WARNING!

i)

j) 3500-0

Deflector plate (moving jaw) 3300-1 Jaw plate 3100-0 Wear plate 1 Lifting cavity 2 Lifting tool

CJ211:01

If the wear plate (3100-0) is attached to the jaw plate (3300-1) when the jaw plate is lifted out, it is necessary to fit a new wear plate (3100-0). See section 7.3 Exchanging wear plates. Place the jaw plate (3300-1) horizontally on the ground.

3500-0 3300-1 1 3100-0


2

47

7. Crushing chamber

7.2.2 Installing jaw plate NOTE!

If planning to exchange wear plates (3100-0), cheek plates, deflector plate (3500-0) and/or support bars (3200-0) at the same time, please proceed to the instructions for those parts before installing the new jaw plate.

CAUTION!

Replace the support bar screws if they are broken. Remove the support bar and clean it carefully. It’s important that the contact faces of the jaw are clean. Tighten nuts. See section 7.4 Exchanging support bars.

NOTE!

Check the condition of the wear plate (3100-0), see section 7.3 Exchanging wear plates. a) Clean the wear plate (3100-0), support bar (3200-0) and corners of the crushing chamber. b) Position the hook of a mobile crane vertically above the new jaw plate (3300-1).

3500-0

Deflector plate (moving jaw) 3300-1 Jaw plate 3100-0 Wear plate 3200-0 Support bar 1 Lifting cavity 2 Lifting tool

3500-0 3300-1 1 3100-0

2

3200-0

NOTE!

Make sure the crane is able to move to the jaw crusher. (Continued)

48


CJ211:01

7. Crushing chamber c) Hang the lifting tool (2) (provided with the crusher) on the hook of the mobile crane and attach the hook of the lifting tool to the lifting cavity (1) on the new jaw plate (3300-1). d) Take up the slack in the lifting tackle.

DANGER!

Hanging load Be aware of the weight of the jaw plate, see table above. Handle the jaw plate with care. The tackle should now be tight but not lifting the jaw plate. Keep clear of hanging loads, see section 2. Safety precautions.

e) f) g) h)

Carefully lift the jaw plate (3300-1) into the crushing chamber. Place the jaw plate (3300-1) on the support bar (3200-0). Adjust the jaw plate (3300-1) into its correct position. Place a crow bar between the jaw plate (3300-1) and the deflector plate (moving jaw) (3500-0) or front frame end (stationary jaw). i) Slacken off the lifting tackle. j) Remove the hook of the lifting tool (2) from the lifting cavity (1). k) Pack a sponge rubber strip or rags into the lifting cavity (1) to keep out dust. NOTE!

Do not use cotton waste! l) Remove the crow bar. m) Put two props between the jaws to fix the jaw plates in place until the clamping bars above are installed, see section 7.1.2 Installing clamping bar.

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49

7. Crushing chamber

7.3 Exchanging wear plates The following wear parts are required: Description

Cat. no.

Qty.

Remarks

Wear plate

1300-0

1


Wear plate

3100-0

1


NOTE!


NOTE!

Remove the jaw plate before removing a wear plate. See section 7.2.1 Removing jaw plate.

7.3.1 Removing wear plate NOTE!

Recommended tools Crow bar

If a jaw shim plate is used, there is no wear plate. See section 7.7.1 Removing jaw shim plate. a) Position the hook of a mobile crane vertically above the wear plate (3100-0).

Lifting tackle and chain Mobile crane

1 3000-0

3000-0 Jaw (moving) 3100-0 Wear plate 3200-0 Support bar 1 Lifting eye

3100-0

3200-0 (Continued)

50


CJ211:01

7. Crushing chamber

WARNING!

Risk of crushing Be aware of the weight of the wear plate, see table above. Make sure the moving jaw is reclined so that the wear plate will not fall forwards while releasing the upper end. Never stand in the crushing chamber while releasing the upper end with a crow bar.

b) Use a crow bar to carefully release the upper end of the wear plate (3100-0) from the jaw (3000-0). c) Attach the lifting hook to the lifting eye (1) on the wear plate (3100-0). NOTE!

WARNING!

Make sure the crane is able to move longitudinally with respect to the jaw crusher. d) Take up the slack in the lifting tackle. Hanging load Be aware of the weight of the wear plate, see table above. Handle the wear plate with care. The tackle should now be tight but not lifting the wear plate. Keep clear of hanging loads, see section 2. Safety precautions.

e) Carefully lift the wear plate (3100-0) out of the crushing chamber. f) Place the wear plate (3100-0) horizontally on the ground.

1 3000-0 Jaw (moving) 3100-0 Wear plate 3200-0 Support bar 1 Lifting eye

3000-0 3100-0

3200-0

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51

7. Crushing chamber

7.3.2 Installing wear plate a) Clean the support bar (3200-0), jaw (3000-0) and corners of the crushing chamber. b) Position the hook of a mobile crane vertically above the new wear plate (3100-0). NOTE!

Make sure the crane is able to move to the jaw crusher c) Attach the lifting hook to the lifting eye (1) on the new wear plate (3100-0). d) Take up the slack in the lifting tackle.

WARNING!

Hanging load Be aware of the weight of the wear plate, see table above. Handle the wear plate with care. The tackle should now be tight but not lifting the wear plate. Keep clear of hanging loads, see section 2. Safety precautions.

e) f) g) h)

Carefully lift the wear plate (3100-0) into the crushing chamber. Place the wear plate (3100-0) on the support bar (3200-0). Adjust the wear plate (3100-0) into its correct position. Place a crow bar between the wear plate (3100-0) and the deflector plate (moving jaw) or front frame end (stationary jaw). i) Slacken off the lifting tackle. j) Remove the lifting hook from the lifting eye (1). k) Remove the crow bar.

52


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7. Crushing chamber

7.4 Exchanging support bars The following wear parts are required:

NOTE!

Description

Cat. no.

Qty.

Support bar

1205-0

1

Remarks stationary jaw, weight 37 kg

Screw M6S M20×140

1206-0

6

stationary jaw, recommended exchange

Self-locking nut M20

1206-1

6


Washer BRB 21×36

1206-2

6


Support bar

3200-0

1


Screw M6S M20×140

3201-0

6

moving jaw, recommended exchange


3201-1

6


Washer BRB 21×36

3201-2

6


These instructions are valid for both moving and stationary jaw. The picture describes the moving jaw.

CAUTION!

Put two props between the jaws to prevent them from moving.

NOTE!

Remove the wear plate before removing the support bar. See section 7.3 Exchanging wear plates.

7.4.1 Removing support bar Recommended tools 30 mm Combination wrench Crow bar Props

3200-0 3201-0 3000-0 3201-2 3201-1

a) Use a combination wrench to loosen the nuts (3201-1) on the outside of the crushing chamber that hold the support bar (3200-0). b) Remove the nuts (3201-1) and washers (3201-2). c) Pull out the screws (3201-0). d) Remove the support bar (3200-0) using a crow bar. There are slots in the support bar for this specific purpose.

Support bar Screw Jaw (moving) Washer Self-locking nut

3200-0 3201-0 3000-0 3201-2 3201-1

WARNING!

CJ211:01

Hanging load Be aware of the weight of the support bar, see table above. Handle the support bar with care. Keep clear of hanging loads, see section 2. Safety precautions.


53

7. Crushing chamber

7.4.2 Installing support bar a) Clean the jaw (3000-0). b) Put the new support bar (3200-0) into place. c) Push the screws (3201-0) into the holes in the support bar (3200-0) and jaw (3000-0). d) Install the washers (3201-2) and nuts (3201-1). e) Tighten the nuts (331 Nm). NOTE!

Re-tighten the nuts after 2 and 4 operating hours and then according to section 5.2 Routine inspection and care.

7.5 Exchanging deflector plate The following wear parts are required: Description

NOTE!

Cat. no.

Qty.

Remarks weight 160 kg

Deflector plate

3500-0

1

Screw M6S M16×50

3502-0

2

Washer BRB 17×30

3502-2

2

Locating pad

3503-0

2

Remove the clamping bar before removing the deflector plate. See section 7.1.1 Removing clamping bar.

7.5.1 Removing deflector plate Recommended tools 24 mm Combination wrench Lifting tackle and chain Mobile crane

3500-0 3502-0 3502-2 3503-0 3000-0 1

Deflector plate Screw Washer Locating pad Jaw (moving) Lifting eye

a) Position the hook of a mobile crane vertically above the deflector plate (3500-0). b) Attach the lifting hooks to the two lifting eyes (1) on the top of the deflector plate (3500-0).

1 3500-0 3502-0 3502-2 3503-0 3000-0 (Continued)

54


CJ211:01

7. Crushing chamber

NOTE!

Make sure the crane is able to move longitudinally with respect to the jaw crusher. c) Take up the slack in the lifting tackle.

DANGER!

Hanging load Be aware of the weight of the deflector plate, see table above. Handle the deflector plate with care. The tackle should now be tight but not lifting the deflector plate. Keep clear of hanging loads, see section 2. Safety precautions.

d) Remove the screws (3502-0), washers (3502-2) and locating pads (3503-0) that hold the deflector plate (3500-0). e) Push the deflector plate (3500-0) away from the moving jaw (3000-0). f) Carefully lift the deflector plate (3500-0) out of the crushing chamber. g) Place the deflector plate (3500-0) horizontally on the ground. h) Remove the lifting hooks from the lifting eyes (1).

7.5.2 Installing deflector plate a) Clean the jaw (3000-0) where the deflector plate (3500-0) will be placed. b) Position the hook of a mobile crane vertically above the new deflector plate (3500-0). NOTE!

Make sure the crane is able to move to the jaw crusher c) Attach the lifting hooks to the two lifting eyes (1) on the top of the deflector plate (3500-0).

3500-0 3502-0 3502-2 3503-0 3000-0 1


1 3500-0 3502-0 3502-2 3503-0 3000-0 (Continued)

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55

7. Crushing chamber d) Take up the slack in the lifting tackle.

DANGER!

Hanging load Be aware of the weight of the deflector plate, see table above. Handle the deflector plate with care. The tackle should now be tight but not lifting the deflector plate. Keep clear of hanging loads, see section 2. Safety precautions.

e) Carefully lift the deflector plate (3500-0) into the crushing chamber. f) Centre the deflector plate (3500-0) into its position. NOTE!

The locating pads (3503-0) must be in close contact with the deflector plate (3500-0) to keep it in place. g) Fasten the deflector plate (3500-0) with the locating pads (3503-0), washers (3502-2) and screws (3502-0). h) Slacken off the lifting tackle. i) Remove the lifting hooks from the lifting eyes (1).

3500-0 3502-0 3502-2 3503-0 3000-0 1

56


1 3500-0 3502-0 3502-2 3503-0 3000-0


CJ211:01

7. Crushing chamber

7.6 Exchanging cheek plates The following wear parts are required: Cat. no.

Qty.

Cheek plate

1103-0

1

Remarks left-hand side, weight 225 kg

Cheek plate

1104-0

1

right-hand side, weight 225 kg

Screw M6S M24×130

1106-0

8


1106-1

8

Flexible washer

1106-4

8

Steel washer D105/26×10

1106-5

8

NOTE!

The crushing chamber contains two mirror image cheek plates. The following instructions are for exchange of one side. Repeat the procedure for the other side.

NOTE!

The cheek plates can be exchanged without removing the clamping bars and jaw plates. However, Sandvik recommends exchanging the cheek plates when these are removed.

WARNING!

CJ211:01

Description

Risk of crushing Never weld external lifting eyes to the cheek plates. Always use the lifting eye on the cheek plate and the lifting tool provided with the jaw crusher. Read section 2. Safety precautions for further information.


57

7. Crushing chamber

7.6.1 Removing cheek plate Recommended tools Crow bar

The cheek plate (1103-0) is attached with 5 screws (1106-0) to the frame (1000-0). Each screw has a flexible washer (1106-4), a steel washer (1106-5) and a self-locking nut (1106-1).

Nylon hammer Lifting tackle and chain Mobil crane Lifting tool 36 mm Combination wrench

a) Remove the upper two nuts and the bottom left nut (1106-1), steel washers (1106-5) and flexible washers (1106-4). b) Knock out the three screws (1106-0). c) Loosen the remaining lower right screw (1106-0) but don’t remove the nut until the lifting tackle is applied. d) Position the hook of a mobile crane vertically above the crushing chamber.

1 1103-0 1106-0 1106-4 1106-5 1106-1 1000-0 1

Cheek plate Screw Flexible washer Steel washer Self-locking nut Frame Lifting eye

1103-0

1106-0 1106-4 1106-5 1106-1

1000-0 NOTE!

Make sure the crane is able to move longitudinally with respect to the jaw crusher. e) Hang the lifting tool (provided with the crusher) on the hook of the mobile crane and attach the hook of the lifting tool to the lifting eye (1) on the cheek plate.

WARNING!

Risk of crushing If the cheek plate is worn down too far, the lifting eye can be worn away or deformed. Sandvik strongly recommends exchanging the cheek plates before this occurs.

(Continued)

58


CJ211:01

7. Crushing chamber

NOTE!

It can be necessary to reinforce a worn away or deformed lifting eye by welding on a plate. The electrode used for welding on the cheek plate must comply with DIN 8555 E8-200 ckZ, for example ESAB’s OK Selectrode 67.45 f) Take up the slack in the lifting tackle.

DANGER!

Hanging load Be aware of the weight of the cheek plate, see table above. Handle the cheek plate with care. The tackle should now be tight but not lifting the cheek plate. Keep clear of hanging loads, see section 2. Safety precautions.

g) Remove the last nut (1106-1) with steel washer (1106-5) and flexible washer (1106-4)and knock out the screw (1106-0). NOTE!

If the cheek plate gets stuck, apply a crow bar between the frame (1000-0) and the cheek plate. h) Carefully lift the cheek plate out of the crushing chamber. i) Place the cheek plate horizontally on the ground.

7.6.2 Installing cheek plate a) Clean the frame (1000-0) and the corners of the crushing chamber on the inside. b) Position the hook of a mobile crane vertically above the new cheek plate. NOTE!

Make sure the crane is able to move to the jaw crusher (Continued)

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59

7. Crushing chamber c) Hang the lifting tool (provided with the crusher) on the hook of the mobile crane and attach the hook of the lifting tool to the lifting eye (1) on the new cheek plate. d) Take up the slack in the lifting tackle.

DANGER!

Hanging load Be aware of the weight of the cheek plate, see table above. Handle the cheek plate with care. The tackle should now be tight but not lifting the cheek plate. Keep clear of hanging loads, see section 2. Safety precautions.

e) Carefully lift the cheek plate into the crushing chamber. f) Position the cheek plate in its place. Use a screw (1106-0) to find the correct position. g) Install all of the screws (1106-0). Place a flexible washer (1106-4), steel washer (1106-5) and self-locking nut (1106-1) on each screw. Do not tighten. h) Slacken off the lifting tackle. i) Remove the hook of the lifting tool from the lifting eye (1). j)

Tighten all nuts (1106-1). The flexible washers (1106-4) must be 3 mm compressed when installation is complete.

1 1103-0 1106-0 1106-4 1106-5 1106-1 1000-0 1

Cheek plate Screw Flexible washer Steel washer Self-locking nut Frame Lifting eye

1103-0

1106-0 1106-4 1106-5 1106-1

1000-0

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CJ211:01

7. Crushing chamber

7.7 Exchanging jaw shim plates The following accessories are required: Description

Cat. no.

Qty.

Jaw shim plate

1302-0

1

Remarks stationary jaw, weight 240 kg

Jaw shim plate

3102-0

1


NOTE!

The jaws can be equipped with jaw shim plates to decrease the nip angle or minimum CSS.

NOTE!

These instructions are valid for both moving and stationary jaw. The picture describes the moving jaw.

NOTE!

Remove the jaw plate before removing a jaw shim plate. See section 7.2.1 Removing jaw plate.

7.7.1 Removing jaw shim plate 3000-0 3102-0 3200-0 1 2

Jaw (moving) Jaw shim plate Support bar Lifting eye Double slot support bar 3 Single slot support bar

1 3000-0 2

3

3102-0 3200-0

NOTE!

If a wear plate is used, there is no jaw shim plate. See section 7.3.1 Removing wear plate. (Continued)

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61

7. Crushing chamber a) Position the hook of a mobile crane vertically above the jaw shim plate (3102-0).

WARNING!

Recommended tools Crow bar Lifting tackle and chain

Risk of crushing Be aware of the weight of the jaw shim plate, see table above. Make sure the moving jaw is reclined so that the jaw shim plate will not fall forwards while releasing the upper end. Never stand in the crushing chamber while releasing the upper end with a crow bar.

b) Use a crow bar to carefully release the upper end of the jaw shim plate (3102-0) from the jaw (3000-0). c) Attach the lifting hook to the lifting eye (1) on the jaw shim plate (3102-0).

Mobile crane

NOTE!

WARNING!

Make sure the crane is able to move longitudinally with respect to the jaw crusher. d) Take up the slack in the lifting tackle. Hanging load Be aware of the weight of the jaw shim plate, see table above. Handle the jaw shim plate with care. The tackle should now be tight but not lifting the jaw shim plate. Keep clear of hanging loads, see section 2. Safety precautions.

e) Carefully lift the jaw shim plate (3102-0) out of the crushing chamber. f) Place the jaw shim plate (3102-0) horizontally on the ground. Exchange for wear plates If a thinner wear plate is to be fitted instead of the thicker jaw shim plate, proceed with the following: g) Exchange the support bar (3200-0) with double slots (2) for one with a single slot (3), see section 7.4 Exchanging support bars.

62


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7. Crushing chamber

7.7.2 Installing jaw shim plate a) Make sure the support bar (3200-0) is undamaged and has double slots (one for the jaw shim plate (3102-0) and one for the jaw plate). If not, exchange support bar according to section 7.4 Exchanging support bars. b) Clean the support bar (3200-0), jaw (3000-0) and the corners of the crushing chamber. c) Position the hook of a mobile crane vertically above the new jaw shim plate (3102-0). NOTE!

Make sure the crane is able to move to the jaw crusher. d) Attach the lifting hook to the lifting eye (1) on the new jaw shim plate (3102-0). e) Take up the slack in the lifting tackle.

3000-0 3102-0 3200-0 1 2


1 3000-0 2

3

3102-0 3200-0

(Continued)

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63

7. Crushing chamber

WARNING!

Hanging load Be aware of the weight of the jaw shim plate, see table above. Handle the jaw shim plate with care. The tackle should now be tight but not lifting the jaw shim plate. Keep clear of hanging loads, see section 2. Safety precautions.

f) Carefully lift the jaw shim plate (3102-0) into the crushing chamber. g) Place the jaw shim plate (3102-0) on the inner slot of the support bar (3200-0). h) Adjust the jaw shim plate (3102-0) into its correct position. i) Place a crow bar between the jaw shim plate (3102-0) and the deflector plate (moving jaw) or front frame end (stationary jaw). j) Slacken off the lifting tackle. k) Remove the lifting hook from the lifting eye (1). l) 3000-0 3102-0 3200-0 1 2


Remove the crow bar.

1 3000-0 2

3

3102-0 3200-0

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8. Setting adjustment system This section describes retraction pre-loading and the principles and basic adjustment of the setting adjustment system. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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65

8. Setting adjustment system

8.1 General The setting adjustment system is designed to compensate for jaw plate wear and to change the CSS (closed side setting) of the jaw crusher. The setting adjustment system is built into the back frame end. CAUTION!

Never run the crusher without hydraulic pressure for pre-load of the retraction cylinder. Insufficient retraction might damage the toggle or retraction system. See section 8.3 Pre-loading of retraction cylinder.

CAUTION!

