04.CH440-03 Maintenance Instructions S223.1239-05.En

Original instructions
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Maintenance Instructions
CH440:03
This publication is copyright of Sandvik – © Sandvik 2015.
It must not be copied*, reproduced or otherwise made available in full or in part to any third party
without Sandvik's prior written consent.
All rights reserved.
* The maintenance checklists in the Maintenance Instructions and Operator's Instructions may be
copied solely for maintenance purposes of Sandvik equipment.
Document number: S 223.1239

Version: 5
Language: en-US
Issue: 10/01/2019
Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
WARNING!
IGNORANCE HAZARD
You can sustain personal injuries or even die if you ignore instructions.
Follow the instructions in the manual when you carry out any work on the
equipment and when you operate it. If anything is unclear, please contact
your local Sandvik representative.
Copyright © Sandvik
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Table of contents
1. Basic maintenance instructions

1.1. Clearing out the crushing chamber..............................................12
1.2. Plastic backing.............................................................................12
1.2.1. Backing procedure........................................................... 12
1.2.2. Hygienic aspects and protective measures......................13
1.3. Accumulators............................................................................... 13
1.3.1. General accumulator information..................................... 13
1.3.2. Flow regulator.................................................................. 14
1.3.3. Charging kit (option).........................................................15
1.3.3.1. Checking the gas pressure.................................. 15
1.3.3.2. Charging with nitrogen.........................................16
2. Periodic maintenance
2.1. Determining inspection and maintenance intervals..................... 20
2.2. Inspection and care when it is dark............................................. 20
2.3. Weekly inspection and care.........................................................20
2.4. Monthly inspection and care........................................................ 20
2.5. Inspection and care for every 6 months.......................................21
2.6. Yearly inspection and care...........................................................22
3. Maintenance instructions
3.1. Feed hopper................................................................................ 24
3.1.1. Replacing the feed hopper............................................... 24
3.1.1.1. Removing the feed hopper.................................. 24
3.1.1.2. Inspecting the feed hopper.................................. 25
3.1.1.3. Installing the feed hopper.................................... 25
3.2. Topshell........................................................................................27
3.2.1. Replacing the spider cap..................................................28
3.2.1.1. Removing the spider cap..................................... 28
3.2.1.2. Spider cap removal checks..................................29
3.2.1.3. Installing the spider cap....................................... 31
3.2.2. Installing the spider cap................................................... 32
3.2.3. Inspecting the crushing chamber..................................... 33
3.2.3.1. Inspecting the liners.............................................34
3.2.3.2. Inspecting the concave and mantle..................... 34
3.2.4. Replacing the spider bushing and the seal ring............... 34
3.2.4.1. Removing the spider bushing and the seal ring...34
3.2.4.2. Checking the spider bushing and the seal ring....36
3.2.4.3. Installing the spider bushing and the seal............36
3.2.5. Checks prior to removal of the top shell...........................38
3.2.6. Replacing the top shell.....................................................38
3.2.6.1. Removing the top shell........................................ 38
3.2.6.2. Checking the top shell......................................... 40
3.2.6.3. Installing the top shell.......................................... 41
3.2.7. Replacing the concave ring..............................................43
3.2.7.1. Removing the concave ring................................. 44
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Table of contents
3.2.7.2. Installing the concave ring................................... 46

3.2.8. Replacing the filler ring.....................................................49
3.2.8.1. Removing the filler ring........................................ 50
3.2.8.2. Inspecting the filler ring........................................51
3.2.8.3. Installing the filler ring.......................................... 52
3.2.9. Replacing the arm shields................................................53
3.2.9.1. Removing the arm shields................................... 53
3.2.9.2. Installing the arm shields..................................... 54
3.3. Mainshaft..................................................................................... 55
3.3.1. Replacing the main shaft and the mantle.........................55
3.3.1.1. Removing the main shaft assembly.....................55
3.3.1.2. Checking the main shaft and the mantle............. 56
3.3.1.3. Installing the main shaft assembly ......................57
3.3.2. Replacing the head nut.................................................... 59
3.3.2.1. Removing the head nut........................................59
3.3.2.2. Checking the head nut.........................................61
3.3.2.3. Installing the head nut..........................................62
3.3.2.4. Removing the inner head nut...............................65
3.3.2.5. Installing the inner head nut.................................66
3.3.3. Replacing the mantle....................................................... 67
3.3.3.1. Checking the play between the head center and
the mantle......................................................................... 67
3.3.3.2. Removing the mantle...........................................68
3.3.3.3. Installing the mantle.............................................69
3.3.4. Replacing the mainshaft sleeve....................................... 72
3.3.4.1. Inspecting the mainshaft sleeve.......................... 72
3.3.4.2. Removing the mainshaft sleeve...........................73
3.3.4.3. Installing the mainshaft sleeve.............................78
3.3.5. Inspecting the head center...............................................84
3.3.6. Replacing the mainshaft step...........................................85
3.3.6.1. Removing the mainshaft step.............................. 85
3.3.6.2. Inspecting the mainshaft step.............................. 87
3.3.6.3. Installing the mainshaft step................................ 87
3.3.7. Replacing the dust seal ring.............................................88
3.3.7.1. Removing the dust seal ring................................ 89
3.3.7.2. Checking the dust seal ring................................. 92
3.3.7.3. Installing the dust seal ring.................................. 93
3.3.8. Replacing the scraper...................................................... 95
3.3.8.1. Checking the scraper...........................................95
3.3.8.2. Removing and installing the scraper....................96
3.4. Dust collar....................................................................................97
3.4.1. Replacing the dust collar..................................................97
3.4.1.1. Removing the dust collar..................................... 97
3.4.1.2. Inspecting the dust collar..................................... 98
3.4.1.3. Installing the dust collar....................................... 99
3.4.2. Replacing the seating ring..............................................100
3.4.2.1. Removing the seating ring................................. 101
3.4.2.2. Installing the seating ring................................... 101
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3.4.3. Replacing the locating bar..............................................102

3.4.3.1. Checking the locating bar clearance..................102
3.4.3.2. Removing the locating bar................................. 103
3.4.3.3. Installing the locating bar................................... 103
3.5. Eccentric.................................................................................... 104
3.5.1. Replacing the eccentric bushing.................................... 104
3.5.1.1. Removing the eccentric bushing........................105
3.5.1.2. Removing the eccentric bushing - Alternative
method............................................................................107
3.5.1.3. Inspecting the eccentric bushing....................... 108
3.5.1.4. Installing the eccentric bushing..........................109
3.5.2. Replacing the eccentric assembly..................................110
3.5.2.1. Removing the eccentric assembly..................... 110
3.5.2.2. Inspecting the eccentric assembly..................... 112
3.5.2.3. Installing the eccentric assembly....................... 113
3.5.3. Replacing the eccentric hub and gear............................113
3.5.3.1. Removing the eccentric hub and gear............... 114
3.5.3.2. Inspecting the eccentric hub and gear............... 117
3.5.3.3. Installing the eccentric hub and gear................. 117
3.5.4. Replacing the eccentric wearing plate........................... 120
3.5.4.1. Inspecting the eccentric wearing plate...............120
3.5.4.2. Removing the eccentric wearing plate...............121
3.5.4.3. Installing the eccentric wearing plate.................123
3.6. Bottomshell................................................................................ 124
3.6.1. Replacing the bottom shell bushing............................... 124
3.6.1.1. Removing the bottom shell bushing...................124
3.6.1.2. Installing the bottom shell bushing.....................125
3.6.2. Replacing the Hardox liners........................................... 126
3.6.2.1. Removing the Hardox liners.............................. 126
3.6.2.2. Installing the Hardox liners................................ 127
3.7. Hydroset cylinder....................................................................... 130
3.7.1. Replacing the Hydroset piston....................................... 130
3.7.1.1. Removing the Hydroset piston...........................130
3.7.1.2. Inspecting the Hydroset piston.......................... 132
3.7.1.3. Installing the Hydroset piston.............................132
3.7.2. Replacing the step bearing components........................133
3.7.2.1. Removing the step bearing components........... 133
3.7.2.2. Inspecting the step bearing components........... 137
3.7.2.3. Installing the step bearing components............. 139
3.7.3. Replacing the chevron packing...................................... 144
3.7.3.1. Removing the chevron packing......................... 144
3.7.3.2. Inspecting the chevron packing......................... 145
3.7.3.3. Installing the chevron packing........................... 146
3.7.4. Checking the torque of the Hydroset cylinder joints.......148
3.7.5. Replacing the Hydroset cylinder bushing.......................149
3.7.5.1. Removing the Hydroset cylinder bushing.......... 149
3.7.5.2. Inspecting the Hydroset cylinder bushing.......... 152
3.7.5.3. Installing the Hydroset cylinder bushing............ 152
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Table of contents
3.7.6. Replacing the Hydroset piston position transmitter

B1N/K1-GT1.............................................................................154
3.7.6.1. Removing the Hydroset piston position transmitter
B1N/K1-GT1................................................................... 154
3.7.6.2. Installing the Hydroset piston position transmitter
B1N/K1-GT1................................................................... 155
3.8. Hydroset system........................................................................ 155
3.8.1. Bleeding air from the Hydroset system ......................... 156
3.8.2. Checking the gas pressure............................................ 156
3.8.3. Relieving the Hydroset pressure.................................... 157
3.8.4. Replacing the hydraulic hose......................................... 158
3.8.4.1. Removing the hydraulic hose............................ 158
3.8.4.2. Inspecting the hydraulic hose............................ 159
3.8.4.3. Installing the hydraulic hose.............................. 159
3.8.5. Replacing the Hydroset oil filter..................................... 161
3.8.6. Checking the valves in the Hydroset control valve.........162
3.9. Pinionshaft housing................................................................... 163
3.9.1. Checking the oil flow to the pinionshaft housing............ 163
3.9.2. Replacing the pinionshaft housing assembly................. 164
3.9.2.1. Checks prior to removal.....................................164
3.9.2.2. Removing the pinion shaft housing assembly... 165
3.9.2.3. Inspecting the pinion shaft housing assembly... 168
3.9.2.4. Installing the pinion shaft housing assembly..... 168
3.9.3. Replacing the pinionshaft and the pinion....................... 172
3.9.3.1. Removing the crusher pulley - Only with V-belt
drive................................................................................ 172
3.9.3.2. Removing the pinion.......................................... 173
3.9.3.3. Removing the pinion shaft................................. 174
3.9.3.4. Removing the roller bearings and the spacers.. 179
3.9.3.5. Installing the roller bearings and the spacers.... 183
3.9.3.6. Installing the pinion shaft................................... 186
3.9.3.7. Installing the outer bearing cover.......................192
3.9.3.8. Installing the level tube and the discharge tube.194
3.9.3.9. Installing the inner bearing cover.......................196
3.9.3.10. Installing the pinion.......................................... 197
3.9.3.11. Installing the crusher pulley..............................198
3.9.3.12. Preparation for the installation of a complete
pinion shaft assembly..................................................... 201
3.9.4. Bevel gears.................................................................... 201
3.9.4.1. Checking the gear backlash.............................. 201
3.9.4.2. Adjusting the gear backlash...............................204
3.9.4.3. Determining the gasket thickness......................205
3.9.4.4. Tooth bearing “footprint”.....................................206
3.10. Dust seal air pressure system................................................. 207
3.10.1. Replacing the overpressure needle valve.................... 207
3.10.1.1. Removing the dust seal air pressure flow valve...
207
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Table of contents
3.10.1.2. Installing the dust seal air pressure needle valve

........................................................................................208
3.10.2. Flow valve setting.........................................................209
3.11. V-belt drive............................................................................... 210
3.11.1. Checking the V-belt tension..........................................210
3.11.2. Replacing the V-belt guards..........................................211
3.11.2.1. Removing the V-belt guards............................. 211
3.11.2.2. Installing the V-belt guards...............................212
3.11.3. Replacing the V-belts................................................... 212
3.11.3.1. Removing the V-belts....................................... 212
3.11.3.2. Installing the V-belts......................................... 213
3.11.4. Replacing the V-belt drive motor.................................. 215
3.11.4.1. Removing the V-belt drive motor......................215
3.11.4.2. Installing the V-belt drive motor........................216
3.11.5. Setting the V-belt speed monitor.................................. 217
3.11.6. Preparations before removing the pinionshaft housing...
217
3.11.7. Restoration after installing the pinionshaft housing......218
3.12. Lubrication systems................................................................. 218
3.12.1. Draining condensation water from the tanks................218
3.12.2. Setting the temperature switches.................................219
3.12.3. Checking the return oil temperature switch L1-TS3..... 220
3.12.4. Checking the main lubrication oil flow.......................... 220
3.12.5. Checking the temperature indicator L1-TI2..................221
3.12.6. Replacing the breather filter L1-FU2 ........................... 221
3.12.7. Changing the main lubrication oil................................. 222
3.12.7.1. Opening the tank covers..................................222
3.12.7.2. Closing the tank covers................................... 222
3.12.7.3. Draining the main lubrication oil tank...............223
3.12.7.4. Draining the Hydroset oil................................. 224
3.12.7.5. Draining the air/oil cooler................................. 224
3.12.7.6. Draining the pinion shaft lubrication system.... 225
3.12.7.7. Replacing the main lubrication oil filter............ 226
3.12.7.8. Replacing the pinionshaft lubrication oil filter...228
3.12.7.9. Cleaning the return oil screen..........................229
3.12.7.10. Cleaning the main lubrication tank.................230
3.12.7.11. Removing oil residues from the air/oil cooler. 231
3.12.7.12. Refilling the Hydroset oil................................ 233
3.12.7.13. Refilling the main lubrication system............. 234
3.13. Air-oil cooler.............................................................................235
3.13.1. Replacing the thermostatic element.............................235
3.14. Start-up after maintenance...................................................... 236
3.14.1. Checklist for an overhauled crusher.............................236
3.15. Starting up the crusher............................................................ 238
3.15.1. Preparing a tank that has been stored more than six
months..................................................................................... 238
3.15.2. Running-in....................................................................239
3.15.3. Replacing the filters for the first time............................242
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Table of contents
4. Maintenance personnel's troubleshooting

4.1. Problems and corrective actions................................................244
4.2. The crusher does not start.........................................................244
4.3. The crusher stops...................................................................... 244
4.4. The lubrication oil temperature is too high.................................245
4.5. The CSS varies or the product is oversized.............................. 246
4.6. The pinion shaft does not operate correctly.............................. 247
4.7. The crusher sounds different..................................................... 247
4.8. The crusher's capacity drops.....................................................248
4.9. The bearing component wear increases................................... 248
4.10. A bearing in the crusher fails................................................... 249
4.11. The main lubrication oil is contaminated..................................249
4.12. The Hydroset bolts are broken................................................ 250
4.13. The concave bolts are broken................................................. 250
4.14. The main lubrication oil capacity is low or non-existent...........250
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1. Basic maintenance
instructions
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1.1. Clearing out the crushing chamber

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

NOTICE Never start the crusher with a loose top shell.
If the crusher stalls with the crushing chamber full of material, clear it
out as follows:
a) Make sure that the crusher’s feeding arrangement is switched off.
b) If there is material in the discharge chute beneath the crusher,
remove the material.
NOTE! The automation system must be switched off to prevent
automatic main shaft regulation.
c) Use the CSS control box L1 to lower the main shaft, keeping an
eye on the Hydroset pressure.
d) If the Hydroset pressure drops below 0.3 MPa, then raise the main
shaft again until the pressure gauge displays at least 0.5 MPa.
e) Start the crusher.
NOTE! Check for material build-up on the bottom shell arms. If
damp, wet feed is causing packing, operate at a larger
setting.
NOTE! Check the interlocking between the feeding arrangement
and discharge system. There must be room beneath the
crusher for material in the crushing chamber and feed
hopper, in case the discharge system stops.
1.2. Plastic backing
1.2.1. Backing procedure

NOTE! When backing is carried out in cold weather, the containers must
be heated to approximately 25 °C (77 °F) before mixing. At a
lower temperature, the components will be too viscous.
NOTE! Heat the components that are to be backed, to between 40 °C
and 50 °C (104 °F and 122 °F) to shorten the setting time. If the
components are very cold, the plastic will not set.
NOTE! Do not heat the plastic backing with an open flame, as this can
damage the material.
To mix the plastic backing, and pour it into the cone crusher, follow this
procedure:
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Toxic hazard
You can suffer eye and skin irritation, sensitization
and burns if you handle the plastic backing
incorrectly.
Follow the instructions on the plastic backing
containers and in each component's MSDS.
WARNING!
a) Mix the plastic backing for a minimum of 5 minutes, according to

the instructions on the containers.
b) Immediately after mixing, pour the mix into the backing space in
the crusher.
c) Let the plastic backing set in the cone crusher. The setting time for
Korrobond 65 varies from 7 to 24 hours, depending on the ambient
temperature.
1.2.2. Hygienic aspects and protective measures

Toxic hazard
incorrectly.
WARNING!
In addition to the instructions on the containers and in each

component's MSDS, follow the recommendations below to minimize the
risks associated with working with the plastic backing components.
a) Establish whether there are any applicable national standards
covering the handling and use of epoxy products. If so, follow the
prescribed procedures.
b) Soap, water and paper towels must be available at the workplace.
c) Mix the plastic backing components in a clean room.
d) Clean up any spill.
1.3. Accumulators
1.3.1. General accumulator information

Explosion hazard
You can suffer severe injuries or even die if the
accumulator explodes.
WARNING! Protect the accumulator from mechanical and
thermal damage (impact, welding, etc.).
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The accumulator (1) is a cylindrical steel pressure vessel which

contains a rubber bladder fixed at the top of the vessel by a charging
valve. The rubber bladder is filled with nitrogen. This crusher type has
one accumulator. It is mounted on a foot opposite of the pinionshaft.
The accumulator is connected to the Hydroset cylinder cover by a hose.
The Hydroset line to the tank unit is connected to the flow regulator
beneath the accumulator.
1 Accumulator
2 Anti-extrusion valve
3 Air bleed screw
4 Flow regulator
Increase of CSS due to overload

Oil is forced out of the Hydroset cylinder and into the accumulator,
allowing the mantle to sink far enough to let the tramp iron pass through
the crushing chamber. The gas pressure in the accumulator forces the
oil back into the Hydroset cylinder as soon as the obstruction has left
the crushing chamber.
Owner’s responsibility
The crusher’s owner must arrange for re-certification of the
accumulator (1) if there are grounds to suspect that the accumulator
has been damaged. New components are best obtained from Sandvik.
1.3.2. Flow regulator

The flow regulator (4) is a throttling check valve between the Hydroset
cylinder and the accumulator (1). It prevents the mainshaft rising too
quickly after the tramp iron has passed through the crusher. When oil
flows from the crusher to the accumulator, it passes unhindered through
the flow regulator. When the oil returns from the accumulator, it is
slowed down so that the mantle is slowly raised to its original position.
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1 Accumulator
2 Anti-extrusion valve
3 Air bleed screw
4 Flow regulator
1.3.3. Charging kit (option)

Explosion hazard
You can suffer severe injuries or even die if the
accumulator explodes.
WARNING! Use only nitrogen (N2) in the accumulator as a
mixture of air (oxygen) and oil under high pressure
can explode.
An optional charging kit (FBU-1) can be used to check the gas pressure
in the accumulator and to add nitrogen when necessary. The charging
kit consists of a connector assembly with pressure gauge and bleed
valve, a hose and an adapter for connection to the accumulator.
1.3.3.1. Checking the gas pressure
a) Fitting the charging kit
a) Unscrew the protective caps (1) and (2) from the accumulator’s
charging valve, located on top of the accumulator.
b) Unscrew the internal hexagon screw (6) so the cut on its side is
visible over the top of the adapter (5).
c) Close the bleed valve (8).
d) Attach the adapter (5) to the accumulator’s charging nipple (3).
Tighten by hand sufficiently to prevent gas leakage.
e) Attach the screw connector (7) to the adapter (5). Tighten by hand
sufficiently to prevent gas leakage.
f) Screw down the spindle (9) so that the valve in the accumulator
opens.
g) Read off the charging pressure on the pressure gauge.
b) Removing the charging kit
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h) Unscrew the spindle (9).

i) Open the bleed valve (8).
j) Unscrew the screw connector (7) and remove the charging
kit (FBU-1)).
k) Remove the adaptor from the accumulator’s charging nipple (3).
l) Check that there is no gas leakage from the valve. Use soapy
water or oil for this check.
m) Refit the protective caps on the accumulator’s charging valve.
8 9 10 11
3 7 FBU-1
4 6
5 11
1 Protective cap 7 Screw connector

2 Protective cap 8 Bleed valve
3 Nipple 9 Spindle
4 O-ring 10 Connector
5 Adaptor 11 Charging hose
6 Hexagon screw
1.3.3.2. Charging with nitrogen
Accumulator charging pressure Tolerance

Without ASR / With ASR Plus 5 MPa (725 psi) ±5 %
With ASRi 6.0 MPa (870 psi) ±5 %
a) Attach the screw connector (7) with the charging hose (11) to the
nitrogen gas bottle.
b) Unscrew the protective caps (1) and (2) from the accumulator’s
charging valve.
c) Unscrew the internal hexagon screw (6) so that the cut on its side
is visible over the top of the adapter (5).
d) Close the bleed valve (8).
e) Attach the adapter (5) to the accumulator’s charging nipple (3).
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f) Attach the screw connector (7) to the adapter (5). Tighten by hand
g) Screw down the spindle (9) so that the valve in the accumulator
opens.
h) Carefully open the valve on the nitrogen gas bottle so that the
bladder expands slowly inside the accumulator and closes the oil
valve. Check that this is the case before raising the pressure to the
full charging pressure given in the table above.
NOTE! Take into account that the pressure in the accumulator will
drop slightly when the compressed gas cools down.
Charge the accumulator bladder to 20% above the desired
pressure.
i) Close the valve on the nitrogen gas bottle and wait for
five minutes. Check the pressure. If the pressure is too high,
release gas through the bleed valve (8) until the correct pressure is
reached.
j) Unscrew the spindle (9).
k) Open the bleed valve (8).
l) Unscrew the screw connector (7) and remove the charging
kit (FBU-1).
m) Remove the adaptor from the accumulator’s charging nipple (3).
n) Check that there is no gas leakage from the valve. Use soapy
o) Refit the protective caps (1) and (2) on the accumulator’s charging
valve.
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p) Remove the charging kit from the nitrogen gas bottle.

NOTE! Check the charging pressure after 1, 2 and 3 weeks and
thereafter at 6-month intervals.
8 9 10 11
3 7 FBU-1
4 6
5 11

3 Nipple 9 Spindle
6 Hexagon screw
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2.1. Determining inspection and

maintenance intervals
Every equipment must be subjected to regular systematic checks. This
will result in fewer and smaller repairs, less downtime and thus lower
overall running costs.
NOTE! New equipment must be inspected often during the initial operating
period. The intervals between inspections can then be increased until a
suitable frequency is found.
Keep a written log including the crusher’s and tank unit's operating
conditions and loads, important data and details of adjustments made
and any repairs carried out.
Since equipment operates under widely differing conditions, it is
impossible to recommend an inspection and care schedule applicable to
all equipment. However, regular inspections are necessary.
2.2. Inspection and care when it is dark

There is no lighting installed in the tank unit so if working when it is dark
use a flashlight.
2.3. Weekly inspection and care
Operation hours - Weekly or every 40 hours of operation

Maintenance procedure Notes
TOPSHELL
Check the tightness of the clamping
48
screws
HYDROSET CYLINDER
Check the torque of the Hydroset
148
cylinder joints
When completed:
Date ............................................................... Operation hours .................................................
Approved .......................................................
2.4. Monthly inspection and care
Operation hours - Monthly or every 160 hours of operation

TOPSHELL
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Operation hours - Monthly or every 160 hours of operation

Clean the air vent passage in the
31
topshell
MAINSHAFT
Check the play between the head center
67
and the mantle
Check the dust seal ring for wear 92
PINIONSHAFT HOUSING
Check the oil flow to the pinionshaft
163
housing
Check the gear backlash 201
LUBRICATION SYSTEMS
Clean the return oil screen 229
When completed:
Approved .......................................................
2.5. Inspection and care for every 6 months
Operation hours - Twice a year or every 1000 hours of operation

TOPSHELL
Check the play in the spider bushing 30
HYDROSET SYSTEM
Check the gas pressure in the
156
accumulator.
LUBRICATION SYSTEMS
Drain condensation water from the tanks 218
Change the breather filter L1-FU2 221
Clean the main lubrication tank 230
When completed:
Approved .......................................................
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2.6. Yearly inspection and care
Operation hours - Yearly or every 2000 hours of operation

MAINSHAFT
Check the mainshaft sleeve for wear 72
ECCENTRIC
Check the eccentric bushing for wear 108
Check the eccentric for wear 112
HYDROSET CYLINDER
Check the step bearing components for
137
wear
Check the chevron packing for wear 145
Check the Hydroset cylinder bushing for
152
wear
LUBRICATION SYSTEMS
Check the return oil temperature switch
220
L1-TS3
Check the main lubrication oil flow 220
Check the temperature indicator L1-TI2 221
Change the main lubrication oil 222
When completed:
Approved .......................................................
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3.1. Feed hopper
3.1.1. Replacing the feed hopper

3.1.1.1. Removing the feed hopper
a) Clean out all process material from the feed hopper (1).
b) Remove the screws (6), the washers (7) and (8), and the nuts (9).
c) Install lifting eye bolts (5) with a smallest recommended size M12
with shackles on the upper flange (10).
• If lifting the whole feed hopper; use at least three lifting eye
bolts (preferably four) installed as shown by (2) and (3).
• If lifting only one half of the feed hopper’s use two lifting eye
bolts installed as a pair at either (2) or (3).
d) Attach suitable lifting slings to the lifting eye bolts and to the hook.
e) Position the hook of a crane vertically above the feed hopper (1).
Suspended load hazard
A feed hopper weighs up to 600 kg (1323 lbs). You
can sustain crush injuries, fall or even die if you are
WARNING! struck by the load.
Make sure that the load is secure. Stand clear of
suspended loads. Use ropes or poles to steady and
maneuver loads – never use hands or feet.
f) Take up the slack in the lifting tackle. The tackle should now be
tight but not lifting the feed hopper (1).
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g) Carefully lift the feed hopper (1) off the topshell and position it on
an even surface on the ground.
1
2
3 2
3
10
4
1 Feed hopper 6 Screw

