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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 222.166 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
CJ211:01
1
Sandvik SRP AB Doc. no. S 222.166 en Ver. 1
Table of contents
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
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
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
CJ211:01
3
Sandvik SRP AB Doc. no. S 222.166 en Ver. 1
Table of contents
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
5
Sandvik SRP AB Doc. no. S 222.166 en Ver. 1
1. Introduction
CJ211:01
1. Introduction
Identification
The figure below shows an example of the crushers 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
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
7
Sandvik SRP AB Doc. no. S 222.166 en Ver. 1
1. Introduction
CJ211:01
1. Introduction
1
1
2
3
4
5
6
Flywheel
Cheek plate
Moving jaw
Stationary jaw
Eccentric shaft
Toggle plate
2
3
4
6
CJ211:01
9
Sandvik SRP AB Doc. no. S 222.166 en Ver. 1
1. Introduction
1.2.1 Description
The following figures show an overview of the jaw crushers 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
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
CJ211:01
1. Introduction
Top view with drive and guards
20
21
22
23
20
21
22
23
CJ211:01
11
1. Introduction
12
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.
CJ211:01
13
2. Safety precautions
General danger
Dangerous voltage
Risk of crushing
Hanging load
Risk of crushing
Flying fragments
Do not remove
guards
Disconnect current
before any work
14
CJ211:01
2. Safety precautions
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
Operators 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.
CJ211:01
15
2. Safety precautions
Ear protection
Safety helmet
Eye protection
Protective gloves
Safety boots
Mask or breathing
apparatus
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)
16
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!
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 crushers feed
opening. Walkways, stairs and ladders must be designed in accordance with
applicable regulations. (These parts are not included in the crushers 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.
CJ211:01
17
2. Safety precautions
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!
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.
CJ211:01
2. Safety precautions
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!
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.
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!
CJ211:01
19
2. Safety precautions
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!
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.
20
CJ211:01
2. Safety precautions
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!
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.
CJ211:01
21
2. Safety precautions
22
CJ211:01
3. Technical data
CJ211:01
23
3. Technical data
Data
Model
CJ211
Type
Jaw crusher
Application
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
Data
1.10 0.70 m
CSS
minmaxa
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.
24
CJ211:01
CJ211:01
25
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.
Check that the jaw crushers 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 crushers flywheels is correct (see figure).
right
wrong
26
CJ211:01
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.
CJ211:01
27
28
CJ211:01
CJ211:01
29
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.
30
CJ211:01
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 crushers 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
Tighten if necessary.
5.4
40 operating hours
80 operating hours
6.1
6.1, 10.1
Refill if necessary.
10.1
CJ211:01
6.1, 10.1
5.5
Replace damaged bolts.
6.1, 10.1
31
32
Tool
Included
in tool kit
Used for
Yes
Setting measurement
Lifting tool
Yes
Slugging wrench 46 mm
Yes
Combination wrench 46 mm
Yes
Combination wrench 30 mm
Yes
Support bars
Combination wrench 36 mm
No
Cheek plates
Combination wrench 24 mm
No
Deflector plate
Crow bar
No
Jaw plates
Props, 2 pcs
No
Jaw plates
No
Bearings
No
Cheek plates
No
Mobile crane
No
Protective gloves
No
CJ211:01
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 its 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 wont help, it is time to exchange the jaw plate.
NOTE!
CJ211:01
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
3200-0
34
CJ211:01
1104-0
1104-0
1103-0
CJ211:01
1103-0
35
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.
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
CJ211:01
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
Data
Diameter
45 to 135 mm
CJ211:01
37
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.
CJ211:01
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!
The handling of lubricants is associated with fire and health risks. Always
follow your suppliers instructions and safety regulations.
Qty.
Remarks
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!
In low temperatures (below 0C), 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 Lubrication distributor
2 Greasing nipple
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.
CJ211:01
41
6. Lubrication
Test method
Requirements
NLGI value
DIN 51 818
2 or 3
Drop point
180
170
100
Mechanical stability
Approved
Corrosion resistance
Approved
Temperature range
Speed range
30C to +110C
Must lubricate effectively throughout the bearings entire operating
speed range
Viscosity index
at least 80
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.