To prevent interruptions in operation, the condition of the toggle plate and the toggle seats should be checked in accordance with section 5. Inspection and care.

small setting = smaller fragments

=

=

large setting = larger fragments

=

=

66


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8.2 Setting adjustment A toggle plate (5006-0) is fitted between an upper toggle seat (5004-0) and a lower toggle seat (5005-0). Behind the toggle seat holder (5003-0), two hydraulic cylinders (6320-0) can push the setting wedges (6300-0) inwards to decrease the discharge setting. The moving jaw (3000-0) is pushed closer to the stationary jaw and when the gap between the two jaws decreases only smaller fragments of processed material are allowed to pass through. If the hydraulic cylinders move outwards, the gap increases and larger fragments of processed material can pass through. The setting adjustment system is kept in place by a retraction arrangement with a hydraulic cylinder.

6320-0 6300-0 5005-0 5006-0 5003-0 5004-0 3000-0

Hydraulic cylinder Setting wedge Toggle seat Toggle plate Toggle seat holder Toggle seat Jaw (moving)

6320-0 6300-0 5003-0 5004-0

3000-0 Never in contact!

5005-0

5006-0

The hydraulic system permits stepless setting adjustment over a wide range, the limits depend on the condition of the jaw plates and length of the toggle plate. The setting wedges are self-locking during operation due to the load from the crushing forces.

CJ211:01

CAUTION!

Never set the jaw plates so close that they can come in contact with each other. The jaws must never be set so close that the jaw crusher becomes overloaded. See section 3.2 Processing data.

CAUTION!

Never lubricate setting wedges made of grey iron.


67


8.3 Pre-loading of retraction cylinder The purpose of the retraction system is to retain the jaw against the toggle plate during operation. Pre-load of the retraction cylinder might have been adjusted before delivery. Nevertheless, adjustment may be necessary for reasons including: • • •

It has not been done in advance Adaptation to local conditions Installation or removal of jaw shim plates (see section 7.7 Exchanging jaw shim plates) • Other operations affecting the adjustment a) Empty the feeder and the crushing chamber from processing material. b) Set the desired discharge setting according to section 8.4.2 Changing the discharge setting for the hand pump or section 8.5.2 Changing the discharge setting for the setting hydraulics. c) Set the hydraulic pressure according to section 8.4.1 Setting the hydraulic pressure for the hand pump or section 8.5.1 Setting the hydraulic pressure for the setting hydraulics. CAUTION! NOTE!

68

Always apply pressure in the hydraulic cylinder before starting the crusher.

If the pre-load is not enough, a clattering noise occurs in the lower end of the hydraulic pressure interval when running the crusher empty. If such noise is heard, increase the pressure (for the hand pump) or increase the low and high pressure of the interval proportionally (for the setting hydraulics).


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8.4 Hand pump NOTE!

If the jaw crusher is equipped with the setting hydraulics option, this section is replaced by section 8.5 Setting hydraulics (option).

1 2 1 Pressure gauge for retraction cylinder 2 Pump lever 3 Control lever for setting wedges 4 Control lever for retraction cylinder

3 4

8.4.1 Setting the hydraulic pressure CAUTION!

As the hand pump is manual, it cannot automatically maintain the pressure in the retraction cylinder. Personnel must regularly check the pressure gauge (1), and if necessary pump up the pressure.

Pressure guideline values: Application

Pressure

Horizontal

135–155 bar

a) Set pressure according to the table above. Raise the control lever for retraction cylinder (4) to increase the pressure or lower it to decrease the pressure. Pump with the pump lever (2) to change the pressure. b) Reset the control lever for retraction cylinder (4) in the middle position.

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69


8.4.2 Changing the discharge setting NOTE!

Jaw shim plates (see section 7.7 Exchanging jaw shim plates) and the length of the toggle plate also affect the discharge setting. Changing the toggle plate is an advanced operation, and is therefore described in the Maintenance manual.

NOTE!

The correct discharge setting is normally measured as the CSS (closed side setting). It is recommended to measure the CSS before and after changing the discharge setting. See section 5.6 Setting measurement.

CAUTION!

Never set the jaw plates so close that they can come in contact with each other. The jaws must never be set so close that the jaw crusher becomes overloaded.

Never in contact!

a) Empty the feeder and the crushing chamber from processing material. b) Look at the pressure gauge for retraction cylinder (1) and remember the set pressure. It should be reset after changing the discharge setting. c) Lower the control lever for retraction cylinder (4) to decrease the pressure. Pump with the pump lever (2) to release pressure in the retraction cylinder. d) Reset the control lever for retraction cylinder (4) in the middle position. e) Raise the control lever for setting wedges (3) to decrease the discharge setting or lower it to increase the discharge setting. Pump with the pump lever (2) to change the discharge setting. f) Reset the control lever for setting wedges (3) in the middle position. g) Raise the control lever for retraction cylinder (4) to increase the pressure. Pump with the pump lever (2) to reset the remembered pressure. h) Reset the control lever for retraction cylinder (4) in the middle position. CAUTION!

Always apply pressure in the retraction cylinder before starting the crusher.

i)

70

If necessary, measure the CSS. See section 5.6 Setting measurement. See section 5.6 Setting measurement.


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8.5 Setting hydraulics (option) NOTE!

If the jaw crusher is equipped with the setting hydraulics option, this section replaces section 8.4 Hand pump.

8.5.1 Setting the hydraulic pressure One programming mode must be enabled before setting the low and high pressure. If this has already been done, proceed to item d. If this has not been done, “LOC” will appear in the display (1) when trying to alter the setting.

1 2 3

1 Display 2 Mode button 3 Arrow buttons

Enabling operating programming mode

mode !I

3s

a) Hold down both arrow buttons (3) simultaneously for 3 seconds (until the display (1) shows “Pr6”). b) Select “ON” with the arrow buttons. c) Wait for 3 seconds (until the display returns to show the pressure). (Continued)

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71

8. Setting adjustment system Setting the low and high pressure

mode

mode

3s

2s

Pressure guideline values: Application

Low pressure

High pressure

Hysteresis

Low-low pressure (alarm)

Horizontal

135 bar

155 bar

20 bar

100 bar

d) e) f) g)

Press the mode button (2) repeatedly until the display (1) shows “S.P.1”. Set high pressure according to the table above with the arrow buttons (3). Press the mode button repeatedly until the display shows “H.Y.1”. Set hysteresis according to the table above with the arrow buttons.

h) Press the mode button repeatedly until the display shows “S.P.2”. i) Set low-low pressure according to the table above with the arrow buttons. j) Press the mode button repeatedly until the display shows “H.Y.2”. k) Set “5.0” with the arrow buttons. l) Wait for 3 seconds (until the display changes back and the settings are saved). NOTE!

72

If a setting has been changed, the display shows “PRG” briefly.


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8.5.2 Changing the discharge setting NOTE!

Jaw shim plates (see section 7.7 Exchanging jaw shim plates) and the length of the toggle plate also affect the discharge setting. Changing the toggle plate is an advanced operation, and is therefore described in the Maintenance manual.

NOTE!

The correct discharge setting is normally measured as the CSS (closed side setting). It is recommended to measure the CSS before and after changing the discharge setting. See section 5.6 Setting measurement.

CAUTION!

Never set the jaw plates so close that they can come in contact with each other. The jaws must never be set so close that the jaw crusher becomes overloaded.

Never in contact!

With stopped crusher a) Empty the feeder and the crushing chamber from processing material. b) Press the “Increase” button on the setting control box (4) to increase the discharge setting or the “Decrease” button to decrease the discharge setting. CAUTION!

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Always apply pressure in the retraction cylinder before starting the crusher.


73

8. Setting adjustment system If necessary, measure the CSS. See section 5.6 Setting measurement. With running crusher CAUTION!

Never run the crusher without hydraulic pressure for pre-load of the retraction cylinder. Insufficient retraction might damage the toggle or retraction system.

CAUTION!

Never change the discharge setting with processing material in the crushing chamber.

a) Empty the feeder and the crushing chamber from processing material. b) Press the “Increase” button on the setting control box (4) to increase the discharge setting or the “Decrease” button to decrease the discharge setting.

4 Setting control box

4

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9. Troubleshooting This chapter comprises a guide for correcting various problems that can appear during operation. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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75

9. Troubleshooting

9.1 Faults and suggested corrective actions The following table shows possible causes and suggested corrective actions for a number of different fault conditions. The symbol “*” denotes a reference to another manual of this machine or a component. No.

Fault

Check

Corrective action

1

Jaw crusher will not start

Does the motor run

Start motor. If not possible, check motor manual*.

Fuses or overload protection

Change or reset fuses and overload protection. Check manual* for action. If the problem persists, call for electrical service.

V-belt condition and tension

Check manual* for action

Is there a jam

Remove the objects from the crushing chamber, see section 2.3.6 Feed and jams

Is the hydraulic pressure present

Check if the retraction cylinder is disengaged or not working. Check hydraulic system. Call for service.

V-belt condition and tension


Fuses or overload protection

Change or reset fuses and overload protection. Check manual* for action. If the problem persists, call for electrical service.


Check if the retraction cylinder is disengaged or not working. Check hydraulic system. Call for service.

Is there an unbreakable object in the crushing chamber

Remove the object from the crushing chamber, see section 2.3.6 Feed and jams

Drive

Check motor and V-belt. Check manual* for action.

Is the discharge setting too small

Widen the discharge setting. See section 8. Setting adjustment system.

Does the V-belt slip


2

3

4

5

76

Jaw crusher stops

Rotation speed fluctuates

Is the hydraulic pressure vary- Check manual* for action ing or falling

Noise from a run- Are the toggle plate, toggle ning crusher seats or toggle seat holder worn

Imbalance

See section 5. Inspection and care. Call for service.

Is the retraction cylinder damaged

Replace the retraction cylinder. Call for service.

Does the toggle plate clatter

Adjust pre-load of the hydraulic cylinder. See section 8. Setting adjustment system. Check if the retraction cylinder is disengaged or not working. Check hydraulic system. Call for service.

Are the jaw plates loose

Check if the screws of the clamping bar are loose or need exchange, see section 5. Inspection and care

Are the jaw plates in contact with each other


Are nuts and screws loose

Fasten nuts and screw or exchange worn parts, see section 5. Inspection and care

Noise from bearings

Exchange bearing. Call for service.

Are the crusher moving lengthways or sideways

Possible damage in frame or foundation. Call for service.


CJ211:01

9. Troubleshooting No.

Fault

Check

Corrective action

6

Vibrations

Are there dirt inside the motor pulley or flywheels

Clean the motor pulley or flywheels

Are the counterweights on the flywheel misplaced or loose

Install the counterweights correctly. See the Maintenance manual*.

7

Bearing tempera- Measure the temperature ture too high

Rising temperature above 75°C indicates bearing failure. Call for service.

8

Jaw plate moves

Is a jaw plate loose

Attach the jaw plate. If not possible, exchange it. See section 5. Inspection and care.

Is a jaw plate bent

Exchange the arching jaw plate, see section 5. Inspection and care

Is the jaw crusher or toggle plate not correctly installed

See the Installation manual*

Are the toggle plate, toggle seats or toggle seat holder worn

See section 5. Inspection and care. Call for service.

9

10

11

Toggle plate moves

Can’t change Is there a jam in the crushing discharge setting chamber

Wrong fragment size

Remove the jam. See section 2.3.6 Feed and jams.

Retraction cylinder

Call for service if disengaged or damaged

Setting wedges

Exchange jaw plates or add/remove jaw shim plates if the wedges have reached their inner/outer limits. See section 8. Setting adjustment system and section 5.6 Setting measurement.


Check hydraulic system. Check manual* for action.

Is the fragment size too large

Reduce the discharge setting. See section 8. Setting adjustment system and section 5.6 Setting measurement. Exchange the jaw plates, see section 5. Inspection and care Add jaw shim plates, see section 5. Inspection and care

12

Overload

Is the fragment size too small

Widen the discharge setting. See section 8. Setting adjustment system and section 5.6 Setting measurement.

Is the discharge setting too small


Are there cavities or “ski slopes” on the jaw plates

Exchange the jaw plates, see section 5. Inspection and care

Are there excessive fines con- Feed material with distributed coarseness. tent in the feed material

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77

9. Troubleshooting


78


CJ211:01

10. Automatic lubricator (option) This section describes how to lubricate the jaw crusher with the optional automatic lubricator and gives information about the lubricants to be used. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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79

10. Automatic lubricator (option)

10.1 General NOTE!

CAUTION!

NOTE!

If the jaw crusher is equipped with the optional automatic lubricator, this chapter replaces section 6. Lubrication. Always use lubricants which fulfil the requirements. The use of wrong lubricants may damage bearings and block lubricating passages. See section 10.1.2 Lubricant requirements.

Never mix different brands or types of grease. A bad mixture may cause precipitation and lose its lubricating characteristics. Consult your lubricant supplier. The grease has in addition a sealing effect in the labyrinth seals which prevents dust and other harmful substances entering the bearings. Sandvik therefore recommends larger grease quantities than are normally required to lubricate roller bearings.

CAUTION!

Never use contaminated lubricants.

The handling of lubricants is associated with fire and health risks. Always follow your supplier’s instructions and safety regulations.

10.1.1 Automatic lubrication NOTE!

For the automatic lubricator with supplied hoses, the operating temperature must be between –25°C and 60°C. The grease outlet (6) of the automatic lubricator is connected to the grease connection (2) on the crusher. A lubrication distributor (1) distributes the grease evenly to the bearings. Monitoring that grease is pumped through the lubrication distributor (1) is possible. The signal can be used to give an alarm or to stop the feeder and crusher. An excess pressure valve (4) protects the lubrication system against excessive pressures. If any blocking causes the operating pressure to increase over 300 bar, the valve will open and grease will emerge.

NOTE!

In low temperatures (below 0°C), a heating cable is recommended around the lubricator and grease lines. (Continued)

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3

1

4

2

PAUSE h/lmp CONTACT min/lmp

SET CS

DK

PS

5

FAULT

6

1 2 3 4 5 6

Lubrication distributor Grease connection Filling nipple Excess pressure valve Display cover Grease outlet

Grease quantity Delivery

Pause time

Operation time

8 g/h

0.5 h

6.4 min.

Set pause time and operation time corresponding to the required delivery (see table above): a) Unscrew the plastic display cover (5). b) Hold down the set button (10) for longer than 2 seconds. The display (7) flashes “000”. (Continued)

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81


PAUSE h/lmp

7 8 9 10 11 12 13

Display Pause LED Contact LED Set button Arrow buttons DK button Fault LED

CONTACT min/lmp

7 8 9 10

SET CS

DK

11

PS

FAULT

12 13

c) Press the set button shortly to confirm. The display shows “tPA” (timer pause) and the pause LED (8) flashes. d) Press the set button shortly. The display shows the pause time (in hours). e) Set the pause time (see table above) with the arrow buttons (11). f) Press the set button shortly to confirm. The display show “tCO” (timer contact) and the contact LED (9) flashes. g) Press the set button shortly. The display shows the operation time (in minutes). h) Set the operation time (see table above) with the arrow buttons. i) Press the set button shortly to confirm. j) Hold down the set button for longer than 2 seconds to save the new values. The display shuts off. k) Screw back the plastic display cover.

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10. Automatic lubricator (option) Checks After every 40 hours of operation, check the level of grease. Refill through the filling nipple (3). Check that all hoses are properly connected. With the crusher stopped, check also that old grease has been forced out of the labyrinth seals (see figure below). If not, slightly increase the quantity pumped to the bearings. This is to prevent dirt and water entering the bearings.

After maintenance work or a long out of operation period, extra lubrication is needed. Press the DK button (12) during the pause time to release intermediate lubrication. Do this repeatedly until old grease is forced out of the labyrinth seals. NOTE!

CJ211:01

When the fault LED (13) is lit, press the DK button (12) to acknowledge and delete fault messages.


83


10.1.2 Lubricant requirements The grease must contain anti-rust and EP additives and fulfil the following minimum requirements: Property

Test method

Requirements

NLGI value

DIN 51 818

2 or 3

Drop point

DIN ISO 2176

≥ 180


≥ 170


≥ 100

Mechanical stability

SKF V2F 1000 rpm

Approved

Corrosion resistance

DIN 51 802 SKF Emcor

Approved

Temperature range Speed range

–30°C to +110°C Must lubricate effectively throughout the bearing’s entire operating speed range

Viscosity index

at least 80

Examples of lubricants, which according to their manufacturer fulfil Sandvik’s requirements: Aral Aralub HLP 2 BP Energrease LS-EP 2 ESSO Beacon EP 2 N Mobil Mobilgrease HP 222

Molub-Alloy Tribol 4020/220-2 Shell Ariax Li X 2 Statoil UniWay Li X 62 Texaco Hytex EP 2

For other types of grease, consult your lubricant supplier.

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CJ211:01

maintenance manual

Doc. no. S 222.157 en

SANDVIK CJ211:01



Sign.

SANDVIK CJ211:01 © Copyright 2007 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 222.157 en Issue: 20070625 Version: 1

Sandvik SRP AB Stationsplan, SE-233 81 Svedala, Sweden Tel: +46 (0)40 409000, Fax: +46 (0)40 409260 www.sandvik.com

Table of contents

1. Introduction 1.1 Equipment information.......................................................... 4 1.1.1 Document information.............................................. 6 1.1.2 Description ............................................................... 7

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..................................................... 2.2 Personnel............................................................................ 2.2.1 Personal protection ................................................ 2.3 General safety precautions................................................. 2.3.1 Machine safety guards........................................... 2.3.2 Electrical safety...................................................... 2.3.3 Welding .................................................................. 2.3.4 Hydraulic systems.................................................. 2.3.5 Lifting and moving loads ........................................ 2.3.6 Feed and jams ....................................................... 2.4 Emissions ........................................................................... 2.4.1 Dust........................................................................ 2.4.2 Noise...................................................................... 2.4.3 Radioactivity...........................................................

10 10 10 10 10 11 12 12 13 14 14 15 15 16 17 17 17 17

3. Basic maintenance instruction 3.1 General ............................................................................... 3.2 Preventive maintenance ..................................................... 3.2.1 Routine inspection and care .................................. 3.2.2 Periodical maintenance.......................................... 3.3 Spare parts in this manual .................................................. 3.4 Recommended tool box...................................................... 3.5 Tightening threaded fasteners ............................................ 3.5.1 Requirements for joints with threaded fasteners....

CJ211:01


20 20 20 20 21 22 23 23

1

Table of contents

4. Setting adjustment system 4.1 Exchanging the retraction cylinder...................................... 26 4.1.1 Removing retraction cylinder.................................. 26 4.1.2 Installing retraction cylinder.................................... 27 4.2 Exchanging hydraulic cylinders and setting wedges........... 28 4.2.1 Removing hydraulic cylinder and setting wedge .... 28 4.2.2 Installing setting wedge and hydraulic cylinder ...... 30 4.3 Exchanging guide plates..................................................... 32 4.3.1 Removing the guide plates..................................... 32 4.3.2 Installing the guide plates....................................... 33 4.4 Exchanging toggle plate and toggle seats .......................... 34 4.4.1 Removing toggle plate and toggle seats ................ 35 4.4.2 Installing toggle plate and toggle seats .................. 37

5. Flywheels 5.1 Exchanging flywheels ......................................................... 42 5.1.1 Removing flywheel ................................................. 43 5.1.2 Installing flywheel ................................................... 45

6. Bearings 6.1 Exchanging bearings .......................................................... 6.1.1 Removing moving jaw ............................................ 6.1.2 Installing moving jaw .............................................. 6.1.3 Removing frame bearings ...................................... 6.1.4 Installing frame bearings ........................................ 6.1.5 Removing moving jaw bearings ............................. 6.1.6 Installing moving jaw bearings ...............................