2 Lifting eye bolt 7 Washer
4 Shackle 9 Nut
5 Lifting eye bolt 10 Upper flange
3.1.1.2. Inspecting the feed hopper

Examine the feed hopper, the feed distributor and/or the cone plates for
wear and damage.
3.1.1.3. Installing the feed hopper
The crusher can be installed with or without a distributor.
• If the crusher is installed without a distributor the spider arms must be

aligned with the feeder or the conveyor.
Cone crusher without a distributor
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• If the crusher is installed with a distributor the spider arms are at right
angles to the feeder or conveyor.
Cone crusher with a distributor
a) Position the hook of a crane vertically above the feed hopper (1).
b) Attach the lifting slings to the lifting eye bolts (2) and (3) with
shackles (4) on the feed hopper and to the lifting hook.
c) Take up the slack in the lifting tackle. The tackle should now be
tight but not lifting the feed hopper.
A feed hopper weighs up to 600 kg (1323 lbs). You
d) Carefully lift the feed hopper (1) on to the upper flange of the
topshell.
e) Remove the lifting gear.
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f) Install the screws (6), the washers (7, 8) and the nuts (9).
1
3
2 2
3
10
4
1 Feed hopper
2 Lifting eye bolt
3 Lifting eye bolt
4 Shackle
5 Lifting eye bolt
6 Screw
7 Washer
8 Washer
9 Nut
g) Regulate the feed so there is a build-up of process material in the

feed hopper (choke feed). The process material should be level
with the top of the spider cap. Choke feeding will create a better
result in the form of a finer and more uniform product size. This will
also make the crusher run more smoothly and lower the power
consumption.
3.2. Topshell
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3.2.1. Replacing the spider cap

NOTE! Remove the feed distributor/splitter and clean out all process
material from the feed hopper before removing the spider cap.
3.2.1.1. Removing the spider cap

a) Clean out all process material from the spider cap.
b) Remove the four screws (3) and the washers (4) that hold the
spider cap (2) to the top shell.
c) Position the hook of a crane vertically above the spider cap (2).
d) Attach the lifting equipment to the lifting lug (1).
e) Take up the slack in the lifting equipment.
3, 4
1 Lifting lug
2 Spider cap
3 Screw
4 Washer

A spider cap weighs up to 160 kg (353 lbs). You can
sustain crush injuries, fall or even die if you are
Risk of equipment and property damage

You can damage the air vent pipe if it is struck by the
NOTICE spider cap.
Mind the air vent pipe located just inside the spider
cap when you remove/install the spider cap.
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f) Carefully lift the spider cap (2) from the top shell.
g) Remove the O-ring from the spider cap.
h) Place the spider cap (2) on the ground. Make sure that internal parts are prote
i) Clean out all the grease from the top shell and the
spider bushing (5).
5 Spider bushing
3.2.1.2. Spider cap removal checks

a) Measure the play in the spider bushing at the pivot point with a
feeler gauge. Record the play and compare with earlier
measurements. See section Inspecting the spider bushing on page
30.
b) Clean the O-ring (2).
c) Check the O-ring (2) and the rim (1) of the spider cap and the top
shell where the O-ring fits. If the O-ring is damaged it must be
replaced.
1 2
1 Rim of the spider cap
2 O-ring
d) Check the spider cap for wear. If it is worn, change the spider cap.
e) Clean the air vent passage in the top shell. Make sure that it is not
clogged. See section Cleaning the air vent passage in the topshell
on page 31.
f) Check that the lubrication passage through the top shell is
unobstructed.
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3.2.1.2.1. Inspecting the spider bushing

Max. permissible play and position of pivot point
S L
0.7-1.1 mm (0.028-0.043 in) 165 mm (6.5 in)
Check the play (S) in the spider bushing each time the liners are
changed or at least twice per year (1 000 h). Check the play more
frequently if the material being crushed is abrasive or if a leakage is
suspected or confirmed.
a) Measure the play (S) at the pivot point on distance (L) from top of
the bushing, using a feeler gauge. Insert the feeler gauge until the
pivot point (L) is passed. Measure the play where the distance
between the mainshaft and the spider bushing is the greatest.
Make a note of the value and compare it to earlier measurements.
When the play between the mainshaft and the spider
bushing increases, the grease is exposed to more
NOTICE contaminants.
If the play (S) is close to the maximum, change the
spider bushing grease more frequently.
b) If the play exceeds the maximum permissible value, the spider

bushing and/or the mainshaft sleeve must be replaced.
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3.2.1.2.2. Cleaning the air vent passage in the topshell

a) Clean the air vent passage (2).
1 2 3
1 Air vent pipe

2 Air vent passage
3 Air vent line
3.2.1.3. Installing the spider cap

a) Position the hook of a crane vertically above the spider cap.
b) Attach the lifting equipment to the lifting lug (1) on the
spider cap (2).
c) Take up the slack in the lifting equipment. The equipment should
now be tight but not lifting the spider cap (2).
d) Carefully lift the spider cap from the ground.

e) Lubricate the contact surfaces of the spider cap (2) and it seating.
f) Lubricate the O-ring and install it on the spider cap (2).
g) With the main shaft in its lowest position, fill the spider bushing
with grease to the same level as the top of the spider bearing
screws. Refer to Grease for spider bushing lubrication in the
Technical specifications.
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NOTICE spider cap.
h) Place the spider cap (2) on the top shell.

i) Install the screws (3) and the washers (4). Refer to Tightening
torques in the Technical specifications.
3, 4
1 Lifting lug
2 Spider cap
3 Screw
4 Washer
3.2.2. Installing the spider cap

a) Position the hook of a crane vertically above the spider cap.
b) Attach the lifting equipment to the lifting lug (1) on the
spider cap (2).
c) Take up the slack in the lifting equipment. The equipment should
now be tight but not lifting the spider cap (2).
d) Carefully lift the spider cap from the ground.
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e) Lubricate the contact surfaces of the spider cap (2) and it seating.
f) Lubricate the O-ring and install it on the spider cap (2).
g) With the main shaft in its lowest position, fill the spider bushing
with grease to the same level as the top of the spider bearing
screws. Refer to Grease for spider bushing lubrication in the
NOTICE spider cap.
h) Place the spider cap (2) on the top shell.

i) Install the screws (3) and the washers (4). Refer to Tightening
3, 4
1 Lifting lug
2 Spider cap
3 Screw
4 Washer
3.2.3. Inspecting the crushing chamber
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3.2.3.1. Inspecting the liners

Inspection of the liners must be carried out at the correct intervals.
Refer to Operator's inspection and care in the Operator’s Instructions. A
new machine must be inspected at frequent intervals. After one or two
liner changes, the intervals between inspections can be successively
increased.
These routine inspections will give an indication of when the liners must
be changed. It is difficult to give an exact limit at which the liners are
worn out. They are probably worn out when the thickness has been
reduced so much that indentations or cracks have occurred.
Extreme operating conditions can require liner replacement before the
liners are worn out. One reason can be incorrect feeding so that
increased wear occurs over a certain section of the concave ring. This
may also mean that the setting varies according to where the
measurement is carried out around the crushing chamber. Examples of
different feed arrangements are given in the Installation manual.
An unevenly graded mixture of feed material can also cause wear. The
crushing chamber is selected on the basis of the maximum feed size. If
almost all of the feed is close to the maximum size, crushing will be
concentrated to the upper portion of the chamber. This can give rise to a
groove around the upper portion of the chamber. If the feed material
consists primarily of fines, the crushing is concentrated to the lower part
of the chamber.
3.2.3.2. Inspecting the concave and mantle
The concave and mantle must be replaced if the maintenance of the
desired setting entails raising the mainshaft so high that the distance
between the head nut and the underside of the spider (the A-dimension)
is less than 15 mm (0.59 in).
3.2.4. Replacing the spider bushing and the seal ring

NOTE! Two different procedures are used to exchange the spider
bushing and seal ring depending on whether the topshell has
been removed or is still installed on the bottomshell. The following
procedure is applicable when the topshell is still installed on the
bottomshell.
3.2.4.1. Removing the spider bushing and the seal ring

a) Remove the spider cap, see section Removing the spider cap on
page 28.
b) Inspect the spider bushing, see section Inspecting the spider
bushing on page 30.
c) Drive in wooden wedges between the mantle and the concave ring
to lock and center the mainshaft in the spider bushing.
d) Remove the screws (6) and washers (7) which retain the spider
bushing (8).
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e) Press the spider bushing (8) up out of the spider by using the
screws as jacking screws in the threaded holes (5) in the top
flange of the bushing.
f) Tighten all of the screws in rotation with gradually increasing
torque so that the spider bushing (8) is pressed out.
g) Attach the lifting eye bolts to the empty threaded holes in the
spider bushing (8).
h) Position the hook of a crane vertically above the
spider bushing (8).
i) Attach three lifting chains to the hook of the crane.
j) Attach the lifting chains to the lifting eye bolts.
k) Take up the slack in the lifting tackle. The tackle should now be
tight but not lifting the spider bushing.
A spider bushing weighs up to 70 kg (155 lbs). You
l) Carefully lift out the spider bushing (8).

m) Lower the spider bushing (8) and set it carefully down on a clean
area on the ground.
6, 7
5
8
4
3
2
1
1 Wooden wedges
2 Mainshaft
3 Seal ring
4 Mainshaft sleeve
5 Threaded hole
6 Screw
7 Washer
8 Spider bushing
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3.2.4.2. Checking the spider bushing and the seal ring

a) Clean the seat for the O-ring (5) between the spider cap and the
topshell. Check for wear or damage.
b) Clean the contact surfaces between the topshell and the spider
bushing (7) and the seal ring (1). Check for wear or damage.
c) Clean the spider bushing (7). Make sure that the circulation holes
(6) in the spider bushing (7) are clean and unobstructed.
d) Check the seal ring (1). Replace it if it is worn or damaged.
e) Make sure that the lubrication (9) and air vent passages (4) in the
topshell are not blocked.
4 5
2, 3 9
1 7
1 Seal ring 6 Circulation hole

2 Screw 7 Spider bushing
3 Washer 8 Temperature transmitter
4 Air vent passage 9 Lubrication passage
5 O-ring
3.2.4.3. Installing the spider bushing and the seal

NOTE! Center the top of the mainshaft in the spider hub and lock it in
position with wooden wedges. See figure in section Removing the
spider bushing and the seal ring on page 34.
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a) Snap the seal ring (2) onto the locating tongue at the bottom of the
spider bushing (1) and make sure that the sealing lip points
upward.
1
2
3
1 Spider bushing
2 Seal ring
3 Topshell
b) Position the hook of a crane vertically above the

spider bushing (1).
c) Attach three lifting chains to the hook.
d) Attach the lifting chains to the lifting eye bolts.
e) Take up the slack in the lifting chains. The tackle should now be
tight but not lifting the spider bushing.
f) Grease the inner surface of the spider bushing (1) well, so that it is
coated with a thick layer of grease.
A spider bushing weighs up to 70 kg (155 lbs). You
g) Carefully lift the spider bushing (1) above the topshell and carefully
lower it into place.
h) Use a sliding caliper in any threaded hole to measure the gap
between the top shell and the spider bushing flange.
Gap (C) between top shell and spider bushing flange

New spider bushing 5 mm (0.20 in)
Worn spider bushing, replacement necessary Approaching 0
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i) Perform this measurement every time the spider bushing is

reinstalled. When the gap approaches zero, prepare for a spider
bushing replacement.
j) Tighten all the screws in rotation, gradually increasing the torque.
The flange on the spider bushing (1) should be flush against the
topshell. Tighten the screws to the correct torque, refer to
Tightening torques in Technical Specifications.
k) Risk of property damage. Make sure to use the correct
grease for the spider bushing.
The mainshaft must be at its lowest position. Fill the spider
bushing (1) with grease until the screw heads are covered (7). This
corresponds to approximately 6-8 kg (13.2-17.6 lbs). Refer to
section Grease for spider bushing lubrication in the Technical
Specifications.
l) Grease the O-ring and place it in its seating on the spider cap.
m) Install the spider cap. See section Installing the spider cap on page
31.
7 Grease level
3.2.5. Checks prior to removal of the top shell

NOTE! The checks that are described in this section must be carried out
before the top shell is removed, in order to determine how much
of the crusher must be removed if, for instance, a liner change is
planned.
a) Check the play between the dust seal ring and the dust collar.
Refer to Checking the dust seal ring for wear in the Operator’s
instructions.
b) Check the backlash in the gears. See section Bevel gears on page
201.
3.2.6. Replacing the top shell

3.2.6.1. Removing the top shell
NOTE! Before starting these procedures it is necessary to first remove
the feed hopper, the arm shields, and the spider cap.
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a) Lower the main shaft to its bottom position, with the Hydroset
piston resting on the Hydroset cylinder cover.
b) Remove the protective caps (7) and (9).
c) Remove the clamping screws (4) that clamp the top shell (3) to the
bottom shell (10).
d) Tighten the jacking screws (8) in sequence to press the top shell
upwards.
3
4, 5, 6, 7
8, 9
10
1 Lifting sling
2 Spider arm
3 Top shell
4 Clamping screw
5 Nut
6 Washer
7 Protective cap
8 Jacking screws
9 Protective cap
10 Bottom shell
e) Position the hook of a crane vertically above the top shell.

f) Put the lifting slings (1) around the spider arms.
g) Attach the lifting slings (1) to the hook.
h) Take up the slack in the lifting tackle.
NOTE! Be careful when lifting the top shell to avoid damage to the
main shaft, the spider bushing or any other machined
surfaces.
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A top shell assembly weighs up to
5 110 kg (11 266 lbs). You can sustain crush injuries,
WARNING! fall or even die if you are struck by the load.
i) Carefully lift the top shell (3) from the bottom shell (10).
j) Place the top shell (3) on timber supports so that the machined
surfaces are not damaged.
3.2.6.2. Checking the top shell
a) Clean the tapered mating surfaces on the top shell (1) and the
bottom shell (2).
b) Check the tapered mating surfaces (1) and (2) for rust and
damage.
NOTE! If motion between the top shell and the bottom shell has
caused damage to the tapered mating surfaces the
surfaces must be built up by welding and re-machined.
Consult Sandvik for further information.
1 Tapered mating surface, top shell

2 Tapered mating surface, bottom shell
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3.2.6.3. Installing the top shell

a) Coat the tapered mating surfaces and the contact faces of the
flanges with thick oil or grease.
NOTE! Oil containing molybdenum disulfide will reduce the risk of
contact corrosion.
b) Lubricate the spider bushing, the seal ring and the main shaft with
ordinary spider bushing grease. See Grease for spider bushing
lubrication in Technical specifications.
c) Adjust the jacking screws (8) in the top shell flange, so that they
protrude approximately 5 mm (0.20 in).
d) Position the hook of a crane vertically above the top shell.
e) Put the lifting slings around the spider arms.
f) Attach the lifting slings to the hook.
g) Take up the slack in the lifting tackle.
Risk of property damage
NOTICE It is very important that the top shell (3) is kept
level to protect the tapered bore from damage.

h) Carefully lift the top shell off the timber supports.

Make sure that the main shaft does not damage the
NOTICE seal ring when the top shell is lowered onto the
bottom shell.
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i) Carefully lower the top shell until the jacking screws (8) rest upon
the bottom shell (10).
1
2
3
3
4, 5, 6, 7
8, 9
A–B
10
10
1 Lifting gear
2 Spider arm
3 Top shell
4 Clamping screw
5 Nut
6 Washer
7 Protective cap
8 Jacking screws
9 Protective cap
10 Bottomshell
Distance between flanges (A-B above)
Minimum (new parts) Maximum (new parts) Minimum (worn parts)

2.7 mm (0.11") 4.3 mm (0.17") 2.1 mm (0.08")
j) Use clamping screws (4) to adjust the position of the top shell.
k) Retract the jacking screws (8) until the top shell is resting on the
bottom shell.
l) When the top shell is resting on the bottom shell, measure the gap
between the flanges of the top shell and the bottom shell. Make
four measurements around the periphery, with 90° between them.
There should be an even gap between the flanges, see the table
above for values. If the gap is less than 2.1 mm (0.08"), contact
Sandvik.
m) Tighten the clamping screws in circular rotation in stages, until the
flanges are tight against each other.
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n) Torque the screws until there is no play between the flanges.

NOTE! Wear and damage can cause the joint between the top
shell and the bottom shell to deteriorate after a long period
of operation. There must be no movement in the joint after
the screws have been tightened. If there are signs of
movement, the tapered mating surfaces must be corrected.
Consult Sandvik for instructions.
o) NOTE! Risk of property damage. Make sure to use the correct
grease for the spider bushing.
Fill the spider bushing with 6-8 kg (13.2-17.6 lbs) of grease. Refer
to Grease for spider bushing lubrication in Technical specifications.
p) Lubricate the contact surfaces of the spider cap (4) and its seating.
q) Install the spider cap.
2, 3 1
2, 3
4
1 Lifting lug
2 Screw
3 Washer
4 Spider cap
3.2.7. Replacing the concave ring

The design of this cone crusher is such that all
concave rings (3),from EC to EF, can be fitted into a single top shell (1).
This is possible, despite the differences in shape of the various concave
rings, by using filler rings.
No filler ring (2) is used with C and EC concave rings. These are
mounted directly in the topshell, with plastic backing.
The concave ring is pulled into the top shell by a support ring (4) with
clamping screws (5). The concave ring has locating bosses (6) which fit
into recesses in the support ring, while the ring itself is positioned
against the top shell by locating dowels.
If lifting lugs are to be welded onto the concave ring, make sure that the
lugs are amply dimensioned. Use an electrode that meet the
requirements of EN 1600: E 18 8 Mn B 4 2, for example
S 223.1239 - 5 en-US 10/01/2019 09:35:46 43
ESAB OK 67.45. Refer to Safety and Environmental instructions for

information about welding, and to Lifting lugs for the mantle in Technical
specifications for dimensions of suitable lifting lugs.
2
EF EC
3 5
4 6
1 Top shell
2 Filler ring
3 Concave ring
4 Support ring
5 Clamping screw
6 Locating boss
3.2.7.1. Removing the concave ring

Remove the topshell (2) before removing the concave ring (3).
See section Removing the top shell on page 38. Position the
topshell on wooden blocks, so that the machined surfaces are not
damaged and the concave ring is accessible.
a) Clean the area around the top of the filler ring (4).
Risk of crushing
Do not stand inside the top shell when the concave
ring is removed.
WARNING! Only stay on the equipment if it is necessary for
inspections and maintenance work.
b) Remove the locking nuts, sleeves, washers and disc springs which
hold the concave ring in the topshell. Make a note of the way the
disc springs are arranged.
NOTE! The screws (5) in the upper flange of the topshell hold the
filler ring and should not be removed during a normal
concave change.
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Toxic hazard
You can suffer damage to the lungs, eyes, liver,
kidney and central nervous system and you are at
risk of cancer if you inhale flame cutting fumes.
Use a suitable welding helmet and a respirator that is
approved for the emissions that are released.
WARNING! Remember that some parts of the crusher contain
manganese.
Make sure that the area is well ventilated.
Follow the instructions provided by the flame cutting
equipment supplier/s.
c) Remove the concave ring from the topshell. If the concave ring is
backed with plastic, it may have to be driven out of the topshell.
Use one of the following methods:
• Hit the top rim of the concave ring with a sledge hammer. This
is the method described below in steps d) to i).
• If hitting the concave ring is insufficient, two jacks can be used
between the top rim and the topshell arms. Hit the concave
ring around the top rim at the same time as the jacks are
operated. Place the topshell on wooden blocks on the ground
and use jacks.
• If the concave ring can not be removed using either of the two
methods described above, the concave ring must be split with
a cutting torch. Take great care to avoid damage to the
topshell and the filler ring.
d) Position the hook of a crane vertically above the topshell (2).
e) Put lifting slings around the spider arms.
f) Attach the lifting slings to the hook.
g) Take up the slack in the lifting tackle. The tackle should now be
tight but not lifting the topshell.
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A concave ring weighs up to 845 kg (1 863 lbs). You
If you lift the top shell with the concave ring in it,
remember that the concave ring can come loose and
fall out.
h) Carefully lift the topshell off the ground.

i) Place the topshell (2) on wooden blocks next to the concave
ring (3).
7
6
5
4
3
2
1
1 Support ring
2 Topshell
3 Concave ring
4 Filler ring
5 Screw
6 Shim
7 Square washer
3.2.7.2. Installing the concave ring

a) Position the support ring (9) on wooden blocks, with the six
clamping screws (11) installed in their holes.
b) Position the concave ring on the support ring. Make sure that the
locating bosses (16) on the concave ring fit the corresponding
recesses in the support ring.
c) Make sure that the locating dowels are securely installed in the
lower edge of the topshell.
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d) Lightly lubricate the surfaces of the topshell and the filler ring (5)
that will be in contact with plastic backing, with grease or silicone
spray.
e) Position the hook of a crane vertically above the topshell (1).
f) Put lifting slings around the spider arms.
g) Attach the lifting slings to the hook.
h) Take up the slack in the lifting tackle. The tackle should now be
tight but not lifting the topshell.
i) Carefully lift the topshell and lower it onto the support ring. Use the
locating dowels to ensure correct positioning. Make sure that the
gap between the support ring and the topshell is even all around.
11
12
13
1 14
2, 3 15
4
5 T
6
7
8
9
16
10
1 Topshell 9 Support ring

2 Screw 10 Wooden block
3 Square washer 11 Clamping screw
4 Washer 12 Lock nut
5 Filler ring 13 Sleeve
6 Plastic backing level hole 14 Disc spring
7 Concave ring 15 Washer
8 Gap between the support ring and the topshell 16 Locating boss
NOTE! In order to increase the life of the support ring, with respect
to wear on the inner surface, it can be rotated relative to
the topshell (6 × 60°).
S 223.1239 - 5 en-US 10/01/2019 09:35:46 47
j) Arrange the disc springs the way they were before the topshell was
removed. See the note of how the disc springs were arranged in 2.
under section Removing the concave ring on page 44, and the
figure in the previous step.
k) Measure dimension (T). See the figure in the previous step.
l) Make sure that there is an even fit all around the topshell, by
tightening the screws in circular rotation until the dimension
T-4.5 mm (T-0.18 in) is reached. This corresponds to
approximately a 460° rotation of the nut.
m) After all the screws have been tightened, make sure that there is
no play between the spacer ring (2) and the lower part of the
concave (3). Use a feeler gauge.
1 Topshell
2 Spacer ring
3 Concave
NOTE! There are holes in the support ring to facilitate this check.
Toxic hazard
incorrectly.
WARNING!
n) Fill the space between the concave ring and the topshell or filler
ring with plastic backing, refer to Plastic backing in the Technical
Specifications.
3.2.7.2.1. Checking the tightness of the clamping screws

a) Check the tightness of the clamping screws after a short period of
operation. If necessary, retighten the screws.
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b) Check that the dimension (T) is T-4.5 mm (T-0.18 in).

NOTE! If crushing hard, but less abrasive material, it can be
necessary to loosen the nuts after the concave ring’s half
lifetime. If the distance between the lower disc springs
group and the middle disc spring group is close
to 0 mm (0″) loosen the nut.
1
2
3
1 Topshell
X
2 Sleeve
3 Disc spring
3.2.8. Replacing the filler ring

The filler ring in the cone crusher reduces the volume of the space
between the topshell and the concave, and therefore reduces the
amount of plastic backing that is required.
Two types of filler rings are used, the MF and the MC:
The MF filler ring is backed with plastic composition in its upper part
and has metallic contact with the topshell in the lower part.
The MC filler ring has full-height metallic contact and is not backed
against the topshell.
The MF filler ring (4) is intended for F and MF concaves (3), while the
MC filler ring is intended for M and MC concaves. The C and EC
concaves are installed directly in the topshell, without a filler ring, and
are backed with plastic.
S 223.1239 - 5 en-US 10/01/2019 09:35:46 49
NOTE! If a filler ring comes loose during operation it must be removed,

inspected, reinstalled and backed with plastic again.
3.2.8.1. Removing the filler ring

NOTE! The filler ring cannot be removed until the concave ring has been
removed.
NOTE! If the intention is to change to a coarser crushing chamber, the
filler ring may have to be removed.
A filler ring weighs up to 596 kg (1 314 lbs). You can
a) Remove the screws (5) that hold the filler ring (4) in the topshell
(2).
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b) The filler ring has a tapered seating in the topshell and jacks must
be used to press it out. Use two jacks, each with a capacity of
approximately 40 000 kg (88 000 lbs), as follows:
a. Position the jacks between the top edge of the filler ring and
the topshell arms.
b. Press out the filler ring and at the same time use a sledge
hammer to hit around the top edge and the inside of the filler
ring.
c. If the filler ring still does not come free, it may be necessary to
heat the topshell while the jacks are operated.
7
6
5
4
3
2
1
1 Support ring
2 Topshell
3 Concave ring
4 Filler ring
5 Screw
6 Shim
7 Washer
3.2.8.2. Inspecting the filler ring

a) Clean the filler ring.
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b) Examine the tapered surfaces of the filler ring (2) and the
topshell (1). If there are any ridges or depressions, these must be
ground off before the reassembly is started.
1 Tapered surface, topshell

2 Tapered surface, filler ring
3.2.8.3. Installing the filler ring

a) Put a little grease into each threaded hole in the filler ring.
Toxic hazard
incorrectly.
WARNING!
b) For MF filler: Push a piece of plastic hose over the screws (5) to
protect them from the plastic backing.
c) Install the screws, the square washers (7) and the shims (6) under
the square washer.
d) When the screws are threaded all the way into the filler ring, the
holes must be completely filled with grease to prevent corrosion
and the accumulation of dirt.
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e) Pull the filler ring up into position in the topshell by tightening the
six screws in circular rotation, refer to Tightening torques in the
Technical Specifications.
NOTE! For MF filler: When an MF filler has been properly seated,
back it with plastic, see section Plastic backing in the
f) Check the tightness of the screws after a few days of operation. If
necessary, re-tighten the screws.
7
6
5
4
3
2
1
1 Support ring 5 Screw

2 Topshell 6 Shim
3 Concave ring 7 Washer
4 Filler ring
3.2.9. Replacing the arm shields

3.2.9.1. Removing the arm shields
a) Weld a suitable lifting lug on the worn arm shield (1). Use an
electrode that meet the requirements of EN 1600: E 18 8 Mn B 42
or ISO 3581: E 18 8 Mn B (for example ESAB OK 67.45).
b) Cut the worn arm shield with an angle grinder.
c) Position the hook of a crane vertically above the arm shield.
d) Attach a lifting sling to the lifting lug.
e) Connect the lifting hook to the lifting sling.
f) Take up the slack in the lifting tackle.
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An arm shield weighs up to 43 kg (95 lbs). You can
g) Carefully lift the arm shield off the top shell.

3.2.9.2. Installing the arm shields
a) Weld a suitable lifting lug on the new arm shield (1). The electrode
must meet the requirements of EN 1600: E 18 8 Mn B 42 or ISO
3581: E 18 8 Mn B (for example ESAB OK 67.45).
b) Attach a lifting sling to the lifting lug.
c) Arrange the lifting equipment.
1 Arm shield

An arm shield weighs up to 43 kg (95 lbs). You can
d) Carefully lift the arm shield (1).

e) Carefully lower the arm shield onto the top shell.
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f) Weld the arm shield (1) to the top shell. The electrode must meet
the requirements of EN 1600: E 18 8 Mn B 42 or ISO 3581: E 18 8
Mn B (for example ESAB OK 67.45).
NOTE! Weld only the side of the attachment slots that is closest to
the middle of the arm shield.
a-dimension 4-6 mm (0.16-0.24″)
3.3. Mainshaft
3.3.1. Replacing the main shaft and the mantle

3.3.1.1. Removing the main shaft assembly
NOTE! If the main shaft and the eccentric bushing has seized up.
NOTE! These instructions can be performed without removing the main
shaft cover.
a) Carefully clean the main shaft (4), the flange of the bottom shell,
the arms of the bottom shell and around the dust seal ring retainer,
to prevent dirt from entering the bearings when the main shaft is
removed.
b) Install a lifting eye bolt (3) in the top of the main shaft (4).
A main shaft assembly with mantle weighs up to
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d) Lift the main shaft approximately 20 mm (0.8").

