Original instructions

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Operator's Instructions

CS660:05
This publication is copyright of Sandvik – © Sandvik 2016.

It must not be copied*, reproduced or otherwise made available in full or in part to any third party
without Sandvik's prior written consent.

All rights reserved.

* The maintenance checklists in the Maintenance Instructions and Operator's Instructions may be
copied solely for maintenance purposes of Sandvik equipment.

Document number: S 223.1337

Version: 1
Language: en-US
Issue: 02/05/2016

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

You can sustain personal injuries or even die if you ignore instructions.

Follow the instructions in the manual when you carry out any work on the
equipment and when you operate it. If anything is unclear, please contact
your local Sandvik representative.

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 Table of contents

1. Operating instructions
1.1. Starting and stopping the crusher..................................................8
1.1.1. Starting the crusher............................................................8
1.1.1.1. Starting the crusher in low ambient temperatures...
8
1.1.2. Stopping the crusher.......................................................... 8
1.2. Adjusting the CSS..........................................................................8
1.3. Adjusting the CSS..........................................................................9
1.4. Clearing out the crushing chamber.............................................. 11
1.5. Opening the tank covers..............................................................12
1.6. Closing the tank covers............................................................... 12
1.7. Opening and closing the tank doors............................................ 13

2. Operator's inspection and care

2.1. Inspection and care when it is dark............................................. 16
2.2. Determining inspection and maintenance intervals..................... 16
2.3. Daily inspection and care.............................................................16
2.4. Weekly inspection and care.........................................................17
2.5. Monthly inspection and care........................................................ 18
2.6. Yearly inspection and care...........................................................18
2.7. Checks before starting the pumps............................................... 19
2.7.1. Checking the guards and dust sealing components for
defects........................................................................................19
2.7.2. Inspecting the electrical cables and connectors...............19
2.7.3. Checking the crushing chamber for wear.........................19
2.7.3.1. Checking the crushing chamber for uneven wear...
19
2.7.3.2. Checking the mantle and concave.......................19
2.7.3.3. Checking the A-dimension...................................20
2.7.4. Checking the movement between the flanges of the
topshell and the bottomshell...................................................... 21
2.7.5. Checking the oil level in the main lubrication tank before
starting the pump....................................................................... 21
2.7.6. Checking the shut-off valves............................................ 22
2.7.7. Checking the filter indicator..............................................22
2.7.8. Cleaning the return oil screen.......................................... 23
2.7.9. Cleaning the pump motors............................................... 23
2.7.10. Checking the crusher for jammed material.................... 24
2.7.11. Cleaning the air/oil cooler...............................................24
2.7.12. Checking the oil temperature in the tank........................24
2.8. Checks after starting the pumps.................................................. 24
2.8.1. Checking the oil level in the main lubrication tank after
starting the pump....................................................................... 24
2.8.2. Checking the condition of the lubrication oil.....................25
2.8.3. Analyzing the lubrication oil..............................................26

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Table of contents

2.8.4. Inspecting the oil hoses, pipes, valves, connections and

fittings.........................................................................................26
2.8.5. Checking the pressure of the pinionshaft lubrication
system........................................................................................26
2.9. Checks when idling......................................................................27
2.9.1. Checking the dust seal air pressure system.................... 27
2.9.1.1. Dust seal air pressure fan....................................27
2.9.1.2. Regulator for compressed air.............................. 27
2.9.2. Checking the pressure of the main lubrication system.....28
2.9.3. Checking the return oil temperature.................................28
2.9.4. Checking the CSS with lead.............................................29
2.9.5. Listening for abnormal noise............................................ 29
2.9.6. Checking the function of the return oil flow switch........... 30
2.10. Checks while crushing............................................................... 30
2.10.1. Checking the Hydroset pressure....................................30
2.10.2. Checking the temperature of the pinionshaft housing....31
2.10.3. Checking if bolts have come loose.................................31
2.10.4. Checking the pressure of the main lubrication system...31
2.10.5. Checking the return oil temperature...............................32
2.10.6. Checking the oil level in the Hydroset tank.................... 32
2.11. Checks during stop.................................................................... 33
2.11.1. Cleaning the return oil screen........................................ 33
2.11.2. Checking the wear and tension of the V-belt..................34
2.11.3. Checking the dust seal ring for wear.............................. 35
2.11.4. Checking the condition of the scraper above the dust
collar...........................................................................................36
2.11.5. Checking the grease level in the spider bearing............ 37
2.11.6. Checking the air vent filter..............................................38

3. Operator's troubleshooting
3.1. Possible causes and corrective actions.......................................40
3.2. The crusher does not start...........................................................40
3.3. The crusher stops........................................................................ 40
3.4. The lubrication oil temperature is too high...................................41
3.5. The CSS varies or the product is oversized................................ 41
3.6. The pinionshaft does not operate correctly................................. 42
3.7. The crusher sounds different....................................................... 42
3.8. The crusher's capacity drops.......................................................42
3.9. A bearing in the crusher fails....................................................... 42
3.10. The oil is contaminated..............................................................43

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1. Operating instructions

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1. Operating instructions

1.1. Starting and stopping the crusher

Normally, the crusher´s control system restricts the ways in which the
crusher can be started. Read complementary information from the
manufacturer of the control system. Nevertheless, make sure that the
control system follows the start and stop procedures below.
Follow the Checks before starting the pumps on page 19 and
procedures on the maintenance card Daily inspection and care on page
16 before starting the crusher.