2


48 48 50 51 53 57 59

CJ211:01

1. Introduction To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

CJ211:01


3

1. Introduction

1.1 Equipment information Purpose The purpose of this Sandvik equipment is to be a crusher component in a crushing and screening unit or site within an aggregate, recycling or mining process. It can also be configured as a stand-alone machine complete with motor, motor support, V-belts and pulley, and guards. The machine reduces the size of rocks, minerals, recycling material and similar materials. This jaw crusher component has been exclusively designed for these applications. It is not the responsibility of Sandvik SRP AB to secure the design and usage for the complete aggregate, recycling or mining process. Sandvik SRP AB 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 Stationsplan SE-233 81 Svedala Sweden www.sandvik.com For maintenance Contact the nearest Sandvik company, agent or representative, or the manufacturer directly: Sandvik SRP AB Service department SE-233 81 Svedala Sweden. Telephone +46 (0)40 409000 Telefax +46 (0)40 409260

4


CJ211:01

1. Introduction Identification The figure below shows an example of the crusher’s identification plate. The identification plate contains data needed when contacting Sandvik SRP AB concerning this specific equipment. Enter the serial number of the associated machine in the intended field on the second page of this manual (the copyright page).

8 7

1

2 1 2 3 4 5 6 7 8

3

4

5

6

Machine type Part number Serial number Mass (kg) Order number Manufacturer Year of manufacture CE mark

CE marking This equipment complies with the basic health, environment and safety regulations of the European Union and European Economic Area. Sandvik SRP AB will not take responsibility for this compliance when a customer modifies the jaw crusher in any way.

CJ211:01


5

1. Introduction

1.1.1 Document information Purpose of this Maintenance manual The instructions in this manual are valid only for maintenance personnel trained or authorized by Sandvik. The purpose of this Maintenance manual is to provide maintenance personnel with: •

information on all scheduled maintenance procedures listed in the checklists • information for unscheduled maintenance such as: – additional maintenance procedures The structure, codes and descriptions of this manual are used in the Spare parts catalog (SPC) and in the checklists. 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 installation and operation of this equipment are: • Installation manual (IM) • Wear parts catalog (WPC) • Operator’s manual (OM) Technical publications related to maintenance of this equipment are: • Maintenance manual (MM) • Spare parts catalog (SPC) These publications are only available to trained maintenance personnel. Sandvik SRP AB can provide adequate training and authorize personnel. Read more about the document structure and accompanying work roles in section 2.2 Personnel. When ordering technical publications, always specify the language and quote the machine serial number. Number of pages This document contains a total of 62 pages. Feedback If you have comments on this Maintenance manual or problems connected to the jaw crusher’s documentation, send an e-mail to: [email protected]

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CJ211:01

1. Introduction

1.1.2 Description The following drawings show an overview of the jaw crusher’s nomenclature and components. Bottom view 1 Flywheel 2 Eccentric shaft (concealed) 3 Frame 4 Front frame end 5 Fastening for cheek plate 6 Foot 7 Hydraulic cylinder – wedge 8 Setting wedge (concealed) 9 Support bar 10 Retraction cylinder 11 Back frame end

1 2 3 4 5 6

7

8

9

10

11

Top view 12 13 14 15 16 17 18 19

Bearing housing Moving jaw Counterweight Deflector plate Clamping bar Cheek plate Jaw plate – moving Jaw plate – stationary

CJ211:01

12 13

14 15 16 17 18 19


7

1. Introduction Top view with drive and guards 20 21 22 23

Guard over V-belts and flywheel Motor Motor support Guard over free flywheel

20 21 22 23

8


CJ211:01

2. Safety precautions To ensure maximum safety, always read this section carefully before doing any work on the equipment or making any adjustments.

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9


2.1 Hazard information 2.1.1 Warning signs

General danger

Dangerous voltage

Risk of crushing

Hanging load

Risk of crushing

Flying fragments

2.1.2 Risk levels Throughout the manual, level of risk is indicated as “DANGER”, “WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels are accompanied by a warning sign (see above). 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 damage to equipment!

2.1.3 Prohibition signs

Do not remove guards

2.1.4 Mandatory signs

Disconnect current before any work

10

Read the manual


CJ211:01


2.2 Personnel All work on the equipment is to be carried out only by trained or authorized personnel. – “Trained” means that the person in question has been given practical instruction by an authorized person on how the various tasks are to be carried out. – “Authorized” means that a person has undergone a theoretical and practical test of knowledge, organized by Sandvik SRP AB. He/she is therefore judged to have the knowledge and competence to carry out the tasks assigned to the appropriate role. All expected work tasks on this production equipment have been defined by Sandvik SRP AB as belonging to one of three categories – work roles – based on different competence profiles. These three work roles are: • Installation • Operation • Maintenance Sandvik SRP AB provides technical documentation appropriate to all three work roles: • Installation manual • Operator’s manual and Wear parts catalog • Maintenance manual and Spare parts catalog Sandvik SRP AB can provide adequate training for all three work roles and can carry out authorization of trained personnel. The technical documentation from Sandvik SRP AB covers only 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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11


2.2.1 Personal protection Sandvik SRP AB strongly recommends that personal protective equipment is always worn when working in the vicinity of the equipment. The Sandvik SRP AB recommendation for personal protective equipment includes:

Ear protection

Safety helmet

Eye protection

Protective gloves

Safety boots

Mask or breathing apparatus

2.3 General safety precautions

WARNING!

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

Always switch off power and lock out the equipment (secure it cannot 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 being done. Before maintenance work, place two wooden blocks between the moving jaw and the back frame end to prevent the moving jaw from falling back. Dangerous work Never stand inside the crushing chamber when heavy parts (e.g. jaw plates and cheek plates) are being lifted out or in. WARNING!

(Continued)

12


CJ211:01

2. Safety precautions Avoid remaining on the crusher, unless necessary for maintenance work. Risk of crushing Never remain on the crusher while crushing. Moving parts constitute a risk of crushing. WARNING! Ejection Never look into the crusher while crushing. Fragments and possibly harmful substances fed to the crusher may be ejected. WARNING!

2.3.1 Machine safety guards Do not remove guards Make sure that all guards are in place and functioning, to prevent exposure to flying fragments and rotating parts. Never operate the PROHIBITION! equipment unless guards are mounted. Rotating parts Exposure to rotating parts of the equipment shall be prevented by guards. Always attach guards after maintenance work. WARNING!

WARNING!

Flying fragments Fragments ejected upwardly may fall down in the vicinity of the crusher. Provide adequate guards and warning signs at appropriate places around the danger zone.

Upwardly ejected fragments may fall down in the vicinity of the crusher. Therefore Sandvik SRP AB recommends additional protection. Platforms with guard rails shall be installed around the crusher’s feed opening. Walkways, stairs and ladders must be designed in accordance with applicable regulations. (These parts are not included in the crusher’s standard specification). NOTE!

To prevent the ejection of large stones the feed hopper should be equipped with a pivoted stone guard. The stone guard must not be raised during crushing. Make sure all defective guards and dust sealing components are checked, repaired and replaced before starting the equipment.

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13


2.3.2 Electrical safety CAUTION!

Only electrical personnel working according to European Standard EN 50110 or similar are permitted to perform electrical operations on the crusher. 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.

2.3.3 Welding CAUTION!

Welding on the crusher is only permitted when and as described in the manual. For all other welding operations on the crusher local Sandvik service personnel must be consulted.

CAUTION!

Only welders qualified according to European Standard EN 287 or similar are permitted to perform welding operations on the crusher.

If welding an item to the crusher, ground must be attached to the item itself. If a crusher component is to be welded, ground should be attached as near to the welding area as possible.

WARNING!

14

Toxic gases Inhalation of welding fumes can be dangerous to health. Always follow instructions provided by the welding equipment supplier. Several parts of the crusher are made of manganese steel. Long-term exposure to manganese oxide can affect the nervous system.


CJ211:01


2.3.4 Hydraulic systems CAUTION!

Only personnel certified in hydraulics are permitted to perform operations on the hydraulic system.

WARNING!

Oil pressure Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system.

CAUTION!

Never adjust pressure relief valves beyond the recommended values. Oil temperature Hydraulic oil can get very hot in operation. Allow the oil to cool before working on the hydraulic system.

WARNING!

Make sure all defective hoses, valves or fittings are checked, repaired and replaced before starting the equipment.

WARNING!

Risk of crushing Never touch or alter hydraulic cylinders when the equipment is in operation. The hydraulic cylinders may suddenly change position. Always keep body parts away from hydraulic cylinders in operation.

2.3.5 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 from a hanging load.

WARNING!

Make sure that the capacity of the lifting equipment is adequate and that the equipment itself is in good working order. If a lifting tackle has to be made up by joining separate components, make sure that the joints are secure and have the same lifting capacity 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 manoeuvre loads. Do not 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 lower the load to the floor quickly and safely in an emergency. When depositing loads, keep the lifting equipment in place until the stability of the load has been checked.

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15


2.3.6 Feed and jams CAUTION!

When the crushing chamber is empty, avoid feeding solitary large boulders into the upper part of the chamber. In unfavourable circumstances the moving jaw may be pushed forward and bring the toggle plate out of position.

CAUTION!

Never feed combustible process material into the crusher.

WARNING!

Flying fragments Never use wedges etc. to clear jams in the feed opening. Stones and fragments can be thrown out at high speed from the crushing chamber.

WARNING!

DANGER!

Explosives Never remove blocking boulders from the crusher by blasting. Blasting may cause personal injury and seriously damage bearings or other parts. Sandvik SRP AB takes no responsibility for injury to personnel or damage to the equipment when blasting is used. Risk of crushing Never stand inside the crusher when a blockage is removed. You might be pulled forcefully and suddenly downwards together with the material in the crushing chamber and be crushed.

If it is possible to change the direction of rotation of the jaw crusher’s flywheel for a while to clear a jam. Always return to the normal rotation direction when the jam has been cleared. In some cases it is also possible to increase the CSS (closed side setting) temporarily to clear a jam. CAUTION!

If a hydraulic hammer is installed, never use it to fracture stones in the crushing chamber. This may seriously damage bearings or other vital components.

However, Sandvik SRP AB recommends that a jam in the feed opening is cleared by using a hydraulic hammer. If a blockage occurs, use the hydraulic hammer to poke the stones to break the blockage. A hydraulic hammer can also be used to knock off corners and edges from slightly oversized stones so that they can enter the crushing chamber. Always follow local regulations when attempting to clear a jam.

16


CJ211:01


2.4 Emissions 2.4.1 Dust Health hazard Crushing and processing material will create dust. Such dust can be more or less dangerous to the health. Use a breathing mask DANGER!

Sandvik SRP AB strongly recommends using additional equipment for dust suppression. Examples are dust extraction (vacuum) and dust encapsulation by water spray or foam. Such equipment is not included in the crusher’s standard specification. Sandvik SRP AB declines all responsibility for any health hazards caused by dust, generated when processing minerals in the crusher.

2.4.2 Noise Health hazard Crushing and processing material will create noise. Such noise can be more or less dangerous to the hearing. Use ear protection. WARNING!

2.4.3 Radioactivity

DANGER!

Health hazard Radon is a radioactive gas that occurs naturally in bedrock. Radon may cause lung cancer. Mineral type, ventilation and water are all factors that influence the contents of radon gases.

Sandvik SRP AB declines all responsibility for any health hazards caused by the release of radon or any other harmful substances when processing minerals in the crusher.

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17



18


CJ211:01

3. Basic maintenance instruction This section describes the basic maintenance instruction for the jaw crusher. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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19

3. Basic maintenance instruction

3.1 General The instructions in this manual are limited to the jaw crusher component. Instructions for the motor, drive belt, hydraulic system, control system etc. can be found in other documentation from the applicable equipment manufacturer.

3.2 Preventive maintenance 3.2.1 Routine inspection and care For routine inspection and care, see section 5. Inspection and care in the Operator’s manual.

3.2.2 Periodical maintenance This list is a complement to section 5. Inspection and care in the Operator’s manual. All service intervals are based on estimations of average wear. Section

Intervals (operating hours)

Instruction

Note

4.1

6 000

Exchange retraction cylinder

4.4

–

Exchange toggle plate and toggle seats and check the retraction cylinder and its bushings

4.2

–

Exchange hydraulic cylinders and setting wedges

4.3

–

Exchange guide plates

Worn > 3 mm

6.1

> 15 000

Exchange frame bearings when unusual noise is heard

Must only be executed by certified personnel.

6.1

> 20 000

Exchange moving jaw bearings when unusual noise is heard

Must only be executed by certified personnel.

Worn 20 mma

a. Compare with the original length in the Spare parts catalog

20


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3.3 Spare parts in this manual

CJ211:01

Description

Cat. no.

Quantity

See section

Retraction cylinder

7050-0

1

4.1

Piston pin

7051-0

1

4.1

Retraction cylinder bushing

7052-0

2

4.1, 4.4

Washer SRB 41×80×3

7052-2

2

4.1

Cylinder pin

7053-0

1

4.1

Toggle plate

5006-0

1

4.4

Toggle seat, upper

5004-0

1

4.4

Toggle seat, lower

5005-0

1

4.4

Setting wedge

6300-0

2

4.2

Hydraulic cylinder

6320-0

2

4.2

Guide plate

6310-0

4

4.3

Screw MC6S M20×70

6311-0

12

4.3

Washer BRB 21×36

6311-2

12

4.3

Flywheel, flat

2205-0

1

5.1

Flywheel, grooved

2206-0

1

5.1

Roller bearing, frame

2006-0

2

6.1.4

V-ring

2010-1

2

6.1.4

V-ring

2007-1

2

6.1.4

Roller bearing, moving jaw

2101-0

2

6.1.6

V-ring

2104-1

2

6.1.6


21


3.4 Recommended tool box The following is a list of recommended tools for use during maintenance work.

22

Tool

Used for

24 mm Open end wrench

Retraction cylinder / Hydraulic cylinders and setting wedges / Frame bearings / Moving jaw bearings


Hydraulic cylinders and setting wedges / Guide plates

Bushing press

Retraction cylinder bushing

Chain block

Hydraulic cylinders and setting wedges / Toggle plate and toggle seats

20 mm Round iron

Toggle plate and toggle seats



Wooden wedges


Chopping bit

Flywheels

Hydraulic nut HMV 27

Flywheels

18 mm Combination wrench

Flywheels

Extractor

Flywheels

Hydraulic pump with manometer

Flywheels

Deep gauge

Flywheels

Dial indicator

Flywheels

Hammer

Flywheels / Frame bearings

Hook wrench

Flywheels / Frame bearings


Moving jaw


Frame bearings


Frame bearings

Soft hammer

Frame bearings

Feeler gauge

Frame bearings

Gas torch

Frame bearings

Sledge hammer

Moving jaw bearings

Copper punch

Moving jaw bearings

Crow bar

–

Lifting tackle and chain

–

Lifting sling

–

Mobile crane

–


CJ211:01


3.5 Tightening threaded fasteners Unless otherwise specified, the threaded fasteners used in the crusher must be tightened to the correct torque for the size in question. STRENGTH GRADE (SS-ISO 898/1) THREAD M

8.8 Bright zinc-coated

mm

Nm

8

21

ft lbs 15

10

40

30

12

70

52

16

169

125

20

331

244

24

572

422

30

1130

833

36

1960

1446

42

3130

2309

48

4690

3459

3.5.1 Requirements for joints with threaded fasteners – – – – – –

Steel screws of grade 8.8, bright zinc-coated finish. Nuts of grade 8, bright zinc-coated finish. Hardened washers – at least HB200, bright zinc-coated finish. Lightly oiled components. Threads in castings cleaned out. Tightening carried out with a torque wrench which can be calibrated, or with a bolt/nut runner with a torque limiter. – Max. permissible torque spread: ± 10 %.

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23



24


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4. Setting adjustment system This section describes the scheduled maintenance work for the setting adjustment system. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

CJ211:01


25


4.1 Exchanging the retraction cylinder The following spare parts are required: Description

Cat. No.

Qty.

Remark

Retraction cylinder Piston pin

7050-0

1

Incl. retraction cylinder bushings 7052-0

7051-0

1

Washer SRB 41×80×3

7052-2

2

Cylinder pin

7053-0

1

4.1.1 Removing retraction cylinder Recommended tools 24 mm Open end wrench

a) Release pressure in the retraction cylinder (7050-0) and remove the hydraulic connection. b) Dismantle the cylinder pin (7053-0) and piston pin (7051-0) with washers (7052-2) and remove the retraction cylinder.

7051-0 Piston pin 7052-2 Washer 7050-0 Retraction cylinder 7052-0 Retraction cylinder bushing 7053-0 Cylinder pin

7051-0

26

7052-2


7050-0

7053-0

CJ211:01


4.1.2 Installing retraction cylinder a) Clean the moving jaw bracket (1) and back frame end bracket (2). b) Attach the piston of the retraction cylinder (7050-0) to the moving jaw bracket (1) by mounting the piston pin (7051-0). Place a washer (7052-2) on each side of the piston between the moving jaw bracket. c) Mount the other end of the retraction cylinder to the back frame end bracket (2) with the cylinder pin (7053-0). d) Connect the hydraulic connection to the retraction cylinder (7050-0) and apply pressure.

7051-0 7052-2 7050-0 7052-0 7053-0 1 2

Piston pin Washer Retraction cylinder Retraction cylinder bushing Cylinder pin Moving jaw bracket Back frame end bracket

1

CJ211:01

7051-0

7052-2


7050-0

7053-0

2

27


4.2 Exchanging hydraulic cylinders and setting wedges The following spare parts are required:

NOTE!

Description

Cat. No.

Qty.

Remark

Setting wedge

6300-0

2

weight 135 kg

Hydraulic cylinder

6320-0

2

weight 35 kg

The following instructions are for removal/installation of one side. Repeat the procedure for the other side. The pictures show exchange of the right side.

4.2.1 Removing hydraulic cylinder and setting wedge NOTE!

Adjust to maximum CSS before depressurizing the hydraulic system to facilitate the hydraulic cylinders and setting wedges removal. See section 8. Setting adjustment system in the Operator’s manual.

NOTE!

Sandvik recommends to remove the wedge furthest away from the jaw (left side) first to prevent the wedge from dropping.

WARNING!

Hydraulic systems Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the pressurized system.

a) Position the hook of a mobile crane vertically above the toggle plate (5006-0).

6320-0 6300-0

Hydraulic cylinder Setting wedge (concealed) 5006-0 Toggle plate 1 Bracket 2 Lifting sling 4 Holes in toggle plate

2 1 6320-0 6300-0 5006-0 4 (Continued)

28


CJ211:01


Recommended tools Crow bar 24 mm Combination wrench 30 mm Combination wrench Lifting tackle and chain Lifting sling Mobile crane Chain block

WARNING!

b) Connect the lifting device to the toggle plate (5006-0) from above. Use the two elliptical holes (4) for the lifting sling (2). c) Take up the slack in the lifting tackle. d) Loosen the retraction cylinder as described in section 4.1.1 Removing retraction cylinder. e) Attach a chain block to the moving jaw bracket (1). Let the chain pass under the jaw crusher’s discharge opening and tighten it to a position in front of the jaw crusher so that the moving jaw is pulled slightly forward. f) Remove the hydraulic connections on the hydraulic cylinder (6320-0). g) Loosen the hydraulic cylinder by removing the screws (6333-0) and washers (6333-2) with a combination wrench. Risk of crushing The hydraulic cylinder is now loose and may fall sideways. Handle the hydraulic cylinder with care.

h) Use a combination wrench to remove the screws (6331-0) and washers (6331-2) that hold the cylinder brackets (6330-0). 6331-0 6331-2 6330-0 6333-0 6333-2 6320-0 6300-0 6301-0 6301-2

6331-0, 6331-2 6330-0 6333-0, 6333-2

Screw Washer Bracket Screw Washer Hydraulic cylinder Setting wedge Pin Retaining ring

6320-0 6300-0 6301-0, 6301-2 i)

Release the hydraulic cylinder (6320-0) from the setting wedge (6300-0) by removing the retaining ring (6301-0) and pin (6301-2). j) Pull out the setting wedge (6300-0) less than half-way. k) Position the hook of a mobile crane vertically above the setting wedge (6300-0). (Continued)

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29

4. Setting adjustment system l)

Screw an M16 lifting lug on the setting wedge and attach a lifting sling to it. m) Take up the slack in the lifting tackle.