NOTE! The step washer can fall off the main shaft at once, but
sometimes it sticks to the main shaft, depending on the
temperature and viscosity of the oil. Wait for 10 minutes
before you continue, to make sure that the step washer
has fallen off the main shaft.
e) Carefully lift out the main shaft and make sure that the step washer
has dropped off.
f) Make sure that the step washer (9) has not landed upside down
(the concave surface should face upward).
g) Lower the main shaft (4) onto a trestle (5) at working height.
h) When the main shaft is removed, the inner dust seal ring (6)
usually remains inside the dust collar (8). Remove the inner dust
seal ring (6) from the inside of the dust collar (8).
i) Put a cover over the dust collar (8), to prevent dirt from
contaminating the oil and the bearings.
3 6
7
4 8
3 Lifting eye bolt

4 Main shaft
5 Trestle
6 Inner dust seal ring
7 Seating ring
8 Dust collar
9 Step washer
3.3.1.2. Checking the main shaft and the mantle
Main shaft diameter Maximum play between the main shaft and the eccentric
bushing mm (")
340 mm (13.40 in) 1.8 mm (0.071 in)
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a) Measure the diameters of the main shaft and the eccentric bushing
and calculate the play. The play must not exceed
1.8 mm (0.071 in).
NOTE! A larger play is permissible, if the bearing surfaces are
evenly worn, and neither part is to be repaired (that is, a
larger play is permissible for components that have worn
against each other). If the eccentric bushing is changed,
the spider bushing must also be checked, see section
Checking the spider bushing and the seal ring on page 36.
b) Check the main shaft sleeve for wear, see section Inspecting the
mainshaft sleeve on page 72.
c) Clean the dust seal ring, and make sure that the drain holes in the
dust collar are free from obstructions.
d) Check that the inner dust seal ring rests horizontally on the seating
ring. The seating ring should be flat in the dust collar.
e) Measure the play between the inner dust seal ring (2) and the main
shaft (3). The play must not exceed 2.5 mm (0.10 in).
1 Dust seal ring

3 Main shaft
4 Main shaft step
5 Dust collar
f) If there is more dirt than is to be expected on the inside of the dust

collar, see section Inspecting the dust collar on page 98.
g) Check the lower bearing surface of the main shaft. A dull surface is
a sign of contaminated oil. A shiny surface usually indicates clean
oil.
3.3.1.3. Installing the main shaft assembly
a) Install a lifting eye in the top of the main shaft (3).
b) Arrange the lifting equipment.
c) Align the step washer so that it is centered on the piston wearing
plate. Make sure that the concave surface is facing upwards.
d) Coat the lower part of the main shaft with oil.
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e) Fix the inner dust seal ring (2) on the main shaft (3) by placing it
askew. When the main shaft has entered the eccentric bushing,
the ring will be released from the main shaft inside the dust collar
(5).
A main shaft assembly with mantle weighs up to
f) Carefully lift the main shaft (3).

Risk of equipment or property damage
Be very careful when installing the main shaft and
NOTICE the inner dust seal ring. Make sure that the bearing
surfaces of the main shaft, and the main shaft step,
are not damaged by impact with the bottom shell.

Make sure that the dust seal ring (1) moves correctly
NOTICE over the dust collar (5), otherwise the dust seal ring
(1) may be damaged when the shaft is lowered.
g) Lower the main shaft (3) into the bottom shell. Be very careful
when you lower it into the eccentric bushing.
NOTE! With a larger eccentric throw, it may be necessary to move
the crane slightly as the bottom of the main shaft slides
into the eccentric bushing.
h) Lower the inner dust seal ring (2) into the dust collar (5).
i) Use the inspection holes to check how the dust seal ring (1) lies in
relation to the dust collar (5). Adjust if necessary.
NOTE! The dust seal ring (1) can be adjusted by pushing it with a
suitable pole or similar. An alternative method is to spin the
main shaft (3) rapidly by hand when the dust seal ring
approaches the dust collar. Stop the spinning as soon as
the dust seal ring (1) has seated properly.
j) Centralize the dust seal ring (1) and make sure the dust seal ring
(1) slides smoothly over the dust collar (5).
k) Rotate the main shaft (3) slowly to check that it does not jam in the
eccentric bushing.
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l) As soon as the dust seal ring (1) has passed the top edge of the
dust collar (5), stop the rotation of the main shaft (3).
4
5
1 Dust seal ring

3 Main shaft
4 Main shaft step
5 Dust collar
3.3.2. Replacing the head nut

3.3.2.1. Removing the head nut
NOTE! The weld between the mantle (1) and the burning ring (3) is made
with a stainless electrode. Since it is difficult to cut stainless
material with a cutting torch, it is advisable to grind off the weld
first. This procedure also minimizes the heat input to the inner
head nut (5), which reduces the risk that the adhesion of the
locking fluid to the main shaft is destroyed.
Toxic hazard
manganese.

NOTICE Make sure you keep the flame away from the main
shaft and the head center.
a) Burn off the burning ring (3) between the mantle (1) and the head
nut (4).
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Worn part hazard

You can sustain musculoskeletal injuries if you miss
the lug on the head nut when you attempt to strike it.
WARNING! Weld on new lugs if the existing lugs on the head nut
are reduced to about half their original size.
b) Inspect the head nut. If the lugs on the head nut are worn more
than 50%, weld new lugs onto the head nut. Replace the head nut
with a new before installation.
Ergonomic hazard
When striking the head nut with a sledgehammer be
careful not to bend or twist your back to avoid
WARNING! injuries to discs and back muscles.
Take a wide stance and find the best positions for
your feet, bend your hips and knees and use your leg
muscles.
c) The head nut is right hand threaded.

Hit the lugs of the head nut with a sledgehammer. Unscrew the
head nut.
5 6
1 Mantle 4 Head nut

2 Head center 5 Inner head nut
3 Burning ring 6 Main shaft sleeve
d) Attach lifting slings to the lugs (7) on the head nut (8).
A head nut with burning ring weighs up to 56 kg (123
lbs). You can sustain crush injuries, fall or even die if
WARNING! you are struck by the load.
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Hot surface hazard

You can suffer severe burns from the heated
components.
WARNING! Allow the components to cool down before you
touch them.
e) Arrange the lifting equipment. Lift off the head nut. Remove any
remains of the burning ring (9).
9
7 Lifting lug
8 Head nut
9 Burning ring
3.3.2.2. Checking the head nut

a) Check the condition of the lugs on the head nut. If the lugs are
worn more than 50%, replace the head nut.
b) Carefully clean the threads on the head nut (4) and on the inner
head nut (5) (which remains installed on the mainshaft) with a wire
brush.
c) Check the condition of the threads on the head nut (4) and on the
inner head nut (5).
d) Lubricate the threads with molybdenum disulfide paste (or an
equivalent anti-seizing paste).
NOTE! Remove the inner head nut only if its outer threads have
been damaged, see section Removing the inner head nut
on page 65.
e) Check the surface of the mainshaft below the threads. Polish any
damaged areas until a smooth surface is obtained.
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f) To check the fit of the headcenter (2), measure the distance from
the top of the headcenter to the top of the main shaft. Compare
this dimension to the larger of the two values that are stamped on
the top of the main shaft, see section Inspecting the head center
on page 84.
5 6
1 Mantle 4 Head nut

2 Headcenter 5 Inner head nut
3 Burning ring 6 Mainshaft sleeve
3.3.2.3. Installing the head nut

NOTE! If a new mantle (1) is to be installed, install the mantle (1) and the
burning ring (3) before installing the head nut (4). Apart from the
instructions in this section, see also section Installing the mantle
on page 69 before you install the mainshaft and the mantle.
a) Lubricate the outer threads of the inner head nut (5) with an ample
amount of copper paste.
A head nut with burning ring weighs up to 56 kg (123
lbs). You can sustain crush injuries, fall or even die if
WARNING! you are struck by the load.

Worn part hazard
You can sustain musculoskeletal injuries if you miss
the lug on the head nut when you attempt to strike it.
WARNING! Replace the head nut if the lugs are reduced to about
half their original size.
Also replace the head nut if you think the lugs will be
reduced to about half their original size when you
need to remove the head nut next time.
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c) The head nut is right hand threaded.
Install the head nut (4) and tighten it hard by using a

sledgehammer to hit the lugs. To make sure that the head nut is
tightened evenly, it is recommended that installation is carried out
by two persons who simultaneously hit on one nut lug each.
Toxic hazard
manganese.
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d) Weld the burning ring (3) to the head nut (4) and the mantle (1) as
follows:
a. Begin by welding between the burning ring (3) and the
head nut (4) and lay down welds (A) that are approximately
80 mm (3") long, with gaps (B) of approximately 130 mm (5")
between them.
b. Align the welds to the mantle (1) with the gaps between the
welds to the head nut.
c. The weld size (a-dimension) should be between
6 and 7 mm (0.25 and 0.30").
3
A
B 1
1 Mantle
3 Burning ring
4 Head nut

Always ground close to the welding area.
NOTICE Always connect the ground to the head nut/
mantle.
NOTE! Avoid welding immediately below the lugs on the

head nut (4). A weld in this area makes it more difficult to
remove the head nut.
In some cases, when moist material is crushed for
example, it can be necessary to weld all the way around
the burning ring (3).
NOTE! In order to prevent fine material from entering through the
opening in the burning ring, close the opening with a weld.
Use an electrode that meets the requirements of
EN ISO 2560-A: E 42 4 B 42 H5 for example
ESAB OK 48.00 electrode.
The electrode that is used to weld between the burning ring and
the mantle (1) must meet the requirements of
EN 1600: E 18 8 Mn B 42 or ISO 3581: E 18 8 Mn B, for example
ESAB OK 67.45.
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e) For the welding between the burning ring (3) and the head nut (4),
the electrode must meet the requirements of
EN ISO 2560-A: E 42 4 B 42 H5, for example ESAB OK 48.00.
5 6
1 Mantle
2 Headcenter
3 Burning ring
4 Head nut
5 Inner head nut
6 Mainshaft sleeve
3.3.2.4. Removing the inner head nut

NOTE! Remove the inner head nut (3) only if its outer threads have been
damaged.
Risk of property or equipment damage
NOTICE Be very careful when you grind or chisel. Make sure
that you do not damage the threads of the mainshaft.
a) Carefully grind or chisel a groove in the inner head nut (3).

b) Split the inner head nut (3) with a wedge.
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c) Remove the inner head nut (3).
1
2
1 Mainshaft
2 Mainshaft sleeve
3 Inner head nut
3.3.2.5. Installing the inner head nut

a) Clean the threads of the mainshaft (1) and of the inner head nut (3)
with a degreasing fluid.
b) Check that the inner head nut (3) can be run down to the end of
the thread.
c) Remove the inner head nut (3) again.
d) Apply an ample amount of Loctite 270 or similar (hight strength), to
the threads of the mainshaft (1) and of the inner head nut (3). The
threads should be completely filled.
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e) Install the inner head nut (3) and make sure it is tight against the
mainshaft.
1
2
1 Mainshaft
2 Mainshaft sleeve
3 Inner head nut
3.3.3. Replacing the mantle

3.3.3.1. Checking the play between the head center and the mantle
Manganese flow in the mantle can cause a gap between the head
center and the mantle, allowing these components to move relative to
each other. This causes wear, particularly on the lower part of the
contact surface on the head center. If this occurs, the fit must be
restored by grinding and polishing. If the wear is severe, consult
Sandvik for advice.
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a) Check with a feeler gauge, all around the periphery (see arrows),
that there is contact between the lower part of the mantle (1) and
the head center (2).
1 Mantle
2 Head center
3 Head nut
3.3.3.2. Removing the mantle

NOTE! Start by removing the complete main shaft assembly, see section
Removing the main shaft assembly on page 55, and then section
Removing the head nut on page 59.
Toxic hazard
risk of cancer if you inhale welding fumes.
Use a welding helmet and a respirator that is
Remember that some parts of the crusher contain
manganese.
WARNING! Follow the instructions provided by the welding
Comply with national and local regulations.

NOTICE Always ground close to the welding area. Always
connect the ground to the mantle.
a) Weld two lifting lugs (3) on the mantle (2). The lifting lugs must be
amply dimensioned and must be welded with an electrode suitable
for manganese. See section Lifting lugs for the mantle in the
b) Attach suitable lifting slings to the lifting lugs (3) on the mantle (2).
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A mantle weighs up to 765 kg (1 687 lbs). You can

The plastic backing Korrobond 65 decomposes at a
NOTICE temperature of approximately 160 °C (320 °F). Make
sure that the working area is well ventilated.

Take care to avoid damaging the bearing surfaces
NOTICE and the threads of the main shaft with the mantle
when it is lifted off.
d) Lift the mantle (2) off the head center. The mantle (2) can be
difficult to remove because of the plastic backing. If the mantle (2)
cannot be lifted off, hit it with a sledgehammer while you lift it. If
necessary, heat the mantle (2).
3
2
1 Main shaft
2 Mantle
3 Lifting lug
3.3.3.3. Installing the mantle

a) Thoroughly clean the head center (5) and the mantle (2).
b) Lightly lubricate the outer surface of the head center (5) with a thin
coat of grease or silicone spray, to simplify future removal of the
mantle (2).
NOTICE Always ground close to the welding area. Always
connect the ground to the mantle.
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c) Weld two lifting lugs (3) on the mantle (2). The lifting lugs must be
amply dimensioned and must be welded with an electrode suitable
for manganese, refer to section Lifting lugs for the mantle in the
3
2
1 Main shaft
2 Mantle
3 Lifting lug
d) Attach the lifting slings to the lifting lugs (3).

e) Arrange the lifting equipment.
A mantle weighs up to 765 kg (1 687 lbs). You can
f) Carefully lift the mantle (2).

g) Position the mantle on the head center (4).
h) Lubricate the outer threads of the inner head nut (5) with a
lubricating paste. Use an ample amount of spider bushing grease.
i) Install the head nut (5).
j) Tighten the head nut (5) so that the bottom edge of the mantle (2)
touches the head center (4) all round.
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k) Check with a feeler gauge, all around the periphery, that there is
contact between the lower part of the mantle (2) and the
head center (4).
4 Head center
5 Head nut
6 Inner head nut
l) Remove the head nut (5).

m) Lubricate the outer threads of the inner head nut (6) with
lubricating paste, to protect it from the plastic backing that is to be
poured in.
Toxic hazard
incorrectly.
WARNING!
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n) Fill the space between the mantle (2) and the head center (4) with
plastic backing through a pouring hole (7). Do not let the level of
the plastic backing rise above the pouring hole (7) in the
mantle (2), see section Plastic backing on page 12 and refer to
section Plastic backing in the Technical Specifications.
2 Mantle 7 Pouring hole (max level for plastic backing)

4 Head center
o) As soon as the plastic backing has been poured in, install the
head nut (5) again and tighten it.
5 Head nut
p) Remove the lifting lugs.
3.3.4. Replacing the mainshaft sleeve

3.3.4.1. Inspecting the mainshaft sleeve
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a) Examine the bearing surface of the mainshaft sleeve (1) for wear.
If the surface wear exceeds 0.4 mm (0.016 in), the mainshaft
sleeve (1) must be replaced. Wear on the bearing surface of the
mainshaft sleeve (1) can form a regular pattern. The lip of the
spider bearing seal can cause similar wear.
b) The lower part of the mainshaft sleeve (1) is exposed to wear from
the feed material. Remove burrs and ridges with emery paper,
every time the topshell is removed (e.g. for manganese
replacement).
1 Mainshaft sleeve
3.3.4.2. Removing the mainshaft sleeve

a) Remove the screws (1) and the mainshaft cover (2)
1
2
1 Screw
2 Mainshaft cover
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b) Attach the nipple (6) to the threaded hole on top of the

mainshaft (7).
c) Turn the cover (5) so that the protrusion (9) points downward.
d) Place the cover (5) on top of the mainshaft sleeve (8), so that the
nipple (6) passes through the widest hole of the cover (5).
e) Lubricate the screws (3) with oil.
f) Attach the cover (5) to the mainshaft (7) with the screws (3) and
the washers (4). Tighten the screws (3) by hand.
3
4
5 9 5
6
7
8
3 Screw
4 Washer
5 Cover
6 Nipple
7 Mainshaft
8 Mainshaft sleeve
9 Protrusion
g) Connect the hose (10) to the nipple (6).

h) NOTE! The mainshaft sleeve (6) releases its grip suddenly, and
can emit a loud banging noise.
Pump up the oil pressure with the oil pump (11) until the mainshaft
sleeve (6) releases its grip from the mainshaft.
i) Release the oil pressure at the pump (11).
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j) Disconnect the hose (10) from the nipple (6) and remove the
pump (11).
11
10
6
6 Nipple
8 Mainshaft sleeve
10 Hydraulic hose
11 Hydraulic oil pump
k) Remove the screws (3), the washers (4) and the cover (5) from the
top of the mainshaft (7) and the mainshaft sleeve (8).
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l) Remove the nipple (6) from the threaded hole on top of the
mainshaft (7).
3
4
5
6
7
8
3 Screw 6 Nipple
4 Washer 7 Mainshaft
5 Cover 8 Mainshaft sleeve
m) Attach lifting eye bolts (12) to the threaded holes on the mainshaft
sleeve (8).
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n) Arrange the lifting equipment (13).
13
12
8 Mainshaft sleeve
12 Lifting eye bolt
13 Lifting equipment

A main shaft sleeve weighs up to 36 kg (80 lbs). You
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o) Lift off the mainshaft sleeve (8) from the mainshaft (7).
7 Mainshaft
8 Mainshaft sleeve
3.3.4.3. Installing the mainshaft sleeve

a) Make sure that all surfaces are clean and smooth.
b) Attach lifting eye bolts (2) to the threaded holes on the rim of the
mainshaft sleeve (1).
c) Arrange the lifting equipment (3).
3
2
1 Mainshaft sleeve
2 Lifting eye bolt
3 Lifting equipment
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A main shaft sleeve weighs up to 36 kg (80 lbs). You
d) Lift the mainshaft sleeve (1) and lower it onto the mainshaft (5).
1 Mainshaft sleeve
4 Mainshaft
e) Remove the lifting equipment (3).
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f) Remove the lifting eye bolts (2) from the mainshaft sleeve (1).
1 Mainshaft sleeve
2 Lifting eye bolt
3 Lifting equipment
g) Attach the nipple (8) to the threaded hole on top of the

mainshaft (4).
h) Turn the cover (7) so that the protrusion (9) points upward.
i) Place the cover (7) on top of the mainshaft sleeve (1), so that the
nipple (8) passes through the widest hole of the cover (7).
j) Lubricate the screws (5) with oil.
k) Attach the cover (7) to the mainshaft (4) with the screws (5) and
the washers (6).
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l) Tighten the screws (5) using a torque wrench.
8
7 9
4
1 Mainshaft sleeve
4 Mainshaft
5 Screw
6 Washer
7 Cover
8 Nipple
9 Protrusion
m) Connect the hose (10) to the nipple (8).

n) Pump oil through the hose (10) with the oil pump (11). Pump until
the oil grooves are filled.
o) Pump up the oil pressure with the oil pump (11) and jack down the
mainshaft sleeve (1) with the cover (7) by tightening the screws (5)
in a circular motion. Torque all screws (5) up to 649 Nm
(479 ft lbs).
p) Wipe off superfluous oil with a cloth.
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q) Release the oil pressure at the pump (11).
11
10
5 8
7 1
1 Mainshaft sleeve
5 Screw
7 Cover
8 Nipple
10 Hydraulic hose
11 Hydraulic pump
r) Use a feeler gauge in the gap (12) to check that the bottom end of
the mainshaft sleeve (1) does not bear against the mainshaft (4).
s) Contact Sandvik if the mainshaft sleeve (1) bears against the
mainshaft (4).
t) Remove the screws (5), the washers (6) and the cover (7).
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u) Remove the nipple (8) from the threaded hole on top of the
mainshaft (4).
4 Mainshaft
5 Screw
6 Washer
7 Cover
8 Nipple
v) Wipe off superfluous oil with a cloth.

w) Use a steel ruler (13) to make sure that the top surface of the
mainshaft sleeve (1) is aligned with the top surface of the
mainshaft (4).
13
4
1
1 Mainshaft sleeve
4 Mainshaft
13 Steel ruler
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x) If necessary, repeat steps g) to w).

y) Install the mainshaft cover (15). Apply Loctite 222, or an
equivalent, to the screws (14).
14
15
14 Screw
15 Mainshaft cover
z) Install and tighten the screws (14) in a circular sequence, gradually

increasing the torque to 220 Nm (162 ft lb).
aa) Seal the gap (12) with silicon.
4 1
12
1 Mainshaft sleeve
4 Mainshaft
12 Gap
3.3.5. Inspecting the head center

NOTE! Before making repairs on the head center, consult Sandvik.
The head center (2) is installed with a shrink fit on the main shaft (1) at
the factory. To confirm that the shrink fit is still sound, check the position
of the head center by measuring from the top of the head center to the
top of the main shaft. See dimension “B” in the figure below. The
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measured dimension “B” must correspond to the larger value that is

stamped on the top end of the main shaft.
Also, check the fit at the larger end of the head center and main shaft.
No play is permitted. If dimension “B” does not correspond to the
stamped value, or if there are other signs that the head center has
come loose, consult Sandvik.
1 Main shaft
2 Head center
3.3.6. Replacing the mainshaft step

3.3.6.1. Removing the mainshaft step
a) Put the mainshaft on stands so that it rests horizontally.
b) Attach the lifting eye bolt (2) to the threaded hole (1) on the
mainshaft step (3).
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d) Remove the retaining ring (4).
1 2
1 Threaded hole
2 Lifting eye bolt
3 Mainshaft step
4 Retaining ring

A main shaft step bearing weighs up to
23 kg (51 lbs). You can sustain crush injuries, fall or
WARNING! even die if you are struck by the load.
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e) Remove the mainshaft step (3) from the mainshaft (5).
5 3
3 Mainshaft step
5 Mainshaft
3.3.6.2. Inspecting the mainshaft step

a) Inspect the step bearing components, see section Inspecting the
step bearing components on page 137.
3.3.6.3. Installing the mainshaft step
a) Attach the lifting eye bolt (1) to the threaded hole (2) on the
mainshaft step (3).
b) Arrange the lifting equipment (4).
2 3 4
1 Lifting eye bolt

2 Threaded hole
3 Mainshaft step
4 Lifting equipment
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c) Lift the mainshaft step (3) carefully to a vertical position.

d) Align the hole (5) on the mainshaft step (3) with the pin (6) at the
bottom of the mainshaft (7).
e) Secure the mainshaft step (3) to the mainshaft (7) with the
retaining ring (8).
f) Remove the lifting equipment and the lifting eye bolt (1).
7 6 5
7 3 8
1 Lifting eye bolt 6 Pin

3 Mainshaft step 7 Mainshaft
5 Hole 8 Retaining ring
3.3.7. Replacing the dust seal ring

The dust seal consists of the dust seal ring (3) and a retaining ring (4).
The dust seal ring (3), which is supported below the head center, has
a sliding fit on the dust collar (1). It is the most important seal for the
crusher’s oil system.
The retaining ring (4) is secured to the head center with screws.
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The crusher also has an inner dust seal ring (2), see section Replacing
the main shaft and the mantle on page 55.
1
2
3
4
5
1 Dust collar
3 Dust seal ring
4 Retaining ring
5 Scraper
3.3.7.1. Removing the dust seal ring

a) Remove the main shaft, see section Removing the main shaft
assembly on page 55.
b) Place the main shaft on suitable supports (planks or similar) on its
side, so that the retaining ring is accessible. Chock up with the
wooden wedges so that the main shaft assembly cannot roll.
c) Protect the bearing surfaces on the main shaft and main shaft
step.
d) Remove the scraper, see section Removing and installing the
scraper on page 96.
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e) Remove the screws (3) and the washers (2) from the retaining ring
(1).
1 Retaining ring
2 Washer
3 Screw
f) Attach the M12x70 screws (5) into the threaded jacking holes (4) in
the retaining ring (1).
g) Attach the lifting eye bolt (6) to the threaded hole (7) on the
retaining ring (1).
h) Take up the slack in the lifting equipment (9) in order to prevent the
retaining ring (1) from falling and damaging the main shaft (10).
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i) Tighten the screws (5) to press off the retaining ring (1) from the
head center (8).
4 5
1
7
9 1
6
5
1
10
1 Retaining ring 7 Threaded hole

4 Threaded hole 8 Head center
5 Screw M12x70 9 Lifting equipment
6 Lifting eye bolt 10 Main shaft

A retaining ring for the dust seal ring weighs up to

A dust seal ring weighs up to 15 kg (33 lbs). You can
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j) Remove the retaining ring (1) and the dust seal ring (11) from the
head center (8).
8 11 1
1 Retaining ring
8 Head center
11 Dust seal ring
3.3.7.2. Checking the dust seal ring

a) Check the machined surfaces on the retaining ring (1) for damage
and rust. Remove scratches and rust by polishing.
b) Check the fit between the retaining ring (1) and the head center
(2). No movement is permissible between these two components.
c) Make sure that the dust seal ring (3) moves easily on the dust
collar under its own weight. If it does not, the hole in the dust seal
ring (3) can be deformed. Adjust the dust seal ring (3) so that it can
easily be moved up and down on the dust collar.
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d) Measure the play between the dust seal ring (3) and the dust
collar. The play must not exceed 0.4-0.8 mm (0.016-0.031″).
3 1
1 Retaining ring
2 Head center
3 Dust seal ring
3.3.7.3. Installing the dust seal ring

a) If the same retaining ring (1) is to be re-used, make sure that the
jacking screws are removed from the threaded holes (4).
b) Attach the lifting eye bolt (3) to the threaded hole (2) on the
retaining ring (1).
c) Arrange the lifting equipment (5).
4 5
3 2 1
1 Retaining ring
2 Threaded hole
3 Lifting eye bolt
4 Threaded hole
5 Lifting equipment
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A dust seal ring weighs up to 15 kg (33 lbs). You can
d) Lift the dust seal ring (7) into place in the recess at the bottom of
the head center (6).
A retaining ring for the dust seal ring weighs up to
e) Lift the retaining ring (1) and position it at the head center (6).
6 7 1
1 Retaining ring
6 Head center
7 Dust seal ring
f) Attach the retaining ring (1) to the head center (6) with the washers
(8) and the screws (9).
g) Remove the lifting equipment and the lifting eye bolt (3).
h) Torque the screws (9) to 169 Nm (125 ft lb).
i) Make sure that the dust seal ring (7) can move freely between the
head center (6) and the retaining ring (1).
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j) Make sure that there is no movement between the retaining

ring (1) and the head center (6).
1 Retaining ring 7 Dust seal ring

6 Head center 9 Screw
3.3.8. Replacing the scraper

3.3.8.1. Checking the scraper
a) Check the scraper for wear and damage. Use the inspection holes
in the bottom shell. If necessary, remove the scraper.
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b) Measure the length (A) of the hanging scraper. If the length of the
hanging scraper is less than 130 mm (5.1 in), replace it according
to section Removing and installing the scraper on page 96.
1 Scraper
3.3.8.2. Removing and installing the scraper

a) Remove the screws (6) and (7), the washers (5), the spacers (4),
the retaining plate (3) and the scraper (2) from the retaining ring
(1).
b) Replace the scraper and assemble in the reverse order.
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c) Torque the screws (6) and (7) to 70 Nm (52 ft lb).
4 4
5 5
6
7
1 Retaining ring 5 Washer