1.1.1. Starting the crusher

a) Start the main lubrication oil pump.
b) When the “Ready for start” signal is received, start the crusher’s
drive motor.
c) Start the feeder. The crusher should be choke fed without
segregation.
1.1.1.1. Starting the crusher in low ambient temperatures
In low ambient temperatures, before normal operating temperature is
reached, the lubrication oil can overflow the dust collar when the main
lubrication pump is started. Refer to section Operating in low
temperatures in the Installation Instructions for further information.

1.1.2. Stopping the crusher

a) Stop the feeder, and let the crusher run until the crushing chamber
is empty.
b) Stop the crusher’s drive motor.
c) After the crusher has stopped completely, stop the main lubrication
pump.

1.2. Adjusting the CSS

Use the push button box CB1 to increase or decrease the CSS.
a) Stop the crusher, see section Stopping the crusher on page 8.
b) Make sure the crusher is empty.
c) Press (1) to raise the mainshaft and decrease the CSS.

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 1. Operating instructions

d) Press (2) to lower the mainshaft and increase the CSS.

1 Decrease the CSS

2 Increase the CSS

1.3. Adjusting the CSS

Use the Hydroset pump K1-P1 to increase or decrease the CSS.
a) Stop the crusher, see section Stopping the crusher on page 8.
b) Make sure the crusher is empty.

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1. Operating instructions

c) Start the pump (1) to raise the mainshaft and decrease the CSS.

Main shaft up = HYDROSET

CSS decrease

K1-HA1
K1-PS1

K1-F1

K1-CV3

K1-M1 K1-P1

M
K1-RV1

Hydroset tank

1 K1-CV1

K1-V1

1 Hydroset pump

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 1. Operating instructions

d) Start the pump (1) in reverse to lower the mainshaft and increase
the CSS.

Main shaft down = HYDROSET

CSS increase

K1-HA1
K1-PS1

K1-F1

K1-CV3

K1-M1 K1-P1

M
K1-RV1

Hydroset tank

1 K1-CV1

K1-V1

1 Hydroset pump

1.4. Clearing out the crushing chamber

Risk of equipment or property damage.
Do not start the crusher if it has stalled because of
NOTICE uncrushable material (metal, wood etc.). Empty the
crusher manually or unbolt the topshell so that all
material can leave the crushing chamber.

Risk of equipment or property damage.

NOTICE Never start the crusher with a loose topshell.

If the crusher stalls with the crushing chamber full of material, clear it
out as follows:
a) Make sure that the crusher’s feeding arrangement is switched off.

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1. Operating instructions

b) If there is material in the discharge chute beneath the crusher,

remove the material.
NOTE! If there is an ASRi system, switch it off. The ASRi system
must be disconnected to prevent an automatic raising or
lowering of the mainshaft.
c) Use the CB1 push button box to lower the mainshaft, keeping an
eye on the Hydroset pressure.
d) If the Hydroset pressure drops below 0.3 MPa, then raise the
mainshaft again until the pressure gauge displays at least
0.5 MPa.
e) Start the crusher.
NOTE! Check for material build-up on the bottomshell arms. If
damp, wet feed is causing packing, operate at a larger
setting.
NOTE! Check the interlocking between the feeding arrangement
and discharge system. There must be room beneath the
crusher for material in the crushing chamber and feed
hopper, in case the discharge system stops.

1.5. Opening the tank covers

a) NOTE! Clean the area around the covers before opening them to
avoid contamination of the oil.
Loosen the handles (1) and fold them down. Do not remove the
handles (1).
b) Lift off the tank cover (2).

2
1

1 Handle
2 Tank cover

1.6. Closing the tank covers

a) Put the tank cover (2) back.

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 1. Operating instructions

b) Fold up the handles (1) and tighten them.

2
1

1 Handle
2 Tank cover

1.7. Opening and closing the tank doors

a) Turn the handles (1) counter clockwise to open the doors and the
hatch.
b) Use the support (2) to keep the hatch open.
c) Turn the handles clockwise to close the doors and the hatch.

1 2

1 Handle
2 Support

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 2. Operator's inspection and care

2. Operator's inspection and

care

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2. Operator's inspection and care

2.1. Inspection and care when it is dark

There is no lighting installed in the tank unit so if working when it is dark
use a flashlight.