DANGER!

Hanging load Be aware of the weight of the setting wedge, see table above. Handle the setting wedge with care. The tackle should now be tight but not lifting the setting wedge. Keep clear of hanging loads, see section 2. Safety precautions.

n) Gently lift and pull the setting wedge (6300-0) out of its compartment. o) Place the setting wedge (6300-0) horizontally on the ground.

4.2.2 Installing setting wedge and hydraulic cylinder Back side

Left side

Right side

NOTE!

If it is planned to exchange guide plates and/or toggle plate and toggle seats at the same time, please proceed to the instructions for those parts before installing the new wedges and hydraulic cylinders.

NOTE!

It is important to place the setting wedges correctly. The wedge on the right side must be closest to the jaw and the wedge on the left side closest to the back side. The shorter side of the wedge should be in contact with the compartment and the longer side with the longer side of the other wedge. Sandvik recommends to install the wedge closest to the jaw (right side) first to prevent the other wedge from dropping.

CAUTION!

Never lubricate setting wedges made of grey iron.

a) Position the hook of a mobile crane vertically above the new setting wedge (6300-0). b) Screw an M16 lifting lug on the setting wedge and attach a lifting sling to it. (Continued)

30


CJ211:01

4. Setting adjustment system c) Take up the slack in the lifting tackle.

DANGER!

Hanging load Be aware of the weight of the setting wedge, see table above. Handle the setting wedge with care. The tackle should now be tight but not lifting the setting wedge. Keep clear of hanging loads, see section 2. Safety precautions.

d) Gently lift and push the setting wedge more than half-way into its compartment. Remove the M16 lifting lug. e) Fasten the hydraulic cylinder (6320-0) to the setting wedge (6300-0) with the pin (6301-0) and retaining ring (6301-2). f) Push the setting wedge into position. g) Fasten the screws (6331-0) and washers (6331-2) that hold the cylinder brackets (6330-0) in place. h) Fasten the hydraulic cylinder (6320-0) with screws (6333-0) and washers (6333-2) to the cylinder brackets (6330-0). i) Connect the hydraulic connections to the hydraulic cylinder (6320-0). j) Make sure the toggle plate and toggle seats are properly lined up. k) Slacken off the chain and remove it from the moving jaw bracket (1) and the lifting sling (2) from the toggle plate (5006-0). l) Install the retraction cylinder as described in section 4.1.2 Installing retraction cylinder. 6331-0 6331-2 6330-0 6333-0 6333-2 6320-0 6300-0 6301-0 6301-2

6331-0, 6331-2 6330-0 6333-0, 6333-2

Screw Washer Bracket Screw Washer Hydraulic cylinder Setting wedge Pin Retaining ring

6320-0 6300-0 6301-0, 6301-2

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31


4.3 Exchanging guide plates The following spare parts are required: Description

Cat. No.

Qty.

Remark

Guide plate

6310-0

4

Original thickness 16 mm

Screw MC6S M20×70

6311-0

12

Washer BRB 21×36

6311-2

12

NOTE!

Remove the hydraulic cylinders and setting wedges before removing the guide plates. See section 4.2.1 Removing hydraulic cylinder and setting wedge.

NOTE!

The guide plates are located inside the back frame end. The screws that hold them in place are attached from the outside.

4.3.1 Removing the guide plates Recommended tools 30 mm Open end wrench

6311-0 6311-2 6310-0 1

a) Heat the head of the screws (6311-0) to dissolve the Loctite. b) Use an open end wrench to remove the screws (6311-0) and washers (6311-2) that hold the guide plates (6310-0).

Screw Washer Guide plate Back frame end

1 6311-0, 6311-2 6310-0

(Continued)

32


CJ211:01


WARNING!

Risk of crushing The guide plates can be loose after removing the screws from the back frame end. Keep clear of falling guide plates, see section 2. Safety precautions.

c) Remove the guide plates. NOTE!

Apply a crow bar if the guide plates (6310-0) get stuck. Never use arms or feet.

4.3.2 Installing the guide plates a) Install the screws (6311-0) and washers (6311-2). b) For each guide plate (6310-0), place the guide plate and tighten the screws with Loctite no. 243 and torque 220 Nm. c) Install the setting wedges and hydraulic cylinders as described in section 4.2.2 Installing setting wedge and hydraulic cylinder. 6311-0 6311-2 6310-0 1

Screw Washer Guide plate Back frame end

1 6311-0, 6311-2 6310-0

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33


4.4 Exchanging toggle plate and toggle seats The following spare parts are required:

5013-2 5014-0 5003-0 5018-0 5019-0 5004-0 5006-0 5005-0 3000-0

Description

Cat. No.

Qty.

Remark

Toggle plate

5006-0

1

weight 160 kg

Toggle seat, upper

5004-0

1

weight 25 kg

Toggle seat, lower

5005-0

1

weight 25 kg

NOTE!

There are toggle plates of different lengths to choose from. The chosen length depends on what setting the crusher will be operated at and if the crusher is equipped with jaw shim plates.

NOTE!

Adjust to maximum CSS before depressurizing the hydraulic system to facilitate removal of the toggle plate and toggle seats. See section 8. Setting adjustment system in the Operator’s manual.

CAUTION!

The crusher must be stopped and the retraction assembly must be removed when exchanging the toggle plate and toggle seats.

Toggle seat retainer Screw Toggle seat holder Side block Screw Upper toggle seat Toggle plate Lower toggle seat Moving jaw

5013-2 5014-0

5003-0 5018-0, 5019-0 5004-0 5006-0 5005-0 3000-0

34


CJ211:01


4.4.1 Removing toggle plate and toggle seats Recommended tools Crow bar Lifting tackle and chain Lifting sling Mobile crane

a) Position the hook of a mobile crane vertically above the toggle plate (5006-0). b) Connect the lifting device to the toggle plate (5006-0) from above. Use the two elliptical holes (4) for the lifting sling (2). c) Take up the slack in the lifting tackle.

20 mm round iron 18 mm Open end wrench Wooden wedges Chain block

1 2 3 4

2 3

Bracket Lifting sling Wooden wedge Holes in toggle plate

1 4

DANGER!

Hanging load Be aware of the weight of the toggle plate, see table above. Handle the toggle plate with care. The tackle should now be tight but not lifting the toggle plate. Keep clear of hanging loads, see section 2. Safety precautions.

d) Loosen the retraction cylinder as described in section 4.1.1 Removing retraction cylinder and remove the hydraulic cylinders and setting wedges as described in section 4.2.1 Removing hydraulic cylinder and setting wedge. e) Check the retraction cylinder (7050-0) and its bushings (7052-0) and replace them with a press and seal with Loctite if worn or damaged. See section 4.1 Exchanging the retraction cylinder. f) Remove the upper guide plate on the side in which direction to pull out the toggle seat holder, see section 4.3.1 Removing the guide plates. g) Attach a chain block to the moving jaw bracket (1). Let the chain pass under the jaw crusher’s discharge opening and tighten it to a position in front of the jaw crusher. (Continued)

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35

4. Setting adjustment system h) Place two wooden wedges (3) between the moving jaw and back frame end to prevent the moving jaw from falling back. i) To prevent the toggle seat holder from falling down, insert a round iron (5) through the hole (6) in the frame and under the toggle plate so that the toggle seat holder can rest on the iron. j) Pull the jaw forward using the chain.

5 6

5 Round iron 6 Hole 5006-0 Toggle plate

5006-0

k) Lower the toggle plate (5006-0) to the surface. NOTE!

Apply a crow bar or wedges if the toggle plate (5006-0) gets stuck. Never use arms or feet. l) m) n) o)

p) q)

36

Release the lifting device from the toggle plate and remove the toggle plate from the jaw crusher. Use the round iron as a guide and pull out the toggle seat holder (5003-0) half way through the hole (6). Connect the toggle seat holder to a lifting sling and withdraw it from the crusher. Unscrew the toggle seat retainer (5013-2) in the middle and the side blocks (5018-0) on both ends of the toggle seat holder with an open end wrench. Remove the toggle seat from the toggle seat holder. Remove the lower toggle seat (5005-0).


CJ211:01


4.4.2 Installing toggle plate and toggle seats NOTE!

Before starting this procedure, it is necessary to secure the moving jaw as described in section 4.4.1 Removing toggle plate and toggle seats items f–g and to remove the retraction cylinder (7050-0) as described in section 4.1.1 Removing retraction cylinder. a) Wash the new toggle plate (5006-0) and the new toggle seats (5004-0), (5005-0). b) Clean the slots where the upper and lower toggle seats fit. c) Install the lower toggle seat (5005-0).

5013-2 5014-0 5003-0 5018-0 5019-0 5004-0 5006-0 5005-0 3000-0

Toggle seat retainer Screw Toggle seat holder Side block Screw Upper toggle seat Toggle plate Lower toggle seat Moving jaw

5013-2 5014-0

5003-0 5018-0, 5019-0 5004-0 5006-0 5005-0 3000-0

d) Push the upper toggle seat (5004-0) into the toggle seat holder (5003-0). e) Fasten the toggle seat retainer (5013-2) in the middle with screws (5014-0) and washers (5014-2) and the side blocks (5018-0) on both ends with screws (5019-0) and washers (5019-2). f) Connect the toggle seat holder to a lifting sling. (Continued)

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37

4. Setting adjustment system g) Insert a round iron into the hole (6) in the frame. h) Use the round iron as a guide and insert the toggle seat holder into right position. i) Disconnect the lifting sling from the toggle seat holder. j) Connect the lifting device to the toggle plate (5006-0). Use the two elliptical holes (4) for the lifting sling (2).

DANGER!

Hanging load Be aware of the weight of the toggle plate, see table above. Handle the toggle plate with care. The tackle should now be tight but not lifting the toggle plate. Keep clear of hanging loads, see section 2. Safety precautions.

k) Carefully lift the toggle plate (5006-0) below the back frame end. l) Lower the toggle plate to the surface.

5004-0 Upper toggle seat 5006-0 Toggle plate 5005-0 Lower toggle seat 3000-0 Moving jaw

5004-0 5006-0 5005-0 3000-0 (Continued)

38


CJ211:01

4. Setting adjustment system m) Release the lifting sling (2) from the hook. n) Reconnect the lifting sling (2) to the hook, this time through the back end frame. o) Lift and drag the toggle plate (5006-0) so it comes in position under the back end frame. p) Lift the toggle plate (5006-0) gently. q) Position the back of the toggle plate (5006-0) in the upper toggle seat (5004-0). r) Lift up the lower end of the toggle plate in line with the lower toggle seat (5005-0). NOTE!

Use a crow bar if the toggle plate gets stuck. Never use arms or feet. s) Remove the wooden wedges (3). t) Move the moving jaw slowly backward and make sure that the toggle plate fits in the toggle seat (5005-0). u) Check that the toggle plate (5006-0) is seated correctly.

NOTE!

Pull the jaw slightly backwards if needed to adjust the toggle plate into correct position. v) Slacken off the lifting tackle and remove the lifting sling (2). w) Install the guide plates, see section 4.3.2 Installing the guide plates. x) Install the setting wedges and hydraulic cylinders as described in section 4.2.2 Installing setting wedge and hydraulic cylinder and the retraction cylinder as described in section 4.1.2 Installing retraction cylinder.

CJ211:01


39



40


CJ211:01

5. Flywheels This section describes the scheduled maintenance work for the flywheels and the tools to use. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

CJ211:01


41

5. Flywheels

5.1 Exchanging flywheels Description

Cat. No.

Qty.

Remark

Flywheel, flat

2205-0

1

weight 850 kg

Flywheel, grooved

2206-0

1

weight 850 kg

The jaw crusher has a flywheel (2205-0), (2206-0) on each side of the frame. One of these is used for the drive and this flywheel is grooved for V-belts (2206-0). The dimensions of the flywheels are chosen to ensure that the jaw crusher runs smoothly and evenly, even under heavy loads. The two flywheels can switch places with each other. The jaw crusher is balanced and tested before shipping. NOTE! CAUTION!

The following instructions are for exchange on one side. Repeat the procedure for the other side. If the flywheels are to switch places with each other it is important to change also the counterweights (2212-0). These are mounted inside the flywheel rim at an angle ahead of the flywheel’s line of symmetry, in the direction of rotation (see figure below). With the counterweights in the wrong position there will be vibrations in the jaw crusher.

22,5°

2212-0 2206-0 1

2212-0 Counterweight 2206-0 Flywheel grooved for V-belts 1 Lightening holes

NOTE!

The hydraulic nut and the extractor mentioned in the following instruction can be hired from Sandvik.

NOTE!

Never grease the flywheels’s V-belt grooves. If lubricant comes in contact with the flywheel, clean it off with a degreasing agent.

WARNING!

42

Risk of crushing Always use the appropriate tools for exchanging flywheels. If the flywheel is mounted incorrectly, there is a risk that the flywheel can come off unintentionally.


CJ211:01

5. Flywheels

5.1.1 Removing flywheel Recommended tools Hammer Chopping bit Hydraulic nut HMV 27 18 mm Combination wrench Extractor Crow bar Hydraulic pump Lifting tackle and chain Lifting sling Mobile crane

DANGER!

a) Remove the guards over the V-belt drive and/or flywheel. b) Remove the V-belts, if applicable. c) Remove the screws (2211-0) and washers (2211-2) that hold the end cover (2210-0) in place. d) Position the hook of a mobile crane vertically above the flywheel. e) Connect the lifting gear to the flywheel. Use a lightening hole (1) for the lifting sling. f) Take up the slack in the lifting tackle. g) Connect a second adjustable lifting gear to the flywheel and the lifting hook. Use the lightening hole (1) on the other side of the counterweight to balance the flywheel. h) Take up the slack in the second lifting tackle. Hanging load Be aware of the weight of the flywheel, se table above. Handle the flywheel with care. The tackle should now be tight. Keep clear of hanging loads, see section 2. Safety precautions.

i)

2211-0 2211-2 2210-0 2209-1 2209-4 2208-0 2 3

Screw Washer Cover Shaft nut Tab washer Spacer ring Key way Screw holes

Use a hammer to loosen the locking nut (2209-1) and remove the lug of the locking washer (2209-4) that locks it.

2211-0 2211-2

2209-1 2208-0

2210-0 2209-4

2 3 (Continued)

CJ211:01


43

5. Flywheels j)

Remove the locking nut (2209-1) and locking washer (2209-4) from the threaded shaft. k) Loosen the spacer ring (2208-0). l) Fit the hydraulic nut (5) on the shaft, with the piston on the outside, leaving a gap of 5 mm to the spacer ring (2208-0). NOTE!

The extractor has a lifting eye bolt (4). Use it for lifting. m) Screw the extractor’s (6) studs into the threaded holes (3) in the flywheel. n) Loosen the flywheel’s fit on the shaft with the pump and hydraulic nut. o) Disconnect the lifting gear from the flywheel and connect it to the extractor plate. p) Remove the extractor (6) from the shaft and place it on the ground. q) Disconnect the lifting gear from the extractor plate and reconnect it to the flywheel. r) Remove the hydraulic nut (5). s) Remove the spacer ring (2208-0). t) Gently remove the flywheel from the shaft and place it horizontally on the ground.

4 5 4 Lifting eye bolt 5 Hydraulic nut 6 Extractor

44

6


CJ211:01

5. Flywheels

5.1.2 Installing flywheel NOTE!

Recommended tools Hammer Chopping bit Hydraulic nut HMV 27

18 mm Combination wrench Crow bar Deep gauge

NOTE!

Dial indicator Hydraulic pump with manometer Lifting tackle and chain Lifting sling Mobile crane Hook wrench

DANGER!

Lock the other flywheel to prevent the eccentric shaft from rotating. a) Inspect and clean the key way (2), the key (2207-0) and the bore of the flywheel. b) Clean the seating on the shaft. c) Lightly lubricate the sides of the key way on the flywheel. Do not lubricate the whole bore. d) Position the hook of a mobile crane vertically above the flywheel. e) Connect two lifting gears to the flywheel. Use lightening holes (1) for the lifting slings on both sides of the counterweight (2212-0). The second lifting gear must be adjustable so that the flywheel can be aligned with the key in the shaft. f) Lift the flywheel and slide it into position on the shaft with the key (2207-0) in the key way (2). Hanging load Be aware of the weight of the flywheel, see table above. Handle the flywheel with care. The tackle should now be tight. Keep clear of hanging loads, see section 2. Safety precautions.

g) Push the flywheel up onto its seating and install the spacer ring (2208-0).

2211-0 2211-2 2211-0 2211-2 2210-0 2209-1 2209-4 2208-0 2 3

2209-1 2208-0

Screw Washer Cover Shaft nut Tab washer Spacer ring Key way Screw holes

2210-0 2209-4

2 3 (Continued)

CJ211:01


45

5. Flywheels

NOTE!

To ensure full metallic contact it is necessary to adjust the vertical position of the flywheel. h) Fit a hydraulic nut (5) on the shaft, with the piston on the inside. i) Tighten the hydraulic nut manually so the bore of the flywheel comes in full metallic contact with the taper on the shaft. j) Slacken off the lifting tackle. k) Pump the hydraulic nut to 6 MPa. l) Install a dial indicator. m) Measure with a depth gauge as well. n) Pump up the hydraulic nut to push up the flywheel 0.9–1.1 mm on the taper (equals approx. 65–70 MPa). o) Leave the hydraulic nut in place under pressure for 30 minutes. p) Remove the hydraulic nut (5) from the shaft. q) Ensure correct axial displacement by measuring with a depth gauge again. r) Fit the tab washer (2209-4) and shaft nut (2209-1). s) Tighten the shaft nut (2209-1) with a hook wrench. t) Bend down a lug on the tab washer (2209-4) into the slot on the shaft nut. u) Grease the parts to prevent corrosion. v) Fit the end cover (2210-0) with the screws (2211-0) and washers (2211-2). w) Remove the lifting gear. x) Install the V-belts, if applicable.

WARNING!

Risk of crushing Exposure to rotating parts of the equipment shall be prevented by guards. Always attach guards after maintenance work.

y) Install the guards over the V-belt drive and/or flywheel. NOTE!

Remove the lock from the other flywheel. z) Run the jaw crusher without load for a while to test the function before crushing.

46


CJ211:01

6. Bearings This section describes the scheduled maintenance work for the bearings and the tools to use. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

CJ211:01


47

6. Bearings

6.1 Exchanging bearings The crusher has four spherical roller bearings on the eccentric shaft. The moving jaw bearings have cylindrical bores while the frame bearings have tapered bores and are consequently installed on tapered withdrawal sleeves. If trouble occurs in an eccentric shaft bearing, try to determine if it’s in the frame (outer) bearing or in the moving jaw (inner) bearing. The bearing temperature or unusual noise from the bearing gives an idea of the situation. CAUTION!

The exchange of the bearings must be executed by certified personnel.

CAUTION!

It is important that correct tools are used when maintenance work is being executed on the bearings.

NOTE!

The hydraulic nuts mentioned in the following instructions can be hired from Sandvik.