CJ211:01
43
7. Crushing chamber
NOTE!
Cat. no.
Qty.
Remarks
Clamping bar
1210-0
1211-0
stationary jaw
1211-1
stationary jaw
Washer D95/3510
1211-5
stationary jaw
Flexible washer
1211-6
stationary jaw
Clamping bar
3400-0
3401-0
moving jaw
3401-1
moving jaw
Washer D95/3510
3401-5
moving jaw
Flexible washer
3401-6
moving jaw
These instructions are valid for both moving and stationary jaw. The pictures
describe the moving jaw.
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).
CJ211:01
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
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
WARNING!
Description
Cat. no.
Qty.
Remarks
Jaw plate
1208-1
Jaw plate
3300-1
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!
These instructions are valid for both moving and stationary jaw. The pictures
describe the moving jaw.
NOTE!
Remove the clamping bar before removing a jaw plate. See section
7.1.1 Removing clamping bar.
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.
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
47
7. Crushing chamber
CAUTION!
Replace the support bar screws if they are broken. Remove the support
bar and clean it carefully. Its 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
3200-0
NOTE!
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!
CJ211:01
49
7. Crushing chamber
Cat. no.
Qty.
Remarks
Wear plate
1300-0
Wear plate
3100-0
NOTE!
These instructions are valid for both moving and stationary jaw. The pictures
describe the moving jaw.
NOTE!
Remove the jaw plate before removing a wear plate. See section
7.2.1 Removing jaw plate.
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).
1
3000-0
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
CJ211:01
51
7. Crushing chamber
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
CJ211:01
7. Crushing chamber
NOTE!
Description
Cat. no.
Qty.
Support bar
1205-0
Remarks
stationary jaw, weight 37 kg
1206-0
1206-1
1206-2
Support bar
3200-0
3201-0
3201-1
3201-2
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.
3200-0
3201-0
3000-0
3201-2
3201-1
Support bar
Screw
Jaw (moving)
Washer
Self-locking nut
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
Re-tighten the nuts after 2 and 4 operating hours and then according to
section 5.2 Routine inspection and care.
NOTE!
Cat. no.
Qty.
Remarks
weight 160 kg
Deflector plate
3500-0
3502-0
3502-2
Locating pad
3503-0
Remove the clamping bar before removing the deflector plate. See section
7.1.1 Removing clamping bar.
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.
3500-0
3502-0
3502-2
3503-0
3000-0
1
Deflector plate
Screw
Washer
Locating pad
Jaw (moving)
Lifting eye
1
3500-0
3502-0
3502-2
3503-0
3000-0
(Continued)
CJ211:01
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
Deflector plate
Screw
Washer
Locating pad
Jaw (moving)
Lifting eye
1
3500-0
3502-0
3502-2
3503-0
3000-0
CJ211:01
7. Crushing chamber
Qty.
Cheek plate
1103-0
Remarks
left-hand side, weight 225 kg
Cheek plate
1104-0
1106-0
1106-1
Flexible washer
1106-4
1106-5
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
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 dont 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!
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.
CJ211:01
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.
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
60
CJ211:01
7. Crushing chamber
Cat. no.
Qty.
1302-0
Remarks
stationary jaw, weight 240 kg
3102-0
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.
Jaw (moving)
Jaw shim plate
Support bar
Lifting eye
Double slot
support bar
3 Single slot
support bar
1
3000-0
2
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)
CJ211:01
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
CJ211:01
7. Crushing chamber
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
3102-0
3200-0
(Continued)
CJ211:01
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
Jaw (moving)
Jaw shim plate
Support bar
Lifting eye
Double slot
support bar
3 Single slot
support bar
1
3000-0
2
3102-0
3200-0
64
CJ211:01
CJ211:01
65
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!
small setting =
smaller fragments
large setting =
larger fragments
66
CJ211:01
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!
67
68
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).
CJ211:01
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
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
Horizontal
135155 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.
CJ211:01
69
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!
i)
70
If necessary, measure the CSS. See section 5.6 Setting measurement. See
section 5.6 Setting measurement.
CJ211:01
If the jaw crusher is equipped with the setting hydraulics option, this section
replaces section 8.4 Hand pump.