2 Scraper 6 Screw
3 Retaining plate 7 Screw
4 Spacer
3.4. Dust collar
3.4.1. Replacing the dust collar

NOTE! Remove the dust collar only if the eccentric assembly is to be
removed.
3.4.1.1. Removing the dust collar

NOTE! Be careful when the dust collar is removed, so that you do not
damage the underlying gasket.
a) Remove the screws (1) and the washers (2) from the dust collar
(3).
b) Use the full-length threaded screws (4) to press the dust collar off
the bottomshell. Remove the screws.
c) Install the lifting eye bolts (7), distributed evenly in the threaded
holes.
d) Attach the lifting slings to the lifting eye bolts (7). Use four slings
(8).
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A dust collar weighs up to 200 kg (441 lbs). You can
f) Carefully lift the dust collar (3) from the bottomshell.
1, 2
3
4
8
5
7
6
3
1 Screw 5 Hydraulic wrench

2 Washer 6 Hole
3 Dust collar 7 Lifting eye bolts
4 Screw 8 Lifting sling
g) Clean out the remains of the gasket on the mating surfaces of the
dust collar and of the bottomshell.
h) Remove the O-ring. Check the O-ring condition.
3.4.1.2. Inspecting the dust collar
a) Before inspection, make sure to prevent dust from entering the
crusher.
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b) Inspect the fit of the dust collar (1) against the bottomshell (2). If
the dust collar (1) has come loose and the fit against the
bottomshell (2) has been lost, consult Sandvik.
1 Dust collar
2 Bottomshell
c) Inspect the outer surface (4) of the dust collar (1). Make sure that
wear or damage has not made it possible for dust to enter the
crusher between the dust collar (1) and the dust seal ring (5).
1 Dust collar
4 Dust collar outer surface
5 Dust seal ring
3.4.1.3. Installing the dust collar

a) Attach the lifting slings to the lifting eye bolts (2).
A dust collar weighs up to 200 kg (441 lbs). You can
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c) Carefully lift the dust collar (3) and position it above the
bottomshell.
d) Grease the gasket (4) and place it on the dust collar (3).
e) Align the holes in the gasket (4) with the corresponding holes in
the dust collar (3).
f) Align the locating dowel (1) in the bottomshell with the
corresponding hole in the dust collar (3).
g) Lower the dust collar (3), with the gasket (4), onto the bottomshell.
h) Remove the lifting equipment and the lifting eye bolts (2).
i) Install the screws and the washers in the dust collar.
j) Torque the screws in a diagonal sequence in several stages until
the specified torque is reached, refer to Tightening torques in
2 3
4 1
1 Locating dowel
2 Lifting eye bolt
3 Dust collar
4 Gasket
3.4.2. Replacing the seating ring
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3.4.2.1. Removing the seating ring

a) Gently tap the seating ring (1) from below to release it from its
seating in the dust collar (2).
1
2
1 Seating ring
2 Dust collar
b) Lift out the seating ring (1) from the dust collar (2).
1 Seating ring
2 Dust collar
3.4.2.2. Installing the seating ring

a) Lower the seating ring (1) into its seating in the dust collar (2).
1 Seating ring
2 Dust collar
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b) Gently tap the seating ring (1) into place from above.
1
2
1 Seating ring
2 Dust collar
3.4.3. Replacing the locating bar

3.4.3.1. Checking the locating bar clearance
NOTE! If the gear backlash is adjusted, the locating bar clearance

must be checked.
a) Remove the inner dust seal ring (1), the seating ring (2) and the
bushing retaining ring (3).
b) Measure the clearance “A” between the locating bar (4) and the
hub (7) with a feeler gauge.
• The clearance “A” is normally 0.2 mm (0.008").
• The maximum permissible clearance is 0.4 mm (0.016").
c) If necessary, adjust the clearance “A” by removing or adding
shims (8) between the locating bar (4) and the dust collar (5).
1 5
2 8
3 A
4
4
5
7
1 Inner dust seal ring 5 Dust collar

2 Seating ring 6 Eccentric bushing
3 Bushing retaining ring 7 Hub
4 Locating bar 8 Shims
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3.4.3.2. Removing the locating bar

a) Remove the screws that hold the locating bar (4) to the underside
of the dust collar (5).
b) Remove the locating bar (4).
1 5
2 8
3 A
4
4
5
7

3.4.3.3. Installing the locating bar

a) Position the locating bar (4) on the underside of the dust collar (5).
Make sure that the holes in the locating bar (4) are aligned with the
corresponding holes in the dust collar (5) and remember to fit the
shims, see section Checking the locating bar clearance on page
102.
b) Apply locking fluid, Loctite 243 or similar (medium strenght), to the
threads.
c) Install the screws that hold the locating bar (4) to the dust collar
(5).
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d) Tighten the screws to 45 Nm (33 ft lbs) ±10 %. (This torque is

calculated with the strength of the threads in the locating bar (4)
taken into consideration, and is independent of what grade of
screw is used.) Refer to Tightening torques in Technical
specifications.
1 5
2 8
3 A
4
4
5
7

3.5. Eccentric
3.5.1. Replacing the eccentric bushing

The eccentric bushing is part of the eccentric assembly and it is held in
place by a retaining ring and a key. The eccentric throw of the crusher is
altered by changing the eccentric bushing or by lifting up the bushing
and moving the key to another keyway in the eccentric. Three different
bushings are available for the crusher, each with different eccentric
throws.
NOTE! The throw (in mm) (1) is stamped into the top edge of the bushing
near the relevant keyway (2) together with the letter H for an H-
type Cone crusher. An arrow stamped into the top of the eccentric
in line with the keyway indicates which eccentric throw has been
set (e.g. H-32).
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4
3 H3
6
0
H4
H44
1
H48
2
1 Machine type and throw

2 Keyway
3 Oil groove
4 Lifting eye hole
Eccentric throw combinations

mm inches
13 0.51
16 0.63
20 0.79
24 0.94
24 0.94
28 1.10
32 1.26
32 1.26
36 1.42
40 1.57
44 1.73
For details of the play between the mainshaft and the eccentric bushing,
see section Checking the main shaft and the mantle on page 56.
If the bushing is a tight fit, the whole eccentric assembly can be
removed, see section Removing the eccentric assembly on page 110.
There are two alternative methods to remove the eccentric bushing from
the cone crusher. If the first method does not work, then try the
alternative method.
3.5.1.1. Removing the eccentric bushing
NOTE! Before starting these procedures it is necessary to remove the
mainshaft, the inner dust seal ring and the seating ring.
If the ambient air temperature is < 30 °C (86 °F), then continue as

described below. If the ambient air temperature is > 30 °C (86 °F), cool
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the bushing with a plastic bag of dry ice placed inside the bushing for
30 minutes before removal is started.
a) Remove the eccentric bushing retaining ring (1) from the top of the
eccentric (3). The ring is in two parts, of which only the part locking
the eccentric bushing need be removed.
b) Use the special lifting tool (5) in the tool kit which is supplied with
the cone crusher to pull the eccentric bushing (4) from the
eccentric.
c) Attach the lifting slings to the lifting tool (5).
d) Arrange the lifting equipment.
An eccentric bushing weighs up to 130 kg (287 lbs).
You can sustain crush injuries, fall or even die if you
WARNING! are struck by the load.

Never start the lift by using just the lifting eye bolts,
threaded into the top edge of the eccentric bushing.
NOTICE If the eccentric is jammed, the threads may be
damaged. Always start removal by using the special
lifting tool.
e) Carefully lift the eccentric bushing (4) approximately

10 mm (0.39").
NOTE! The eccentric bushing (4) can still be stuck in the
eccentric (3). Make sure not to overload the lifting
equipment.
f) Install four lifting eyes in the threaded holes in the top of the
eccentric bushing (4).
g) Arrange the lifting equipment.
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h) Carefully lift out the eccentric bushing (4) for a better balanced
removal.
2 3
1 4
5
1 Bushing retaining ring

2 Hub
3 Eccentric
4 Eccentric bushing
5 Lifting tool
3.5.1.2. Removing the eccentric bushing - Alternative method

NOTE! If the eccentric bushing (3) is a tight fit, the whole eccentric
assembly can be removed, see section Removing the eccentric
If the ambient air temperature is < 30 °C (86 °F), then continue as
described below.
If the ambient air temperature is > 30 °C (86 °F), cool the
eccentric bushing (3) with a plastic bag of dry ice placed inside
the bushing for 30 minutes before removal is started.
Drive out the eccentric bushing (3) from the eccentric (4) with a wooden
block (5) and a hammer.
NOTICE Protect the bearing surface on the upper side of the
hub from damage.
NOTE! If the bushing cannot be driven out in this way, it must be pressed
out with a hydraulic jack, as shown below:
If the mainshaft and the mantle have rotated at the same speed as
the eccentric (4) during operation, it is probable that the eccentric
bushing (3) has seized on the mainshaft. If so, the mainshaft can not
be removed the normal way. The dust collar must be freed so that the
mainshaft and eccentric assembly can be lifted out.
Try to remove the screws that hold the eccentric bushing retaining
ring to the top of the eccentric.
If it is not possible to remove the screws, try to push the eccentric
downwards. If this cannot be done, the dust collar must be destroyed.
The eccentric (4) can then be removed from the mainshaft and the
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1
2
3
1 Reaction beam
2 Plate
3 Eccentric bushing
4 Eccentric
5 Wooden blocks
3.5.1.3. Inspecting the eccentric bushing

a) Inspect the bore (1) of the eccentric (2). It must be smooth and not
oval or conical. Any ovality or conicity must be corrected by
scraping or grinding the bore of the eccentric with a belt grinder.
b) Measure and calculate the play between the eccentric bushing
bearing surface (5) and the eccentric (1). The maximum permitted
play is 0.22 mm (0.009 in).
c) Inspect the bearing surface (6) of the main shaft for wear and
damage.
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d) Inspect the bore (4) of the eccentric bushing (3) to make sure that
it is not deformed, and that the surface is smooth.
3 4
6
2 1
1 Eccentric bore 4 Eccentric bushing bore

2 Eccentric 5 Eccentric bushing bearing surface
3 Eccentric bushing 6 Main shaft bearing surface
NOTE! If the main shaft is seized in the eccentric bushing, the

resulting high temperature can lead to so-called heat
cracks (reminiscent of fish scales) on the bearing surface
of the main shaft. These heat cracks are narrow vertical
lines, between 3 and 5 mm (0.12-0.2 in) long and up to
0.5 mm (0.02 in) deep, and can be difficult to discover. If
they are not dealt with there is a major risk of a new failure.
Consult Sandvik for information on corrective measures.
3.5.1.4. Installing the eccentric bushing

a) Make sure that the key is correctly installed in the eccentric
bushing (4) before the bushing is installed in the eccentric (3).
b) Install lifting eye bolts (5) into the threaded holes in the top of the
c) Attach lifting slings to the lifting eye bolts (5).
e) Coat the outer surface of the eccentric bushing (4) with oil.
NOTE! Under certain circumstances, for instance if the ambient air
temperature is higher than 35°C (95°F), the bushing can
be distorted. If so, let it cool and then carefully press the
bushing into place. Never hit the bronze bushing. An out-
of-round bushing must be replaced.
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f) Carefully lift the eccentric bushing (4).

g) Make sure that the top flange of the eccentric bushing (4) seats
properly in the recess at the top of the eccentric (3), and does not
lie above the top of the eccentric (3).
h) Fit the eccentric bushing retaining ring (1) which locks the
eccentric bushing (4) in the eccentric (3).
i) Apply locking fluid to the screws and tighten them to the correct
torque, refer to Locking fluids for threaded fasteners and
Tightening torques in Technical Specifications.
j) If the eccentric throw has been changed, be sure to make a note of
the new value.
2 3
1 4

2 Hub
3 Eccentric
4 Eccentric bushing
5 Lifting eye bolt
k) If a new eccentric bushing has been installed, follow the procedure

described in Running-in on page 239
3.5.2. Replacing the eccentric assembly

3.5.2.1. Removing the eccentric assembly
a) Remove the top shell, see section Removing the top shell on page
38.
b) Remove the main shaft, see section Removing the main shaft
c) Remove the dust collar, see section Removing the dust collar on
page 97.
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The eccentric may fall out if the bushing retaining
NOTICE ring (4) is removed before the lift.
Do not remove the bushing retaining ring (4) before
the lift.
d) Attach lifting eye bolts (3) to the threaded holes on top of the gear
carrier (2).
3
2
1
1 Inspection hole
2 Gear carrier
3 Lifting eye bolt

An eccentric assembly weighs up to
750 kg (1654 lbs). You can sustain crush injuries, fall
WARNING! or even die if you are struck by the load.
f) Lift the eccentric assembly approximately 10 mm (0.4").

g) NOTE! If the eccentric has seized in the bottom shell bushing, the
bottom shell bushing and the wearing plate will also be
removed when the eccentric assembly is lifted out.
Use a screwdriver through the inspection hole (1) in the gear
carrier (2) to make sure that the wearing plate has not been lifted
with the eccentric assembly, but remains in the bottom shell.
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h) NOTE! If there is severe damage to the bearing surface of the

bottom shell bushing, the bushing must sometimes be split
in order to remove it.
Carefully lift out the eccentric assembly and place it on trestles.
Make sure that you do not damage the bottom shell bushing.
3.5.2.2. Inspecting the eccentric assembly

a) Examine the bearing surfaces of the eccentric (2) for scratches
and signs of heavy wear or excessive temperature, such as dark
spots or patterns of heat cracks.
NOTE! If the main shaft is seized in the eccentric bushing (1), the
resulting high temperature can lead to so-called heat
cracks (reminiscent of fish scales) on the bearing surface
of the main shaft. These heat cracks are narrow vertical
lines, 3 to 5 mm (0.12 to 0.20") long and up
to 0.5 mm (0.02") deep and can be difficult to discover. If
they are not dealt with there is a major risk of a new failure.
Consult Sandvik for information about corrective
measures.
b) Examine the inner surface of the eccentric bushing (1) for wear,
scratches or dark spots, which can indicate that the bushing has
been subjected to high temperatures.
c) Inspect the bottom shell bushing according to section Installing the
bottom shell bushing on page 125.
1 Eccentric bushing
2 Eccentric
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3.5.2.3. Installing the eccentric assembly

a) Attach lifting eye bolts (3) to the threaded holes on the gear
carrier (2).
c) Coat the outer surface of the eccentric with oil.
The eccentric may fall out if the bushing retaining
NOTICE ring (4) is not mounted.
Make sure that the bushing retaining ring (4) is
mounted before the lift.

An eccentric assembly weighs up to
d) Lift the eccentric assembly.

e) Carefully lower the eccentric assembly into the bottomshell
bushing. Make sure that you do not damage the bottomshell
bushing.
f) When the eccentric is approximately 10 mm (0.4") from its final
position, rotate the pinionshaft slightly, in both directions, while
carefully lowering the eccentric assembly, to ensure that the gear
and the pinion mesh correctly.
3
2
1
1 Inspection hole
2 Gear carrier
3 Lifting eye bolt
3.5.3. Replacing the eccentric hub and gear
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3.5.3.1. Removing the eccentric hub and gear

a) Remove the eccentric assembly, see section Removing the
eccentric assembly on page 110 and put it on a stand.
b) Remove the eccentric bushing from the eccentric, see section
Removing the eccentric bushing on page 105.
c) Remove the screws (2) and (3) and the washers (1).
2 3
1
1
1 Washer
2 Screw
3 Screw
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d) Release the gear (6) from the hub (7) by using the screws (2)
and (3) as jacking screws in the threaded holes (4) and (5) on the
hub (7).
2
3
4
5
6
7
2 Screw 5 Threaded hole

3 Screw 6 Gear
4 Threaded hole 7 Hub
e) Attach lifting eye bolts (8) to the threaded holes on the hub (7).
7 Hub
8 Lifting eye bolt
f) Arrange the lifting equipment.
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A hub assembly weighs up to 330 kg (728 lbs). You
g) Carefully lift off the hub and eccentricassembly (7, 9) from the gear
(6) and place it on a wooden support.
6 Gear
7 Hub
9 Eccentric
h) Heat the hub (7) to 40 °C (104 °F) above the ambient air
temperature. For example, heat to 60 °C (140 °F) in an ambient air
temperature of 20 °C (68 °F).
A hub weighs up to 170 kg (375 lbs). You can sustain
crush injuries, fall or even die if you are struck by the
WARNING! load.
i) Carefully lift off the hub (7) from the eccentric (9) and place it on a
wooden support.
j) Make sure to collect the key (10).
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k) Remove the lifting equipment and the lifting eye bolts.
10
9
7 Hub
9 Eccentric
10 Key
3.5.3.2. Inspecting the eccentric hub and gear

a) Examine the bearing surfaces (2) on the hub (1) for wear and
damage.
b) Examine the teeth (4) on the gear (3) for signs of wear, see section
Tooth bearing “footprint” on page 206.
1 Hub
2 Bearing surface
3 Gear
4 Teeth
3.5.3.3. Installing the eccentric hub and gear

a) Remove the eccentric assembly, see section Removing the
eccentric assembly on page 110.
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b) Remove the eccentric bushing, see section Removing the

eccentric bushing on page 105.
c) Heat the hub (3) to 40 °C (104 °F) above the ambient air
temperature. For example, heat to 60 °C (140 °F) in an ambient air
temperature of 20 °C (68 °F).
Hot surface hazard
component.
Use heat-resistant protective gloves.
WARNING!
d) Attach lifting eye bolts (5) to the hub (3).

f) Make sure that the key (2) is in place on the eccentric (1).
A hub weighs up to 170 kg (375 lbs). You can sustain
crush injuries, fall or even die if you are struck by the
WARNING! load.
g) Carefully lift the hub (3). Align the groove (4) on the hub (3) with
the key (2) on the eccentric (1) and lower the hub (3) onto the
eccentric (1).
h) Allow the hub (3) to cool down before continuing the installation.
1
1 Eccentric 4 Groove
2 Key 5 Lifting eye bolt
3 Hub
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i) Put the gear (7) on a suitable support (6).

A hub assembly weighs up to 330 kg (728 lbs). You
j) Carefully lift the hub and eccentric assembly (1, 3). Align the
unthreaded holes on the hub (3) with the threaded holes on the
gear (7) and lower the hub and eccentric assembly (1, 3) onto the
gear (7).
1 Eccentric 6 Support
3 Hub 7 Gear
k) Remove the lifting equipment.

l) Apply locking fluid, Loctite 241 or similar (medium strength), to the
threads of the screws (9) and (10).
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m) Attach the gear (7) to the hub (3) with the washers (8) and the
screws (9) and (10). Tighten the screws (9) and (10), refer to
Tightening torques in Technical specifications.
9 10
8
8
8 Washer
9 Screw
10 Screw
3.5.4. Replacing the eccentric wearing plate

3.5.4.1. Inspecting the eccentric wearing plate
a) Measure the thickness of the eccentric wearing plate (2). Replace
the eccentric wearing plate (2) if the thickness is less than
25 mm (0.98 in).
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b) NOTE! Check the gear backlash, see section Checking the gear
backlash on page 201, if the eccentric wearing plate is
worn, but has not yet reached the minimum thickness. This
to prevent damage to the gear and pinion.
Inspect the spiral pins (3) that lock the eccentric wearing plate (2)
to the bottom shell (4). If the spiral pins are damaged, replace
them.
2
3
4
5
2 Eccentric wearing plate

3 Spiral pin
4 Bottom shell
5 Bottom shell bushing
3.5.4.2. Removing the eccentric wearing plate

a) Remove the topshell, see section Removing the top shell on page
38.
b) Remove the mainshaft, see section Removing the main shaft
c) Remove the dust collar, see section Removing the dust collar on
page 97.
d) Remove the eccentric assembly, see section Removing the
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e) Attach lifting eye bolts (1) to the threaded holes (2) on the
eccentric wearing plate (3).
1 Lifting eye bolt

2 Threaded hole
An eccentric wearing plate weighs up to
f) Lift out the eccentric wearing plate (3) from the bottomshell (4).

4 Bottomshell
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3.5.4.3. Installing the eccentric wearing plate

a) Attach the lifting eye bolts (1) to the threaded holes (2) on the
eccentric wearing plate (3).
An eccentric wearing plate weighs up to
c) Lift the eccentric wearing plate (3).

d) Lower the eccentric wearing plate (3) to a position just above the
bottomshell bushing (7).
e) Align the holes on the eccentric wearing plate (3) with the spiral
pins (5).
f) Align the recesses (6) on the bottomshell bushing (7) with the
locking lugs (8) on the eccentric wearing plate (3) by turning the
bottomshell bushing (7).
1 3
4
8
5
6
1 Lifting eye bolt 5 Spiral pin

2 Threaded hole 6 Recess
3 Eccentric wearing plate 7 Bottomshell bushing
4 Hole 8 Locking lug
g) Lower the eccentric wearing plate (3) into the bottomshell (9).
h) Remove the lifting equipment.
i) Remove the lifting eye bolts (1) from the eccentric wearing plate
(3).
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j) Install the eccentric assembly, see section Installing the eccentric

k) Install the dust collar, see section Inspecting the dust collar on
page 98.
l) Install the mainshaft, see section Installing the main shaft
m) Install the topshell, see section Installing the top shell on page 41.
1 Lifting eye bolt

9 Bottomshell
3.6. Bottomshell
3.6.1. Replacing the bottom shell bushing

NOTE! There must be enough space for the bottom shell bushing to
expand due to friction heat.
3.6.1.1. Removing the bottom shell bushing

Normally, the bottom shell bushing (3) can be easily removed.
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a) Place a lifting tool (4) under the bottom edge of the bottom shell
bushing (3). Use the lifting tool in the tool kit that is supplied with
the crusher.
3
4
1 Bottom shell
2 Threaded hole
4 Lifting tool
b) Lift the bushing slightly from its seating in the bottom shell (1).
NOTE! The lifting tool is not to be used to lift the bushing out of the
bottom shell.
c) Install lifting eye bolts in the holes (2) in the bottom shell bushing
(3). Use the lifting eye bolts that are supplied with the crusher’s
tool kit.
NOTE! The lifting eye bolts are not to be used to pull the bushing
from its seating in the bottom shell.
A bottom shell bushing weighs up to
e) Lift the bottom shell bushing (3) out of the bottom shell.
NOTE! The bottom shell bushing (3) can still be stuck to the
bottom shell. Make sure not to overload the lifting
equipment.
3.6.1.2. Installing the bottom shell bushing

a) Install lifting eye bolts in the holes (2) in the bottom shell
bushing (3). Use the lifting eye bolts that are supplied with the
crusher’s tool kit.
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A bottom shell bushing weighs up to
c) NOTE! The lugs on the eccentric wearing plate are fixed in relation
to the bottom shell, so that the bottom shell bushing must
be rotated to a position where its indentations match the
eccentric wearing plate protrusions. The flange around the
top of the bottom shell bushing (3) must be in contact with
the top of the bottom shell hub.
Lift the bottom shell bushing (3) and lower it into the
bottom shell (1).
a. If the bore of the bottom shell is not circular, it can be difficult
to install the bottom shell bushing (3). Any ovality or conicity
of the bottom shell bore must be removed by scraping or
grinding.
b. If the bottom shell bore is circular, a slightly oval bushing can
be carefully pressed down into place.
1 Bottom shell
2 Threaded hole
3.6.2. Replacing the Hardox liners

3.6.2.1. Removing the Hardox liners
To protect the bottomshell from wear, it is necessary to replace the
liners on the inside of the bottomshell, when they are worn out. If holes
have been worn in the liners, they must be replaced immediately.
a) Remove the old liner plates from the inside of the bottomshell.
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b) Remove the old bottomshell arm liners.
6 7 8 4 4 9 3
5 4 3 2 1
1 Liner -pin shaft arm 6 Wearing plates

2 Wearing plates 7 Wearing plates
5 Liner - narrow arm
3.6.2.2. Installing the Hardox liners

To protect the bottomshell from wear, it is necessary to replace the
liners on the inside of the bottomshell, when they are worn out. If holes
have been worn in the liners, they must be replaced immediately.
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a) Clean the new liner plates for the inside of the bottomshell.
b) Weld lifting lugs to the liners. The electrode must meet the
requirements of SS-EN ISO 2560: E42 4 B 42 H5(for example, an
ESAB OK 48.00 electrode). Use an A-dimension of 6 mm (0.24").
c) Position the plates as shown in the figure below. Use timber or
similar to press the plates into position.
d) Weld the plates to the inside of the bottomshell in the recesses
provided. Use an A-dimension of 6 mm (0.24").
e) Clean the new bottomshell arm liners.
f) Position the arm liners on the bottomshell arms.
g) Use pieces of round bar to fill the gaps between the manganese
liners and the bottomshell.
h) Weld between the round bar and the bottomshell. The electrode
must meet the requirements of SS-EN ISO 2560: E42 4 B 42
H5(for example ESAB OK 48.00 electrode). Use an A-dimension of
6 mm (0.24").
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i) Weld between the round bar and the manganese liners. The
electrode must meet the requirements of EN ISO 1600: E 18 8 Mn
B 4 2(for example ESAB OK 67.45 electrode). Use an A-dimension
of 6 mm (0.24").
6 7 8 4 4 9 3
5 4 3 2 1
1 Liner -pin shaft arm (1010-1) 6 Wearing plates (1320-4)

2 Liner - narrow arm (1010-2) 7 Wearing plates (1320-5)
3 Wearing plates (1320-1) 8 Wearing plates (1320-6)
4 Wearing plates (1320-2) 9 Wearing plates (1320-7)
5 Wearing plates (1320-3)
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3.7. Hydroset cylinder
3.7.1. Replacing the Hydroset piston