6.1.1 Removing moving jaw Recommended tools Crow bar Lifting tackle and chain 65 mm Open end wrench

DANGER!

a) Remove retraction cylinder and toggle plate. See section 4.1.1 Removing retraction cylinder and section 4.4.1 Removing toggle plate and toggle seats. b) Remove the flywheels. See section 5.1.1 Removing flywheel. c) Remove the screws (2004-0), washer and twin nuts (2004-7) that clamp the bearing housings to the frame. d) Position the hook of a mobile crane vertically above the moving jaw (3000-0). e) Connect the lifting gear to the lifting lug (1) on the moving jaw (3000-0) and take up the slack in the lifting tackle. Hanging load A moving jaw weighs up to 6000 kg. Handle the moving jaw with care. The tackle should now be tight. Keep clear of hanging loads, see section 2. Safety precautions.

(Continued)

48


CJ211:01

6. Bearings f) Lift out the moving jaw (3000-0) with eccentric shaft (2200-0) and bearings.

3000-0

3000-0 Moving jaw 2200-0 Eccentric shaft 2004-0 Screw 2004-7 Twin nut 1 Lifting lug

1

2200-0 2004-0 2004-7

g) Place the jaw horizontally on the ground with the flat side where the deflector plate normally is fastened downwards. h) If applicable, continue to dismantle the frame bearing and/or moving jaw bearing according to section 6.1.3 Removing frame bearings and section 6.1.5 Removing moving jaw bearings.

CJ211:01


49

6. Bearings

6.1.2 Installing moving jaw a) Clean the contact surfaces on the frame sides, and the bearing seating in the lower bearing housings. b) Remove any corrosion. c) Position the hook of a mobile crane vertically above the moving jaw (3000-0). d) Connect the lifting gear to the lifting lug (1) on the moving jaw (3000-0).

DANGER!

Hanging load A moving jaw weighs up to 6000 kg. Handle the moving jaw with care. The tackle should now be tight. Keep clear of hanging loads, see section 2. Safety precautions.

e) Lift the moving jaw (3000-0) and lower it into the frame. f) Make sure that the eccentric shaft (2200-0) and frame bearing housings are correctly aligned so that the V-rings do not jam in an incorrect position. g) Install the screws (2004-0), washer and twin nuts (2004-7). h) Tighten to the correct torque, 3900 Nm, with a torque wrench. NOTE!

The torque above applies for bolts treated with Dacromet. Do not use bolts treated with molybdenum disulphide.

NOTE!

Lubricate the nuts with one string of oil.

WARNING!

Flying fragments Never lubricate screws, washers or other contact surfaces. Do not exceed the torque value stated above or the bolts could stretch and break due to excessive prestressing force.

i) j)

Fit the flywheels. See section 5.1.2 Installing flywheel. Clean and install the toggle plate. See section 4.4.2 Installing toggle plate and toggle seats. k) Install the retraction cylinder. See section 4.1.2 Installing retraction cylinder. l) Adjust the discharge setting to the desired value. See section 5.6 Setting measurement in the Operator’s manual. m) Start up the crusher and press in grease as if the crusher was new. See section 6. Lubrication of roller bearings in the Operator’s manual.

50


CJ211:01

6. Bearings

6.1.3 Removing frame bearings NOTE!

The frame bearing housing is either locating or non-locating. The instructions are valid for both locating and non-locating bearing housings. The pictures describe the non-locating bearing housing.

NOTE!

Lift out the moving jaw before removing the frame bearing. See section 6.1.1 Removing moving jaw.

NOTE!

Sandvik recommends exchanging both frame bearings at the same time.

CAUTION! Recommended tools Crow bar Lifting tackle and chain Hydraulic nut HMV 48 24 mm Open end wrench Hammer Hook wrench Soft hammer Feeler gauge Gas torch

The work described in the instructions below requires experience and special training from SKF. The exchange of the bearings must be executed by certified personnel.

a) Clean all surfaces around the bearing housing. This is particularly important if the bearing is to be re-used. b) Remove the shaft nut (2201-0) and tab washer (2201-4). c) Remove the screws (2009-0) that hold the labyrinth cover (2008-0). d) Warm the labyrinth ring (2010-0) slightly with a gas torch. e) Remove the labyrinth cover (2008-0) with the labyrinth ring (2010-0) by levering carefully with a crowbar. f) Remove the V-ring (2010-1) from the labyrinth ring (2010-0).

2006-0 2000-0 2006-0 2006-1 2009-0 2010-0 2201-4 2200-0 2008-0 2010-1 2011-0 2201-0

Bearing housing (non-locating) Roller bearing, frame Withdrawal sleeve Screw Labyrinth ring Tab washer Eccentric shaft Labyrinth cover V-ring Key Shaft nut

2006-1 2009-0

2010-0

2201-4

2000-0 2200-0 2008-0 2010-1 2011-0 2201-0

g) Remove the key (2011-0). h) Measure the bearing play if the bearing is to be re-used. (Continued)

CJ211:01


51

6. Bearings i)

Connect the lifting device to the lifting eye (1) on the bearing housing and take up the slack in the lifting tackle.

1 1 Lifting eye 2006-0 Roller bearing, frame 2006-1 Withdrawal sleeve 2200-0 Eccentric shaft 2000-0 Bearing housing (non-locating)

2006-0 2006-1 2200-0 2000-0

j)

DANGER! NOTE!

Remove the withdrawal sleeve (2006-1) with the hydraulic nut.

High pressure Oil that sprays out with high pressure is very dangerous. Any leakage in the hydraulic system must immediately be repaired.

The removal of a large bearing fitted on a tapered seating or a withdrawal sleeve can also be carried out with the oil injection method. When oil has been pumped in between the mating surfaces the bearing slides off its tapered seating very rapidly. You must therefore limit the axial movement of the bearing or sleeve by screwing a nut onto the shaft. k) Lift off the bearing housing with the bearing from the eccentric shaft (2200-0) and place it on the ground. l) Remove the bearing (2006-0) from the bearing housing. m) Warm the inner labyrinth ring (2007-0) slightly with a gas torch and remove it from the eccentric shaft. n) Remove the V-ring (2007-1) from the inner labyrinth ring (2007-0).

2007-0

2200-0 Eccentric shaft 2007-0 Labyrinth ring 2007-1 V-ring

2007-1 2200-0 o) If the moving jaw bearings are to be exchanged, proceed to section 6.1.5 Removing moving jaw bearings.

52


CJ211:01

6. Bearings

6.1.4 Installing frame bearings The following spare parts are required: Cat. No.

Qty.

Roller bearing, frame

2006-0

2

V-ring

2010-1

2

V-ring

2007-1

2

The frame bearing housing is either locating or non-locating. The instructions are valid for both locating and non-locating bearing housings. The pictures describe the non-locating bearing housing.

NOTE!

The moving jaw must be lifted out of the crusher and placed on the ground before proceeding with this instruction. The work described in the instructions below requires experience and special training from SKF. The exchange of the bearings must be executed by certified personnel.


Recommended tools Crow bar Lifting tackle and chain Hydraulic nut HMV 38 24 mm Open end wrench Hook wrench Hammer Soft hammer Feeler gauge

CJ211:01

Remark

NOTE!

CAUTION!

2000-0 2006-0 2006-1 2009-0 2010-0 2201-4 2200-0 2008-0 2010-1 2011-0 2201-0

Description

2006-0

2006-1 2009-0

2010-0

2201-4

2000-0 2200-0 2008-0 2010-1 2011-0 2201-0 a) Clean the bearing housing (2000-0), labyrinth ring (2010-0), labyrinth cover (2008-0) and eccentric shaft (2200-0). Remove any burrs. b) Measure the inside diameter of the bearing housing to check that it is correct. For diameter tolerance, consult Sandvik SRP. c) Lubricate the shaft (2200-0), bearing (2206-0) and withdrawal sleeve (2206-1). Use SKF Mounting fluid LHMF 300/5 or similar. (Continued)


53

6. Bearings d) Measure the bearing play before assembly. See table further below. NOTE!

With bearings of this type the original radial play and the required expansion of the inner ring are relatively large so it is easy to establish the reduction in play by measuring the play before and after fitting. Normally a feeler gauge with blade thickness from 0.03 mm upwards is used. The bearing should preferably be rotated a few turns before the play is measured. This is to ensure that the rollers are correctly aligned. Measurement is always made between the outer ring and an unloaded roller. Push the roller lightly inwards when the measurement is being made. The resultant play measurements for both rows of rollers must be equal. e) With the bearing housing horizontal on the ground, install the bearing (2206-0). f) Warm the labyrinth ring slightly and install it on the eccentric shaft (2200-0). g) Install a new V-ring (2007-1) in the inner labyrinth ring (2007-0).

2007-0

2200-0 Eccentric shaft 2007-0 Labyrinth ring 2007-1 V-ring

2007-1 2200-0

NOTE!

Always replace used V-rings with new ones when exchanging bearings. h) Connect the lifting device to the lifting eye on the bearing housing and raise the bearing housing to the vertical position. i) Grease the inner labyrinth ring (2007-0) slightly. j) Lift the bearing housing onto the eccentric shaft (2200-0). Make sure the bearing has metallic contact with the inner labyrinth ring (2007-0). (Continued)

54


CJ211:01

6. Bearings k) Adjust the crane if necessary and push in the withdrawal sleeve (2206-1) until it is tight against the shaft (2200-0) and the bearing (2006-0).

1 1 Lifting eye 2006-0 Roller bearing, frame 2200-0 Eccentric shaft 2000-0 Bearing housing (non-locating)

2006-0 2006-1 2200-0 2000-0

NOTE!

The inner ring of a tapered bore bearing is always installed with a firm fit. The tightness of the fit does not depend on the shaft tolerance (as with a parallel-bore bearing) but on how far the bearing is driven up on the withdrawal sleeve. The original play in the bearing is reduced when the bearing is driven up and this reduction in play is a measure of the bearing interference fit. l)

Install the hydraulic nut on the shaft (2200-0) and ensure metallic contact. m) Reduce the clearance according to table below. Assemblage of bearings Item

Frame bearing

NOTE!

Reduction of clearance

Axial displacement

Min.

Max.

Min.

Max.

0.100

0.140

1.6

2.2

Min. residual clearance

0.120

When spherical roller bearings with tapered bore are being fitted it is either the reduction in the original radial play or the axial displacement on the taper, which is used to measure the bearing interference fit. n) Leave the hydraulic nut in place under pressure for 30 minutes. o) Remove the hydraulic nut. p) Fill the bearing with grease. (Continued)

CJ211:01


55

6. Bearings q) Install the key (2011-0) into the key way on the shaft. r) Install the labyrinth cover (2008-0) and fill it with grease. s) Mount the V-ring (2010-1) in the labyrinth ring (2010-0). NOTE!

Always replace used V-rings with new ones when exchanging bearings. t)

2000-0 2006-0 2006-1 2009-0 2010-0 2201-4 2200-0 2008-0 2010-1 2011-0 2201-0

Warm the labyrinth ring (2010-0) slightly and install it on the shaft (2200-0).


2006-0

2006-1 2009-0

2010-0

2201-4

2000-0 2200-0 2008-0 2010-1 2011-0 2201-0 u) v) w) x)

56

Fit the tab washer (2201-4) and shaft nut (2201-0). Tighten the shaft nut in place with a hook wrench. Bend down a lug on the tab washer into the slot on the shaft nut. Install the moving jaw with eccentric shaft and bearings in the crusher. See section 6.1.2 Installing moving jaw.


CJ211:01

6. Bearings

6.1.5 Removing moving jaw bearings NOTE!

Lift out the moving jaw and remove the frame bearing before removing the moving jaw bearing. See section 6.1.1 Removing moving jaw and section 6.1.3 Removing frame bearings.

NOTE!

Sandvik recommends exchanging both moving jaw bearings at the same time.

CAUTION!

The work described in the instructions below requires experience and special training from SKF. The exchange of the bearings must be executed by certified personnel.

2104-1

2104-1 V-ring 2104-0 Labyrinth ring 2200-0 Eccentric shaft 2101-0 Roller bearing, moving jaw 2102-0 Labyrinth cover 2103-0 Screw

2104-0 2200-0

2101-0 Recommended tools Crow bar Lifting tackle and chain Lifting sling 24 mm Open end wrench Sledge hammer Copper punch

CJ211:01

2102-0

2103-0

a) Remove the screws (2103-0) that hold the labyrinth cover (2102-0). b) Slightly heat the labyrinth ring (2104-0). c) Remove the labyrinth cover (2102-0) with the labyrinth ring (2104-0) and V-ring (2104-1) by levering carefully with a crowbar. d) Repeat items a-c on the labyrinth on the other end of the shaft. (Continued)


57

6. Bearings

2101-0 Moving jaw bearing 1 Lifting sling 2200-0 Eccentric shaft 2 Lifting eye

2101-0

1

2200-0

2

e) Connect a lifting eye (2) to the end of the eccentric shaft (2200-0). f) Connect a tackle to the eye and secure it to a point straight in front of the shaft. g) Pull out the shaft slightly with the tackle. h) Connect a lifting sling (1) to the eccentric shaft (2200-0) and take up the slack in the lifting tackle so that the shaft doesn’t fall to the ground. i) Continue to pull the shaft out of the moving jaw. Secure it with another lifting sling. j) Remove the rollers from the bearing. NOTE!

If the bearing is not to be re-used it can be more convenient to cut the outer ring in two and remove the rollers. k) Raise up the shaft vertically. l) Warm the inner ring quickly until it comes off the shaft. m) Turn the eccentric shaft upside-down and heat the other inner ring until it comes off.

58


CJ211:01

6. Bearings

6.1.6 Installing moving jaw bearings The following spare parts are required:

NOTE! CAUTION!

Recommended tools Crow bar Lifting tackle and chain Lifting sling 24 mm Open end wrench Sledge hammer Copper punch

Description

Cat. No.

Qty.

Roller bearing, moving jaw

2101-0

2

V-ring

2104-1

2

Remark

The moving jaw must be lifted out of the crusher and placed on the ground before proceeding with this instruction. The work described in the instructions below requires experience and special training from SKF. The exchange of the bearings must be executed by certified personnel.

a) Clean the eccentric shaft (2200-0), labyrinth cover (2102-0) and labyrinth ring (2104-0). Remove any burrs. b) Heat the bearing to maximum 125°C. Use an inductive heater, oven or oil bath. c) Lubricate the shaft (2200-0). Use SKF Mounting fluid LHMF 300/5 or similar. d) Mount the bearing on the shaft and let it cool down. e) Fill the bearing with grease. f) Connect a lifting eye to the end of the eccentric shaft (2200-0) g) Connect a tackle through the bore of the moving jaw to the eye and secure it on the other side of the jaw. h) Connect a lifting sling to the eccentric shaft (2200-0) and take up the slack in the lifting tackle. i) Lift the shaft up into alignment with the jaw. j) Pull the eccentric shaft into the jaw with the tackle.

2104-1

2104-1 V-ring 2104-0 Labyrinth ring 2200-0 Eccentric shaft 2101-0 Roller bearing, moving jaw 2102-0 Labyrinth cover 2103-0 Screw

2104-0 2200-0

2101-0

2102-0

2103-0 (Continued)

CJ211:01


59

6. Bearings k) Install the labyrinth cover (2102-0) and use Loctite on the screws (2103-0). l) Fill the labyrinth cover (2102-0) with grease. m) Mount the V-ring (2104-1) in the labyrinth ring (2104-0). NOTE!

Always replace used V-rings with new ones when exchanging bearings. n) Warm the labyrinth ring (2104-0) slightly and install it on the shaft. o) Install the frame bearings. See section 6.1.4 Installing frame bearings. p) Install the moving jaw with eccentric shaft and bearings in the crusher. See section 6.1.2 Installing moving jaw.

60


CJ211:01

spare parts catalog

Doc. no. R 222.349 en

SANDVIK CJ211:01



Sign.

SANDVIK CJ211:01 © Copyright 2007 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: R 222.349 en Issue: 20080211 Version: 1

Sandvik Stationsplan, SE-233 81 Svedala, Sweden Tel: +46 (0)40 409000, Fax: +46 (0)40 409260 www.sandvik.com

SPC Sandvik CJ211:01

General Ordering information When ordering parts, always state the machine type and serial number according to the identification plate on the jaw crusher. State quantity, article number and denomination for each ordered part. Identification plate The figure below shows an example of the crusher’s identification plate. The identification plate contains data needed when contacting Sandvik SRP AB concerning wear parts. Please enter the serial number of the associated machine in the intended field on the first page of this wear part catalog (the copyright page).

1 2

3

4

Identification plate: 1 Machine type 2 Part number 3 Serial number 4 Order number

Think ahead! Avoid unnecessary downtime and increased freight charges by ordering parts well in advance.

© 2007 Sandvik SRP AB

Doc. no. R 222.349 en Ver. 1

3


Overview

6.

3. 1.

4.

5a. 5b.

7.

2.

4

Doc. no. R 222.349 en Ver. 1



1. Retraction cylinder

7021-0, 7021-2 7020-0 7051-0

7052-2 7050-0

7053-0

Retraction cylinder Cat. no.

Qty.

Part number

7020-0

1

400.0612-901

Alternative

Description

7021-0

4

840.0667-00

Screw M6S 24×60

7021-2

4

847.0124-00

Washer BRB 25×45

7050-0

1

400.1161-901

Hydraulic cylinder 80/50-300/85

1

908.0481-00

Seal kit cyl. 80/50-300/85

7051-0

1

400.1154-901

Piston Pin

7052-2

2

847.0323-00

Washer SRB 41×80×3 fzb

7053-0

1

400.1154-902

Cylinder pin


Remarks

Retraction cylinder bracket

Doc. no. R 222.349 en Ver. 1

5


2. Hydraulic cylinders and setting wedges

6331-0, 6331-2 6330-0 6333-0, 6333-2 6320-0 6300-0 6301-0, 6301-2

Hydraulic cylinders and setting wedges Cat. no.

Qty.

Part number

6300-0

2

400.2180-001

Setting wedge

6301-0

2

400.0856-001

Pin setting wedge

6301-2

4

855.0014-00

Retaining ring SgA

6320-0

2

400.0753-901

Hydraulic cylinder 100/60×290/86

1

908.0480-00

Seal kit cyl. 100/60×290/86

6330-0

4

400.0852-901

Cylinder bracket

6331-0

8

840.0650-00

Screw M6S 20×65

6331-2

8

847.0165-00

Washer TBRB 21×36

6333-0

4

840.0065-00

Screw M6S 16×35

6333-2

4

400.0839-001

Washer

6

Alternative

Description

Doc. no. R 222.349 en Ver. 1

Remarks



3. Guide plates

6311-0, 6311-2 6310-0

Guide plates Cat. no.

Qty.

Part number

6310-0

4

400.0611-001

6311-0

12

841.0574-00

Screw MC6S 20×70

6311-2

12

847.0132-00

Washer BRB 21×36


Alternative

Description

Remarks

Guide plate

Doc. no. R 222.349 en Ver. 1

7


4. Toggle plates and toggle seats

5013-2 5014-0, 5014-2

5003-0 5018-0 5019-0, 5019-2 5006-0 5005-0

5004-0

Remarks

Toggle plates and toggle seats Cat. no.

Qty.

Part number

Alternative

Description

5006-0

1

400.0549-001

L=600 mm

Toggle plate

L=640 mm

Toggle plate

1

400.0549-002

5003-0

1

400.0603-001

Toggle seat holder

5004-0

1

400.0548-001

Upper toggle seat

5005-0

1

400.0548-001

Lower toggle seat

5013-2

1

400.0707-002

Toggle seat retainer

5014-0

2

840.0046-00

Screw M6S 12×35

5014-2

2

847.0147-00

Washer BRB 13×24

5018-0

2

400.0707-001

Side block

5019-0

4

840.0046-00

Screw M6S 12×35

5019-2

4

847.0147-00

Washer BRB 13×24

8

Doc. no. R 222.349 en Ver. 1



5a. Frame bearing assembly 2211-0 2211-2

2201-4

2209-1 2208-0

2210-0 2209-4 2207-0

2010-0

2009-0, 2009-2 2006-1

2201-0 2011-0 2010-1 2008-0

2006-0

2200-0

Frame bearing assembly Cat. no.