1
2
3
1 Display
2 Mode button
3 Arrow buttons
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)
CJ211:01
71
mode
mode
3s
2s
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
CJ211:01
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!
CJ211:01
73
Never run the crusher without hydraulic pressure for pre-load of the retraction cylinder. Insufficient retraction might damage the toggle or retraction system.
CAUTION!
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.
74
CJ211:01
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.
CJ211:01
75
9. Troubleshooting
Fault
Check
Corrective action
Is there a jam
Drive
76
Jaw crusher
stops
Rotation speed
fluctuates
Imbalance
CJ211:01
9. Troubleshooting
No.
Fault
Check
Corrective action
Vibrations
10
11
Toggle plate
moves
Cant change
Is there a jam in the crushing
discharge setting chamber
Wrong fragment
size
Retraction cylinder
Setting wedges
12
Overload
Are there excessive fines con- Feed material with distributed coarseness.
tent in the feed material
CJ211:01
77
9. Troubleshooting
78
CJ211:01
CJ211:01
79
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!
The handling of lubricants is associated with fire and health risks. Always
follow your suppliers instructions and safety regulations.
For the automatic lubricator with supplied hoses, the operating temperature
must be between 25C and 60C.
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!
80
CJ211:01
PAUSE
h/lmp
CONTACT
min/lmp
SET
CS
DK
PS
FAULT
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)
CJ211:01
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.
82
CJ211:01
CJ211:01
When the fault LED (13) is lit, press the DK button (12) to acknowledge and
delete fault messages.
83
Test method
Requirements
NLGI value
DIN 51 818
2 or 3
Drop point
180
170
100
Mechanical stability
Approved
Corrosion resistance
Approved
Temperature range
Speed range
30C to +110C
Must lubricate effectively throughout the bearings entire operating
speed range
Viscosity index
at least 80
84
CJ211:01
maintenance manual
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
CJ211:01
20
20
20
20
21
22
23
23
Table of contents
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 ...............................
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
1. Introduction
CJ211:01
1. Introduction
Identification
The figure below shows an example of the crushers 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
2
1
2
3
4
5
6
7
8
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
1. Introduction
CJ211:01
1. Introduction
1.1.2 Description
The following drawings show an overview of the jaw crushers 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
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
1. Introduction
Top view with drive and guards
20
21
22
23
20
21
22
23
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.
CJ211:01
2. Safety precautions
General danger
Dangerous voltage
Risk of crushing
Hanging load
Risk of crushing
Flying fragments
Do not remove
guards
Disconnect current
before any work
10
CJ211:01
2. Safety precautions
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
Operators 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.
CJ211:01
11
2. Safety precautions
Ear protection
Safety helmet
Eye protection
Protective gloves
Safety boots
Mask or breathing
apparatus
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!
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 crushers feed
opening. Walkways, stairs and ladders must be designed in accordance with
applicable regulations. (These parts are not included in the crushers 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.
CJ211:01
13
2. Safety precautions
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!
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. Safety precautions
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!
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.
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!
CJ211:01
15
2. Safety precautions
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!
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.
16
CJ211:01
2. Safety precautions
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!
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.
CJ211:01
17
2. Safety precautions
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.
CJ211:01
19
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.
Instruction
Note
4.1
6 000
4.4
4.2
4.3
Worn > 3 mm
6.1
> 15 000
6.1
> 20 000
Worn 20 mma
20
CJ211:01
CJ211:01
Description
Cat. no.
Quantity
See section
Retraction cylinder
7050-0
4.1
Piston pin
7051-0
4.1
7052-0
4.1, 4.4
7052-2
4.1
Cylinder pin
7053-0
4.1
Toggle plate
5006-0
4.4
5004-0
4.4
5005-0
4.4
Setting wedge
6300-0
4.2
Hydraulic cylinder
6320-0
4.2
Guide plate
6310-0
4.3
6311-0
12
4.3
6311-2
12
4.3
Flywheel, flat
2205-0
5.1
Flywheel, grooved
2206-0
5.1
2006-0
6.1.4
V-ring
2010-1
6.1.4
V-ring
2007-1
6.1.4
2101-0
6.1.6
V-ring
2104-1
6.1.6
21
22
Tool
Used for
Bushing press
Chain block
20 mm Round iron
Wooden wedges
Chopping bit
Flywheels
Flywheels
18 mm Combination wrench
Flywheels
Extractor
Flywheels
Flywheels
Deep gauge
Flywheels
Dial indicator
Flywheels
Hammer
Hook wrench
Moving jaw
Frame bearings
Frame bearings
Soft hammer
Frame bearings
Feeler gauge
Frame bearings
Gas torch
Frame bearings
Sledge hammer
Copper punch
Crow bar
Lifting sling
Mobile crane
CJ211:01
mm
Nm
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
CJ211:01
23
24
CJ211:01
CJ211:01
25
Cat. No.