2.2. Determining inspection and

maintenance intervals
Every equipment must be subjected to regular systematic checks. This
will result in fewer and smaller repairs, less downtime and thus lower
overall running costs.
NOTE! New equipment 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 and tank unit's operating
conditions and loads, important data and details of adjustments made
and any repairs carried out.
Since equipment operate under widely differing conditions, it is
impossible to recommend an inspection and care schedule applicable to
all equipment. However, regular inspections are necessary.

2.3. Daily inspection and care

Operation hours - Daily or every 8 hours of operation

Maintenance procedure Notes
CHECKS BEFORE STARTING
THE PUMPS
Check the guards and dust sealing
19
components for defects
Inspect the electrical cables and
19
connectors
Check the oil level in the main lubrication
21
tank before starting the pump
Check the shut-off valves 22
Check the crusher for jammed material 24
Check the oil temperature in the tank 24
CHECKS AFTER STARTING
THE PUMPS
Check the oil level in the main lubrication
24
tank after starting the pump
Inspect the oil hoses, pipes, valves,
26
connections and fittings

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 2. Operator's inspection and care

Operation hours - Daily or every 8 hours of operation

Maintenance procedure Notes
Check the pressure of the pinionshaft
26
lubrication system
CHECKS WHEN IDLING
Check the pressure of the main
28
lubrication system
Check the return oil temperature 28
Check the CSS with lead 29
Listen for abnormal noise 29
CHECKS WHILE CRUSHING
Check the Hydroset pressure (N/A for
30
crushers with ASRi)
Check the temperature of the pinionshaft
31
housing
Check if bolts have come loose 31
Check the pressure of the main
31
lubrication system
Check the return oil temperature 32
Check the oil level in the Hydroset tank 32

When completed:
Date ............................................................... Operation hours .................................................
Approved .......................................................

2.4. Weekly inspection and care

Operation hours - Weekly or every 40 hours of operation

Maintenance procedure Notes
CHECKS BEFORE STARTING
THE PUMPS
Check the crushing chamber for wear 19
Check the movement between the
flanges of the topshell and the 21
bottomshell
Check the filter indicator 22

Clean the pump motor 23

Clean the air/oil cooler 24

CHECKS AFTER STARTING

THE PUMPS
Check the condition of the lubrication oil 25

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2. Operator's inspection and care

Operation hours - Weekly or every 40 hours of operation

Maintenance procedure Notes
CHECKS WHEN IDLING
Check the dust seal air pressure system 27
CHECKS DURING STOP
If applicable: Check the wear and
34
tension of the V-belt

When completed:
Date ............................................................... Operation hours .................................................
Approved .......................................................

2.5. Monthly inspection and care

Operation hours - Monthly or every 160 hours of operation

Maintenance procedure Notes
CHECKS BEFORE STARTING
THE PUMPS
Clean the return oil screen 23

CHECKS WHEN IDLING

Check the function of the return oil flow
30
switch
CHECKS DURING STOP
Clean the return oil screen 33

Check the dust seal ring for wear 35

Check the condition of the scraper above
36
the dust collar
Check the grease level in the spider
37
bearing
Check the air vent filter 38

When completed:
Date ............................................................... Operation hours .................................................
Approved .......................................................

2.6. Yearly inspection and care

Operation hours - Yearly or every 2000 hours of operation

Maintenance procedure Notes
CHECKS AFTER STARTING
THE PUMPS

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 2. Operator's inspection and care

Operation hours - Yearly or every 2000 hours of operation

Maintenance procedure Notes
Analyze the lubrication oil 26

When completed:
Date ............................................................... Operation hours .................................................
Approved .......................................................

2.7. Checks before starting the pumps

2.7.1. Checking the guards and dust sealing

components for defects
a) Check that all guards are in place.
b) Visually check all guards and dust sealing components for defects.
c) If any defects are detected, contact maintenance personnel.

2.7.2. Inspecting the electrical cables and connectors

a) Inspect electrical cables and connectors.
b) If any damage is detected, contact maintenance personnel.

2.7.3. Checking the crushing chamber for wear

If the crusher capacity is reduced, this can indicate that the mantle
and/or concave is worn out.
2.7.3.1. Checking the crushing chamber for uneven wear
Regular inspection of the crushing chamber is recommended for good
total economy and to make sure that it has not been worn unevenly or
that it has become oval. Check the crushing chamber as often as
necessary.
a) Visually inspect the crushing chamber through the inspection
hatches. Look for any localized wear or other damage in the
crushing chamber.
b) If any uneven wear is detected, contact maintenance personnel.
2.7.3.2. Checking the mantle and concave
If a large proportion of the feed is close to the maximum material size,
crushing is concentrated to the upper part of the chamber. This can
cause an annular groove (B) around the top of the entire crushing
chamber. With a large proportion of fine material in the feed, crushing is
concentrated to the lower part of the chamber, which can cause a
similar groove (C) in the lower part of the chamber.
NOTE! The mantle and concave are worn out when they have been worn
down to about ⅓ of the original thickness.