Qty.

Part number

Description

Remarks

2006-0

2

868.0756-00

Alternative

Roller bearing

Outer bearing

2006-1

2

868.0755-00

Sleeve AOH

2008-0

2

10-314-515-000

Labyrinth cover

2009-0

24

840.0068-00

Screw M6S 16×50

2009-2

24

847.0016-00

Washer BRB 17×30

2010-0

2

10-314-516-000

Labyrinth ring

2010-1

2

873.1008-00

V-ring V-250A

2011-0

2

79-401-252-001

Key

2200-0

1

400.0545-001

Eccentric shaft

2201-0

2

845.0168-00

Shaft nut KM 38 190×3

2201-4

2

847.0096-00

Tab washer 190 MB 38

2207-0

2

59-425-417-009

Key

2208-0

2

53-467-374-000

Spacer ring

2209-1

2

845.0161-00

Shaft nut KM 27 135×2

2209-4

2

847.0173-00

Tab washer 135 MB 27

2210-0

2

53-367-328-500

Cover

2211-0

6

840.0044-00

Screw M6S 12×25

2211-2

6

847.0180-00

Washer 13×24


Doc. no. R 222.349 en Ver. 1

9


5b. Jaw bearing assembly 2104-0 2104-1

2007-1

2103-0, 2103-2

2007-0

2102-0

2101-0

Jaw bearing assembly Cat. no.

Qty.

Part number

2007-0

2

10-314-514-000

Labyrinth ring

2007-1

2

873.1008-00

V-ring V-250A

2101-0

2

868.0522-00

Roller bearing

2102-0

2

10-314-512-000

Labyrinth cover

2103-0

24

840.0068-00

Screw M6S 16×50

2103-2

24

847.0016-00

Washer BRB 17×30

2104-0

2

10-314-513-000

Labyrinth ring

2104-1

2

873.1008-00

V-ring V-250A

10

Alternative

Description

Doc. no. R 222.349 en Ver. 1

Remarks

Inner bearing



6. Flywheels 2212-0

2213-0, 2213-2

2205-0

2206-0

Flywheels and counterweights Cat. no.

Qty.

Part number

2205-0

1

400.0554-001

Flywheel flat

2206-0

1

400.0554-002

Flywheel 10×5V

1

400.0554-003

Flywheel 7×SPC

2212-0

1

400.0786-001

Counterweight

2213-0

2

840.0653-00

Screw M6S 20×100

2213-2

2

847.0165-00

Washer TBRB 21×36


Alternative

Description

Doc. no. R 222.349 en Ver. 1

Remarks

11


7. Bearing housing 2000-1

2000-0 2200-0

2004-0, 2004-2 2004-7

Bearing housing Cat. no.

Qty.

Part number

2000-0

1

53-273-771-500

Bearing house, non-locating bearing

2000-1

1

10-215-286-500

Bearing house guide, locating bearing

2004-0

16

840.1188-00

Screw M6S 42×3×140

2004-2

16

847.0312-00

Washer BRB 43×80

2004-7

8

53-373-766-000

Twin nut M42×3

2200-0

1

400.0545-001

Eccentric Shaft

12

Alternative

Description

Doc. no. R 222.349 en Ver. 1

Remarks



8. Driving arrangement 3 2

Pos no.

Qty.

Sets

Part number

Alternative

Description

1

1

400.1384-901

X

Grooved pulley alt

2

1

400.1385-901

X

Bushing alt

3

1

400.1383-901

X

V-belt alt


Doc. no. R 222.349 en Ver. 1

1

Remarks

13


9. Frame

Pos no.

14

Qty.

Sets

Part number

Alternative

Description

400.0537-901

Frame assembly

400.0910-901

Feet assembly

Doc. no. R 222.349 en Ver. 1

Remarks


wear parts catalog

Doc. no. R 222.351 en

SANDVIK CJ211:01



Sign.

SANDVIK CJ211:01 © Copyright 2007 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: R 222.351 en Issue: 20070625 Version: 1

Sandvik SRP AB Stationsplan, SE-233 81 Svedala, Sweden Tel: +46 40-40 90 00, Fax: +46 40-40 92 60 www.sandvik.com

Wear Parts Catalog

General Ordering information When ordering parts, always state the machine type and serial number according to the identification plate on the jaw crusher. State quantity, article number and denomination for each ordered part. (Quantities listed in this catalog are number of parts that are usually exchanged at the same time in a certain position or function.) Identification plate The figure below shows an example of the crusher’s identification plate. The identification plate contains data needed when contacting Sandvik SRP AB concerning wear parts. Please enter the serial number of the associated machine in the intended field on the first page of this wear part catalog (the copyright page).

1

2

1 Machine type 2 Serial number

Think ahead! Avoid unnecessary downtime and increased freight charges by ordering parts well in advance.

CJ211:01

© Sandvik SRP AB – Doc. no. R 222.351 en Ver. 1

3

Wear Parts Catalog

Clamping bars and deflector plate 1211-0

1211-2 1211-6

1210-0

1211-2 1211-3

Clamping bars and fixings, stationary jaw Cat. no.

Qty.

Part number

Alternative

Description

Remarks

1210-0

1

400.0556-001

Clamping bar

1211-0

3

840.1074-00

Screw M6S M30×280

with wear plate configuration

1211-0

3

840.1003-00

Screw M6S 30×300

with jaw shim plate configuration

1211-2

6

89-442-690-013

Washer D95/35×10

1211-3

3

845.0284-00


1211-6

3

53-469-936-000

Flexible washer

3400-0

3401-2 3401-6

3401-0

3401-2 3401-3

Clamping bars and fixings, moving jaw Cat. no.

Qty.

Part number

3400-0

1

400.0556-001

Clamping bar

3401-0

3

400.1138-001

Screw M6S M30×780

3401-2

6

89-442-690-013

Washer D95/35×10

3401-3

3

845.0284-00


3401-6

3

53-469-936-000

Flexible washer

4

Alternative

Description


Remarks

CJ211:01

Wear Parts Catalog

3500-0 3502-0 3502-2 3503-0

Deflector plate and fixings Cat. no.

Qty.

Part number

Description

Remarks

3500-0

1

400.0575-001

Alternative

Deflector plate

moving jaw

Screw M6S M16×50

3502-0

2

840.0068-00

3502-2

2

847.0016-00

Washer BRB 17×30

3503-0

2

400.0749-001

Locating bar

3507-0 3508-0 3508-0 3506-0 3506-2 3506-3

3505-0

Lower deflector plate and fasteners (option) Cat. no.

Qty.

Part number

Description

Remarks

3505-0

1

400.1166-001

Alternative

Deflector plate, lower

Option

3506-0

4

840.0080-00

Screw M6S 20x80

Lower deflector plate fasterners

3506-2

8

847.0017-00

Washer BRB 20x36

3506-3

4

845.0203-00

Self-locking nut

3507-0

2

400.1165-001

Deflector bracket

3508-0

4

840.0668-00

Screw 24x65

3508-2

4

847.0124-00

Washer BRB 25x45

CJ211:01


5

Wear Parts Catalog

Jaw plates

1208-1

3300-1

Jaw plates Cat. no.

Qty.

Part number

1208-1

1

3300-1

1

Alternative

Description

400.2207-001

C, M1

Jaw plate, stationary jaw

400.2207-002

C, M2

Remarks corrugated, material M1 corrugated, material M2

400.0739-001

ST, M1

sharp teeth, material M1

400.0739-002

ST, M2


400.1101-001

C, M1

400.1101-002

C, M2

Jaw plate, moving jaw

corrugated, material M1 corrugated, material M2

400.0738-001

ST, M1


400.0738-002

CC, M2


(Continued)

6


CJ211:01

Wear Parts Catalog The table below illustrates different jaw plate alternatives. Jaw plate alternatives

Stationary jaw

Moving jaw

Corrugated C

Sharp teeth ST

CJ211:01


7

Wear Parts Catalog

Wear plates

3100-0 1300-1

Wear plates Cat. no.

Qty.

Part number

Alternative

Description

Remarks

1300-0

1

400.0830-001

10 mm

Wear plate

stationary jaw, instead of jaw shim plate

3100-0

1

400.0830-001

10 mm

Wear plate

moving jaw, instead of jaw shim plate

Jaw shim plates

1202-0 3102-0

Jaw shim plates Cat. no.

Qty.

Part number

Alternative

Description

Remarks

1202-0

1

400.0830-002

30 mm

Jaw shim plate

stationary jaw, instead of wear plate

3102-0

1

400.0830-002

30 mm

Jaw shim plate

moving jaw, instead of wear plate

8


CJ211:01

Wear Parts Catalog

Support bars

1206-1

1206-2

1206-0

1205-0 3200-0 3201-0

3201-2 3201-1

Support bars and fixings Cat. no.

Qty.

Part number

1205-0

1

400.0543-001 400.1118-001

Alternative

Description

Remarks

single slot

Support bar

stationary jaw. with wear plate

double slot

Support bar

stationary jaw, with jaw shim plate

1206-0

6

840.0656-00

Screw M6S M20×140

stationary jaw

1206-1

6

845.0203-00


stationary jaw

Washer BRB 21×36

stationary jaw

1206-2

6

847.0132-00

3200-0

1

400.0543-001

single slot

Support bar

moving jaw. with wear plate

400.1118-001

double slot

Support bar

moving jaw, with jaw shim plate

Screw M6S M20×140

moving jaw

3201-0

6

840.0656-00

3201-1

6

845.0203-00

Self-locking nut ML6M M20

moving jaw

3201-2

6

847.0132-00

Washer BRB 21×36

moving jaw

CJ211:01


9

Wear Parts Catalog

Cheek plates

1104-0

1103-0

1103-0

1106-0 1106-4 1106-5 1106-1

Cheek plates and fixings Cat. no.

Qty.

Part number

Alternative

Description

Remarks

1103-0

1

400.0639-001

Cheek plates

left-hand side

1104-0

1

400.0639-001

Cheek plates

right-hand side

1106-0

10

840.0675-00

Screw M6S 24×130

both sides

1106-1

10

845.0387-00


both sides

1106-4

10

402.4720-01

Flexible washer

both sides

1106-5

10

402.4721-01

Steel washer 26/105×10

both sides

10


CJ211:01

1107 Crusher Wear Parts

Position Qty/Mc 1A 1B 2A 2B 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20 21 22 23 24 24 25 26 27 28 29

1 or 1 1 or 1 2 10 10 10 2 3 6 6 6 1 2 2 2 2 2 6 3 6 6 4 2 2 0 1 1 6 6 2 2

Sandvik Part Number

Fintec Part Number

400.1101.001 400.0738.001 400.2207.001 400.0739.001 400.0639.001

25-11-0075 25-11-0057 25-11-0078 25-11-0024 25-11-0012 25-11-0063

400.0556.001

25-11-0015

89.442.690.013 25-11-0090 53.469.936.000 25-11-0072 400.0575.001

25-11-0054

400.0749.001 400.0830.001 400.0543.001

25-11-0060 25-11-0033 25-11-0003

400.0752.001 400.0548.001 400.0549.001 400.0549.002 400.2382.001

25-11-0117 25-11-0006 25-11-0009 25-11-0048 25-11-0135

400.0707.001 400.0603.001

25-11-0126 25-11-0018

Description Jaw plate (Corrugated 12) M1 Jaw plate (Sharp Tooth 5) M1 Jaw plate (Corrugated 13) M1 Jaw plate (Sharp Tooth 6) M1 Side Liner (Check Plate) Screw M6S M24x130 8.8 ISO4014 Plastic Side washer (Check Plate) Lock nut M24 8 ISO7040 Wedge (Jaw Plate Tension) Screw M6S M30x760 8.8 ISO4014 Washer (Jaw Tension) Flexible washer (Jaw Plate Tension) Lock nut M30 8 DIN 985 Deflector plate Screw M6S M16x50 8.8 ISO4014 Washer BRB 17x30 HB200 ISO 7089 Deflector plate support Wear Plate (Jaw liner) Support Strip (Jaw Plate) Screw M6S M20x140 8.8 ISO4014 Screw M6S M30x280 8.8 ISO4014 Washer BRB 21x36 HB200 Lock nut M20 8 ISO 7040 Screw M6S M16x40 8.8 ISO4017 Toggle stop (Toggle Seat Lower) Toggle seat Toggle plate 600mm Toggle plate 640mm Toggle Cylinder Screw M6S M12x35 8.8 ISO4017 Washer BRB 13x24 HB200 ISO 7089 Stop block (Toggle Seat Upper) Toggle seat holder

Sandvik Parts List 03/12/2007

RX11 - 15

Sandvik Mining and Construction Oy, Keskikankaantie 19, FI-15860 Hollola, Finland Tel. +358 205 44 181, Fax +358 205 44 180

MAINTENANCE AND OPERATION INSTRUCTIONS

Equipment type

VIBRATING FEEDER

ROX 11-15 rev D 31.03.2006

Equipment number

Manufacturing year/month

CONTENTS

page

1. ORDERS AND INSTRUCTIONS

2

1.1. FOREWORD 1.2 OWNER'S DUTIES AND RESPONSIBILITIES 1.3 ORDERS AND INSTRUCTIONS TO MACHINE INSPECTORS AND MAINTENANCE PERSONNEL 1.4 INSTRUCTIONS AND RECOMMENDATIONS TO MACHINE OPERATORS 1.5 SAFETY 1.6 GUARANTEE 2.1 SHIPPING AND HANDLING 2.2 STOCKING

2 2

7 SPARE PARTS RECOMMENDATION

19

7.1 SPARE PART SERVICE 7.2 SPARE PART LIST 7.3 SPARE PARTS DRAWING LIST

19 19 19

8 DE-COMMISSIONING, TEAR DOWN AND RECYCLING 19

2 8.1 GENERAL

19

3 3 3 3 3

9 IN CASE OF EMERGENCY

19

9.1 FIRE EXTINGUISHING 9.2 MATERIAL DUST

19 19

3 INSTALLATION AND START UP

4

10 ASSEMBLY DRAWING

19

3.1 COMPONENT LIST AND LAYOUT 3.2 INSTALLATION 3.3 START UP

4 4 5

10.1 ASSEMBLY DRAWINGS LIST

19

4 OPERATING PRINCIPLE AND SYSTEM DESCRIPTION

6

4.1 TECHNICAL DATA 4.2 OPERATION PRINCIPLE 4.3 SYSTEM DESCRIPTION

6 7 8

5 DEVICE OPERATING

9

5.1 OPERATION 5.2 SYSTEM CONDITIONS 5.3 SAFETY INSTRUCTIONS

9 9 9

6 MAINTENANCE INSTRUCTIONS

10

6.1 MAINTENANCE AND REPAIR INSTRUCTIONS 10 6.2 ADJUSTMENTS 10 6.3 AMOUNT OF COUNTERWEIGHTS WHEN USING FREQUENCY ADJUSTING EQUIPMENT 11 6.4 BEARING REPLACEMENT 12 6.5 LUBRICATION SCHEME OF FEEDER 14 6.6 RECOMMENDED LUBRICANTS 14 6.7 SHAFT OIL CAPACITY 15 6.8 INSPECTION AND MAINTENANCE SCHEDULE 15 6.9 MAINTENANCE LOG 15 6.10 TROUBLE SHOOTING TABLE 15 6.11 DESCRIPTION OF DAMAGE 18 Vibrating feeder

ROX 11-15 rev D 31.03.2006

1

•

1. ORDERS AND INSTRUCTIONS 1.1. FOREWORD This instruction manual is for the use of personnel engaged in the tasks of assembly, inspection, operation and maintenance. It must always be kept in an easily accessible place and the personnel must make sure they are familiar with it. The instructions, guidance and illustrations contained in this manual are necessary for proper installation, inspection, adjustment, start-up, operation and maintenance of the machine. An operator new to the Sandvik equipment will in this manual find all the basic information on the machine and its operation. Operational skills will develop with increased experience. Because of Sandvik's policy of continuous product development, some technical details published in this manual might differ slightly compared to the equipment that you have purchased. The manual is continuesly altered and improved, so that it’s content is as up-to-date as it can be. SANDVIK reserves the right to modify the equipment without further notice.

•

• •

• •

•

FEEDBACK

Area around is well lit,and that maintenance levels and all access points to the device are kept free. The device is inspected and serviced at the intervals recommended by the manufacturer and that a log is kept of all service or maintenance work. The logbook must also be available for inspection if requested by a Sandvik representative. Doing inspections and maintenance according to the instructions of the manufacturer is a precondition for the SANDVIK guarantee. all reported faults and malfunctions are identified and corrected without delay. if the device is stopped because of a fault, emergency situation or malfunction, it is not to be restarted before the cause is identified and corrected. properly trained and authorized operating, inspection and maintenance personnel are available at all times. if the plant is modified in any way, such modifications are to be carried out by experienced personnel with due regard to the strength, power and capacity of the devices. any visible fault that appears on the equipment or its components, is entered into the damage form (ENCLOSURE 3) and forwarded to Sandvik to support possible claims.

If you have any questions concerning a Sandvik product or it's manual, please contact Sandvik, for example by using the feedback form (ENCLOSURE 4).

1.3 ORDERS AND INSTRUCTIONS TO MACHINE INSPECTORS AND MAINTENANCE PERSONNEL

1.2 OWNER'S DUTIES AND RESPONSIBILITIES

1

The duties and responsibilities of the owner of the device include ensuring.

•

•

• • •

The current regulations to safety, operation, maintenance and inspection are observed at all times. These regulations must always be available to all personnel who need them. All personnel are well aware of the inherent dangers of this kind of machinery and that they are quite familiar with both normal and emergency stopping procedures, remote controlled starting and stopping signals, both audio and visual, as well as all other safety aspects. Only properly trained and authorized personnel are allowed to operate or work with the equipment. The machines operators are fully familiar with its settings, ‘performance ‘values and all other features. The device is not to be used in any application or any circumstances other than what it was designed for.

Vibrating feeder

The condition and the operation of the equipment must be observed daily and all observed faults must be corrected immediately.

2. Maintenance and inspection must be carried out with the device at a complete stop, with controls locked out and the power supply to the machine disconnected. Only for specific maintenance and inspection tasks, for which separate and detailed instructions apply, may the device be connected to the mains and activated. Even under these special circumstances must safeguards be in place and the work be carried out with special caution. 3. Inspection and maintenance must be carried out at the intervals specified by the manufacturer (refer to inspection and lubrication charts and instructions). All work carried out must be entered in the logbook for the device (ENCLOSURE 2). 4. Mechanical and/or electrical adjustments may be carried out by authorized personnel only. 5. The final task in maintenance and inspection must always be to confirm that all safety and protective devices are in place and functional, that the machine is clean and that all foreign items (tools, other things a.s.o) are removed.

ROX 11-15 rev D 31.03.2006

2

6. Only original Sandvik spare parts may be used.

1.5 SAFETY

7. All damage to the exterior surface of the machine must be repaired immediately.

Follow the general instructions of the supplier when you are operating the device or performing maintenance on it.

8. Timely replacement of wear parts is important in preventing damage.

1.4 INSTRUCTIONS AND RECOMMENDATIONS TO MACHINE OPERATORS A ‘Procedures ‘ Before starting the machine

•

2. Make absolutely sure of the following:

• • • •

1.6 GUARANTEE ATT!

1. Ensure that you have read and clearly understood all operating instructions.

•

In addition, the operator must be fully familiar with all the safety instructions, point 5.3 (page 9) in this manual and the maintenance personnel with all the maintenance instructions in point 6 (pages 10-19) in this manual.

•

no service or inspection personnel are working on, in or near the equipment. no unauthorized people or animals are near the equipment. all safety guards are in place and functional. all warning devices are in place and functional.