Qty.
Remark
Retraction cylinder
Piston pin
7050-0
7051-0
7052-2
Cylinder pin
7053-0
7051-0
26
7052-2
7050-0
7053-0
CJ211:01
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
CJ211:01
7051-0
7052-2
7050-0
7053-0
27
NOTE!
Description
Cat. No.
Qty.
Remark
Setting wedge
6300-0
weight 135 kg
Hydraulic cylinder
6320-0
weight 35 kg
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 crushers 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.
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)
CJ211:01
29
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.
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!
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
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
CJ211:01
31
Cat. No.
Qty.
Remark
Guide plate
6310-0
Original thickness 16 mm
6311-0
12
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.
6311-0
6311-2
6310-0
1
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.
Apply a crow bar if the guide plates (6310-0) get stuck. Never use arms or
feet.
Screw
Washer
Guide plate
Back frame end
1
6311-0, 6311-2
6310-0
CJ211:01
33
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
weight 160 kg
5004-0
weight 25 kg
5005-0
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!
CAUTION!
The crusher must be stopped and the retraction assembly must be removed when exchanging the toggle plate and toggle seats.
5013-2
5014-0
5003-0
5018-0,
5019-0
5004-0
5006-0
5005-0
3000-0
34
CJ211:01
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.
CJ211:01
35
5
6
5 Round iron
6 Hole
5006-0 Toggle plate
5006-0
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
5013-2
5014-0
5003-0
5018-0
5019-0
5004-0
5006-0
5005-0
3000-0
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)
CJ211:01
37
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
5006-0
5005-0
3000-0
(Continued)
38
CJ211:01
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
Cat. No.
Qty.
Remark
Flywheel, flat
2205-0
weight 850 kg
Flywheel, grooved
2206-0
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 flywheels 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!
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
DANGER!
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 extractors (6) studs into the threaded holes (3) in the
flywheel.
n) Loosen the flywheels 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
CJ211:01
5. Flywheels
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!
WARNING!
Risk of crushing
Exposure to rotating parts of the equipment shall be prevented by
guards. Always attach guards after maintenance work.
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
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.
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
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
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!
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)
50
CJ211:01
6. Bearings
NOTE!
Lift out the moving jaw before removing the frame bearing. See section
6.1.1 Removing moving jaw.
NOTE!
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
2006-0
2000-0
2006-0
2006-1
2009-0
2010-0
2201-4
2200-0
2008-0
2010-1
2011-0
2201-0
2006-1 2009-0
2010-0
2201-4
2000-0
2200-0 2008-0 2010-1 2011-0 2201-0
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!
High pressure
Oil that sprays out with high pressure is very dangerous. Any leakage
in the hydraulic system must immediately be repaired.
2007-0
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
Qty.
2006-0
V-ring
2010-1
V-ring
2007-1
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
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
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
CJ211:01
6. Bearings
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!
CAUTION!
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
2200-0
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 doesnt 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
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.
2101-0
V-ring
2104-1
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.
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
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
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 crushers 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
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.
Overview
6.
3.
1.
4.
5a. 5b.
7.
2.
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
400.0612-901
Alternative
Description
7021-0
840.0667-00
7021-2
847.0124-00
7050-0
400.1161-901
908.0481-00
7051-0
400.1154-901
Piston Pin
7052-2
847.0323-00
7053-0
400.1154-902
Cylinder pin
Remarks
6331-0, 6331-2
6330-0
6333-0, 6333-2
6320-0
6300-0
6301-0, 6301-2
Qty.