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2. Operator's inspection and care

a) Visually inspect the mantle and concave through the inspection

hatches. Look for any indentations, cracks or other damage to
them.
b) If any indentations, cracks or other damage is detected, contact
maintenance personnel.

A A-dimension
B Groove
C Groove

2.7.3.3. Checking the A-dimension

Check the A‑dimension as often as necessary.
NOTE! This check is unnecessary if your crusher is equipped with ASRi.
Refer to the ASRi's Installation and Operator's Manual for
instructions about how to check the A‑dimension.
NOTE! The concave and/or mantle can be completely worn out before
the minimum A‑dimension is reached, especially if the CSS and
the eccentric throw are small.
NOTE! If the mainshaft is raised further than the minimum A‑dimension, it
can damage the spider bearing.
a) Measure the A-dimension between the head nut and the underside
of the topshell as indicated in the illustration.

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 2. Operator's inspection and care

b) If the A‑dimension is less than 20 mm (0.78"), the concave and/or

mantle is worn out and must be replaced. Contact maintenance
personnel.

A A-dimension

2.7.4. Checking the movement between the flanges of

the topshell and the bottomshell
a) Use a feeler gauge to check if there is play between the flanges of
the topshell and the bottomshell.
b) If any play is detected, contact maintenance personnel.

2.7.5. Checking the oil level in the main lubrication

tank before starting the pump
a) Check the oil level on the level indicator L1-LI1.
b) The oil level must be at max. If necessary, top up with oil.

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2. Operator's inspection and care

2.7.6. Checking the shut-off valves

a) Make sure that the red shut-off valves L1-V1 and K1-V1 between
the tanks and the pumps are open.
b) Make sure that the red tank shut-off valves L1-V5 and K1-V4 are
closed.

1 2 3
1 L1-V5 Shut-off valve, lubrication tank
2 L1-V1 Shut-off valve, lubrication oil to pump
3 K1-V1 Shut-off valve, Hydroset oil to pump
4 K1-V4 Shut-off valve, Hydroset tank

NOTE! All valves are in open position in the illustration above.

2.7.7. Checking the filter indicator

a) NOTE! This check is not necessary if the crusher is controlled via
a plant control system.
Check the filter indicators L1-PS1, L2-PS1 and K1-PS1 (1). If the
indicator is red, contact maintenance personnel. There is an
indicator on top of each filter.

1 Filter indicator

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 2. Operator's inspection and care

2.7.8. Cleaning the return oil screen

Toxic hazard
Read the lubricant's MSDS for information about its
health effects.
Handle new lubricants as well as waste lubricants
with care and according to the MSDS and local
regulations.
WARNING! Collect waste lubricants in suitable containers and
dispose of them as recommended in the MSDS and
according to local regulations.

a) Open and remove the tank cover, see section Opening the tank
covers on page 12.
b) Remove the return oil screen (1) from the lubrication tank.
c) Inspect the screen for swarf, needle-like particles, lead flakes,
bronze particles and dirt. If you notice an increase in
contamination, contact maintenance personnel.
d) NOTE! Use white spirit only if diesel oil does not dissolve the
residues.
If white spirit is used for cleaning, wipe it off carefully and
allow it to evaporate.
Clean the return oil screen with diesel oil or white spirit.
e) Blow the return oil screen clean with compressed air.
f) Check the return oil screen for damage. If it is damaged, replace it.
g) Put the return oil screen back.
h) Close the tank cover, see section Closing the tank covers on page
12.

1
1 Return oil screen

2.7.9. Cleaning the pump motors

a) Clean the pump motors L1-M1 and K1-M1. The air channels and
cooling ribs of the electric motors must be clean and the air intake
must be kept clear.

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2. Operator's inspection and care

2.7.10. Checking the crusher for jammed material

NOTE! Remove any jammed material from the top of the crusher.
a) Check the feed hopper and the distributor for any jammed material,
that may be blocking the feed opening.
b) Check that no material has built up on the bottomshell arms.
c) Remove any jammed material.

2.7.11. Cleaning the air/oil cooler

The air channels and cooling ribs of the electric motors must be clean
and the air intake must be kept clear.
a) Clean the cooler with compressed air. Be careful not to damage
the cooler.
b) If necessary, also clean the outside of the coil with compressed air.
c) Check if the fan vibrates. Replace it if it does.

2.7.12. Checking the oil temperature in the tank

a) Check the oil temperature in the tank on the temperature
indicator L1-TI3.
b) The temperature must be higher than 5 °C below the setpoint of
the temperature switch L1-TS1. If the temperature is lower, wait
until the oil has warmed up. Example: If the setpoint is 30 °C, the
temperature must be at least 25 °C.

2.8. Checks after starting the pumps

2.8.1. Checking the oil level in the main lubrication

tank after starting the pump
a) Check the oil level. It must be above min. on the level
indicator L1-LI1.

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 2. Operator's inspection and care

b) If the oil level is near or below the minimum level, stop the crusher.
Wait for the oil to return to the tank, then top up with oil to the
maximum level.