The chevron packing (1) is attached to the bottom of the piston with a
clamping ring.
Narrow oil channels on the outside of the piston (2) supply oil to an oil
groove in the upper part of the piston. This lubricates the upper part of
the piston, and prevents dirt from entering between the piston and the
Hydroset bushing (3). The oil enters the crusher through the wall of the
Hydroset cylinder, flows through the Hydroset piston and up through the
step bearing.
1 Chevron packing
2 Hydroset piston
3 Hydroset bushing
3.7.1.1. Removing the Hydroset piston

a) Disconnect the supply line for the lubricating oil.
b) Raise the piston (2) far enough for the oil inside the piston to drain.
c) Remove the Hydroset piston position transmitter, see section
Removing the Hydroset piston position transmitter B1N/K1-GT1 on
page 154, to avoid damage when the piston is lowered.
d) Lower the piston (2) to its lowest position.
NOTE! Do not remove the Hydroset oil hoses (3). The oil can be
drained from the Hydroset hoses and the Hydroset cylinder
by removing the drain plugs. This will also ensure that
there is no vacuum when the piston is lifted.
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e) Remove the drain plug (1).
1 Drain plug
f) NOTE! The oil volume to be drained is

approximately 8 liters (2.1 US gallons). The oil volume can
vary depending on hose length.
Drain the Hydroset line by disconnecting the hose from the back of
the Hydroset tank unit.
g) Install the lifting eye bolts (4) in the holes in the Hydroset piston.
h) Position the hook of a crane vertically above the bottom shell (5).
Attach lifting slings to the hook.
i) Arrange the lifting equipment.
A Hydroset piston weighs up to 186 kg (410 lbs). You
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j) Lift the Hydroset piston (2) out of the bottom shell (5).
NOTE! A small quantity of oil can still remain inside the Hydroset
piston (2). Be prepared to collect this oil.
2 Hydroset piston
3 Connections for Hydroset hoses
4 Lifting eye bolt
5 Bottom shell
3.7.1.2. Inspecting the Hydroset piston

a) Clean the Hydroset piston.
b) Inspect the outer surface of the piston for wear and damage.
c) Inspect the chevron packing. If necessary, replace it, see section
Replacing the chevron packing on page 144.
d) Inspect the bore of the Hydroset cylinder bushing, see section
Inspecting the Hydroset cylinder bushing on page 152.
3.7.1.3. Installing the Hydroset piston
a) Coat the rubbing surfaces of the piston and the Hydroset cylinder
bushing with molybdenum disulfide.
b) Carefully lubricate the sealing lips of the chevron packing.
c) Install lifting eye bolts in the threaded holes in the Hydroset piston.
d) Position the hook of a crane vertically above the Hydroset piston.
Attach lifting slings to the hook.
e) Attach the lifting slings to the lifting eye bolts.
A Hydroset piston weighs up to 186 kg (410 lbs). You
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Make sure that you do not damage the sealing lips of
NOTICE the chevron packing when the piston is lowered into
the Hydroset cylinder and into the Hydroset cylinder
bushing.
g) Lift the Hydroset piston, then carefully lower it into the bottom shell.
NOTE! A new chevron packing can make it difficult to push the

piston down into the bushing. If so, install the step bearing
components and use the main shaft as a weight to
carefully press the piston into the bushing.
h) Install the drain plug (1).
1 Drain plug
i) Fill the Hydroset system with oil and bleed out all air, see section
Bleeding air from the Hydroset system on page 156.
3.7.2. Replacing the step bearing components

Sandvik recommends that you inspect the step bearing components in
conjunction with liner changes and renew the bearing components at
intervals which are based on experience.
NOTE! If wear on the step bearing components is severe, see Operator's

troubleshooting in the Operator's Instructions.
3.7.2.1. Removing the step bearing components

The step bearing components can be lifted up through the eccentric
bushing with the help of the special lifting tool kit, which is supplied with
the crusher.
NOTE! Since the step bearing components are covered in oil, they stick
together. When removing the plates it is crucial to make a circular
movement before lifting the bearing components. The adhesive
oil film will then let go. The procedure is done with advantage
when the oil is warm. It is important to lift the step washer
extremely slow, without sudden snatch.
a) Step washer
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a) NOTE! WLL (working load limit) for the lifting tool is

700 kg (1545 lbs).
NOTE! Avoid damaging or scratching the eccentric bushing.
Attach the lifting tool (1) to the threaded hole (2) on the step
washer (3).
11
3 2
1 Lifting tool
2 Threaded hole
3 Step washer
b) Make a circular movement while holding the lifting sling, until the
adhesive oil film lets go. It is advisable to lift the step washer (3) a
few centimeters at first, and then have a break for a few minutes.
In case the piston wearing plate (4) is stuck to the step washer (3),
it will then let go.
c) Lift off the step washer (3) very slowly upwards until it reaches the
brim of the eccentric bushing.
d) Carefully lift until the whole step washer (3) is visible. Check that
the washer (3) has come loose. If not, lower the step washer (3)
carefully to its bottom position and follow the instructions from b)
again.
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e) Lift off the step washer (3) from the piston wearing plate (4) and
out from the Hydroset cylinder (5). Lower it onto timber supports on
the ground.
33
3
3 44 55 4
4
3 Step washer
4 Piston wearing plate
5 Hydroset cylinder
b) Piston wearing plate
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f) NOTE! WLL (working load limit) for the lifting tool is

700 kg (1545 lbs).
Attach the lifting tool (1) to the threaded hole (2) on the
piston wearing plate (3).
3 2
1 Lifting tool
2 Threaded hole

A piston wearing plate weighs up to 25 kg (56 lbs).
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g) Lift off the piston wearing plate (3) from the Hydroset piston (4) and
out from the Hydroset cylinder (5). Lower it onto timber supports on
the ground.
5 4

4 Hydroset piston
5 Hydroset cylinder
c) Mainshaft step
h) Remove the main shaft step, see section Removing the mainshaft
step on page 85.
3.7.2.2. Inspecting the step bearing components
The mainshaft step (1) and the piston wearing plate (3) are made of
bronze with a high lead content, which sometimes causes a temporary
blackening of the rubbing surfaces. The step washer (2) is made of
steel. Even though the step washer manually wears less than the other
two components all three must be changed at the same time to ensure
that the geometry of the bearing is correct.
Recurrent problems with the step bearing indicate that the crusher is
overloaded or that the oil is contaminated.
If the surfaces have been overheated, it is very likely that they are
uneven. With the three step bearing components assembled on top of
each other, use feeler gauges to measure the play between the step
bearing components, as shown by the arrows.
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1 Main shaft step

2 Step washer
Measure both from the outside and the inside at four points 90° apart.
This means totally 16 measurements. The maximum permitted play is
0.03 mm (0.001 in).
a) Make sure that the step bearing and the main shaft step are clean
from burr. By hand, use sand paper to make the edges sharp.
4 5
4 Burr
5 Sharp edge
b) NOTE! If the wear on the step bearings is severe, see section The
pinion shaft does not operate correctly on page 247.
Use a straight-edge to measure the total thickness (H-dimension)
of the step bearing. The thickness of a new step bearing is
110 mm (4.33 in). When the total thickness of the step bearing has
been reduced to 95 mm (3.74 in), all three step bearing
components must be replaced.
1
H 2
3
1 Mains haft step

2 Step washer
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3.7.2.3. Installing the step bearing components

a) Piston wearing plate
a) NOTE! WLL (working load limit) for the lifting tool is
700 kg (1545 lbs).
Clean the piston wearing plate (3).
b) Turn the piston wearing plate (3) so that the flat (grooved) surface
is facing upwards.
c) Attach the lifting tool (1) to the threaded hole (2) on the piston
wearing plate (3).
11
33 22
1 Lifting tool
2 Threaded hole
A piston wearing plate weighs up to 25 kg (56 lbs).
d) Lift the step piston wearing plate (3).

e) Apply a coat of lubricating oil to the top surface of the piston
wearing plate (3).
f) Align the hole (7) on the piston wearing plate (3) with the pin (6) on
the Hydroset piston (4).
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g) Lower the piston wearing plate (3) onto the Hydroset piston (4) in
the Hydroset cylinder (5).
77 33
66 4
4
55

4 Hydroset piston
5 Hydroset cylinder
6 Pin
7 Hole
h) Remove the lifting equipment.
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i) Remove the lifting tool (1) from the piston wearing plate (3).
11
33
1 Lifting tool
b) Step washer
j) NOTE! WLL (working load limit) for the lifting tool is
700 kg (1545 lbs).
Clean the step washer (3).
k) Turn the step washer (3) so that the flat surface is facing
downwards.
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l) Attach the lifting tool (1) to the threaded hole (2) on the
step washer (3).
11
33 2
1 Lifting tool
2 Threaded hole
3 Step washer

m) Lift the step washer (3).

n) Apply a coat of lubricating oil to both surfaces of the
step washer (3).
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o) Lower the step washer (3) onto the piston wearing plate (4) in the
Hydroset cylinder (5).
33
55 44
3 Step washer
5 Hydroset cylinder
p) Remove the lifting equipment.
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q) Remove the lifting tool (1) from the step washer (3).
11
1 Lifting tool
3 Step washer
c) Main shaft step
r) Install the main shaft step, see section Installing the mainshaft step
on page 87.
s) If a new set of step bearing components has been installed, follow
the procedure described in Running-in on page 239
3.7.3. Replacing the chevron packing

3.7.3.1. Removing the chevron packing
a) Remove the Hydroset piston, see Removing the Hydroset piston
on page 130.
b) Remove the screws (1) and the packing clamping plate (2) from
the Hydroset piston (3).
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c) Remove the chevron packing (4) from the Hydroset piston (3).
3 3
4
2
1 Screw
2 Packing clamping plate
3 Hydroset piston
4 Chevron packing
3.7.3.2. Inspecting the chevron packing

a) Remove the Hydroset cylinder, see section Removing the Hydroset
piston on page 130.
b) Inspect each ring of the chevron packing (2) for damage.
c) Inspect the step bearing components, see section Inspecting the
step bearing components on page 137 and the Hydroset cylinder
bore, see section Inspecting the Hydroset cylinder bushing on
page 152.
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d) Install the Hydroset cylinder, see section Installing the Hydroset

piston on page 132.
1 Hydroset cylinder
2 Chevron packing
3 Hydroset cylinder bore
3.7.3.3. Installing the chevron packing

a) Lubricate each ring of the chevron packing (2).
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b) Install the chevron packing (2) on the Hydroset piston (1). Make
sure that the sealing lips (3) point downward.
3 3
1 Hydroset piston
2 Chevron packing
3 Sealing lips
c) Apply locking fluid to the screws (5).

d) Attach the packing clamping plate (4) to the Hydroset piston (1)
with the screws (5).
e) Torque the screws (5) to 70 Nm (52 ft lb.)
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f) Make sure that the packing clamp plate (4) is pulled up tight
against the Hydroset piston (1), so that the chevron packing (2) is
compressed slightly.
1 Hydroset piston
2 Chevron packing
4 Packing clamping plate
5 Screw
NOTE! The chevron packing (2) will be correctly clamped once it

and the piston (1) is installed in the Hydroset cylinder.
3.7.4. Checking the torque of the Hydroset cylinder

joints
Normally, it is not necessary to remove the Hydroset cylinder (2) from
the bottom shell (1) or the Hydroset cylinder cover (3) from the Hydroset
cylinder (2).
The joints between the Hydroset cylinder (2) and the bottom shell (1)
and the joint between the Hydroset cylinder cover (3) and the Hydroset
cylinder (2) are sealed with O-rings. Unless there is severe leakage,
they do not need to be replaced.
Hydroset cylinder cover/Hydroset cylinder and Hydroset cylinder/
bottomshell joints
a) Lightly lubricate the screws (4) and (5) with oil.
b) Clean the threads in the bottom shell (1) and in the Hydroset
cylinder (2).
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c) Torque the screws (4) and (5) in stages, and in circular rotation. Refer
to Tightening torques in Technical specifications. Use a torque
wrench that can be calibrated, or a bolt/nut runner with a torque
limiter.
1
2 5
3 4
1 Bottom shell 4 Screw
2 Hydroset cylinder 5 Screw
3 Hydroset cylinder cover
3.7.5. Replacing the Hydroset cylinder bushing

3.7.5.1. Removing the Hydroset cylinder bushing
a) Depending on the on-site circumstances, step 2 can be performed
first or last.
A crusher weighs up to 16 200 kg (35 715 lbs). You
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b) Remove the crusher from its foundation/subframe and place it in a

clean environment. Place the crusher on a suitable support (1),
which is placed on a hard surface. Make sure that there is enough
room under the Hydroset cylinder in order to be able to remove the
Hydroset cylinder bushing from below with the help of a hydraulic
jack.
1 Support
c) Remove the feed hopper, see section Removing the feed hopper
on page 24.
d) Remove the spider cap, see section Removing the spider cap on
page 28 and the spider bearing grease.
e) Remove the top shell, see section Removing the top shell on page
38.
f) Remove the main shaft, see section Removing the main shaft
g) Remove the dust collar, see section Removing the dust collar on
page 97.
h) Remove the eccentric assembly, see section Removing the
i) Remove the step washer and the piston wearing plate, see section
Removing the step bearing components on page 133.
j) Remove the Hydroset piston position transmitter and the Hydroset
piston, see section Removing the Hydroset piston on page 130.
k) Place a hydraulic jack with a wooden block under the Hydroset
cylinder (5). Raise the jack until the wooden block supports the
Hydroset cylinder cover (4) from below.
l) Remove the screws (2) and the washers (3).
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m) Lower the jack and remove the Hydroset cylinder cover (4) from
2
2 Screw 4 Hydroset cylinder cover
3 Washer 5 Hydroset cylinder
n) Place the hydraulic jack with a wooden block under the Hydroset
cylinder (5). Raise the jack until the wooden block supports the
Hydroset cylinder bushing (9) from below.
o) Remove the screw (6) and the washer (7).
p) Lower the jack and remove the Hydroset cylinder bushing (9) from
q) Remove the o-ring (8) from the Hydroset cylinder bushing (9).
9
8
7
6
5 Hydroset cylinder 8 O-ring
6 Screw 9 Hydroset cylinder bushing
7 Washer
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3.7.5.2. Inspecting the Hydroset cylinder bushing

a) Inspect the inner surface of the Hydroset cylinder bushing for
damage, such as scratches or unevenness. No damage is
permitted. (Scratches or unevenness can allow Hydroset oil to leak
past the chevron packing into the lubrication system, and cause
the Close Side Setting (CSS) to increase.)
b) Inspect the upper part of the Hydroset cylinder, above the bushing,
which acts as a locating surface for the piston. Remove any
scratches or unevenness by polishing.
3.7.5.3. Installing the Hydroset cylinder bushing
a) Install a new O-ring (3) on the Hydroset cylinder bushing (4).
b) Coat the contact faces of the Hydroset cylinder bushing (4) and the
Hydroset cylinder (5) with molybdenum disulfide.
c) Use a hydraulic jack and a wooden support to press the Hydroset
cylinder bushing (4) into the Hydroset cylinder (5).
d) Lock Hydroset cylinder bushing (4) in position with the screw (1)
and a the washer (2).
4
3
2
1 Screw 4 Hydroset cylinder bushing

2 Washer 5 Hydroset cylinder
3 O-ring
e) Use the hydraulic jack and a wooden support to raise the Hydroset
cylinder cover (8) into position under the Hydroset cylinder (5).
f) Attach the Hydroset cylinder cover (8) to the Hydroset cylinder (5)
with the screws (6) and the washers (7).
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g) Tighten the screws (6), see section Checking the torque of the
Hydroset cylinder joints on page 148.
5 Hydroset cylinder 7 Washer

6 Screw 8 Hydroset cylinder cover
h) Depending on the on-site circumstances, step 17 can be
performed first or last.
i) Install the Hydroset piston position transmitter and the Hydroset
piston, see section Installing the Hydroset piston on page 132.
j) Install the step washer and the piston wearing plate, see section
Installing the step bearing components on page 139.
k) Install the eccentric assembly, see section Installing the eccentric
l) Install the dust collar, see section Installing the dust collar on page
99.
m) Install the main shaft, see section Installing the main shaft
n) Install the top shell, see section Installing the top shell on page 41.
o) Install the spider cap, see section Installing the spider cap on page
31 and the spider bearing grease.
p) Install the feed hopper, see section Installing the feed hopper on
page 25.
A crusher weighs up to 16 200 kg (35 715 lbs). You
q) Install the crusher onto its foundation/subframe.
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3.7.6. Replacing the Hydroset piston position

transmitter B1N/K1-GT1
The Hydroset piston position transmitter B1N/K1-GT1 is fitted if the
crusher is equipped with ASRi or Automation & Connectivity System.
3.7.6.1. Removing the Hydroset piston position transmitter B1N/K1-
GT1
a) Lower the main shaft to its lowest position.
b) Remove the cover for the Hydroset piston position transmitter
B1N/K1-GT1.
c) Place a suitable container under the Hydroset cylinder.
NOTE! The oil volume to be drained is approximately 8 liters
(2.1 US gallons).
High pressure hazard
You can sustain injection and severing injuries if you
are struck by a jet of oil.
WARNING! Relieve the pressure before you carry out any work
on the hydraulic/lubrication system.
d) Open the drain plug (4) to drain the crusher of oil.

e) Disconnect the signal cable (5) from the transmitter.
f) Remove the screws (1).
g) Carefully remove the transmitter.
3 4
2 5
1
1 Screw
2 Transmitter
3 O-ring
4 Drain plug
5 Connector
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3.7.6.2. Installing the Hydroset piston position transmitter B1N/K1-

GT1
High pressure hazard
You can sustain injection and severing injuries if you
are struck by a jet of oil.
WARNING! Relieve the pressure before you carry out any work
on the hydraulic/lubrication system.
a) NOTE! The 0.15 m signal convert cable W4103-01 for the

hydroset piston position transmitter, with the black sticker,
K1-GT1 must be used and always connected. It provides a
pin reconfiguration.
Lubricate the O-ring (3) and its seating with oil.
b) Install the transmitter (2) and the O-ring (3).
c) Install the transmitter attachment screws (1). Refer to Tightening
d) Connect the sensor cable to the transmitter.
e) Close the drain plug (4).
f) Install the cover for the Hydroset piston position transmitter
B1N/K1-GT1.
g) Bleed the Hydroset system of air before operation, see section
h) Also calibrate the A-dimension before operation.
3 4
2 5
1
1 Screw
2 Transmitter
3 O-ring
4 Drain plug
5 Connector
3.8. Hydroset system

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3.8.1. Bleeding air from the Hydroset system

The air bleed measuring nipple (1) is mounted on the throat of the
accumulator.
a) Raise the main shaft 2-4 millimeters (0.08-0.16") by using the CSS
control box (3) L1, which is located near the crusher.
b) Prepare to connect the air bleed hose (2) to the test point (1).
c) Position the free end of the air bleed hose in a suitable container.
d) Screw the hose onto the test point (1). The non-return valve in the
test point (1) will automatically open when the hose is screwed on.
e) When the amount of air in the oil decreases, raise the main shaft
2-4 millimeters (0.08-0.16") more.
f) Repeat this until bubble-free oil comes out of the air bleed hose.
g) Unscrew the hose from the test point (1). The non-return valve in
the test point (1) will automatically close.
1 2 3
1 Test point
2 Air bleed hose
3 CSS control box L1
3.8.2. Checking the gas pressure

a) Fitting the charging kit
a) Remove the protective caps (1) and (2) from the accumulator’s
charging valve.
b) Unscrew the internal hexagon screw (6) so the cut on its side is
visible over the top of the adapter (5).
c) Unscrew the spindle (9) as much as possible.
d) Close the bleed valve (8).
e) Attach the adapter (5) to the accumulator’s charging nipple (3).
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f) Attach the screw connector (7) to the adapter (5). Tighten by hand
g) Screw down the spindle (9) so that the valve in the accumulator
opens.
h) Read off the charging pressure on the pressure gauge.
b) Removing the charging kit
i) Unscrew the spindle (9).
j) Open the bleed valve (8).
k) Unscrew the screw connector (7) and remove the charging kit
(FPU-1).
l) Remove the adapter (5) from the accumulator’s charging nipple
(3).
m) Check that there is no gas leakage from the valve. Use soapy
n) Refit the protective caps on the accumulator’s charging valve.
2 10 11
8 7
3 6
4
5
FPU-1

3 Nipple 9 Spindle
6 Hexagon screw
3.8.3. Relieving the Hydroset pressure
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a) Lower the main shaft to the bottom position to relieve the Hydroset
pressure. Use the arrow down button (1) on the CSS control
box L1.
CB1
1 Arrow down button

CB1 CSS control box
3.8.4. Replacing the hydraulic hose

3.8.4.1. Removing the hydraulic hose
a) Relielve the pressure in the Hydroset system, see section
Relieving the Hydroset pressure on page 157.
b) Remove the cover (1).
1 Cover
c) Put a suitable container under the hose (2).
d) Disconnect the hose (2) from the adapter (3) and drain the oil from
the hose into the container.
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e) Disconnect the hose (2) from the adapter (4).
2 Hydraulic hose
3 Adapter
4 Adapter
3.8.4.2. Inspecting the hydraulic hose

a) Check the hose (1) for wear or damage. Replace if necessary.
1 Hydraulic hose
3.8.4.3. Installing the hydraulic hose

a) Connect the hose (1) to the adapter (2).
b) Connect the hose (1) to the adapter (3).
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c) At both ends, torque the hose (1) to 300 Nm (221 lbf ft).
1 Hydraulic hose
2 Adapter
3 Adapter
d) Install the cover (4).
4 Cover
e) Restore and bleed the Hydroset system, see section Bleeding air
from the Hydroset system on page 156.
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3.8.5. Replacing the Hydroset oil filter

Hot surface hazard
You can suffer severe burns from hot surfaces and
from the hot oil.
WARNING! Allow the oil, the equipment and hoses/pipes to cool
down before you work in the tank unit or on the
hydraulic or lubrication systems.
Slippery surface hazard

You can slip if you step in an oil stain.
Remove any spilled oil immediately.
WARNING!
Toxic hazard
Read the oil’s MSDS for information about health
effects.
When you replace filters, place a container below the
filter to catch any spilled oil.
Handle used filters with care and according to the
WARNING! oil’s MSDS and local regulations.
Collect used filters and waste oil in suitable
containers and dispose of them as recommended in
the MSDS and according to local regulations.
a) Lower the mainshaft to its lowest position.

b) Turn the motors off.
c) Close the shut-off valve K1-V1.
d) Replace the Hydroset oil filter element K1-FE1 on the filter
unit K1-FU1 .
e) Open the shut-off valve K1-V1.
f) Start the motors.
g) Check for leaks.
1 2 3
1 K1-FU1 Hydroset oil filter unit
2 K1-FE1 Hydroset oil filter element
3 K1-V1 Shut-off valve, Hydroset tank to Hydroset control valve
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3.8.6. Checking the valves in the Hydroset control

valve
a) Lower the main shaft as far as possible with the CSS control
box L1.
b) Stop and lock out the crusher so that it cannot be accidentally
started.
c) Make sure the Hydroset pump motor K1-M1 cannot be started.
d) Close the shut-off valve K1-V1 between the Hydroset tank and the
Hydroset control valve.
e) Loosen the lock nut (1) on the needle valve K1-V2 with a ring
wrench.
f) Loosen the Allen head screw (2) on the needle valve K1-V2 with
an Allen key.
g) Wait until the mainshaft reaches its bottom position.
h) Press the push button K1-V3 and make sure that the pressure is 0
on the indicator K1-PI1.
i) Disconnect the hose from connection C in the Hydroset control
valve K1-HA1 and plug the hose.
j) Unscrew and perform a visual inspection for any dirt in the valves
K1-CV2, K1-CV1, K1-RV1, K1-RV2, K1-RV3 and K1-V2.
k) If needed, blow clean with compressed air.
l) Refit and tighten the valves carefully.
NOTICE The valve breaks if it is tightened too much.
Be careful when you tighten the Allen head screw.
m) Tighten the Allen head screw (2) on the needle valve K1-V2.
n) Refit and tighten the lock nut (1) on the needle valve K1-V2.
o) Unplug and reconnect the hose to connection C.
p) Make sure there is oil in the valve K1-CV2, see section Preparing a
tank that has been stored more than six months on page 238.
q) IMPORTANT! Open the shut-off valve K1-V1 between the
Hydroset tank and the Hydroset control valve.
r) Enable start of the Hydroset pump motor K1-M1. The crusher must
be switched off.
s) Test raising and lowering the mainshaft.
t) If needed, bleed air from the Hydroset system, see section
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u) Set the mainshaft to the desired position.