Part number
6300-0
400.2180-001
Setting wedge
6301-0
400.0856-001
6301-2
855.0014-00
6320-0
400.0753-901
908.0480-00
6330-0
400.0852-901
Cylinder bracket
6331-0
840.0650-00
6331-2
847.0165-00
6333-0
840.0065-00
6333-2
400.0839-001
Washer
Alternative
Description
Remarks
3. Guide plates
6311-0, 6311-2
6310-0
Guide plates
Cat. no.
Qty.
Part number
6310-0
400.0611-001
6311-0
12
841.0574-00
6311-2
12
847.0132-00
Alternative
Description
Remarks
Guide plate
5013-2
5014-0,
5014-2
5003-0
5018-0
5019-0,
5019-2
5006-0
5005-0
5004-0
Remarks
Qty.
Part number
Alternative
Description
5006-0
400.0549-001
L=600 mm
Toggle plate
L=640 mm
Toggle plate
400.0549-002
5003-0
400.0603-001
5004-0
400.0548-001
5005-0
400.0548-001
5013-2
400.0707-002
5014-0
840.0046-00
5014-2
847.0147-00
5018-0
400.0707-001
Side block
5019-0
840.0046-00
5019-2
847.0147-00
2201-4
2209-1 2208-0
2210-0 2209-4
2207-0
2010-0
2009-0,
2009-2 2006-1
2006-0
2200-0
Qty.
Part number
Description
Remarks
2006-0
868.0756-00
Alternative
Roller bearing
Outer bearing
2006-1
868.0755-00
Sleeve AOH
2008-0
10-314-515-000
Labyrinth cover
2009-0
24
840.0068-00
2009-2
24
847.0016-00
2010-0
10-314-516-000
Labyrinth ring
2010-1
873.1008-00
V-ring V-250A
2011-0
79-401-252-001
Key
2200-0
400.0545-001
Eccentric shaft
2201-0
845.0168-00
2201-4
847.0096-00
2207-0
59-425-417-009
Key
2208-0
53-467-374-000
Spacer ring
2209-1
845.0161-00
2209-4
847.0173-00
2210-0
53-367-328-500
Cover
2211-0
840.0044-00
2211-2
847.0180-00
Washer 1324
2007-1
2103-0,
2103-2
2007-0
2102-0
2101-0
Qty.
Part number
2007-0
10-314-514-000
Labyrinth ring
2007-1
873.1008-00
V-ring V-250A
2101-0
868.0522-00
Roller bearing
2102-0
10-314-512-000
Labyrinth cover
2103-0
24
840.0068-00
2103-2
24
847.0016-00
2104-0
10-314-513-000
Labyrinth ring
2104-1
873.1008-00
V-ring V-250A
10
Alternative
Description
Remarks
Inner bearing
6. Flywheels
2212-0
2213-0,
2213-2
2205-0
2206-0
Qty.
Part number
2205-0
400.0554-001
Flywheel flat
2206-0
400.0554-002
Flywheel 105V
400.0554-003
Flywheel 7SPC
2212-0
400.0786-001
Counterweight
2213-0
840.0653-00
2213-2
847.0165-00
Alternative
Description
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
53-273-771-500
2000-1
10-215-286-500
2004-0
16
840.1188-00
2004-2
16
847.0312-00
2004-7
53-373-766-000
2200-0
400.0545-001
Eccentric Shaft
12
Alternative
Description
Remarks
8. Driving arrangement
3
2
Pos no.
Qty.
Sets
Part number
Alternative
Description
400.1384-901
400.1385-901
Bushing alt
400.1383-901
V-belt alt
Remarks
13
9. Frame
Pos no.
14
Qty.
Sets
Part number
Alternative
Description
400.0537-901
Frame assembly
400.0910-901
Feet assembly
Remarks
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
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 crushers 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 Machine type
2 Serial number
Think ahead!
Avoid unnecessary downtime and increased freight charges by ordering parts
well in advance.
CJ211:01
1211-2
1211-6
1210-0
1211-2
1211-3
Qty.