2.8.2. Checking the condition of the lubrication oil

If there is an increased amount of metal particles on the return oil
screen L1-OS1, the cause should be investigated to prevent possible
damage.
a) Clean the inspection glass.
b) Check the color of the oil. The color darkens as the oil becomes
more contaminated.
A yellow shimmer indicates bronze deposits in the oil.
c) Check the return oil screen L1-OS1.
• An increased amount of swarf indicates a bearing or bushing
failure inside the crusher. Contact maintenance personnel.
• Needle-like particles indicate a seizure or wear in bevel gears
inside the crusher. Contact maintenance personnel.
• Lead flakes indicate high temperature or localized overheating
and partial seizure in bushings or step bearing components.
Contact maintenance personnel.
• Bronze particles indicate a bearing or bushing failure inside
the crusher. Contact maintenance personnel.
• Dirt can indicate that the dust seal air pressure system is
malfunctioning or that the dust seal ring is worn.
NOTE! Dirt can also enter the system when the liners are
changed.

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2. Operator's inspection and care

d) If necessary, clean the return oil screen L1-OS1, see section

Cleaning the return oil screen on page 23.

1
1 L1-OS1 Return oil screen

2.8.3. Analyzing the lubrication oil

It is recommended to make an analysis of the oil shortly after the first
start up.

Cleanliness when taking samples is essential for the reliability of

the result.
a) Take a sample in the return oil box .
b) Send the sample for analysis. A complete change should be
undertaken when recommended by the company performing the
analysis. After a major breakdown and when the hydraulic fluid is
discolored, it should be changed completely.

2.8.4. Inspecting the oil hoses, pipes, valves,

connections and fittings
a) Inspect all oil hoses, pipes, valves, connections and fittings.
b) If any damage detected, contact maintenance personnel.

2.8.5. Checking the pressure of the pinionshaft

lubrication system
Check the pressure and keep a record of the readings. If the pressure
rises, it usually means that the filter is clogging up. If the pressure is
low, the pump can be worn.

Normal pressure (dependent on the length of the pipes between 0.05-0.4 MPa (7.25-58 psi)
tank and crusher)

a) Check the pressure on the pressure indicator L2-PI1 (1).

b) Record the value.
c) The value must be above 0,05 MPa (7.25 psi). If the value is below
or above the normal pressure, contact maintenance personnel.

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 2. Operator's inspection and care

1 L2-PI1 Pressure indicator

2.9. Checks when idling

2.9.1. Checking the dust seal air pressure system

a) Check the covers on the tank unit. The covers on the tank unit
must be air tight.
b) If necessary, adjust or replace the sealing strips.
2.9.1.1. Dust seal air pressure fan
a) Visually check the filter L3-FU1 (1). If necessary, change the filter
element.
b) Visually check all the hoses (2) of the dust seal air pressure
system. If any leak is detected, contact maintenance personnel.

1 Filter, dust seal air pressure fanL3-FU1

2 Hose

2.9.1.2. Regulator for compressed air

a) Visually check all the hoses (1) of the dust seal air pressure
system. If any leak is detected, contact maintenance personnel.

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2. Operator's inspection and care

b) Visually check the filter L3-FU2 (2). If necessary, change the filter
element.

1 Hose
2 Filter, pressure regulatorL3-FU2

2.9.2. Checking the pressure of the main lubrication

system
NOTE! When the fan of the air/oil cooler is running, the pressure in the oil
system generally rises. Avoid reading off the pressure at such
times.
Check the pressure and keep a record of the readings. If the pressure
rises, it usually means that the filter is clogging up. If the pressure is
low, the pump can be worn.

Normal pressure (tank installation dependent) 0.5 - 1.4 MPa (72.5 - 203 psi)

a) Check the pressure on the pressure indicator L1-PI1 (1).

b) Record the value.
c) If the value is below or above the normal pressure, contact
maintenance personnel.

1 L1-PI1 Pressure indicator

2.9.3. Checking the return oil temperature

The return oil temperature is affected by the load on the crusher and the
ambient air temperature.

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 2. Operator's inspection and care

NOTE! The crusher is automatically stopped if the oil temperature is too

high.
a) Check the return oil temperature on the temperature
indicator L1-TI2.

Return oil temperature during normal conditions 40 to 45 °C (104 to 113 °F)

b) If the temperature deviates from the values in the table, contact

maintenance personnel.

2.9.4. Checking the CSS with lead

NOTE! This check is not necessary if your crusher is equipped with ASRi.
Refer to the ASRi's Installation and Operator's Manual for
instructions about how to check and calibrate the CSS.
Moving parts hazard
You can sustain crush and severing injuries or even
die if you fall into the crusher during operation.
DANGER! Only stay on the equipment if it is necessary for
inspections and maintenance work.

a) Fasten a lump of lead to a steel wire. Make sure that the lead lump
is larger than the CSS.
b) Slowly lower the lead lump into the discharge area of the crushing
chamber.
c) Check the CSS at four points evenly spaced around the crushing
chamber, in order to detect uneven wear. After each point,
measure the thickness of the lead lump. The thickness of the
squeezed lead lump corresponds to the CSS.
d) If any uneven wear is detected, contact maintenance personnel.