•

Condition for the warranty are;

The exclusive use of Sandvik original spare parts A machine survey after about 12 months from its commissioning. That the instructions in this manual are followed in every respect.

2.1 SHIPPING AND HANDLING A Generally

there is nothing in the immediate vicinity of the device that can interfere with its proper function or vice versa.

3. Check and confirm that the device is unaffected by dust, dirt, rubbish, ice, etc. 4. Select the operating and control method in the proper way (refer to operating instructions if necessary). 5. Check and confirm during the first few minutes of operation that the device has started normally and is running smoothly. B When the device is running

When shipping and handling the device, common treatment and packing instructions and orders concerning metal and electric technical devices must be observed. Damaged surface becomes easily rusty when pure metal contacts with humidity, especially in marine atmophere. To avoid this, carriage, packing and treatment must be arranged in dry and sheltered conditions. The device must be dried properly after carriage, maintenance and cleaning treatments, and electric equipment must be protected according to their own special instructions. B Handling

1. Make sure that no unauthorized people or animals are in the immediate vicinity of the device. 2. Check the flow of material into and out of the device. 3. Make sure that the process material does not get into places where it could cause damage. 4. Check the operation and function of the device and report any damage or malfunction immediately to your supervisor and to the maintenance personnel. C At the stop of the device 1. If possible, run the device until it is empty. 2. Stop the device in accordance with instructions.

Lifting or hoisting the equipment must be done by using the so called four-point lifting method. To assist this there are lifting eyes at both ends of the longitudinal frame. The lifting eyes are also shown in the assembly drawing. The capacity of the lifting device should match the weight for the equipment handled which can be between 1400-14600 kg. The weight of the equipment and it’s parts are shown in the assembly drawing.

2.2 STOCKING Stock the equipment in a dry, sheltered and clean location. Humid conditions must be avoided when stocking for an extended period. Especially the electrical equipment must be protected against moisture in a proper manner.

3. Report all disturbances and/or malfunctions to the next operator and to the maintenance staff.

Vibrating feeder

ROX 11-15 rev D 31.03.2006

3

3 INSTALLATION AND START UP

2 4

1 2 3 4 5 6

5

1

3.1 COMPONENT LIST AND LAYOUT Feeder body Mechanism shafts Drive motor Grizzly bars Spring unit Supporting structure and hopper (delivery as option)

3

B Loading the feeder Generally material feeding to the feeder is possible from the front with the hopper. Picture of loading

3.2 INSTALLATION A Supporting structures

The supporting steel structures on which the feeder and drive motor are mounted must be sufficiently strong and braced to accept without deflection the dynamic loads caused by the vibration of the feeder and by the loading of material. The natural frequency of the structures must be at least 1.5 times the operating frequency of the feeder. Adequate clearances must be allowed between the feeder and the fixed structure, chutes etc., to allow space for resonance vibrations when starting and stopping the feeder (at least 100 mm vertically, 50 mm horizontally). Each pair of spring foundation must be on the same sideways level and at exactly the same height vertically. Ensure that there are no beams or other protrusions under the feeder, that can allow the build-up of material and obstruct the movement of the feeder. (Obs. the resonance movements)

Vibrating feeder

C Installation of the feeder

• • • •

•

Mount the feeder body upon the springs Check that the difference between the separate springs is not more than + 3 mm Check that all of the spring axes are vertical. Reposition the supporting pedestals if necessary. Check that there is at least a clearance of 100 mm vertically and 50 mm horizontally between any part of the feeder and the fixed structure, chutes etc. Check that the clearances between the rubber pusher and the stop buffer are as shown in the assembly drawing of the feeder. Adjust the clearance if necessary.

ROX 11-15 rev D 31.03.2006

4

The feeder must be mounted transversely (horizontally in the sideways direction). This is to ensure that the oil level is at the same height at both ends of the shaft. This is inherently important for proper lubrication of the mechanism and in ensuring sufficient bearing life.

A Before start up the following must be checked:

• •

D Installation of drive unit

•

The motor of the hydraulic drive is straight at the end of the feeder shaft and it does not require any separate base of drive unit.

•

Before placing the motor for the electrical direct drive at a vertical position, the horizontal distance between the motor and the feeder must be set so that the cardan shaft is straight and the flexible couplers are not compressed. After this, the vertical position of the motor must be fixed so that the centre line on the feeder shaft is approx. 10-15 mm higher than the centre line of the motor shaft.

• • • ! !

•

The installation has been made according to instructions given The feeder shaft has been mounted horizontally in the sideways direction. Clearances between opposing surfaces are correct. Oil levels are correct in the mechanism, gearbox and the hydraulic coupling (if applicable) The number of counterweights is correct and are the same at both sides of the mechanism. V-belts are in line and tensioned correctly. Rotation speed and direction of the motors are correct all guards are in place and secure feeder is clear of foreign objects. Operator is fully aware of the proper operating procedures.

B After start check, that

• • • • • • 3.3 START UP Before the device is activated for the very first time one must check the points which are listed on the table enclosed in this manual (ENCLOSURE 1). There is also a explanation for the remarks and codes in the enclosure.

•

C Trial run with material for the first time, check:

•

ATTENTION!

IF THE EQUIPMENT IS INSTALLED BY THE CLIENT THEMSELVES, A COPY OF THE COMPLETED COMMISSIONING CHECKLIST SHOULD BE SENT TO THE PRODUCT MANAGER OR TO THE AREA SALES MANAGER AT SANDVIK. Before the equipment is put into regular operation it should be tested in two phases: 1 2

This procedure shall be carried out after any maintenance, cleaning or repair work or when the machine has been out of operation for an extended period of time.

Vibrating feeder

• • • • • •

Running empty Running with material under supervision.

mechanism, gearbox and motors run without overheating or unusual noise the feeder drive runs smoothly and operates without vibration feeder support is stable without vibration motor rotation direction is correct stroke length and stroke angle are correct feeder does not come into contact with any part of the fixed structure or chutes, particularly during starting and stopping if rotation adjusting equipment is used, it operates correctly and normally.

the material depth and flow is correct and that the feed to the feeder is spread over the full width of the deck if grizzly is in operation, it does not clog. If cardan shafts are in use, make sure that the height difference between the drive equipment and the drive shaft is accurate. The stroke length and the stroke angle in different parts of the feeder are accurate feeding action is satisfactory if dust enclosures are fitted, check that no dust escapes them. the material flow in the chutes is satisfactory.

Adjust as necessary according to the instructions included (see point adjustments in maintenance instructions and trouble shooting table).

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4 OPERATING PRINCIPLE AND SYSTEM DESCRIPTION 4.1 TECHNICAL DATA Vibrating feeders

SANDVIK

Feeder type SV1032 SV1232 SV1532 SV1832 SV2132 SV2432

Deck Motor- Total Dimensions in mm area size weight A B C D E F G H I m2 kW kg 0,9 15 3210 1400 1020 1855 1048 480 1310 2600 3170 850 1,1 15 3500 1600 1220 2055 1148 480 1310 2600 3170 850 1,4 15 4030 1900 1520 2355 1298 480 1310 2600 3170 850 1,6 22 4700 2200 1820 2785 1523 480 1325 2600 3170 850 1,9 22 5440 2500 2120 3085 1673 480 1325 2600 3170 850 2,2 22 5975 2800 2420 3385 1823 480 1325 2600 3170 850

K

L

M

N

O

1x900 1x900 1x900 1x900 1x900 1x900

160 160 160 170 170 170

1452 1652 1952 2312 2612 2912

737 837 987 1167 1317 1467

1970 2070 2220 2450 2600 2750

SV1052 SV1252 SV1552 SV1852 SV2152 SV2452

1,2 1,5 1,8 2,1 2,5 2,9

15 22 22 22 37 37

4120 4795 5460 6040 7415 8075

1400 1600 1900 2200 2500 2800

1020 1220 1520 1820 2120 2420

1855 2185 2485 2785 3080 3380

1048 1223 1373 1523 1674 1824

480 480 480 480 600 600

1310 1325 1325 1325 1495 1495

3600 3600 3600 3600 3600 3600

4670 4670 4670 4670 4670 4670

850 850 850 850 850 850

1x1200 1x1200 1x1200 1x1200 1x1200 1x1200

160 170 170 170 265 265

1452 1712 2012 2312 2642 2942

737 867 1017 1167 1332 1482

1970 2150 2300 2450 2655 2805

SV1062 SV1262 SV1562 SV1862

1,8 2,2 2,7 3,3

22 22 22 37

5425 6225 7240 8630

1400 1600 1900 2200

1020 1220 1520 1820

1985 2185 2485 2780

1123 1223 1373 1524

480 480 480 600

1525 1525 1525 1695

4900 4900 4900 4900

6170 6170 6170 6170

1050 1050 1050 1050

2x900 2x900 2x900 2x900

170 170 170 265

1512 1712 2012 2342

767 867 1017 1182

2050 2150 2300 2505

Feeder with hopper

SANDVIK

Feeder unit type SV1052 unit SV1252 unit SV1552 unit

Vibrating feeder

Hopper Capacity m3 26 28 30

Total weight kg 19300 20465 21825

Dimensions in mm A 4760 4960 5260

B 5370 5570 5870

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C 1020 1220 1520

D 2200 2400 2700

E 2480 2680 2980

6

Feeder with expanded hopper

SANDVIK

Feeder unit type SV1062 unit SV1262 unit SV1562 unit SV1862 unit

Hopper Capacity m3 35 37 42 45

Totalweight kg 28025 29400 31210 33400

Hopper extension m³ 22 23 25 27

4.2 OPERATION PRINCIPLE Feeding means the loading of materials in comprehensive volume. For this process to be continuous the feed material must be made to move on the feeder. This is done with the help from the vibration unit. Feeder is loaded by the hopper as evenly as possible and the feeder feed is generally directed f.ex. to the crusher. Feeders are superior for primary and secondary feeding in mines, quarries and various other industries. They can be used for feeding but also in combination with scalping and feeding.

A

B

4500 4700 5000 5300

5050 5250 5550 5850

Dimensions in mm C D 1020 1220 1520 1820

2350 2550 2850 3150

E 2700 3000 3300 3600

The drive unit for the feeder can be either an adjustable hydraulic machinery or a squirrel motor with an adjustable inverter control. it is not allowed to use a feeder to any other purpose than what has been agreed, unless first consulting with the manufacturer. Sandvik carries no responsibility for damages caused by inappropriate operation.

It is recommended that the fed material flows evenly to the feeder and the pressure from the stockpile and the forces caused by the loading does not inflict the feeder bottom. If however this is not possible, the influence of the pressure of the stockpile must be as minimal as possible. If there is a possibility that loaded material can fall directly to the feeder bottom, the feeder should not be run completely empty before the following load is dumped into it. Only when the feeder is stopped for a longer period of time in winter should it be run completely empty, because of the risk of material freezing.

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2 4

1

4.3 SYSTEM DESCRIPTION Feeder consists of the following main components.

• • •

feeder structure with its wearing plates and grizzly bars if required. vibrating mechanism drive unit and supporting structures.

1 Feeder structure The feeder structure is welded steel/profile steel construction with wearing plates fastened by bolting, vibrating mechanism, spring support and grizzly bars when required. 2 Vibrating mechanism

3

5

The hydraulic motor has been placed tightly onto the mechanism therefore there is no need for an extra drive machinery base. Between the electric motor and the mechanism there is a cardan shaft which is connected by flexible couplings. The speed of rotation i.o.w. stroke intensity can be adjusted by a frequency converter or a hydraulic unit. The direction of the stroke can be adjusted by changing the position of the tooth-wheels. The side for the drive of the feeder can be freely chosen. 4 Grizzly bars The grizzly bars are made of wear resistant steel. They are fastened by bolting to the feeder structure and the space between them is adjustable. 6 Springs

The vibrating mechanism has been fastened by bolting it to the under edge of the side plates. Eccentric shafts rotate in the opposite direction thus causing a directional stroke. Eccentric masses have been placed to the heads of the mechanism and onto the shafts and their magnitude can be varied by adding or reducing counterweights thus allowing the stroke length to be adjusted accordingly.

The spring supports are bolted to the feeder body, allowing the feeder assembly to have any inclination angle. The coil springs are made of steel.

Special bearings are used in the feeders to guarantee a long lifetime. The shafts are oil lubricated. 3 Drive machinery An electric or a hydraulic motor can be used in the feeder. The opposite rotation movement of the drive shafts is caused by tooth-wheels in the shaft.

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maintenance work and the safety signs may not be taken off in any circumstances.

5 DEVICE OPERATING

•

5.1 OPERATION The mechanical use of the equipment is explained in this manual, but the control devices have their own separate instruction manual. The separate instruction of the control with its safety requirements must be followed. Sandvik is responsible for the suitability of the machine only to the purpose it has been purchased for. It is forbidden to use the feeder for any other purpose without prior consultation with the manufacturer.

• • • •

A Operating targets

The feeder because of its structure has been designed for heavy and demanding feeding tasks f.ex. as the following:

• • •

•

at the bottom of the feeder a large charge exists because of the feeding material. spesific size material sorting is demanded to the grizzly bars at the discharge end. continuos adjusting is demanded for the feeding capacity during operation.

5.2 SYSTEM CONDITIONS Feeding means the loading of materials in useable volume. For the process to be continuous the feed has to be made to move on the feeder. This is executed by asisstance from the vibration unit. Materials to be fed are ore, sand, gravel, coal, coke, minerals and powders, to name but a few. The operating conditions for these materials are generally quite demanding, and service and maintenance must be carried out accordingly. The general as well as the owners own instructions for metal and electrical equipment must be followed.

•

•

when cleaning the device with water care must be taken not to point the water towards the electrical motor or other electrical equipment. when changing the settings of the machine the absolute minimum distance between the fixed structure and the device is vertically 100 mm and horizontally 50 mm. after the machine has been cleaned or serviced take care that nothing has been left inside the device or in the chutes. the chutes must never be cleaned while the machine is activated. to minimize the risk of dust explosion, the machine and the chutes must be hosed down with water, especially if the equipment has been out of operation for several days. during each and every workshift the device must be observed in operation to check that there is not any abnormal temperatures or noise. If something abnormal is observed, the device must be stopped immediately. The cause must be investigated and if possible corrected accordingly and if required contact the supplier of the machine, before restarting. when changing wearing parts, only original SANDVIK spare parts should be used to ensure complete compatibility as well as to uphold the precondition for the Sandvik guarantee. if you need to go to the vicinity of the machine, where the process noise levels are high, use hearing protectors.

The user must have their own instructions for the control of the equipment which includes their own safety regulations that must be followed carefully.

5.3 SAFETY INSTRUCTIONS Before starting any kind of maintenance work, all general and site safety instructions have to be followed. Some of the general safety instructions are:

• •

only fully qualified and authorized electricians may carry out electrical work on the machine. none of the inspection hatches shall never be opened or left open when the device is running. Before a hatch is opened, all safety switches for the device and the feed or discharge chutes must be locked in the activated position by means of a lock to which only the maintenance personnel responsible for the work has a key. The warning signs on and around the machine must be followed e.g. in

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6 MAINTENANCE INSTRUCTIONS

All these measures require that the feeder has to be stopped during adjustment.

6.1 MAINTENANCE AND REPAIR INSTRUCTIONS

If stepless adjustments of the feed rate of the motor speed during operation are done, it is possible to use a device, with which the vibrating frequency is adjusted.

Do not attach any foreign objects to the feeder body without first consulting the manufacturer, as this may impair the feeder efficiency or can damage the feeder itself.

!

If welding is necessary, do not allow the welding current to pass through the feeder bearings.

• •

•

•

Repair damaged paintwork promptly. After the feeder has been in operation for one week, tighten all fastenings in the supporting structures, drive unit and feeder body. The same applies to any part that has been changed. Check also the fastening of grizzly bars in the grizzly feeders very carefully. Fastening surfaces must be cleaned and unpainted before the mounting of the bars. It is advisable to check the fastenings every day and to re-tighten every 1 - 2 months. Use tightening moments given below.

• • • • •

B. Adjusting need Before making adjustments make sure that they are necessary and not viable only for a short period e.g. for a small amount of material. Check also that the feeder is loaded correctly and supporting structures and chutes are installed correctly, as these may cause disturbances in the running of the feeder.

HV-screws

Screw

•

The minimum and maximum values for the vibration frequency of the feeder must be adhered too. Minimum value is approximately 550 rpm. Maximum value must be defined case by case.

Always make only minimum adjustment necessary to achieve the desire result.

Strength class

M12 M16 M20 M24

The feeder can have an inverter adjusted squirrel motor, frequency converter adjusted DC motor or hydraulic drive for stepless adjustment of feed rate. These all have the same adjusting properties.

8.8

10.9

Mechanism screws 10.9

80 Nm 200 Nm 380 Nm 650 Nm

115 Nm 280 Nm 550 Nm 950 Nm

100 Nm 250 Nm 450 Nm 800 Nm

!

If there is a change in the fed material or the gap between the grizzly bars is altered, do consult the manufacturer first for possible adjustment specifications.

C. Adjusting the feeder settings

Replace wearing parts before wear can damage the feeder itself. Do not carry out maintenance of any kind when the feeder is in operation.

If further adjustments are necessary, they should be done according to the order below. Try the action of each measure separately and singly. Try one action at a time and observe the result before taking the next one:

Do not re-use old gaskets, seals or O-rings, when remounting the machine.

1. gates or hindrance plates adjustement in the feed hopper.

Cover conveyor belts, and wood or rubber linings before cutting or welding. Do have a fire extinguisher always on hand.

2. stroke direction adjustment

Keep a good log of all service and maintenance works, which is also,a precondition for the Sandvik guarantee.

!

Follow special maintenance instructions for the vibrating shaft, the gearbox, the motor, the Vbelts and it's drive, the hydraulic coupling, etc.

ATT!

6.2 ADJUSTMENTS A. Adjusting of feed rate Feed rate can be adjusted by changing the stroke angle, stroke length, frequency, and inclination of the feeder or by using gates or hindrance plates.

Vibrating feeder

3. stroke length adjustment Always use the minimum number of counterweights so that the stroke length is the minimum necessary for satisfactory feeding. Do not exceed the following values without first consulting the manufacturer.

Stroke frequency 1020 rpm 920 rpm 820 rpm 730 rpm

Stroke length SV-feeder 8 mm 10 mm 13 mm 16 mm

4. stroke frequency adjustment

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ATT!

Always check the feeder stroke frequency/stroke length combination.

SANDVIK

5. adjusting the inclination angle of the feeder body. D Adjusting the stroke length Adjustment of the stroke length is done by changing the counterweights. At both ends of the same shaft there has to be exactly the same number of counterweights.

!

To choose the right counterweight we recommend you get in contact with the manufacturer first.

•

Example:

E Adjusting the stroke angle

Stroke length 12 mm

Stroke angle 55 degrees

6.3 COUNTERWEIGHTS WHEN USING FREQUENCY ADJUSTING EQUIPMENT If the feeder is equipped with rotation speed adjusting equipment, the amount of counterweights should be selected so that the average required feed rate is reached with a rotation speed reading, which is

•

-0.5x (nmin+nmax)

1. Remove the tooth-wheel (E). When removing the cover from the tooth-wheel, the oil sup comes off as well. 2. Turn the counterweight (B) to point straight down and lock the shaft (A) so that it cannot turn in either directions. 3. Remove the bracket (C) of the shaft (B) and draw the drive gear (D) outwards so that it comes apart from the other one. 4. Turn the shaft (B) to the required direction as much as it is needed and set the drive gear in place (D). One gullet area corresponds with 2,25 degrees changing of the stroke angle. 5. Tighten the bracket (C) and remove locking of the shaft (A) and attach the cover (E). F Checking the stroke length and angle There are stickers attached to each end of the machine’s sideplates where the stroke length, and the stroke angle can be checked while the feeder is running.