NOTE! If the Hydroset control valve still does not operate correctly,
check for wear and/or damage and replace the damaged
part.
Always keep the Hydroset system clean to reduce the risk that
contamination interferes with the valve.
1 2 3 4 5 6 7 8 9
12 11 10
1 K1-PI1 Hydroset pressure indicator

2 K1-V3 Activates the Hydroset pressure indicator
3 K1-HA1 Hydroset control valve
5 C Connection, Hydroset control valve to crusher
6 K1-V2 Needle valve, relieves the hydraulic pressure
7 K1-RV3 Valve, limits the maximum pressure in the Hydroset
cylinder
8 K1-CV2 Check valve, used when increasing the CSS
9 K1-CV1 Check valve, used when decreasing the CSS
10 K1-RV2 Valve, limits the pump pressure
11 K1-RV1 Valve, used to build up the pilot pressure for the check
valve K1-CV3
12 L1 CSS control box
3.9. Pinionshaft housing
3.9.1. Checking the oil flow to the pinionshaft housing

Carry out this check above the opening of the main lubrication oil tank –
after removing the cover – to avoid oil spillage.
a) Disconnect the oil hose L2-H4 from the pinionshaft housing.
b) Put the hose into a container with a known volume.
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c) Measure the time it takes to fill the container. Examples: It takes

60 seconds to fill a 1 liter container. The oil flow is
(60/60) ×1 = 1 l/min. It takes 60 seconds to fill a ¼ US gallon
container. The oil flow is (60/60) × ¼ = ¼ US gal/min.
1 L2-H4 Oil hose
d) Reconnect the oil hose L2-H4 to the pinionshaft housing.
3.9.2. Replacing the pinionshaft housing assembly

3.9.2.1. Checks prior to removal
NOTE! If the pinion shaft housing is warm, allow it to cool before you
perform the steps below.
a) Measure the gear backlash. See section Checking the gear
backlash on page 201.
b) Check the axial play in the bearings by pulling the crusher pulley
outwards. Play can be an indication that a bearing replacement is
necessary.
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c) NOTE! This measure will be useful if the gasket is damaged when

the pinion shaft assembly is removed from the crusher.
Measure the distance between the pinion shaft housing flange and
the bottom shell with a feeler gauge. There is a recess (5) in the
edge of the gasket to facilitate this. Make a note of the measured
distance.
6 1
5 4 3 2
1 Hole for jacking screw

2 Adjustment screws
3 Pinion shaft
4 Screw, Washer
5 Recess for measurement with feeler gauge
6 Oil inlet hose
3.9.2.2. Removing the pinion shaft housing assembly

NOTE! It is necessary to remove drive parts before proceeding with this
instruction, see section Removing the V-belt drive motor on page
215.
NOTE! If the pinion shaft housing is warm, allow it to cool before
performing the steps below.
a) Remove the oil hose (1) from the pinion shaft housing (2).
b) Remove the magnetic drain plug (6) in the bottom of the pinion
shaft housing (2) and drain out the oil.
NOTE! Check if there is metal swarf or similar on the drain plug. If
this is the case, the pinion shaft bearings have probably
been damaged.
c) Make sure that the lock nut (4) on the upper backlash adjustment
screw (3) is tight.
d) Loosen the lock nut (5) on the lower backlash adjustment
screw (6).
e) Remove the lower backlash adjustment screw (3).
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f) Remove the screws (9) and the washers (10) that attach the pinion
shaft housing assembly (2) to the bottom shell.
1 2 3
4
9, 10 8 7 6
1 Oil hose
2 Pinion shaft housing assembly
3 Upper backlash adjustment screw
4 Lock nut
5 Lock nut
6 Lower backlash adjustment screw
7 Pinion shaft
8 Drain plug (obscured in the illustration)
9 Screw
10 Washer
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g) Rotate the pinion shaft housing assembly (2) so that the

protrusion (11) on the flange rests against the bracket (12) of the
lower backlash adjustment screw (4).
11
12
2
11 Protrusion
12 Bracket
h) Position the hook of a crane vertically above the pinion shaft.

i) Place a lifting sling (13) around the end of the pinion shaft housing
assembly (2) and attach the sling to the lifting hook.
j) Install two press screws in the holes, at 180° spacing.
k) Tighten the press screws to push the pinion shaft housing
assembly (2) out from its seating in the bottom shell. Let the
assembly hang in the opening in the bottom shell.
l) Move the lifting sling (13) to the opposite side of the housing flange
(14).
m) Place a lifting sling (13) around the pinion shaft housing assembly
(2) and attach it to the lifting hook. Remove the present lifting chain
from the hook.
n) Pull the pinion shaft housing assembly further and move the lifting
sling inwards until the assembly is in balance.
A pinion shaft housing assembly weighs up to
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o) Lift the pinion shaft housing assembly out of the bottom shell and
place it on a pair of trestles.
2 14 13

13 Lifting sling
14 Flange
3.9.2.3. Inspecting the pinion shaft housing assembly

Inspect the tooth bearing “footprint” according to section Tooth bearing
“footprint” on page 206.
If no components have been replaced and the pinion shaft housing
assembly is to be re-installed, fit a gasket of appropriate thickness
between the pinion shaft flange and the bottom shell. Use the
measurement noted during the removal. See section Checks prior to
removal on page 164 and the table in section Determining the gasket
thickness on page 205.
Make sure that the gasket/shim is mounted with the measuring

recess (arrow) in the correct position, seen from the side.
3.9.2.4. Installing the pinion shaft housing assembly

a) Place a lifting sling (2) around the pinion shaft housing (3), on the
pinion side of the flange (4).
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b) Position the hook of a crane vertically above the pinion shaft

housing assembly.
c) Attach thelifting sling (2) to the hook.
d) Take up the slack in the lifting tackle.
e) Adjust the position of the sling to keep the assembly in balance.
NOTE! When the pinion shaft assembly is to be put back into the
bottom shell, make sure that theprotrusion (5) in the
housing flange is in the correct position relative to the
bracket (6) for the lower adjustment screw.
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f) Lift the pinion shaft housing assembly and position it in line with
the hole in the bottom shell.
1
2 3 4
1 Seating
2 Lifting sling
3 Pinion shaft housing
4 Flange
5 Protrusion
6 Bracket
Moving and fixed parts hazard

You can sustain crush injuries if body parts get
caught between the pinion shaft housing and the
WARNING! bottom shell.
Be careful when you maneuver the pinion shaft
housing.
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g) Push the pinion shaft housing assembly into the bottom shell. This
may require moving the lifting sling outwards as the assembly
moves into the bottom shell.
3 4 2
2 Lifting sling
4 Flange
h) When the pinion shaft housing assembly gets closer to its correct
position in the bottom shell, slowly turn the shaft backwards and
forwards to make sure that the pinion meshes correctly with the
eccentric gear.
i) Install the screws (9) and the washers (10) in the bottom shell.
j) Install the lower backlash adjustment screw (8) and its lock nut (7).
7
8
9, 10
7 Lock nut
8 Adjustment screw
9 Screw
10 Washer
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k) Torque the screws that clamp the pinion shaft housing assembly to
the bottom shell, refer to Tightening torques in the Technical
Specifications.
l) Make sure that the distance between the flange of the pinion shaft
housing and the bottom shell is the same as before the pinion shaft
assembly was removed, see section Checks prior to removal on
page 164.
m) Examine the backlash in the gears, see section Checking the gear
backlash on page 201.
n) Install all the components of the circulatory pinion shaft lubrication
system.
o) Fill the pinion shaft housing with oil to the correct level, see section
Checklist for an overhauled crusher on page 236.
3.9.3. Replacing the pinionshaft and the pinion

3.9.3.1. Removing the crusher pulley - Only with V-belt drive
a) Remove the screw (10), the washer (9) and the retaining
washer (8).
b) Place a lifting sling into one of the grooves near the middle of the
crusher pulley.
c) Remove the screws (7) between the crusher pulley (6) and the
tapered bushing (4).
d) Position the hook of a crane vertically above the crusher pulley and
attach the sling to the hook.
e) Install two of the screws (7) in the threaded holes in the crusher
pulley (6) and tighten them, so that the crusher pulley is pushed
slightly outwards.
Suspended load hazard.
A crusher pulley weighs up to 102 kg (225 lbs). You
g) Pull the crusher pulley (6) off the end of the pinionshaft and lower it
to the ground.
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h) Remove the tapered bushing (4), the spacer (5) and the key (2).
1 2 4 5 6 7 8 9 10
3
1 Pinionshaft housing 6 Crusher pulley

2 Key 7 Screw
3 Pinionshaft 8 Retaining washer
4 Tapered bushing 9 Washer
5 Spacer 10 Screw
3.9.3.2. Removing the pinion

NOTE! Carry out this procedure indoors, in a clean environment.
a) Place the pinion shaft housing on the ground on a sheet of
plywood.
b) Unscrew the oil inlets (1), (2) and (3).
c) Place a lifting sling around the middle of the pinion shaft housing.
1, 2, 3
1 Elbow
2 Screw
3 Adapter
d) Position the hook of a crane vertically above the pinion shaft

housing and attach the sling to the hook.
e) Take up the slack in the lifting tackle.
A pinion shaft housing assembly with pulley weighs
up to 375 kg (828 lbs). You can sustain crush injuries,
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f) Lift the pinion shaft housing assembly, then lower it with the
pinion (5) upwards, onto a suitable support (9) for example a cable
drum.
g) Remove the lifting sling from the pinion shaft housing.
h) Remove the retaining ring (7) from the top of the pinion shaft (3).
i) Remove the screws from the inner bearing cover (8).
j) Mount an extractor (4) with adequate capacity on the end of the
pinion shaft, to remove the pinion (5). The inner bearing cover has
a lip (2) for an extractor.
7 6
5
8
4
1 Pinion shaft housing 6 Key

2 Lip 7 Retaining ring
3 Pinion shaft 8 Inner bearing cover
4 Extractor 9 Support (drum)
5 Pinion
NOTE! If the pinion can not be removed using only the extractor,
then carefully heat the pinion while the extractor is
tightened. Take great care when the pinion heats up and
comes loose. Never heat the pinion in one spot only, as
that could ruin the hardening.
k) Remove the key (6) and make sure that there are no burrs on the
end of the shaft.
3.9.3.3. Removing the pinion shaft
a) Turn the pinion shaft housing assembly (1) so that the oil level plug
(2) is facing upwards.
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b) Remove the screws (7), the washers (6), the inner bearing cover
(5) and the O-ring (4).
c) Attach the extractor screw (3) to the oil level plug (2).
d) Pull out the seal rings (8) from the inner bearing cover (5).
1 2
5
2
8
6
7

2 Oil level plug
3 Extractor screw
4 O-ring
5 Inner bearing cover
6 Washer
7 Screw
8 Seal ring
e) NOTE! The oil level plug (2) must be removed before the pinion
shaft assembly can be pulled out from the pinion shaft
housing assembly.
The pipe (10) has a hole (11) to facilitate the extraction of the pipe
(10). Pull out the pipe (10) with a steel wire hook.
f) Use the screw (3) as a lever and pull out the plug (2) with a crow
bar.
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g) Remove the O-rings (9) from the plug (2).
3
2
2
10
11
2 Plug
3 Extractor screw
9 O-ring
10 Pipe
11 Extraction hole
h) Attach a lifting eye bolt (13) to the pinion shaft (12).

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i) Carefully lift the pinion shaft housing assembly (1) to the vertical
position and place it on a support (14).
12
14
13

12 Pinion shaft
13 Lifting eye bolt
14 Support
j) Remove the screws (15), the washers (16) and the outer bearing
cover (17).
k) Remove the O-ring (18) and the O-rings (19).
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l) Remove the retaining ring (23) from the outer bearing cover (17)
and pull out the seal ring (22), the distance (19) and the seal ring
(20).
15
16
17
17
20
18 21
19 22
23
15 Screw
16 Washer
17 Outer bearing cover
18 O-ring
19 O-ring
20 Seal ring
21 Distance
22 Seal ring
23 Retaining ring

A pinion shaft assembly weighs up to
m) Lift out the pinion shaft assembly (24) from the pinion shaft
housing (25).
n) Carefully lower the pinion shaft assembly (24) and place it
horizontally on a support (26).
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o) Remove the lifting equipment and the lifting eye bolt (13).
24 24
26
25
13
13 Lifting eye bolt

24 Pinion shaft assembly
26 Support
3.9.3.4. Removing the roller bearings and the spacers

a) Heat the outer spacer (1) with a blow torch.
Hot surface hazard
component.
WARNING!
b) Remove the outer spacer.
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c) Cut the outer ring (2) of the outer roller bearing at two diametrically
opposite points.
22
11
11
1 Outer spacer
2 Outer ring
Hot surface hazard

component.
WARNING!
d) Remove the outer ring (2) and the rollers (3).

e) Heat the inner ring (4) of the outer roller bearing.
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f) Remove the inner ring (4) from the pinionshaft (5).
55
44
44
33
22
2 Outer ring
3 Rollers
4 Inner ring
5 Pinionshaft
g) Heat the inner spacer (6).

Hot surface hazard
component.
WARNING!
h) Remove the inner spacer (6).
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i) Cut the outer ring (7) of the inner roller bearing at two diametrically
opposite points.
66 77
6
6 Inner spacer
7 Outer ring
Hot surface hazard

component.
WARNING!
j) Remove the outer ring (7) and the rollers (8).

k) Heat the inner ring (9) of the outer roller bearing.
Hot surface hazard
component.
WARNING!
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l) Remove the inner ring (9) from the pinionshaft (5).
99 55
88 99
77
5 Pinionshaft
7 Outer ring
8 Rollers
9 Inner ring
3.9.3.5. Installing the roller bearings and the spacers

a) NOTE! Carry out this procedure indoors in a clean environment.
Use an oil bath, an induction heater or an oven to heat the
components that are going to be shrunk into place. Avoid
using an open flame since there is a risk of overheating.
Clean the pinion shaft (1) as follows:
a. Spray the pinon shaft (1) with de-greasing fluid and clean it
with a soft cloth
b. Remove shavings, grindings or dirt from the keys ways at
both ends.
c. Clean the pinion shaft (1) ends with compressed air.
11
1 Pinionshaft
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b) NOTE! When heating the bearing, check the temperature with a

thermometer or another technique recommended by the
bearing manufacturer.
Heat the inner roller bearing (2) to 90 °C (194 °F) above the
ambient air temperature. For example, heat to 110 °C (230 °F) in
an ambient air temperature of 20 °C (68 °F).
Hot surface hazard
component.
WARNING!
c) Attach the inner roller bearing (2) to the pinion shaft (1) with a
suitable drive.
d) Push the bearing (2) against the stop on the pinion shaft (1) and
keep the pressure on the drive until the bearing (2) has shrunk
onto the pinion shaft (1).
e) Heat the inner spacer (3) to 90 °C (194 °F) above the ambient air
temperature. For example, heat to 110 °C (230 °F) in an ambient
air temperature of 20 °C (68 °F).
f) Remember to fit a new o-ring between the spacer (3) and
the pinion shaft (1).
Attach the inner spacer (3) to the pinion shaft (1) with a suitable
drive.
g) Push the spacer (3) against the inner ring of the inner roller
bearing (2) and keep the pressure on the drive until the spacer (3)
has shrunk onto the pinion shaft (1).
11 22
11
22 33
1 Pinion shaft
2 Inner roller bearing
3 Inner spacer
h) Let the inner roller bearing (2) and the inner spacer (3) cool down.
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i) NOTE! When heating the bearing, check the temperature with a

thermometer or another technique recommended by the
bearing manufacturer.
Heat the outer roller bearing (4) to 90 °C (194 °F) above the
ambient air temperature. For example, heat to 110°C (230 °F) in an
ambient air temperature of 20 °C (68 °F).
Hot surface hazard
component.
WARNING!
j) Attach the outer roller bearing (4) to the pinion shaft (1) with a
suitable drive.
k) Push the bearing (4) against the stop on the pinion shaft (1) and
keep the pressure on the drive until the bearing (4) has shrunk
onto the pinion shaft (1).
11
22 33
44
1 Pinion shaft
2 Inner roller bearing
3 Spacer
4 Outer roller bearing
l) Heat the outer spacer (5) to 90 °C (194 °F) above the ambient air
Hot surface hazard
component.
WARNING!
S 223.1239 - 5 en-US 10/01/2019 09:35:46 185
m) Remember to fit a new o-ring between the spacer (5) and

the pinion shaft (1).
Attach the outer spacer (5) to the pinion shaft (1) with a suitable
drive.
n) Push the spacer (5) against the inner ring of the outer roller
bearing (4) and keep the pressure on the drive until the spacer (5)
has shrunk onto the pinion shaft (1).
o) Let the outer roller bearing (2) and the outer spacer (3) cool down.
44
11 44 55
55
1 Pinion shaft
4 Outer roller bearing
5 Outer spacer
3.9.3.6. Installing the pinion shaft

a) Attach the lifting eye bolt (2) to the pinion shaft (1).
A pinion shaft assembly weighs up to
c) Carefully lift the pinion shaft assembly (3) to the vertical position.
d) Lower the pinion shaft assembly (3) into the pinion shaft housing
(4).
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e) Disconnect the lifting tackle.
1 Pinion shaft
2 Lifting eye bolt
3 Pinion shaft assembly
f) Grease the seal rings (6) and (8).

g) Insert the seal ring (6), the distance (7) and the seal ring (8) into
the outer bearing cover (9). Make sure that the seal rings (6) and
(8) are mounted in the correct directions, see the illustration below.
h) Lock the seal ring (6), the distance (7) and the seal ring (8) into
place with the retaining ring (5).
i) Attach the lubrication nipple (11) to the threaded hole (10) on the
outer bearing cover (9).
j) Connect a grease gun to the lubrication nipple (11) and fill the
grease channel (12) with grease. Continue to fill until grease is
pressed out at the seal rings (6) and (8)
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k) Disconnect the grease gun and remove the lubrication nipple (11).
11
10
9
12
9
8 7 6
5 Retaining ring 9 Outer bearing cover

6 Seal ring 10 Threaded hole
7 Distance 11 Lubrication nipple
8 Seal ring 12 Grease channel
l) Insert the O-rings (17).

m) Insert the O-ring (18) into the groove the pinion shaft housing
assembly (19).
n) Attach the lubrication nipple (11) to the pinion shaft housing
assembly (19).
o) Connect a grease gun to the lubrication nipple (11) and fill the
grease channel (20) with grease. Fill until clean grease comes out
from the grease channel (20).
p) Disconnect the grease gun and remove the lubrication nipple (11).
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q) Attach the outer bearing cover (9) to the pinion shaft housing
assembly (18) with the washers (16) and the screws (15).
15
9 15 16
17
9
20
17
19
18
14
11
13 19
11
2 Lifting eye bolt 15 Screw

9 Outer bearing cover 16 Washer
11 Lubrication nipple 17 O-ring
12 Grease channel 18 O-ring
13 Spiral pin 19 Pinion shaft housing assembly
14 Hole 20 Grease channel

r) Lift off the pinion shaft housing assembly (19) from the support
(21).
s) Place the pinion shaft housing assembly (19) horizontally on a pair
of stands (22).
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t) Remove the lifting eye bolt (2).
19 19
21
2 Lifting eye bolt

21 Support
22 Support
u) Grease the O-rings (23) and attach them to the plug (25).
v) Insert the plug (25) into the hole (26).
w) Insert the pipe (28) into the hole (27).
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x) Align the hole (24) on the plug (25) with the pipe (28) and tap in the
pipe (28). See the illustration below.
23
25 24
25 28 27
26 27 23
28
23 O-ring
24 Hole
25 Oil level plug
26 Hole
27 Hole
28 Pipe
y) Grease the seal rings (30).

z) Insert the seal ring (30) into the inner bearing cover (29). Make
sure that the seal rings (30) are mounted in the correct directions,
see the illustration below.
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aa) NOTE! Orient the inner bearing cover (29) so that the oil channels
(31) are not blocked by the cover.
Insert the O-ring (32) into the groove the pinion shaft housing
assembly (19).
29
29
30
30
29
29
19
19
31
31
32
32 30
30
29
29
33
33
34
34
19 Pinion shaft housing assembly 32 O-ring

29 Inner bearing cover 33 Washer
30 Seal ring 34 Screw
31 Oil channel
ab) Turn the pinion shaft housing assembly (19) so that the threaded
hole (35) is facing upwards.
19 35

35 Threaded hole
3.9.3.7. Installing the outer bearing cover

a) Clean the inside of the outer bearing cover (3) with a cloth.
b) Lubricate the inside of the bearing cover with oil.
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c) Make sure that the open end of the oil seal ring (4) is
directed towards the center of the crusher.
Install the oil seal ring (4) to the bearing cover with a suitable tool.
Carefully push the oil seal ring inside the bearing cover to avoid
damage.
d) Make sure that the oil seal ring (4) is flush against the bearing
cover all the way around.
4
5, 6 4 3
3
2 7
1 8
8
1 Trestle 5 Screw
2 Spring pin 6 Washer
3 Outer bearing cover 7 Key
4 Oil seal ring 8 Gasket
e) Prepare the inner bearing cover in the same way.

f) Position the outer bearing cover on the outboard end of the
pinionshaft housing so that the spring pin enters the corresponding
hole in the bearing cover.
g) Apply locking fluid to the threads of the screws, refer to Locking
fluid for threaded fasteners in Technical specifications.
h) Install washers on the screws. Tighten the screws in circular
rotation to fasten the bearing cover, refer to Tightening torques in
i) Grind the keys so that they fit into the keyways at each end of the
pinionshaft.
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j) Install the outer key (7) in the keyway at the outboard end of the
pinionshaft.
4
5, 6
3
2 7
8
1
1 Trestle 5 Screw
2 Spring pin 6 Washer
3 Outer bearing cover 7 Key
4 Oil seal ring 8 Gasket
3.9.3.8. Installing the level tube and the discharge tube

a) Loop a lifting sling around the pinionshaft housing (2) near the
inboard end.
b) Attach the lifting sling to the hook of the crane.
c) Take up the slack in the lifting tackle.
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d) Position the pinionshaft housing (2) on its side on sheets of

plywood or a wooden trestles on the floor.
1 2
1 Pinionshaft
2 Pinionshaft housing
3 Lifting eye bolt
e) Install the lifting eye bolts (3) in the inboard end of the pinionshaft
(1).
f) Attach lifting slings to the lifting eye bolts (3) and the pinionshaft
(1).
g) Take up the slack in the lifting tackle.
h) Raise the pinionshaft housing (2) and turn it around to the vertical
position.
i) Position the pinionshaft housing (2) onto a suitable support (11) for
example a cable drum.
j) Clean the level tube (10) and the discharge tube (7). Make sure
that there are no burrs. Use compressed air to remove all loose
dirt.
k) Attach O-rings (9) in the grooves in the level tube (10).
l) Apply grease to the level tube (10) and its O-rings (9). Use a brush
to apply the grease.
m) Install the level tube (10) in the corresponding hole on the outside
of the pinionshaft housing (2).
n) Install the discharge tube (7) in the hole on the end of the
pinionshaft housing (2). Make sure that the small hole (6) on the
discharge tube (7) is upward.
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o) Carefully tap the level tube (10) until it falls into place between the
O-rings (9).
5
6
7
4
8 9 10
11
4 O-ring
5 Steel wire hook
6 Hole in discharge tube for removal
7 Discharge tube
8 Extractor screw
9 O-rings
10 Level tube
11 Support
3.9.3.9. Installing the inner bearing cover

a) Lubricate the inner spacer ring (3) with oil. Pour oil down into the
inner roller bearing (4).
1
2
3
1 Inner bearing cover

2 Seal ring
3 Spacer ring
4 Roller bearing
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b) Make sure that the open end of the oil seal ring (2) is
directed towards the center of the crusher.
Install the oil seal ring (2) to the bearing cover (1) with a suitable
tool. Carefully push the oil seal ring inside the bearing cover to
avoid damage.
c) Position the inner bearing cover (1) on the inboard end of the
pinionshaft housing. Make sure that the chamfering on the bearing
cover is aligned with the three holes in the pinionshaft housing.
See the figure below.
d) Apply locking fluid to the threads of the six screws, refer to Locking
fluid for threaded fasteners in the Technical Specifications.
e) Install washers on the screws. Tighten the screws in circular
rotation to fasten the bearing cover, refer to Tightening torques in
the Technical Specifications.
f) Make sure that the key fits properly into the keyways in the pinion
and on the pinionshaft.
3.9.3.10. Installing the pinion
Hot surface hazard
component.
WARNING!
a) NOTE! Carry out this procedure indoors in a clean environment.

Use an oil bath, an induction heater or an oven to heat the
components that are going to be shrunk into place. Avoid
using an open flame since there is a risk of overheating.
Heat the pinion (3) to 150 °C (302 °F) above the ambient air
b) Fit the key (1) to the pinion shaft (5).
c) Lift the pinion (3) in place.
d) Attach the pinion (3) to the pinion shaft (5).
e) Let the pinion (3) cool down.
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f) Secure the pinion (3) to the pinion shaft (5) with the retaining
ring (6).
6 1
2
3
5 4
1 Key
2 Extractor
3 Pinion
4 Lip
5 Pinion shaft
6 Retaining ring
3.9.3.11. Installing the crusher pulley

To get a better balance when the pinionshaft housing assembly is being
installed, it is recommended to install the pulley before installing the
pinionshaft housing.
a) Loop a lifting sling around the pinionshaft housing near the inboard
end.
b) Attach the lifting sling to the hook of the crane.
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c) Position the pinionshaft housing on its side on sheets of plywood

or wooden trestles on the floor.
1 2
1 Pinionshaft
2 Pinionshaft housing
3 Lifting eye bolt
d) Install lifting eye bolts in the outer end of the pinionshaft housing.
e) Position the hook of a crane vertically above the pinionshaft
housing.
f) Attach suitable lifting slings to the lifting eye bolts.
g) Attach the lifting slings to the hook.
h) Take up the slack in the lifting tackle.
i) Raise the pinionshaft housing and turn it to the vertical position.

j) Position the pinionshaft housing with the outer end upwards and
with the flange supported on two planks resting on suitable
trestles.
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k) Use a screwdriver or similar wedge-shaped tool. Insert the tool as

shown by the arrow. Carefully (to avoid damage to the edges)
enlarge the slit in the tapered bushing (4). The slit must be wide
enough for the bushing to move freely when being installed on the
pinionshaft.
l) Install the tapered bushing (4).

m) Install the spacer (5).
n) Attach two lifting eye bolts on the pulley (6).
o) Position the hook of a crane vertically above the pulley.
p) Attach the lifting sling to the lifting eye bolt on the pulley.
q) Attach a lifting sling to the hook.
r) Take up the slack in the lifting tackle.
A pulley weighs up to 102 kg (225 lbs). You can
s) Lift the pulley.

t) Install the pulley on the pinionshaft.
u) Install the two screws (7).
v) Torque the screws alternately, refer to Tightening torques in
1 2 4 5 6 7 8 9 10
3
1 Pinionshaft housing 6 Crusher pulley

2 Key 7 Screw
3 Pinionshaft 8 Retaining washer
4 Tapered bushing 9 Washer
5 Spacer 10 Screw
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3.9.3.12. Preparation for the installation of a complete pinion shaft

assembly
If the gear and pinion, pinion shaft housing etc. has been replaced, or
when a check was not made on the thickness of the gasket between the
pinion shaft housing flange and the bottom shell during removal, the
tooth bearing “footprint” and the backlash must be adjusted. The
thickness of the gasket can be calculated as follows.
C
1 Wedge
a) Position the pinion shaft assembly upright, resting on the crusher

pulley.
b) To compensate for the axial play in the bearings, drive in a wooden
wedge (1) between the crusher pulley and the outer bearing cover.
c) Calculate the gasket thickness, see section Determining the gasket
thickness on page 205.
d) Fit gaskets of the correct thickness, as determined above.
e) Install the pinion shaft assembly, see section Installing the pinion
shaft housing assembly on page 168.
f) Check the backlash and the tooth bearing “footprint”. Adjust if
necessary.
NOTE! When a new eccentric gear and pinion set is installed, the
correct “tooth print” will be obtained with the gasket
thickness calculation described above.
3.9.4. Bevel gears

The cone crusher has spiral bevel gears. Under normal conditions this
type of transmission requires very little maintenance. The gear and
pinion are manufactured and marked as a matched set. For this reason,
do not use a gear from one set with a pinion from another set.
3.9.4.1. Checking the gear backlash
The correct values for the backlash in the crusher are presented in the
table.
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Pinion pitch Backlash on pitch Crusher pulley Movement on outer

circle diameter circle diameter outer diameter diameter of pulley,
with correct play
192 mm (7.6 in) 0.80 mm (0.031 in) to 385 mm (15.2 in) 1.60 mm (0.063 in) to
1 mm (0.039 in) 2 mm (0.079 in)
NOTE! The values in the table above are theoretically calculated for
reference during manufacture and installation of the gears.
Practical experience has shown that the nominal gear backlash can be
exceeded due to the geometry of the installation, but the values given in
the table above should be considered as guidelines when judging the
condition of the gear and pinion. Consult Sandvik if problems are
encountered. Correct backlash and tooth bearing “footprint” are
essential if the gears are to operate properly.
Since there is play between the eccentric and the bottom shell bushing,
the backlash in the gears will vary with the position of the eccentric.
It is necessary to make four measurements to determine the backlash,
while turning the pinion and rotating the eccentric gear 90° between
each measurement. The gear backlash is calculated as the average of
these measurements.
90° rotation of the eccentric corresponds to slightly less than one
revolution of the pinion shaft.
NOTE! Due to the play in the pinion shaft bearings it is important to pull
the pulley and the shaft outwards when the backlash is
measured. Make sure that the screws that hold the pinion shaft
housing flange are tight.
A dial gauge should be used for these measurements. If a dial gauge is
not available, a set square can be used. In this case, scribe marks are
made on the pulley and the distance between the marks is measured.
With V-belt pulley installed to the left, with direct drive/removed V-belt
pulley to the right.
A
3 1 1 2
1 Dial gauge
2 Lever
3 Set square
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Since the backlash cannot be measured between the pinion and the
eccentric gear, the movement of the crusher pulley is measured to
calculate the backlash.
3.9.4.1.1. Calculating the backlash - with V-belt pulley
Play in gears on pitch line × Crusher pulley outer