2.9.5. Listening for abnormal noise

a) Listen for any abnormal noise from the crusher.
b) Listen for any abnormal noise from the main lubrication pump and
the pinionshaft lubrication pump.

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c) If you hear any abnormal noise, stop the crusher and contact
maintenance personnel.

2.9.6. Checking the function of the return oil flow

switch
a) Check the oil level in the return oil chamber (3). When a sufficient
flow of oil is returning to the tank, the oil level in the return oil
chamber (3) should be 5 mm (0.20") above the spillway (2). With
this oil level in the return oil chamber (3), the float (1) is completely
immersed in oil but the oil’s lifting force pushes the float (1) up
against its upper stop.
b) Check the level monitor by pushing the float (1) down from its
upper stop. The crusher’s drive motor must then stop. If the oil flow
decreases, the oil level will drop in the return oil chamber (3).
When the oil level has dropped about 15 mm (0.59"), the float (1)
of the return oil flow switch will sink about 5 mm (0.20") below the
upper stop. In this position the return oil switch L1-FS1 opens and
stops the crusher’s drive motor.

1
2

1 Float
2 Spillway
3 Return oil chamber

2.10. Checks while crushing

2.10.1. Checking the Hydroset pressure

NOTE! This check is not necessary if your crusher is equipped with ASRi.
The maximum pressure is then automatically regulated.

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a) Push the button K1-V3 (2) to activate the pressure

indicator K1-PI1 (1).

1 K1-PI1 Hydroset pressure indicator

2 K1-V3 Button to activate the Hydroset pressure indicator

b) Check that the maximum Hydroset pressure does not exceed

2.5 MPa (363 psi).
c) If the pressure exceeds, increase the CSS until the pressure falls
below the value, see section Adjusting the CSS on page 8.

2.10.2. Checking the temperature of the pinionshaft

housing
a) Use an infrared temperature sensor to measure the temperature.

Normal temperature 50 to 60 °C (122 to 140 °F)

b) If the housing is too hot, stop the crusher and contact maintenance
personnel.

2.10.3. Checking if bolts have come loose

a) Check if any bolts have come loose.
b) If there are loose bolts, contact maintenance personnel.

2.10.4. Checking the pressure of the main lubrication

system
NOTE! When the fan of the air/oil cooler is running, the pressure in the oil
system generally rises. Avoid reading off the pressure at such
times.
Check the pressure and keep a record of the readings. If the pressure
rises, it usually means that the filter is clogging up. If the pressure is
low, the pump can be worn.

Normal pressure (tank installation dependent) 0.5 - 1.4 MPa (72.5 - 203 psi)

a) Check the pressure on the pressure indicator L1-PI1 (1).

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b) Record the value.

c) If the value is below or above the normal pressure, contact
maintenance personnel.

1 L1-PI1 Pressure indicator

2.10.5. Checking the return oil temperature

The return oil temperature is affected by the load on the crusher and the
ambient air temperature.
NOTE! The crusher is automatically stopped if the oil temperature is too
high.
a) Check the return oil temperature on the temperature
indicator L1-TI2.

Return oil temperature during normal conditions 40 to 45 °C (104 to 113 °F)

b) If the temperature deviates from the values in the table, contact

maintenance personnel.

2.10.6. Checking the oil level in the Hydroset tank

a) Lower the mainshaft to its lowest position, see section Adjusting
the CSS on page 8.
b) Make sure the Hydroset pressure is 0, see section Checking the
Hydroset pressure on page 30.

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c) Stop the crusher, see section Stopping the crusher on page 8.

d) Check the oil level on the level indicator K1-LI1.
e) The oil level must be at max.. If necessary, top up with oil.

2.11. Checks during stop

2.11.1. Cleaning the return oil screen

Toxic hazard
Read the lubricant's MSDS for information about its
health effects.
Handle new lubricants as well as waste lubricants
with care and according to the MSDS and local
regulations.
WARNING! Collect waste lubricants in suitable containers and
dispose of them as recommended in the MSDS and
according to local regulations.

a) Open and remove the tank cover, see section Opening the tank
covers on page 12.
b) Remove the return oil screen (1) from the lubrication tank.
c) Inspect the screen for swarf, needle-like particles, lead flakes,
bronze particles and dirt. If you notice an increase in
contamination, contact maintenance personnel.
d) NOTE! Use white spirit only if diesel oil does not dissolve the
residues.
If white spirit is used for cleaning, wipe it off carefully and
allow it to evaporate.
Clean the return oil screen with diesel oil or white spirit.
e) Blow the return oil screen clean with compressed air.
f) Check the return oil screen for damage. If it is damaged, replace it.
g) Put the return oil screen back.