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6.4 BEARING REPLACEMENT A General It is advisable to change the bearings if one or more of the following symptoms appear in the feeder:

• • •

The bearings tend to overheat There is unusual noise in the bearing during operation The number of bearings operation hours is significantly higher than normal or clearance between the outer ring and the rollers is too big

Usually both bearings on one shaft should be changed at the same time, because if one of the bearings has begann to breakdown, some impurities might have been carried on to the other bearing, which therefore also may be damaged.

3. Push the shaft back but at the same time make sure that the bearing does not go back into the bearing housing by mounting a hindrance plate between the bearing and bearing housing.The shaft is supported from the outside of the bearing. (Figure 2).

When changing the bearings it is very important to clean all parts carefully before reassembling. All parts of the shaft must be carefully protected from impurities during the work. Keep the vessels used in the oil change also clean, and remove all loose dirt around the oil-filling hole. If you are forced to open the mechanism, do not reuse any old seals (O-rings, shaft sealings and labyrinth seals). Use only bearings specially designed for vibrating feeders. Bearings can be changed with the shaft still in the feeder. The shaft may also be removed during repairs. To change the bearings use special tools designed for this type of use. They are numbered in the pictures below.

4. When the bearing to be removed has passed the first shoulder of the shaft, pull it out by hand so that you can change the support to the other side of the bearing. After this loosen the bearing. 5. Put the supporting piece under the shaft end on the side of the loosened bearing (Figure 3).

1. Pulling rods (2 pcs) 2. Beam 3. Nuts (3 pcs) 4. Hydraulic jack 5. Hydraulic pump

6. Loosen the other bearing in the same manner 7. Pull the shaft out by using the supporting wagon (Figure 4).

6. Hindrance plate 7. Supporting piece (2 pcs) 8. Supporting wagon 9. Bushing 10. Pulling rod 11. Flange B Dismounting of shaft: 1. Loosen all parts at both ends of the shaft, so that the bearings can be seen and can be freely pushed out, without any obstacles. 2. By using special tools and the shaft, the bearing is pushed out of the bearing housing (Figure 1). Vibrating feeder

8. Clean all parts of the shaft thoroughly.Check the dimensions and the condition of parts. Replace the damaged or worn-out parts with new ones.

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C Replacing Damaged or worn-out parts should be replaced for instance in the following cases:

When a bearing fit on a shaft is so loose that the inner ring of the bearing turns on the shaft. Do not build up the bearing seat of the shaft by welding since the material used in the shaft requires a special welding procedure and the risk of breaking the shaft is greater after welding. The outer ring of the bearing has spinned in the bearing housing. If the lubrication of the fitting between the bearing and the shaft has been neglected, the fitting rust can damage the shaft and this causes it being changed with a new one. As a result, better care needs to be taken with regular lubrication in the future. If, for instance, stones have damaged the oil tube or there is a sharp dent in the curve part then the tube must be changed with a new one.

5. Measure the bearing clearances and write them down. 6. Mount the parts outside the bearings. Take special care not to damage the shaft sealing during the mounting. Replace all sealings with new ones (O-rings, shaft sealings, V-rings). Check the condition of wear rings. If they have worn out, their surface is scratched or if there has been an oil leak in the feeder, change the wear rings, too (Figure 7).

D Mounting of shaft: 1. Pull the shaft in by using the support wagon (Figure 5) 2. Put the supporting pieces under the shaft ends. The shaft itself should now be approximately in the right place. Fillment of grease with assembly

3. Put the new bearing in the shaft neck. The bearing is pushed into place by using tools. At the same time to prevent any shaft movement, the shaft is held in place with the middle-pulling rod. The axial movement of the bearing in relation to the shaft is prevented at the other end of the shaft. This will normally be executed on the drive side by mounting intermediate rings on both sides of the bearing. The inner ring must be mounted into the shaft neck before the bearing. Observe the right position of the intermediate ring in relation to the bearing (The grooves of the rings must be towards the bearing; Figures 6 and 7) 4. The bearing at the other end is pushed into place in the same manner.

Vibrating feeder

7. Fill the shaft with oil halfway up the oil level mark. Oil qualities and capacities can be seen in item. 6.5, 6.6 and 6.7. If the shaft has been loosened from the feeder body, use measure H as a measure of the proper oil capacity. It is important to always check that the shaft is in a level position in the feeder. This way sufficient lubrication in both bearings can be ensured. In case the shaft is tilted, put intermediate plates under the clusters of springs to adjust the shaft. Use the value of the tightening moment for fastening the shaft assembly to the feeder body according to the assembly drawing of the feeder. Retighten the fixing screws and all other screw joints after 2...3 days of operation. 8. Write down all measures performed on the device to the maintenance log.

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6.5 LUBRICATION SCHEME OF FEEDER

B. Mineral oils ISO VG AGMA

A Shaft devices B Breather C Clearance between shaft and bearing D Motor Shaft 16 20 24 30

H 60 mm 72 mm 91 mm 113 mm

150 4 EP

220 5 EP

320 6 EP

MOBIL 629 630 632 Mobilgear ESSO EP 150 EP 220 EP 320 Spartan SHELL 150 220 320 Omala oil GULF EP Lubricant EP Lubricant EP Lubricant HD 150 HD 220 HD 320 SUNOCO Sunep 1060 Sunep 1070 Sunep 1090 ISO 150 ISO 220 ISO 320 BP Energol Energol Energol GR-PX 150 GR-PX 220 GR-PX 320 TEXACO Meropa 150 Meropa 220 Meropa 320 CHEVRON NL Gear NL Gear NL Gear Compound Compound Compound 150 220 320 NESTE Vaihteisto Vaihteisto Vaihteisto 150 EP 220 EP 320 EP TEBOIL Pressure Oil Pressure Oil Pressure Oil 150 220 320 ARAL Degol Degol Degol BG 150 BG 220 BG 320

C. Synthetic oils

6.6 RECOMMENDED LUBRICANTS

ISO VG AGMA

A. Lubrication groups Ambient temperature

150 4 EP

220 5 EP

320 6 EP

MOBIL SHELL

ISO VG

AGMA

-30...+5

150

4 EP

-5...+25

220

5 EP

+20...+45

320

6 EP

+40...+60

320

6 EP

°C

Synthetic oils

SHC 629 SHC 630 SHC 632 Tivela Oil SA Tivela Oil WB BP SG XP 150 SG XP 220 SG XP 320 NESTE Vaihteisto Vaihteisto Vaihteisto S 150 EP S 220 EP S 320 EP KLUEBER Syntheso Syntheso D 150 EP D 220 EP D. Synthetic lubricants Synthetic lubricants can be used when operating in low or high temperatures or when the changing of the oil is hoped to be done after longer periods of time. The viscosity of synthetic oil should be corresponding to that of mineral oil which otherwise is used in the same circumstances.

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6.7 SHAFT OIL CAPACITY Body width

1000 1200 1500 1800 2100 2400 2700

16 R=84 H=60 1,2 1,4 1,8 2,1

Bearing size 30 24 20 R=109,5 R=136,5 R=162 H=113 H=91 H=72 3,1 4,9 3,7 6,0 6,5 4,6 7,5 8,0 5,5 9,0 10,0 6,5 10,5 11,5 12,0 13,0 14,5

6.9 MAINTENANCE LOG

34 R=177,8 H=129

11,7 13,5 15,3 17,2

6.8 INSPECTION AND MAINTENANCE SCHEDULE A Mechanism The first oil change for the mechanism must be done no later than 100 hours of operation. Regular oil change must then take place according to the following:

Sandvik presupposes that a log is kept by the owner to record all service and maintenance work. This is also a precondition for the Sandvik guarantee. The equipment and components should be serviced in accordance with the supplier’s instructions, and in a fashion that the measures taken can also be verified afterwards. The log could take e.g. the form illustrated in the enclosure (ENCLOSURE 2).

6.10 TROUBLE SHOOTING TABLE If a problem or damage occurs, which requires parts to be replaced, do not only change the part but look for the reason which made it necessary and eliminate the cause if possible. Otherwise contact the manufacturer. The following table acts as contents for the more detailed troubleshooting guides. DEFAULT

POINT

Feeder does not start or it stops during operation

A

Feeder is running incoherently

B

Feeders supporting frame deflects and/or vibrates too much

C

The fitting between the bearing and the shaft should be lubricated once a month with grease molyblensulphide and graphite. This will prevent fitting corrosion between the shaft and the bearing.

Unusual noise during operation.

D

Feeder bearings overheat.

E

Bearing damage.

F

Use the same oil change intervals and quality for the gear wheels (when applicable) as for the mechanism. The correct oil level for the gear wheels is the bottom of the gear teeth.

Oil leakage in the feeder

G

Material flows mostly on one side of the feeder

H

Too much material is collecting at the feed end of the feeder

I

Inspection and maintenance must to be done according to the motor manufacturers recommendations.

Feed rate of the feeder is too low or too high.

J

Material spills from chutes onto maintenance platforms etc.

K

C Must be checked weekly

Dust escapes from from the dust sealed feeders

L

Supporting springs of feeder tilt too much.

M

Type of operation In one shift operation In two- and three shift operation

Interval Half-yearly After 2000 hours of operation or half-yearly

Clean or change the breather regularly.

B Motor

• • • • •

oil levels condition of wear plates condition of grizzly bars condition of springs bolts joints (visual inspection)

Vibrating feeder

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A Feeder does not start or it stops during operation

1 2

Possible cause Electrical fault Hydraulic coupling without oil or oil level too low (where applicable).

D Unusual noise during operation

Correction Check and correct Fill the coupling according to instructions. Check also the condition of the heat plug.

2

3

4

Possible cause Feeder collides with something during operation (base, chute, material, ice etc.) Clearance between resonance buffer limiters is incorrect. Drive equipment is wrongly positioned in relation to the vibrating shaft. Feeder base is not solid enough.

2

3 4

B. Feeder is running incorrectly

1

1

Correction Arrange space for feeder to run properly. Change and adjust the clearance hole according to instructions. Move and adjust according to instructions given.

5

6

1 2

1

2

Possible cause Construction is too light or has insufficient bracing Foundations of feeder frame are not strong enough.

Vibrating feeder

Correction Add support and brace. Build up foundations.

Feeder contacts with something during operation Bearing damage. Broken spring.

There are stones or dust inside the counterweight guards. There are stones between the springs.

Correction Tighten, repair or change the parts. At the same time check all screws and the cause for damage. Arrange space for feeder to run properly. See item F. Change the spring after checking and eliminating the cause. Clean the inside of the counterweight guards . Clean the spring systems regularly and prevent material from building up between the springs.

E Feeder bearings overheat

Support base.

C Feeder supporting frame deflects and vibrates too much

Possible cause There are loose or damaged parts in the feeder

3 4

5

Possible cause Incorrect amount of oil in the vibrating shaft. Wrong oil type or old oil in the shaft. Bearing damage. High temperatures in the environment or material. The drive shaft is not horizontal and there is a lack of oil in the bearing

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Correction Check oil level. Change oil. See item F. Arrange ventilation and change to an oil suitable for high temperatures. Adjust the level of the feeder according to instructions.

16

F Bearing damage

1

Possible cause Normal life span of the bearing is exceeded.

2

Insufficient lubrication.

3 4

Unsuitable oil. Foreign material (steel, sand etc.]in oil

5

Shaft is not in a level position, when the other bearing is overfilled and the other underfilled with oil.

I Too much material is collecting at the feed end of the feeder Correction Check the operating hours and always change the bearing into a new one. Check also possible causes for the damage. Check lubrication maintenance and possible oil leaks. Change type of oil Check reason (damaged part, dirty conditions during oil change, dirty containers in handling of oil etc.) Adjust the feeder to it’s right position according to instructions given.

1 2

Seals are worn out or damaged (for instance during assembly). Do not re-use old seals

3

Wear ring is worn out.

4

Oil gauge glass is loose or there is leakage.

Correction Clean or change the filter regularly. Change the seals and be careful that the new ones are not damaged during installation. Change wear ring to new one. It is advisable to change a new ring at the same time with the shaft sealing. Tighten it.

H Material flows mostly on one side of the feeder

1

Possible cause Incorrect loading of the feeder.

Vibrating feeder

2 3

Correction See item J. Adjust loading rate. Arrange feed as per 6.2.

J Feed rate of the feeder is too low or too high

1

2

Possible cause Adjustment values are incorrect

Incorrect loading of the feeder

Correction Correct adjustments according to instructions (point 6.2) Correct loading according to instructions (point 4.1)

K Material spills from chutes onto the maintenance platforms etc.

G Oil leakage in the feeder Possible cause Filter is clogged.

1

Possible cause Conveying rate of the feeder is too low. Too high loading rate or uneven load. Material fed against the conveying direction of the feeder

Correction Reposition the feed so that it is evenly spread across the whole width.

1

2

Possible cause Feed or discharge chutes are unsuitable or incorrectly installed.

Feeder worn so badly that material is leaking from feed or discharge areas or side plates. This can happen if wear plates are not changed in time or if they are loose.

Correction Reinstall and seal. It is not permitted to connect extra parts to the feeder body, as this can impair the operation or damage the feeder. Check the condition and fixing of wear plates and change in good time according to instructions. Check also the tightening of the bolts regularly..

L Dust escapes the dust sealed feeders

1 2

Possible cause Leakage in the dust enclosure. Insufficient suction in the dust enclosure.

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Correction Seal the enclosure. Increase suction inside the enclosure to regain lowpressure inside it.

17

M Supporting springs of feeder tilt too much

1

Possible cause Fastening screws in the springsystem loose.

Correction Tighten and change if necessary.

6.11 DESCRIPTION OF DAMAGE Damage that occurs to the equipment must be documented on the damage forms with necessary notes and drawings included. Copy of the completed damage form should be send to Sandvik. This feedback helps us maintain a high service quality level to our customers. To have a damage approved under the warranty it is a requirement that the damage form is to be filled in completely and in a timely manner. A copy of the maintenance log must also be included. For warranty issues the completed damage form is demanded for the warranty hearing. The person reporting the damage must be properly trained and authorized. He or she must be able to describe the damage as much in detail as possible and, if necessary, take photographs. An example of the damage form is illustrated in the enclosure. It must be kept together with the maintenance log.

Vibrating feeder

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7 SPARE PARTS RECOMMENDATION 7.1 SPARE PART SERVICE Use only original SANDVIK spare and wear parts. This is also a precondition for the Sandvik guarantee. The drawing number, type, etc. of the parts are given in the parts list of the feeder drawings. When ordering parts, always specify the drawing number or type code of the part as well as the assembly drawing number of the feeder. After installing the new part, follow the same instructions as for the original. Spare parts can be ordered or inquired with the form enclosed in this manual (ENCLOSURE 5).

A Common spare parts for Vibrating feeders Title of spare

SV

Spring HF654 Filter

1y 1

2y 2

2

4

B Spare parts for vibrator units Title of spare

SV 1y 2 1 2 1 1

2y 4 2 4 2 1

C Common wear parts for Vibrating feeders Title of spare Grizzly Adjusting plate Linear plate

8.1 GENERAL De-commissioning and tear down doesn't include any special safety requirements. Oil should be drained and disposed of separately before recycling the feeder. Generally one should follow local or order specific guidelines in recycling or destroying of material and mechanical equipment.

9 IN CASE OF EMERGENCY 9.1 FIRE EXTINGUISHING

7.2 SPARE PART LIST

Shaft sealing V-ring sealing O-ring set Wear ring Bearing

8 DE-COMMISSIONING, TEAR DOWN AND RECYCLING

Length 900 mm

There is no special operation or material in the device that could cause fire danger, but the process material may demand taking into consideration possible dangerous fire related situations.

9.2 MATERIAL DUST Dust can if it gets out of the machine be a hazard, especially when it limits the range of visibility. Dust can escape into the area around the equipment due to broken dust seals, or due to hatches left open e.g. after maintenance, or malfunctioning of air extraction. In such a situation, the equipment must be stopped, dust must be ventilated off and necessary cleaning of the device must be done. The long-term effects of repeated dust exposure can be very serious. The risk is more related to the chemical composition of the material processed than the amount of dust in the air.

10 ASSEMBLY DRAWING There are e.g. the following assembly drawings enclosed in the product file. If you need any further information, please contact Sandvik e.g. by using the spare parts inquiry or order form enclosed in this manual (ENCLOSURE 5).

7.3 SPARE PARTS DRAWING LIST There are spare part drawings of the following parts in the productfile.

• • • •

10.1 ASSEMBLY DRAWINGS LIST

Vibrating shaft system Linear plates Grizzly bars Supporting springs

If you need any other information, please contact Sandvik.ex. by using spare parts inquiry or order form which is enclosed in this manual (ENCLOSURE 5).

Vibrating feeder

• • • • •

Vibrating feeder Vibrator mechanism Drive unit Spring supporting Grizzly bars

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19

POINTS TO BE CHECKED BEFORE USE

ENCLOSURE 1

Sandvik Mining and Construction Oy Keskikankaantie 19 FI 15860 HOLLOLA Finland NAME OF DEVICE

Tel + 358 205 44 181 Fax +358 205 44 180

DATE

INSPECTORS

MARK EXPLANATION: A B C D

Assembled according to drawings and instructions Quantities, dimensions etc. confirmed and values entered "remarks" column Adjust mechanically when necessary Other matter relating to installation

Checkpoint Finishing of assembly Assembly controlling/client Cleaning of device - surrounding - chutes Vibrating feeder - supporting structures fastening - supporting structures bracing - clearance to fixed frames - spring levels and horisontallity - feeder loading - feeder weldings and guards - grizzly bars - drive shaft attachment - inclination according shaft syst. - stroke length adjusting - shaft greasing oil - drive system fastening and guards - drive system operation - fluid coupling (if it is) - guarding and dustproofing - device safety - painting - rating plate - company logo

Vibrating feeder

See assembly instr.

X

To be done again

1

Done

Mark A D

Remarks

D D assembly and maintenance instruction

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A A AC A A A A A A A A, B A A A A A A A A

20

MAINTENANCE LOG

ENCLOSURE 2

Sandvik Mining and Construction Oy Keskikankaantie 19 FI-15860 HOLLOLA Finland NAME OF DEVICE

Tel + 358 205 44 181 Fax +358 205 44 180 DATE

Author:______________________________ Description of maintenance work

Author:______________________________ Description of mainte nance work

Author:______________________________ Description of mainte nance work

Vibrating feeder

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DAMAGE DESCRIPTION FORM

ENCLOSURE 3

Sandvik Mining and Construction Oy Keskikankaantie 19 FI-15860 HOLLOLA Finland NAME OF DEVICE

Tel + 358 205 44 181 Fax +358 205 44 180 DATE

Author:______________________________ Damage description



Vibrating feeder

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FEEDBACK FORM

ENCLOSURE 4

Sandvik Mining and Construction Oy Keskikankaantie 19 FI-15860 HOLLOLA Finland

Tel + 358 205 44 181 Fax +358 205 44 180

1 COMPONENTS • •

Which components cause repeated maintenance or repair work repeatedly? Which components should be developed from the point of view of the operators and what should be the target of the development?

2 DEVICES •

How should the machine be developed and what should be the target of the development?

3 CONTROL SYSTEMS •

Suggestions for the development of the control system (local controls, failures etc.)

4 OTHER FEEDBACKS (instructions, shields, education etc.)

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SPARE PARTS FORM DEVICE NAME

ENCLOSURE 5 DATE

AUTHOR

Sandvik Mining and Construction Oy Keskikankaantie 19 FI-15860 HOLLOLA FINLAND SENDER ADDRESS CITY COUNTRY TEL/FAX

TEL

Tel + 358 205 44 181 Fax +358 205 44 180

FAX

Spare part order Spare part inquiry Position

Spare parts name

Code

Quantity

OTHER INFORMATION

Vibrating feeder

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QJ330-1107-english.pdf

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