Crusher pulley movement on outer diameter
=
diameter
Pinion pitch circle diameter
Example:
The crusher has a crusher pulley with 385 mm (15.2 in) outer diameter.
What movement should be found on the outer diameter of the crusher
pulley (with a 50 Hz gear set)?
See the table below for the correct backlash, and then use the formula
to calculate the movement as follows:
Minimum movement:
0.80 × 385
Min. movement on crusher pulley outer diameter = = 1.60 mm
192.5
or (in inches)
0.031 × 15.2
Min. movement on crusher pulley outer diameter = = 0.062"
7.6
Maximum movement:
1.00 × 385
Max. movement on crusher pulley outer diameter = = 2.00 mm
192.5
or (in inches)
0.039 × 15.2
Max. movement on crusher pulley outer diameter = = 0.079"
7.6
3.9.4.1.2. Calculating the backlash - V-belt pulley removed or direct drive
Play in gears on pitch line x 2 x A

Movement shown on dial gauge =
Pinion pitch circle diameter
The dial gauge is placed 250 mm (9.84") (distance A) 180 mm (7.087")

from the center. What movement should be found at this radius, to
achieve the correct backlash in the gears on the pitch line (with a 50 Hz
gear set)?
See the previous table for the correct backlash, and then use the
formula to calculate the movement as follows:
Minimum movement:
0.80 × 2 × 250
Minimum movement = = 2.1 mm
192
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or (in inches)
0.031 × 2 × 9.84
Minimum movement = = 0.08"
7.6
Maximum movement:
1.00 × 2 × 250
Maximum movement = = 2.6 mm
192
or (in inches)
0.039 × 2 × 9.84
Maximum movement = = 0.10"
7.6
3.9.4.2. Adjusting the gear backlash

NOTE! If the gear backlash is adjusted, the clearance of the locating bar
must be checked, see section Checking the locating bar
clearance on page 102.
Since the pinion shaft housing is eccentrically mounted, the backlash in
the gears can be adjusted by rotating the pinion shaft housing. Follow
the procedure described below:
a) Loosen the screws (2) that hold the pinion shaft assembly.
b) Carefully release the gasket/shim from the flange on the pinion
shaft housing, to avoid damage. The gear backlash can then be
adjusted:
a. Increase the gear backlash by moving the adjustment screws
(3) downwards (= clockwise).
b. Reduce the gear backlash by moving the adjustment screws
(3) upwards (= anti-clockwise).
c) When the backlash is correct, tighten the screws (2) and lock the
adjustment screws (3).
1
2
1 Recess for measurement with feeler gauge
2 Screw, Washer
3 Adjustment screws
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d) Check the backlash again, see section Checking the gear backlash
on page 201. Adjust if necessary.
NOTE! If the pinion shaft assembly is to be removed, and the
backlash is correct, remove only one of the adjustment
screws (3), see section Replacing the pinionshaft housing
3.9.4.3. Determining the gasket thickness

If a check was made on the thickness of the gasket between the pinion
shaft housing flange and the bottom shell before the pinion shaft
assembly was removed, the correct thickness(es) of the new gasket(s)
can be determined with the help of the table below.
a) Position the pinion shaft housing assembly (1) upright, resting on
the flange (2).
1
2

2 Flange
b) Use a rod-type micrometer to measure the distance (A). Note

down dimension (A).
c) Make a note of dimension (B), which is stamped into the small end
of the pinion.
d) Make a note of dimension (C) , which is stamped into the
bottom shell , adjacent to the hole for the pinion shaft housing.
e) Calculate the compressed gasket thickness using this formula:
Compressed gasket thickness = A + B - C
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f) Use the calculated gasket thickness and the table below to

determine the required thickness of the gasket to be installed.
Gasket thickness, uncompressed mm Gasket thickness, compressed mm

(inches) (inches)
0.5 mm (0.02") approximately 0.3 mm (0.012")
g) Fit gaskets of the correct thickness, as determined above.

3.9.4.4. Tooth bearing “footprint”
The gear installation is correct only when the correct “footprint” (3) and
the correct backlash have been obtained.
Checking the “footprint”
Spiral bevel gears are manufactured for operation with a certain tooth
bearing “footprint”. To check the “footprint”. Follow the procedure
described below:
a) Apply Molykote Spray Rapid or marking blue to the teeth of the
pinion (2).
b) Rotate/drive the crusher pulley or drive shaft so that the “footprints”
can be seen clearly.
a. The ideal “footprint” is obtained when the contact mark is
slightly high on the pinion and slightly low on the eccentric
gear (1). Under light load, the length of the “footprint” is
usually half the length of the teeth.
b. Under heavy load, the “footprint” usually moves towards the
“heel” (the large end) (4) of the tooth. Therefore, the gears are
adjusted so that the “footprint” is nearer the
toe (the small end) (5).
2
3
4
5
1 Eccentric gear
2 Pinion
3 "Footprint"
4 Heel
5 Toe
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3.9.4.4.1. Adjustment of the “footprint”

If the tooth bearing “footprint” differs from the ideal, the gear tooth
meshing can be adjusted by using gaskets/shims of different thickness
between the flange of the pinion shaft housing and the bottom shell:
• If the “footprint” is at the large end of the pinion (near the outside of
the gear), move the pinion outward from the center of the eccentric
gear. To do this, increase the thickness of the gasket/shim between
the pinion shaft housing and the bottom shell.
Footprint at the larger end
• If the “footprint” is at the small end of the pinion (toward the inside of
the gear), move the pinion inward towards the center of the eccentric
gear. To do this, reduce the gasket/shim thickness.
Footprint at the smaller end
3.10. Dust seal air pressure system
3.10.1. Replacing the overpressure needle valve

3.10.1.1. Removing the dust seal air pressure flow valve
a) Remove the hose (1) and the seal ring (2) from the flow valve (3).
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b) Remove the flow valve (3) and the seal ring (4) from the dust seal
air pressure unit (5). Note the mounting direction of the flow
valve (3), with the arrow on the flow valve (3) pointing towards the
dust seal air pressure unit (5).
1
2
3
4
5
1 Hose
2 Seal ring
3 Flow valve
4 Seal ring
5 Overpressure unit
3.10.1.2. Installing the dust seal air pressure needle valve

a) Attach the seal ring (4) and the flow valve (3) to the dust seal air
pressure unit (5). The mounting direction of the flow valve (3) is
with the arrow on the flow valve (3) pointing towards the dust seal
air pressure unit (5).
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b) Attach the seal ring (2) and the hose (1) to the flow valve (3).
1
2
3
4
5
1 Hose
2 Seal ring
3 Flow valve
4 Seal ring
5 Overpressure unit
c) Set the flow valve, refer to section Flow valve setting on page 209
3.10.2. Flow valve setting

a) Turn the flow valve knob (1) anticlockwise to fully open.
b) Turn the flow valve knob (1) 7 revolutions clockwise to set the
starting air flow.
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c) If oil is leaking through the dust seal ring at the recommended

starting air flow, then turn the flow valve knob (1) one full revolution
clockwise to reduce the air flow.
1 Flow valve knob
3.11. V-belt drive
3.11.1. Checking the V-belt tension

During the first few days of operation, the V-belt tension must be
checked frequently since new belts stretch. If the V-belts are not
tensioned sufficiently, slipping can occur and the life time of the V-belt
will be reduced considerably.
Proper V-belt tension can be determined with the help of the deflection
load. Check the deflection load with a spring balance or a special
instrument, a tensiometer or its equivalent.
a) Recommended deflection load (F)
The deflection load varies, depending on belt type and
manufacturer and also if it is new or worn belts. Check the
recommended deflection load with the belt manufacturer.
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a) Checking the deflection load with a tensiometer:

a. Measure the V-belt span (W) in meters, as shown below.
b. Multiply the span by 1.5, to give the V-belt deflection (D) in
cm.
c. On the tensiometer: Set the top side of the lower O-ring to the
correct deflection in cm on the meter’s lower scale.
d. Push the upper O-ring up against the lower edge of the outer
sleeve.
e. Press the meter against the V-belt in the middle of the span
and press sufficiently hard to bring the top side of the lower
O-ring level with the V-belt alongside.
f. Remove the meter and read off the load (F) in kp (lbf) at the
top side of the upper O-ring. The correct load is obtained from
the table above, which should be reproduced on the meter.
g. If the load is too low or too high on any of the V-belts, tighten
or slacken them, see section Installing the V-belts on page
213 for information on how to set the tension.
F
2
1
6
6 14 12 10 8
D
5
F
4
2
3
2
D
1
1 F-scale
2 D-scale
D = deflection
W = V-belt span
F = deflection load
3.11.2. Replacing the V-belt guards

3.11.2.1. Removing the V-belt guards
a) Remove the screws, the washers and the nuts from the guard
sections (10).
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b) Remove the guard sections.
V-belt drive, right-hand layout. The entire drive assembly can also
be mounted on the left-hand side.
10
10
10 V-belt guard
3.11.2.2. Installing the V-belt guards

When all adjustments are finished, install the guards.
NOTICE Do not start the motor/crusher before the V-belt
guards have been correctly installed.
a) Position the guard sections (10) over the V-belt drive.

b) Install the screws, the washers and the nuts.
10
10
10 V-belt guard
3.11.3. Replacing the V-belts

3.11.3.1. Removing the V-belts
a) Make sure the drive motor is properly locked out.
b) Remove the guard from the V-belt drive.
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c) Slacken the nuts on the screws (1) that fasten the motor to the
motor beams.
1 Fastening screws
d) Push the motor (2) with the motor pulley (3) towards the crusher
pulley (4) on the motor beams (5).
e) NOTE! V-belt drive, right-hand layout. The entire drive assembly
can also be mounted on the left.
Remove the worn V-belts (6) from the pulleys.
4
3
6
5
4
2
2 Motor
3 Motor pulley
4 Crusher pulley
5 Motor beam
6 V-belt
3.11.3.2. Installing the V-belts

a) Clean both pulleys.
b) Make sure that the fastening screws have been loosened.
c) Install the V-belts (6) on the pulleys (3) and (4).
d) Push the motor (2) away from the crusher to tension the belts (6).
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e) Check the alignment of the crusher pulley and the motor pulley
with a ruler/straight-edge (8). Use a feeler gauge to confirm that
there is metallic contact between the ruler and the pulleys at the
four points in the figure as shown by the arrows below. Metallic
contact confirms that the pulleys are correctly aligned. If necessary
use a crow bar to move the motor into the correct position.
2 Motor
3 Motor pulley
4 Crusher pulley
6 V-belt
8 Ruler/ straight-edge
f) Check the tension of the V-belts (6). See section Checking the V-
belt tension on page 210.
g) Use the adjusting screws (9) to move the motor sideways to obtain
correct belt tension.
9 Screws
h) Make a final check with the tensiometer and the ruler before
locking the nuts on the adjusting screws.
i) Tighten the fastening screws.
j) Install the guards, see section Installing the V-belt guards on page
212.
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3.11.4. Replacing the V-belt drive motor

3.11.4.1. Removing the V-belt drive motor
a) Remove the screws from the nuts and T-bolts.
b) Position the hook of a crane vertically above the electric motor (4)
and connect the lifting slings to the lifting eye bolts on the motor (4)
and to the hook.
c) Take up the slack in the lifting tackle. The tackle should now be
tight but not lifting the motor.
A drive motor weighs up to 1 500 kg (3 307 lbs) ±10%.
d) Lift the motor (4) away from the motor beams (2).
e) Mount the washers and the nuts on the T-bolts. Do not tighten.
5
2 9
9 3
1 4
2
1 V-belt guard
2 Motor beams
3 Inspection door
4 Motor
5 Cone crusher
9 Sub-frame
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3.11.4.2. Installing the V-belt drive motor

a) Position the hook of a crane vertically above the electric motor (2)
and connect the lifting slings to the lifting eye bolts on the motor (2)
and to the hook.
b) Take up the slack in the lifting tackle. The tackle should now be
tight but not lifting the motor.
c) Lower the motor (2) on to the motor beams (3).

d) Mount the washers and the nuts on the T-bolts. Do not tighten.
e) Align the motor (2) and crusher (1).
2
3
1 Crusher
2 Motor
3 Motor beam
f) Put a steel ruler (6) so that it bears against the pulleys (4) and (5)
at four points (see the arrows in the illustration below).
g) Use a crow bar to move the motor lengthwise or to rotate it until
the motor pulley (4) and the crusher pulley (5) are aligned.
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h) Use a feeler gauge to check that there is metallic contact between

the ruler (6) and the pulleys (4) and (5) at the four points. Metallic
contact confirms that the pulleys are correctly aligned.
2 Motor
4 Motor pulley
5 Crusher pulley
6 Ruler/ straight-edge
3.11.5. Setting the V-belt speed monitor

a) Fit a speed monitor, to avoid the problems caused by slipping or
broken V-belts. It should be connected in such a way that the feed
to the crusher is stopped if the pinionshaft speed drops by 5 %.
b) Set the distance A to 7 mm (0.28")
A
1
1 Speed monitor
3.11.6. Preparations before removing the pinionshaft

housing
a) Loosen and remove the V-belts, see section Removing the V-belts
on page 212.
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b) Move the crusher motor away from the crusher, see section
Removing the V-belt drive motor on page 215.
c) Lower the crusher motor at the parking position.
3.11.7. Restoration after installing the pinionshaft

housing
a) Move the crusher motor from the parking position towards the
crusher, see section Installing the V-belt drive motor on page 216.
b) Install the V-belts, see section Installing the V-belts on page 213.
3.12. Lubrication systems
3.12.1. Draining condensation water from the tanks

Drain condensation water from the tanks as often as necessary.
Toxic hazard
effects.
Handle drained condensation water with care and
according to the oil’s MSDS and local regulations.
Collect the drained condensation water in suitable
WARNING! containers and dispose of it as recommended in the
oil’s MSDS and according to local regulations.
a) Put a suitable container under the drain (2 or 3).

b) Remove the plug from the drain (2 or 3) with an Allen key.
c) Open the shut-off valve (L1-V5 or K1-V4) slightly.
d) When the oil content in the condensation water is increasing, close
the shut-offvalve (L1-V5 or K1-V4).
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e) Refit the plug and tighten it.
1 2 3 4
1 L1-V5 Shut-off valve, lubrication tank
2 Lubrication tank drain
3 Hydroset tank drain
4 K1-V4 Shut-off valve, Hydroset tank
3.12.2. Setting the temperature switches

Refer to the Technical Specifications for temperature switch settings.
a) Remove the screws (1) and open the temperature switch housing.
b) Use the adjustment screw (2) to set the basic setting. An indicator
points out the current setting on the range (5).
c) Use the adjustment screw (3) to set the differential setting. An
indicator points out the current setting on the range (4).
3
2
1
4
5
1 Screw
2 Adjustment screw, basic setting
3 Adjustment screw, differential setting
4 Differential setting range
5 Basic setting range
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3.12.3. Checking the return oil temperature switch L1-

TS3
The protective temperature switch L1-TS3 shuts the
crusher down if the oil temperature rises excessively.
NOTICE It is therefore important that none of the components
is by-passed. Check the cause of the stoppage and
correct it before the crusher is re-started.
a) NOTE! Only remove the sensing head (1). Leave the sensor
pocket in place.
Loosen the sensing head (1).
b) Immerse the sensing head and a thermometer in an oil bath that is
warmed slowly.
c) Note at which temperature the contact breaks.
d) Allow the oil to cool down.
e) Note at which temperature the contact closes.
f) Refit the sensing head (1).
1 Sensing head
2 L1-TS3 Return oil temperature switch
3.12.4. Checking the main lubrication oil flow

a) Open the tank cover, see section Opening the tank covers on page
222.
b) Remove the return oil screen, see section Cleaning the return oil
screen on page 229.
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c) Position a container with a known volume inside the tank.

d) Measure the time it takes to fill the container. Examples: It takes 20
seconds to fill a 10 liter container. The oil flow is (60/20) ×10 = 30
l/min It takes 20 seconds to fill a 4 US gallon bucket. The oil flow is
(60/20) × 4 = 12 US gal/min
e) Refit the return oil screen, see section Cleaning the return oil
screen on page 229.
f) Close the tank cover, see section Closing the tank covers on page
222.
3.12.5. Checking the temperature indicator L1-TI2

Check the temperature indicator L1-TI2 when you change oil.
a) NOTE! Only remove the sensing head (1). Leave the sensor
pocket in place.
Loosen the sensing head (1).
b) Immerse the sensing head and a reference thermometer in a
container with oil.
c) Check the reading on the temperature indicator L1-TI2 against the
reference thermometer.
d) Refit the sensing head (1).
1 Sensing head
2 L1-TI2 Return oil temperature indicator
3.12.6. Replacing the breather filter L1-FU2
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a) Replace the breather filter L1-FU2 .
3.12.7. Changing the main lubrication oil

Change the main lubrication oil as often as necessary.
You can send oil samples to the oil supplier so that suitable oil change
intervals can be established in cooperation with the oil supplier.
Unsuitable lubricants can damage the equipment and
cause blockages. If you mix lubricants the mixture
can lose its lubricating properties.
NOTICE Use lubricants that fulfil Sandvik's requirements,
refer to the Technical Specifications.
Check with the lubricants' manufacturers if different
types or brands can be mixed.
3.12.7.1. Opening the tank covers

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

a) Put the tank cover (2) back.
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b) Fold up the handles (1) and tighten them.
2
1
1 Handle
2 Tank cover
3.12.7.3. Draining the main lubrication oil tank

Toxic hazard
Read the lubricant's MSDS for information about its
health effects.
Handle new lubricants as well as waste lubricants
with care and according to the MSDS and local
regulations.
WARNING! Collect waste lubricants in suitable containers and
dispose of them as recommended in the MSDS and
according to local regulations.
a) Put a suitable container under the main lubrication oil drain (2). For
tank volume, refer to the Technical Specifications.
b) Open the tank cover, see section Opening the tank covers on page
222. This equalizes the pressure and the oil drains faster.
c) Remove the plug from the drain (2) with an Allen key.
d) Open the shut-offvalve L1-V5 slowly.
e) Allow the oil to drain completely from the tank.
f) When the tank is emptied, close the shut-offvalve L1-V5
g) Refit the plug and tighten it.
1 2
2 Lubrication oil drain
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3.12.7.4. Draining the Hydroset oil

Toxic hazard
health effects.
regulations.
a) Lower the mainshaft to its bottom position, see section Relieving

the Hydroset pressure on page 157.
b) Put a suitable container beneath the Hydroset oil drain (2).
c) Open the tank cover, see section Opening the tank covers on page
222. This equalizes the pressure and the oil drains faster.
d) Remove the plug from the drain (2) with an Allen key.
e) Open the shut-offvalve K1-V4 slowly.
f) Allow the oil to drain completely from the tank.
g) When the tank is emptied, close the shut-offvalve K1-V4
h) Refit the plug and tighten it.
1 2
1 K1-V4 Shut-off valve, lubrication tank
2 Hydroset oil drain
3.12.7.5. Draining the air/oil cooler
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Toxic hazard
health effects.
regulations.
a) Put a container under the oil outlets U and M on the cooler. The
standard cooler's volume is 12.9 liters (3.4 US gal). The hot climate
cooler's volume is 18.5 liters (4.9 US gal).
b) Disconnect the oil hoses from the oil outlets U and M.
c) Allow the oil to drain completely from the hoses and the cooler.
d) NOTE! Check the Hydroset pressure when you raise the
mainshaft. The Hydroset pressure must only increase by
max. 10-15%.
Raise the main shaft by using the CSS control box L1, to drain the
oil from the crusher via the lubrication inlet hose.
e) Reconnect the oil hoses from the oil outlets U and M.
1 2
1 M Oil to crusher
2 L1 CSS control box
3 U Oil from tank
3.12.7.6. Draining the pinion shaft lubrication system
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Toxic hazard
health effects.
regulations.
a) Put a suitable container under the pinion shaft oil connection Q.

b) Loosen the hose from the pinion shaft oil connection Q and drain
out all oil from the system.
c) Refit the hose to the pinion shaft oil connection Q.
d) Put the container under the drain plug (2) on the pinion shaft
housing.
e) Loosen the drain plug (2) and allow the oil to drain completely from
the pinion shaft housing. For oil volume, refer to the Technical
Specifications.
f) NOTE! Magnetic particles on the plug indicates bearing failure.
Clean the drain plug (2).
g) Refit the drain plug (2) and tighten it.
1 3
2
1 Oil level
2 Drain plug
3 Q Pinion shaft oil connection
3.12.7.7. Replacing the main lubrication oil filter

Hot surface hazard
from the hot oil.
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Toxic hazard
health effects.
regulations.
Toxic hazard
effects.

WARNING!
a) Close the shut-off valve L1-V1.

b) Remove the drain plug (2) with an Allen key and allow the oil to
drain.
c) Refit the drain plug (2) and tighten it.
d) Replace the main lubrication filter element L1-FE1 in the filter
unit L1-FU1 .
e) Open the shut-off valve L1-V1.
f) Start the motors.
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g) Check for leaks.
1 2 3 4
1 L1-FU1 Main lubrication filter unit
2 Drain plug
3 L1-FE1 Main lubrication filter element
4 L1-V1 Shut-off valve, lubrication tank to lubrication pump
3.12.7.8. Replacing the pinionshaft lubrication oil filter

Hot surface hazard
from the hot oil.
Toxic hazard
health effects.
regulations.
Toxic hazard
effects.
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WARNING!
a) Close the shut-off valve L1-V1.

b) Replace the pinionshaft lubrication filter element L2-FE1 on the
filter unit L2-FU1.
c) Open the shut-off valve L1-V1.
d) Start the motors.
e) Check for leaks.
1 2 3
1 L2-FU1 Pinionshaft oil filter unit
2 L2-FE1 Pinionshaft oil filter element
3 L1-V1 Shut-off valve, lubrication tank to lubrication pump
3.12.7.9. Cleaning the return oil screen

Toxic hazard
health effects.
regulations.
a) Open and remove the tank cover, see section Opening the tank
covers on page 222.
b) Remove the return oil screen (1) from the lubrication tank.
c) Inspect the screen for swarf, needle-like particles, lead flakes,
bronze particles and dirt. If you notice an increase in
contamination, contact maintenance personnel.
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d) NOTE! Use white spirit only if diesel oil does not dissolve the
residues.
If white spirit is used for cleaning, wipe it off carefully and
allow it to evaporate.
Clean the return oil screen with diesel oil or white spirit.
e) Blow the return oil screen clean with compressed air.
f) Check the return oil screen for damage. If it is damaged, replace it.
g) Put the return oil screen back.
h) Close the tank cover, see section Closing the tank covers on page
222.
1
1 Return oil screen
3.12.7.10. Cleaning the main lubrication tank

Toxic hazard
health effects.
regulations.

NOTICE Physical interference can damage the sensors.
Be careful when you clean the tank.
a) Put a suitable container under the drain (2).

b) Open and remove the tank cover, see section Opening the tank
covers on page 222.
c) Open the valve L1-V5.
d) Remove the plug from the drain (2) with an Allen key.
e) NOTE! Use white spirit only if diesel oil does not dissolve the
residues.
Rinse the tank with diesel oil or white spirit.
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If white spirit is used for cleaning, wipe it off carefully
NOTICE and allow it to evaporate before filling the tank with
oil.
f) Allow the diesel oil or white spirit to drain completely from the tank.
g) Close the valve L1-V5.
h) Refit the plug and tighten it.
i) Close the lubrication oil tank cover, see section Closing the tank
covers on page 222.
1 2
3.12.7.11. Removing oil residues from the air/oil cooler

Toxic hazard
health effects.
regulations.
a) Disconnect the oil hoses from the oil outlets U and M.

b) Remove the screws from the cover (6) of the air/oil cooler and lift
off the cover.
c) NOTE! Support the pipe (2) between the upper flange adapter and
the thermostatic valve L1-V2.
Remove the bolts from the upper flange adapter (1) with an Allen
key.
d) Loosen the fitting (5) from the lower flange adapter.
e) Remove the pipe (2) between the upper flange adapter and the
thermostatic valve.
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f) Plug the lower flange adapter.

g) NOTE! Use white spirit only if diesel oil does not dissolve the
residues.
Fill the air/oil cooler with diesel oil or white spirit through the hole
where the upper flange adapter was mounted. The standard
cooler's volume is 12.9 liters (3.4 US gal). The hot climate cooler's
volume is 18.5 liters (4.9 US gal).
h) Leave the diesel oil or white spirit to dissolve the lubrication oil
residues in the cooler for a while.
i) Place a suitable container under the lower flange adapter.
If white spirit is used for cleaning, wipe it off carefully
NOTICE and allow it to evaporate before filling the tank with
oil.
j) Remove the plug from the lower flange adapter and allow the
diesel oil or white spirit to drain completely.
k) NOTE! Support the pipe between the upper flange adapter and the
thermostatic valve L1-V2.
Refit the bolts to the upper flange adapter (1) and tighten them.
l) Refit the fitting (5) to the lower flange adapter.
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m) Reconnect the oil hoses to the oil outlets U and M.
1 2
6
5 4 3
1 Upper flange adapter

2 Pipe between the upper flange adapter and the thermostatic valve
3 U Oil from tank
4 M Oil to crusher
5 Fitting
6 Cover
3.12.7.12. Refilling the Hydroset oil

WARNING!

If white spirit has been used for cleaning, wipe it off
NOTICE carefully and allow it to evaporate before filling the
tank with oil.
NOTE! Allow the diesel oil or white spirit to drain completely from the
tank.
a) Make sure that the shut-off valve K1-V4) is closed.
b) Make sure that the drain (2) is plugged.
c) Open and remove the Hydroset tank cover (3), see section
Opening the tank covers on page 222.
d) Fill the Hydroset oil tank. For oil quality and quantity, refer to the
e) Check the Hydroset system for leaks.
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f) Close the tank cover (3), see section Closing the tank covers on
page 222.
1 2
2 Hydroset tank drain
3 Hydroset tank cover
3.12.7.13. Refilling the main lubrication system

WARNING!