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h) Close the tank cover, see section Closing the tank covers on page
12.

1
1 Return oil screen

2.11.2. Checking the wear and tension of the V-belt

The tension of the V-belts must be checked at installation. During the
first few days of operation, the belt tension must be checked frequently
since new belts stretch. If the belts are not tensioned sufficiently,
slipping can occur and belt life will be reduced considerably.
Proper belt tension can be determined with the help of the deflection
load. Check the deflection load with a spring balance, a tensiometer or
similar.
Recommended deflection load (F)
F/belt

Belt Normal deflection load Max. deflection load (newly fitted

profile belts)
SPC 69 N/belt [7.0 kp/belt] (15.4 lbf/belt) 117.7 N/belt [12.0 kp/belt] (26.5 lbf/belt)
8V 88 N/belt [9.0 kp/belt] (19.8 lbf/belt) 137.3 N/belt [14.0 kp/belt] (30.9 lbf/belt)

a) NOTE! The instruction below applies to the tensiometer supplied

in the crusher’s tool box.
Measure the belt span (W) in meters, as shown below.
b) Multiply the span by 1.5, to give the belt deflection (D) in cm.
c) Set the top side of the lower O-ring to the correct deflection in cm
on the meter’s lower scale.
d) Push the upper O-ring up against the lower edge of the outer
sleeve.
e) Press the meter against the belt in the middle of the span and
press sufficiently hard to bring the top side of the lower O-ring level
with the belt alongside.

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f) Remove the meter and read off the load (F) in kp (lbf) at the top
side of the upper O-ring. The correct load is obtained from the
table above, which should be reproduced on the meter.

2
1

6
6 14 12 10 8
W

5
F

4
2

32
D

1
1 F-scale
2 D-scale
D = deflection
W = belt span
F = deflection load

2.11.3. Checking the dust seal ring for wear

You measure the play between the dust seal ring and the dust collar
through one of the inspection hatches.
a) Open one of the inspection hatches.
b) Use feeler gauges to measure the play between the dust seal
ring (1) and the dust collar (2). The play must not exceed
1.9 mm (0.075").

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c) If the play is larger, contact maintenance personnel.

1 Dust seal ring

2 Dust collar
3 Measure the play here

d) Close the inspection hatch.

2.11.4. Checking the condition of the scraper above the

dust collar
a) Check the condition of the scraper (5) at regular intervals. The
scraper (5) should scrape against the dust collar (4).
b) If necessary, clean out the area around the dust collar (4) and the
bottomshell arms.

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c) If the scraper (5) needs to be replaced, contact maintenance

personnel.

2
3 5
4

2 Retaining ring
3 Dust seal ring
4 Dust collar
5 Scraper

2.11.5. Checking the grease level in the spider bearing

During the first few weeks of operation, the grease level should be
checked daily by unscrewing the plug in the spider cap. The type of
grease in the spider bearing at delivery is stated on a label beside the
grease nipple on one of the topshell arms.

NOTE! The spider bearing should be filled with grease to the top of the
bushing, when the mainshaft is in its lowest position.
a) Make sure that the mainshaft is in its lowest position, see section
Adjusting the CSS on page 8.
b) Unscrew and remove the plug in the spider cap (not visible in the
illustration).
c) Examine the grease level by sticking a steel wire or equivalent into
the observation hole (not visible in the illustration) and feeling the
grease level. Make sure that you measure the grease level from
the mainshaft (3) and not from a screw (2) or the bushing (4).
Alternatively shine a flashlight into the hole and observe the level.
Risk of equipment and property damage
Unsuitable lubricants can damage the equipment and
cause blockages. If you mix lubricants the mixture
can lose its lubricating properties.
NOTICE Use lubricants that fulfil Sandvik's requirements,
refer to the Technical Specifications.
Check with the lubricants' manufacturers if different
types or brands can be mixed.

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d) If necessary, top up with grease to the correct level. This

corresponds to approximately the amount given in the table below.
• If the level is low, pump grease in through a pipe (1) inside
one of the topshell spider arms.
• If the level is very low, remove the spider cap and add grease
straight from the drum.

Grease quantity
Spider bearing 7-9 kg (15.4-19.8 lbs)

NOTE! The mainshaft in the illustration is not in its lowest position.

1 2 3 4

1 Grease pipe
2 Screw
3 Mainshaft
4 Bushing

2.11.6. Checking the air vent filter

a) Check the air vent filter (1).
b) If the filter is clogged, contact maintenance personnel.

1
1 Air vent filter

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3. Operator's troubleshooting

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3.1. Possible causes and corrective actions

Risk of equipment or property damage
If the crusher stalls with the crushing chamber full of
NOTICE material, see section Clearing out the crushing chamber on
page 11.

If the problem remains after you have followed the troubleshooting in

this chapter, or if the problem is not covered here, contact maintenance
personnel.
Before you carry out any corrective actions:

• Read and understand the instructions.