Part number
Alternative
Description
Remarks
1210-0
400.0556-001
Clamping bar
1211-0
840.1074-00
1211-0
840.1003-00
1211-2
89-442-690-013
Washer D95/3510
1211-3
845.0284-00
1211-6
53-469-936-000
Flexible washer
3400-0
3401-2
3401-6
3401-0
3401-2
3401-3
Qty.
Part number
3400-0
400.0556-001
Clamping bar
3401-0
400.1138-001
3401-2
89-442-690-013
Washer D95/3510
3401-3
845.0284-00
3401-6
53-469-936-000
Flexible washer
Alternative
Description
Remarks
CJ211:01
3500-0
3502-0
3502-2
3503-0
Qty.
Part number
Description
Remarks
3500-0
400.0575-001
Alternative
Deflector plate
moving jaw
3502-0
840.0068-00
3502-2
847.0016-00
3503-0
400.0749-001
Locating bar
3507-0
3508-0
3508-0
3506-0
3506-2
3506-3
3505-0
Qty.
Part number
Description
Remarks
3505-0
400.1166-001
Alternative
Option
3506-0
840.0080-00
3506-2
847.0017-00
3506-3
845.0203-00
Self-locking nut
3507-0
400.1165-001
Deflector bracket
3508-0
840.0668-00
Screw 24x65
3508-2
847.0124-00
CJ211:01
Jaw plates
1208-1
3300-1
Jaw plates
Cat. no.
Qty.
Part number
1208-1
3300-1
Alternative
Description
400.2207-001
C, M1
400.2207-002
C, M2
Remarks
corrugated, material M1
corrugated, material M2
400.0739-001
ST, M1
400.0739-002
ST, M2
400.1101-001
C, M1
400.1101-002
C, M2
corrugated, material M1
corrugated, material M2
400.0738-001
ST, M1
400.0738-002
CC, M2
(Continued)
CJ211:01
Stationary jaw
Moving jaw
Corrugated
C
Sharp teeth
ST
CJ211:01
Wear plates
3100-0
1300-1
Wear plates
Cat. no.
Qty.
Part number
Alternative
Description
Remarks
1300-0
400.0830-001
10 mm
Wear plate
3100-0
400.0830-001
10 mm
Wear plate
1202-0
3102-0
Qty.
Part number
Alternative
Description
Remarks
1202-0
400.0830-002
30 mm
3102-0
400.0830-002
30 mm
CJ211:01
Support bars
1206-1
1206-2
1206-0
3201-2 3201-1
Qty.
Part number
1205-0
400.0543-001
400.1118-001
Alternative
Description
Remarks
single slot
Support bar
double slot
Support bar
1206-0
840.0656-00
stationary jaw
1206-1
845.0203-00
stationary jaw
stationary jaw
1206-2
847.0132-00
3200-0
400.0543-001
single slot
Support bar
400.1118-001
double slot
Support bar
moving jaw
3201-0
840.0656-00
3201-1
845.0203-00
moving jaw
3201-2
847.0132-00
moving jaw
CJ211:01
Cheek plates
1104-0
1103-0
1103-0
1106-0
1106-4
1106-5
1106-1
Qty.
Part number
Alternative
Description
Remarks
1103-0
400.0639-001
Cheek plates
left-hand side
1104-0
400.0639-001
Cheek plates
right-hand side
1106-0
10
840.0675-00
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
both sides
10
CJ211:01
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
RX11 - 15
Sandvik Mining and Construction Oy, Keskikankaantie 19, FI-15860 Hollola, Finland
Tel. +358 205 44 181, Fax +358 205 44 180
Equipment type
VIBRATING FEEDER
Equipment number
Manufacturing year/month
CONTENTS
page
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
19
19
19
19
2
8.1 GENERAL
19
3
3
3
3
3
9 IN CASE OF EMERGENCY
19
19
19
10 ASSEMBLY DRAWING
19
4
4
5
19
6
7
8
5 DEVICE OPERATING
5.1 OPERATION
5.2 SYSTEM CONDITIONS
5.3 SAFETY INSTRUCTIONS
9
9
9
6 MAINTENANCE INSTRUCTIONS
10
FEEDBACK
Vibrating feeder
1.5 SAFETY
1.6 GUARANTEE
ATT!
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.