If white spirit has been used for cleaning, wipe it off
NOTICE carefully and allow it to evaporate before filling the
tank with oil.
NOTE! Allow the diesel oil or white spirit to drain completely from the
tank.
a) Make sure that the shut-offvalve L1-V5) is closed.
b) Make sure that the drain (2) is plugged.
c) Open and remove the lubrication tank cover (3), see section
Opening the tank covers on page 222.
d) Fill the lubrication oil tank through the return oil screen. For oil
quality and quantity, refer to the Technical Specifications.
e) Check the lubrication system for leaks.
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f) Close the tank cover (3), see section Closing the tank covers on
page 222.
1 2
3 Lubrication tank cover
3.13. Air-oil cooler
3.13.1. Replacing the thermostatic element

The wrong thermostatic element can lead to failure of
the eccentric and bottom shell bushings.
NOTICE The thermostatic element as well as the setting of the
temperature switches L1-TS1, L1-TS2 and L1-
TS3must correspond to the viscosity grade of the oil
you use.
a) Remove the thermostatic element's sign (6) from the thermostatic

valve (5).
b) Disconnect the hoses L1-H3 and L1-H7 from the cooler assembly
and plug them.
c) Remove the bolts (2) and separate the outer housing (7) from the
thermostatic valve (5).
d) Pull out the thermostatic element (1).
e) Remove the outer and inner O-rings (3), (4).
f) Lubricate the new inner O-ring (4) and fit it in the groove.
g) Insert the new thermostatic element (1) with a twisting motion. The
temperature specification (in Fahrenheit) is stamped into the outer
surface of the element.
h) Clean and refit the outer O-ring (3).
i) Refit the outer housing (7) and tighten the bolts (2).
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j) Unplug and reconnect the hoses L1-H3 and L1-H7.

k) Fit the new thermostatic element's sign (6) to the thermostatic
valve (5).
1 2 3 4
5 6
IS
O
VG
15
7 5
0-3
5C
1 Thermostatic element
2 Bolt
3 Outer O-ring
4 Inner O-ring
5 L1-V2 Thermostatic valve
6 Thermostatic element's sign
7 Outer housing
3.14. Start-up after maintenance
3.14.1. Checklist for an overhauled crusher

a) Check that the lubrication and Hydroset lines between the crusher
and the tank units are correctly installed, and that the oil return
lines have sufficient inclination and are adequately dimensioned.
For further information about mechanical installation and
connections, refer to the Installation instructions.
b) Check that the voltage and frequency of the electrical supply
match the data given on the motors and the heaters.
c) Check that the motor overload protection relays are set to the
correct current values.
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d) Fill the lubrication tank and the Hydroset tank with oil. Refer to
Lubrication systems in the Technical specifications, for oil quality
and oil quantity.
NOTE! Use the same type of oil in the Hydroset tank and the main
lubrication tank, but with different viscosities.
e) Switch on the oil heaters.
f) If the pinion shaft housing has been emptied of oil, let the
lubrication pump run for five minutes before starting the crusher.
g) Check that the spider bushing is filled with grease to the top of the
bushing, when the main shaft is in its lowest position. Refer to
Lubrication systems in the Technical specifications, for grease
recommendations.
h) Check that the spider bushing seal does not leak.
i) Check that the direction of rotation of the motor on the lubrication
oil pump is the same as the arrow on the pump.
j) If the crusher is fitted with a cooler, check the direction of rotation
of the fan motor(s) and the air flow direction. Air should be drawn
through the cooler matrix.
k) Start the crusher's lubrication oil pump and check that there is no
leakage in the oil lines. Run the pump for about 30 minutes, then
clean the return oil screen from any contaminants (e.g. remnants
of sealing compound etc.). Start the pump again.
l) Slightly raise and lower the main shaft several times, and check
that the electrical setting control circuits are correctly connected.
m) Lower the main shaft to its lowest position and measure the
distance between the head nut and the underside of the spider.
Make a note of this dimension (A-dimension), it will help determine
the wear on the step bearing, without taking the crusher apart.
n) Raise the main shaft between 10 and 15 mm (0.4 to 0.6") from its
lowest position.
o) Check that the crusher’s drive is correctly aligned. Check that the
V-belts are correctly tensioned, see section Checking the V-belt
tension on page 210.
p) Start the crusher's drive motor and check that the direction of
rotation is correct. Run the crusher without load until the return oil
temperature reaches about 40 °C (104 °F).
q) Check that the pinion shaft lubrication pump starts when the
crusher drive motor starts.
r) Check the operation of the return oil flow switch and, if necessary,
make an adjustment. Refer to Checking the function of the return
oil flow switch in the Operator’s instructions.
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s) The crusher's drive motor must also stop if there is a high

temperature alarm from the protective thermostat. Lower the
temperature limit to a value below the temperature of the oil. The
motor must stop. Reset the temperature limit to the recommended
value, refer to Temperature switches in the Technical
specifications.
NOTICE The lubrication pump must never be stopped until
the crusher has stopped completely.
t) Stop the crusher's drive motor and the lubrication pump.

u) Clean the return oil screen, see section Cleaning the return oil
screen on page 229.
v) Check that material cannot be fed to the crusher unless both the
crusher and the discharge system are running.
3.15. Starting up the crusher
3.15.1. Preparing a tank that has been stored more

than six months
a) Look at the Production Date on the tank unit's identification plate. If
more than six months have passed since the tank unit was
manufactured , the following steps must be performed.
b) Make sure the Hydroset pump motor K1-M1 cannot be started.
c) Close the shut-off valve K1-V1 between the Hydroset tank and the
Hydroset control valve.
d) Unscrew the valve K1-CV2 in the Hydroset valve K1-HA1.
NOTICE Some oils are not compatible.
Use the same oil as in the lubrication tank.
e) Pour oil in the opening K1-CV2 until it is filled.

f) Refit and tighten the valve carefully.
g) IMPORTANT! Open the shut-off valve K1-V1
h) Enable start of the Hydroset pump motor K1-M1. The crusher must
be switched off.
i) Test raising and lowering the mainshaft.
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j) If needed, bleed air from the Hydroset system, see section

1 2
3
1 K1-HA1 Hydroset control valve
2 K1-CV2 Check valve, decreases the CSS
3.15.2. Running-in
The appropriate parts of this section apply also after repair work and the
fitting of new parts.
a) Make sure that the shut-off valves L1-V1 and K1-V1 between the
tanks and the pumps are open, and that the tank shut-off
valves L1-V5 and K1-V4 are closed.
1 2 3
2 L1-V1 Shut-off valve, lubrication oil to pump
3 K1-V1 Shut-off valve, Hydroset oil to Hydroset control valve
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b) NOTE! When the pumps are started, it will take some time before
the oil reaches the pinion shaft housing.
If the pinion shaft housing has been emptied of oil, let the
lubrication pump run for five minutes before starting the crusher.
c) Before the main lubrication oil pump is started check the
oil level L1-LI1. When the pumps are started, the oil tank must be
filled to the Max. level so that the pump does not run dry.
d) Start the main lubrication oil pump. When the pump is started, it
will take some time before the oil reaches the pinion shaft housing.
e) When the “Ready for start” signal is obtained, start the crusher’s
drive motor.
f) Make sure that the main shaft is in its bottom position. Bleed the
Hydroset system, see section Bleeding air from the Hydroset
system on page 156.
g) Check and adjust the setting. Refer to Checking the CSS with lead
in the Operator's instructions.
The load at the start of running-in must never exceed
50% of the maximum load. If possible the crushing
chamber should be full. The crusher will not be run-
in by idling. The crusher is normally run-in after
NOTICE approximately 16 hours of a gradually increase of
power and pressure started at 50% load. Depending
on the availability of material, and for other process
engineering reasons, running-in can take longer. It is
important that steps j) to k) are followed carefully
during the entire running-in procedure.
h) Start the feed to the crusher. Feed the crusher carefully and
gradually increase the power and pressure from 50% load until it
reaches full load after 16 hours. Then run the crusher at full load
during approximately 8 hours. The total time to run in the crusher is
approximately 24 hours. Refer to section Running-in schedule in
the Technical specifications. The load is altered by changing the
setting.
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i) Check the return oil temperature regularly at the temperature

indicator L1-TI2. This temperature should normally be between 40
°C (104 °F) and 45 °C (113 °F).
j) Check that the cooling system cuts in and out at the correct oil
temperatures. For further information about the temperature
switches, refer to the Technical specifications.
NOTE! If operating conditions differ from normal (Oil = ISO VG
150 viscosity), set the temperature switches. For further
information about the temperature switches and oil heating
control, refer to the Technical specifications.
k) Inspect and clean the return oil screen daily. Quite often, a small
quantity of fine steel and bronze particles can be found on the
return oil screen during the initial running-in period. For further
information about the return oil screen, see section Cleaning the
return oil screen on page 229.
l) Bleed the Hydroset system, see section Bleeding air from the
Hydroset system on page 156.
m) Check that there is no movement between the top shell and bottom
shell. Put a finger on the joint between the top shell and bottom
shell flanges to detect any possible relative motion.
n) Check that there are no oil leaks from the lubrication and Hydroset
lines.
o) Check that the Hydroset pressure is within the limits. Push the
button K1-V3 and check the pressure on pressure indicator K1-
PI1. For further information about pressure limits and technical
specifications, refer to the Technical specifications.
1 K1-PI1 Hydroset pressure indicator

2 K1-V3 Button to activate the Hydroset pressure indicator
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p) Check the temperature outside the pinion shaft housing with a

suitable thermometer, for example an infrared temperature sensor.
The normal temperature is 50–60 °C(122–140 °F).
q) Check that the feed is correctly distributed around the crushing
chamber, refer to the Installation instructions.
r) Check the power consumption and Hydroset pressure, refer to
section Maximum load in the Technical specifications. For further
information about the Hydroset pressure indicator K1-PI1, see
section Checking the valves in the Hydroset control valve on page
162.
s) Check and record the main lubrication system’s oil pressure on
pressure indicator L1-PI1. For further information about the main
lubrication system, refer to section Checking the pressure of the
main lubrication system in Operator's instructions.
t) Check and record the pinion shaft lubrication system’s oil pressure
on pressure indicator L2-PI1. For further information about the
pinion shaft lubrication system, refer to section Checking the
pressure of the pinion shaft lubrication system in Operator's
instructions.
u) Check for a ringing sound during crushing, it can indicate a loose
mantle or concave ring.
v) Check that there are no grease leaks from the spider bushing.
w) After a few hours of operation, bleed the Hydroset system again,
see section Bleeding air from the Hydroset system on page 156.
x) After running-in is completed, check the tightness of all bolts and if
the crusher has a V-belt drive re-tension the V-belts, see section
Checking the V-belt tension on page 210.
3.15.3. Replacing the filters for the first time

A set of filters for the tank unit is included at delivery.
a) Change the filters after the first 500 operation hours, see sections
Replacing the Hydroset oil filter on page 161, Replacing the main
lubrication oil filter on page 226, Replacing the pinionshaft
lubrication oil filter on page 228. If the filter's pressure switch is
connected to the plant control system, change the filter as
indicated by the control system.
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4. Maintenance personnel's
troubleshooting
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4.1. Problems and corrective actions

If the crusher stalls with the crushing chamber full of
NOTICE material, see section Clearing out the crushing chamber on
page 12.
Before you carry out any corrective actions:
• Read and understand the instructions.

• Make sure that you have the required training and skills before
performing any corrective actions.
When you perform corrective actions, use appropriate approved
personal protective equipment. Refer to Safety and Environmental
instructions for general safety precautions when handling Sandvik
equipment.
If the problem remains after you have followed the troubleshooting in
this chapter, or if the problem is not covered here, contact Sandvik.
4.2. The crusher does not start
Possible cause Corrective action

No “Ready for start” signal and oil Check the electrical circuits and the starter of the pump
pump not running motor.
No “Ready for start” signal and low Check the oil hoses and pipes and remove any obstacles.
lubrication oil flow
If necessary, change the filter cartridges, see section
Replacing the main lubrication oil filter on page 226.
Check the pump capacity. Also see section The main
lubrication oil capacity is low or non-existent on page 250. If
necessary, change the pump.
No “Ready for start” signal and Check the oil flow to the pinion shaft housing, see section
normal lubrication oil flow Checking the oil flow to the pinionshaft housing on page
163.
If the protective temperature switch L1-TS3 shuts the
crusher down, check the operation of the temperature
switch, see section Checking the return oil temperature
switch L1-TS3 on page 220.
Oil pump running and "Ready for Check starter of crusher’s drive motor and other electrical
start" signal obtained circuits. Refer to the Installation instructions for the crusher.
4.3. The crusher stops

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

Oil pump not running Check the electrical circuits and the starter of the pump
motor.
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Low lubrication oil Check the oil hoses and pipes and remove any
flow obstacles.
If necessary, change the filter cartridges, see section
Replacing the main lubrication oil filter on page 226.
Check the pump capacity. Also see section The main
lubrication oil capacity is low or non-existent on page
250. If necessary, change the pump.
Low lubrication oil flow to the pinion shaft housing Check the oil
flow to the
pinion shaft
housing, see
section
Checking the
oil flow to the
pinionshaft
housing on
page 163.
Oil too hot See section The lubrication oil temperature is too high
on page 245.
If applicable: V-belts Adjust the V-belt tension, see section Checking the V-
slipping belt tension on page 210. Change the V-belts if
necessary.
Crusher’s drive motor Make sure that the eccentric throw and the crushing
overloaded chamber are correct for the chosen CSS and the
material that is crushed.
Check for bearing failure or seizure in the crusher. See
section A bearing in the crusher fails on page 249.
Tramp metal or Reset the drive motor and the overload protection.
blockage in crushing If applicable: Check the V-belt, see section Checking the
chamber V-belt tension on page 210 and adjust if necessary.
If increasing the CSS doesn’t help, it can be necessary
to loosen the top shell bolts and to lift the top shell. For
top shell removal instructions, see section Replacing the
top shell on page 38.
4.4. The lubrication oil temperature is too

high

Protective temperature Air/oil cooler: check the fan motor and the starter.
switch L1-TS3 shuts the
If the contamination in the return oil screen L1-OS1 has increased,
crusher down
check for incipient bearing failure. See section The bearing
component wear increases on page 248.
Check the operation of the oil cooling system.
Check the temperature on the temperature gauge next to the
thermostatic valve. If it is significantly higher than the operating
temperature for the thermostatic element, replace the thermostatic
element. See section Replacing the thermostatic element on page
235.
Cooler cooling continuously See Protective temperature switch L1-TS3 shuts the crusher down
above.
If the lubrication oil viscosity is incorrect, change the oil. Refer to
Oil for the main lubrication system in Technical specifications.
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Low lubrication oil flow Check the oil hoses and pipes for leaks. Replace or seal any
defective parts.
If necessary, change the filter cartridges, see section Replacing
the main lubrication oil filter on page 226.
Check the pump capacity. If necessary, change the pump. See
section Checking the main lubrication oil flow on page 220 and
section The main lubrication oil capacity is low or non-existent on
page 250.
4.5. The CSS varies or the product is

oversized

Low Hydroset pressure Check the capacity of the Hydroset pump. If necessary,
change the pump.
Leakage in Hydroset system Check the Hydroset oil hoses and pipes for leaks.
If possible without going below the smallest A-dimension,
decrease the CSS until the mantle and concave are in
metal-to-metal contact. Check the Hydroset pressure
indicator K1-PI1 by pressing the button K1-V3 to see if the
pressure is falling.
Replace or seal any defective parts.
Hydroset relief valve leaking. If there are overload pressure peaks, change the feed
CSS increase has caused oil level to arrangement. The crusher should be choke fed without
rise in the Hydroset tank segregation, refer to the Installation instructions.
If there are no overload pressure peaks, change the
damaged Hydroset relief valve.
Hydroset hydraulic assembly Clean or replace the Hydroset control valve K1-HA1. See
leaking. section Checking the valves in the Hydroset control valve
CSS increase has caused oil level to on page 162.
rise in the Hydroset tank
Chevron packing leaking Replace the chevron packing, see Replacing the chevron
CSS increase has caused oil level to packing on page 144.
rise in the main lubrication oil tank
Air in Hydroset system or Bleed air from the Hydroset system, see section Bleeding
accumulator gas pressure too low. air from the Hydroset system on page 156.
CSS increases during crushing but
Charge the accumulator to the correct pressure, see
returns to pre-set value during idling
section Checking the gas pressure on page 156. Replace
the accumulator bladder or the complete accumulator if
necessary.
Accumulator bladder damaged. Replace the accumulator bladder or the complete
Mainshaft “climbs” to metal-to-metal accumulator.
position when crusher idles, or Bleed air from the Hydroset system, see section Bleeding
nitrogen leaks from the accumulator air from the Hydroset system on page 156.
bladder and renders Hydroset oil
milky white.
Crusher’s feed not evenly Change the feed arrangement. The crusher should be
distributed. choke fed without segregation, refer to the Installation
Hydroset pump cannot reduce CSS instructions.
because of pressure peaks
Mantle and/or concave worn Fasten the mantle and concave if they are loose. Change
the mantle and concave if they are worn out.
Concave ovality Check the CSS at four points evenly spaced around the
crushing chamber. The difference between the largest and
smallest reading is an indication of the ovality.
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Headcenter loose Check if there is play between the headcenter and the
mainshaft, see section Checking the play between the
head center and the mantle on page 67.
4.6. The pinion shaft does not operate

correctly

High temperature inside and Check that the oil reaches the pinion shaft housing, see section
outside pinion shaft housing. Checking the oil flow to the pinionshaft housing on page 163.
Check that oil returns to the lubrication tank.
High temperature inside and Check if the drain plug leaks, see section Removing the pinion
outside pinion shaft housing. shaft housing assembly on page 165. Check for other leaks.
Oil leakage through outer Replace or seal any defective parts.
bearing cover
Remove the pinion shaft assembly for inspection, see section
Removing the pinion shaft housing assembly on page 165.
Replace worn bearings and seals.
Change the lubrication oil, see section Changing the main
lubrication oil on page 222.
Check if the outer seal ring, the spacer ring or the O-ring is worn
or damaged.
Remove the pinion shaft assembly for inspection, see section
Removing the pinion shaft housing assembly on page 165.
Replace worn components.
Abnormal noise in pinion Remove the pinion shaft assembly for inspection, see section
shaft assembly. Removing the pinion shaft housing assembly on page 165.
Incipient bearing failure Replace worn components.
Change the lubrication oil, see section Changing the main
lubrication oil on page 222.
Vibration in crusher, pinion Remove the pinion shaft assembly for inspection, see section
shaft housing or motor Removing the pinion shaft housing assembly on page 165.
Replace worn components.
If applicable: Check the grooves in the V-belt pulleys.
Check the V-belt tension, see section Checking the V-belt tension
on page 210. If necessary replace them, see section Replacing
the V-belts on page 212.
Excessive axial play in Replace the bearings, see section Replacing the pinionshaft and
bearings because of heavy the pinion on page 172.
wear on rollers and races
Increasing noise or
temperature rise in the pinion
shaft assembly
Poor lubrication Check that the oil reaches the pinion shaft housing, see section
Checking the oil flow to the pinionshaft housing on page 163.
4.7. The crusher sounds different

Incorrectly fitted bevel gears Remove the pinionshaft assembly.
or incorrect gear meshing Adjust the gear backlash, see section Adjusting the gear
causing noise from gears. backlash on page 204.
Insufficient backlash emitting
a high-frequency rattle
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Heavy wear on the eccentric Replace the eccentric wearing plate.
wearing plate leading to Readjust the backlash, see section Adjusting the gear backlash
reduced backlash. on page 204.
Insufficient backlash emitting If the eccentric wearing plate wear accelerates, see section The
a high-frequency rattle bearing component wear increases on page 248.
Mantle and/or concave loose Check and tighten the concave ring bolts.
Check if there is play between headcenter and mantle, see
section Checking the play between the head center and the
mantle on page 67.
Unusual noise from spider Check grease level and add grease more frequently if necessary,
bearing when material is fed refer to Checking the grease level in the spider bearing in the
Operator's instructions.
Measure the play at the pivot point. If more than permissible,
replace the spider bushing and/or the mainshaft sleeve. See
section Replacing the spider bushing and the seal ring on page
34 and section Replacing the mainshaft sleeve on page 72.
“Grating” step bearing Extend the running-in period. See section Running-in on page
components 239.
If the contamination in the return oil screen L1-OS1 has
increased, check for incipient bearing failure. See section The
bearing component wear increases on page 248.
Check for liner ovality. See section The CSS varies or the product
is oversized on page 246.
Packing in crushing chamber Check for concave ovality. See section The CSS varies or the
Mantle and concave in product is oversized on page 246.
“metal-to-metal” contact
Excessive Hydroset action Check the lower section of the crushing chamber for “ski-slopes”
on the mantle and the concave ring. Change the mantle and/or
concave.
4.8. The crusher's capacity drops

If applicable: V-belts Check the grooves in the V-belt pulleys.
slipping Check the V-belt tension. if necessary, tighten or replace them, refer to
Checking the wear and tension of the V-belt in the Operator's
instructions.
Bridging or blocking in Check the mantle and concave. If necessary, replace the mantle and/or
crushing chamber concave, see section Replacing the main shaft and the mantle on page
55 and section Replacing the concave ring on page 43.
4.9. The bearing component wear increases

Contaminated oil Check the oil condition regularly, see section Cleaning the return oil
leading to increased screen on page 229.
wear on eccentric Change the oil at regular intervals, see section Changing the main
wearing plate lubrication oil on page 222. Clean the tank, see section Cleaning the
main lubrication tank on page 230.
Oil filter blocked Change filter cartridges L1-FU1 or L2-FU1, see sections Replacing the
main lubrication oil filter on page 226 and Replacing the pinionshaft
lubrication oil filter on page 228.
Dust seal ring worn or If the play between the dust collar and the dust seal ring exceeds the
damaged value in Checking the dust seal ring for wear in the Operator's
instructions, replace the dust seal ring.
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Dust seal air pressure Inspect the entire dust seal air pressure system and check the operation
system not working of the dust seal air pressure system, refer to section Checking the dust
seal air pressure system in the Operator's instructions.
4.10. A bearing in the crusher fails

Main shaft assembly rotates very fast Disassemble the crusher to inspect the bearing
or at the same speed as the eccentric components, see section Inspecting the eccentric
(high head spin). bushing on page 108.
Seizure between mainshaft and
eccentric bushing
Pinionshaft cannot be turned. If possible, take out the bolts that hold the dust collar.
Seizure between eccentric and bottom Remove the main shaft assembly and the complete
shell bushing eccentric assembly, see section Removing the main
shaft assembly on page 55 and section Removing the
Pinionshaft cannot be turned. See section Replacing the pinionshaft and the pinion on
Bearing failure in pinion shaft page 172.
assembly
Increased amount of lead and/or Remove the step bearing components, see section
bronze on the return oil screen. Replacing the step bearing components on page 133.
Seizure in step bearing or bronze De-burr the edges of the oil grooves.
bushings Polish the bearing surfaces of the bushings and the step
bearing components.
If necessary, replace the step bearing components.
Inspect the bearing surfaces of the bushings.
Needle-like particles on the return oil Check the gear backlash, see section Checking the
screen. gear backlash on page 201. Listen for noise from the
Seizure or wear in bevel gears bevel gears or the pinion.
See section Cleaning the return oil screen on page 229
and section Cleaning the main lubrication tank on page
230.
High temperature or localized See section The lubrication oil temperature is too high
overheating and partial seizure in on page 245.
bushings or step bearing components
Lead flakes in return oil screen
4.11. The main lubrication oil is

contaminated

Contamination in the return Check for incipient bearing failure, see section The bearing
oil screen L1-OS1 has component wear increases on page 248.
increased
High return oil temperature See section The lubrication oil temperature is too high on page
245.
Dirt Check the dust seal. A worn dust seal lets dust into the system.
Check the function of the dust seal air pressure system, refer to
section Checking the dust seal air pressure system in the
Operator's Instructions.
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4.12. The Hydroset bolts are broken

Incorrect torque Replace all the bolts if any of them is defect. Use only bolts intended as
Hydroset bolts. Tighten to recommended torque. Refer to Tightening torques
in Technical specifications.
High Hydroset Feeding the crusher with tramp metal can cause the Hydroset bolts to fail.
pressure Make sure any tramp metal is removed before the material reaches the
crusher.
4.13. The concave bolts are broken

Worn topshell Inspect the seating area for the concave ring during a concave change.
Remove any upset metal that can stop the concave ring from seating
correctly in the topshell.
Incorrectly tightened Tighten bolts correctly. Refer to Tightening torques in Technical
bolts specifications.
4.14. The main lubrication oil capacity is low

or non-existent

Pump sucks air through a leak Check the suction lines. Replace or seal any defective
parts.
Check the shaft seal. Replace or seal any defective parts.
Pump rotates in wrong direction Check if the direction of rotation corresponds to the arrow
on the motor housing. If not, change the direction of
rotation.
High pressure but still low capacity Change the oil, refer to Oil for the main lubrication system
because of wrong type of oil in the Technical Specifications.
Suction line blocked Remove the obstruction.
Broken pump, e.g. cavitation in Replace the pump, see section Checking the main
pump or broken coupling lubrication oil flow on page 220.
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04.CH440-03 Maintenance Instructions S223.1239-05.En

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1. Basic maintenance instructions

3.2.7.2. Installing the concave ring................................... 46

3.4.3. Replacing the locating bar..............................................102

3.7.6. Replacing the Hydroset piston position transmitter

3.10.1.2. Installing the dust seal air pressure needle valve

4. Maintenance personnel's troubleshooting

1.1. Clearing out the crushing chamber

Risk of equipment or property damage.

1.2. Plastic backing

1.2.1. Backing procedure

a) Mix the plastic backing for a minimum of 5 minutes, according to

1.2.2. Hygienic aspects and protective measures

In addition to the instructions on the containers and in each

1.3.1. General accumulator information

The accumulator (1) is a cylindrical steel pressure vessel which

Increase of CSS due to overload

1.3.2. Flow regulator

1.3.3. Charging kit (option)

h) Unscrew the spindle (9).

1 Protective cap 7 Screw connector

1.3.3.2. Charging with nitrogen

Accumulator charging pressure Tolerance

p) Remove the charging kit from the nitrogen gas bottle.

1 Protective cap 7 Screw connector

2.1. Determining inspection and

2.2. Inspection and care when it is dark

2.3. Weekly inspection and care

Operation hours - Weekly or every 40 hours of operation

2.4. Monthly inspection and care

Operation hours - Monthly or every 160 hours of operation

Operation hours - Monthly or every 160 hours of operation

2.5. Inspection and care for every 6 months

Operation hours - Twice a year or every 1000 hours of operation

Change the breather filter L1-FU2 221

Clean the main lubrication tank 230

2.6. Yearly inspection and care

Operation hours - Yearly or every 2000 hours of operation

Change the main lubrication oil 222

3.1. Feed hopper

3.1.1. Replacing the feed hopper

1 Feed hopper 6 Screw

3.1.1.2. Inspecting the feed hopper

• If the crusher is installed without a distributor the spider arms must be

Cone crusher without a distributor

Cone crusher with a distributor

g) Regulate the feed so there is a build-up of process material in the

3.2.1. Replacing the spider cap

3.2.1.1. Removing the spider cap

Suspended load hazard

Risk of equipment and property damage

3.2.1.2. Spider cap removal checks

3.2.1.2.1. Inspecting the spider bushing

b) If the play exceeds the maximum permissible value, the spider

3.2.1.2.2. Cleaning the air vent passage in the topshell

1 Air vent pipe

3.2.1.3. Installing the spider cap

d) Carefully lift the spider cap from the ground.