• Make sure that you have the required training and skills before
performing any corrective actions.
When you perform corrective actions, use appropriate approved
personal protective equipment.

3.2. The crusher does not start

Possible cause Corrective action

No “Ready for start” signal and oil Start the main lubrication oil pump.
pump not running
No “Ready for start” signal and If the return oil flow is low, wait a few minutes to see if it
lubrication oil flow low stabilizes.
Check that oil does not overflow over dust collar, see
section Starting the crusher in low ambient
temperatures on page 8.
Normal lubrication oil flow, but no Check the operation of the return oil flow switch, see
“Ready for start” signal section Checking the function of the return oil flow
switch on page 30.
Oil does not return to tank (in low See section Starting the crusher in low ambient
temperature) temperatures on page 8.

3.3. The crusher stops

The crusher stops when idling or with material in the chamber.

Possible cause Corrective action

Oil pump not running Start the main lubrication oil pump.
Low lubrication oil flow Check that oil does not overflow over dust collar, see section
Starting the crusher in low ambient temperatures on page 8.
Normal lubrication oil flow Check the operation of the return oil flow switch. See section
Checking the function of the return oil flow switch on page 30.
Oil too hot See section The lubrication oil temperature is too high on page
41.

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Possible cause Corrective action

If applicable: V-beltsslipping Reduce the load on the crusher. See Crusher’s drive motor
overloaded below.
Check the wear and tension of the V-belt, see section Checking the
wear and tension of the V-belt on page 34.
Crusher’s drive motor Increase the CSS if it is too small.
overloaded
Packing in crushing Is the material wet? Is the fine content high? Increase the CSS.
chamber
Tramp metal or blockage in See section Clearing out the crushing chamber on page 11.
crushing chamber Increase the CSS and remove the obstruction. Check the mantle
and concave for damage. Also check if they have come loose.
Contact maintenance personnel if necessary.

3.4. The lubrication oil temperature is too

high

Possible cause Corrective action

Protective temperature Air/oil cooler: clean the cooler matrix. Check that there is
switch L1-TS1 shuts down the sufficient cooling air. Refer to section Cleaning the air/oil cooler
crusher on page 24.
Protect the cooler and the tank unit from direct sunlight.
Check the contamination in the return oil screen L1-OS1, see
section Checking the condition of the lubrication oil on page 25.
If the contamination has increased, contact maintenance
personnel.
Cooler cooling continuously See Protective temperature switch L1-TS1 shuts down the
crusher.
Incorrect temperature reading Check the temperature indicator against a reference
thermometer.

3.5. The CSS varies or the product is

oversized

Possible cause Corrective action

Pressure relief valve If there are overload pressure peaks, check the feed arrangement
leaking. and the crushing chamber. Remove any obstacles.
Setting increase has
caused oil level to rise in
the Hydroset tank
Concave ovality Check the CSS at four points evenly spaced around the crushing
chamber, see section Checking the CSS with lead on page 29. The
difference between the largest and smallest reading is an indication
of the ovality.
If ovality is detected, contact maintenance personnel.

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3.6. The pinionshaft does not operate

correctly

Possible cause Corrective action

Vibration in crusher, pinionshaft housing or If applicable: Clean off any dust from the V-belts.
motor

3.7. The crusher sounds different

Possible cause Corrective action

“Grating” step bearing components Reduce the crusher's operating load.
Check the contamination in the return oil screen L1-OS1 see
section Checking the condition of the lubrication oil on page
25.
If the contamination has increased, contact maintenance
personnel.
Packing in crushing chamber Check the operating conditions and the CSS. Increase
Mantle and concave in “metal-to- the CSS.
metal” contact

3.8. The crusher's capacity drops

Possible cause Corrective action

“Ski-slopes” on mantle Check the feed arrangement. Make sure the crusher is choke fed.
and concave Check the largest and smallest sizes of material fed to the crusher.
There must not be a large proportion of material smaller than the
CSS. See section Checking the CSS with lead on page 29. Also
refer to the Installation instructions.
If applicable: V-belts Clean off any dust from the V-belts.
slipping
Feed material or Altered fraction length and material hardness can lead to capacity
composition has been changes. Refer to the Installation instructions.
changed
Bridging or blocking in Check the material level in the feed hopper. If possible, limit the top
crushing chamber size of the feed.

3.9. A bearing in the crusher fails

Possible cause Corrective action

High temperature or local Check for lead flakes in the return oil screen L1-OS1, see
overheating and partial seizure in section Checking the condition of the lubrication oil on page
bushings or step bearing 25.
components If the there are lead flakes, contact maintenance personnel.

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3.10. The oil is contaminated

Possible cause Corrective action

Contamination on the return oil Check the contamination in the return oil screen L1-OS1,
screen: see section Checking the condition of the lubrication oil
• Swarf on page 25.
• Needle-like particles If the contamination has increased, contact maintenance
• Lead flakes personnel.
• Bronze particles
• Dirt

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