Vibrating feeder
2
4
1
2
3
4
5
6
3.2 INSTALLATION
A Supporting structures
Vibrating feeder
!
!
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.
ATTENTION!
Vibrating feeder
Running empty
Running with material under supervision.
SANDVIK
Feeder
type
SV1032
SV1232
SV1532
SV1832
SV2132
SV2432
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
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
C
1020
1220
1520
D
2200
2400
2700
E
2480
2680
2980
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
m
22
23
25
27
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
Vibrating feeder
2
4
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
Vibrating feeder
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
Vibrating feeder
6 MAINTENANCE INSTRUCTIONS
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
Strength class
M12
M16
M20
M24
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
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
Stroke
frequency
1020 rpm
920 rpm
820 rpm
730 rpm
Stroke length
SV-feeder
8 mm
10 mm
13 mm
16 mm
10
ATT!
SANDVIK
Example:
Stroke length
12 mm
Stroke angle
55 degrees
-0.5x (nmin+nmax)
Vibrating feeder
11
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
12
C Replacing
Damaged or worn-out parts should be replaced for
instance in the following cases:
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
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.
13
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
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
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.
Vibrating feeder
14
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
34
R=177,8
H=129
11,7
13,5
15,3
17,2
POINT
Bearing damage.
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.
Type of operation
In one shift operation
In two- and three shift
operation
Interval
Half-yearly
After 2000 hours of
operation or half-yearly
B Motor
oil levels
condition of wear plates
condition of grizzly bars
condition of springs
bolts joints (visual inspection)
Vibrating feeder
15
1
2
Possible cause
Electrical fault
Hydraulic coupling
without oil or oil level
too low (where
applicable).
Correction
Check and correct
Fill the coupling
according to
instructions. Check
also the condition of
the heat plug.
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.
3
4
Correction
Arrange space for
feeder to run
properly.
Change and adjust
the clearance hole
according to
instructions.
Move and adjust
according to
instructions given.
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.
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.
Support base.
Possible cause
There are loose or
damaged parts in the
feeder
3
4
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
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
Possible cause
Normal life span of the
bearing is exceeded.
Insufficient lubrication.
3
4
Unsuitable oil.
Foreign material (steel,
sand etc.]in oil
1
2
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.
Possible cause
Incorrect loading of the
feeder.
Vibrating feeder
2
3
Correction
See item J.
Adjust loading rate.
Arrange feed as per
6.2.
Possible cause
Adjustment values are
incorrect
Correction
Correct adjustments
according to
instructions (point
6.2)
Correct loading
according to
instructions (point
4.1)
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.
Possible cause
Feed or discharge
chutes are unsuitable
or incorrectly installed.
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..
1
2
Possible cause
Leakage in the dust
enclosure.
Insufficient suction in
the dust enclosure.
Correction
Seal the enclosure.
Increase suction
inside the enclosure
to regain lowpressure inside it.
17
Possible cause
Fastening screws in
the springsystem
loose.
Correction
Tighten and change if
necessary.
Vibrating feeder
18
SV
Spring HF654
Filter
1y
1
2y
2
SV
1y
2
1
2
1
1
2y
4
2
4
2
1
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
Shaft sealing
V-ring sealing
O-ring set
Wear ring
Bearing
Length
900 mm
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).
Vibrating feeder
Vibrating feeder
Vibrator mechanism
Drive unit
Spring supporting
Grizzly bars
19
ENCLOSURE 1
DATE
INSPECTORS
MARK EXPLANATION:
A
B
C
D
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.
To be done again
Done
Mark
A
D
Remarks
D
D
assembly and
maintenance
instruction
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
Author:______________________________
Description
of maintenance work
Author:______________________________
Description
of mainte
nance work
Author:______________________________
Description
of mainte
nance work
Vibrating feeder
21
ENCLOSURE 3
Author:______________________________
Damage
description
Author:______________________________
Damage
description
Author:______________________________
Damage
description
Vibrating feeder
22
FEEDBACK FORM
ENCLOSURE 4
1 COMPONENTS
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.)
Vibrating feeder
23
ENCLOSURE 5
DATE
AUTHOR
TEL
FAX
Code
Quantity
OTHER INFORMATION
Vibrating feeder
24