maintenance manual Doc. no. S 223.

518 en

SANDVIK CH440:01
This document is valid for:

Serial no. / Machine no. Sign.

SANDVIK CH440:01

© Copyright 2009 Sandvik SRP AB.

All rights reserved. No parts of this document may be reproduced or copied in any form or by
any means without written permission from Sandvik SRP AB. All data and information in this
manual may be changed without further notice. Reservations for misprints.

Document number: S 223.518 en

Issue: 20090605
Version: 01

Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Phone: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
MM Sandvik CH440:01

1. Introduction
1.1 Equipment information.......................................................... 8
1.1.1 Document information............................................ 11

2. Safety precautions
2.1 Hazard information ............................................................. 18
2.1.1 Warning signs ........................................................ 18
2.1.2 Risk levels.............................................................. 18
2.1.3 Prohibition signs..................................................... 19
2.1.4 Mandatory signs..................................................... 19
2.2 Personnel............................................................................ 19
2.2.1 Personal protection ................................................ 20
2.3 General safety precautions................................................. 21
2.3.1 Machine safety guards........................................... 22
2.3.2 Machine access ..................................................... 22
2.3.3 Electrical safety...................................................... 22
2.3.4 Welding .................................................................. 23
2.3.5 Hydraulic system.................................................... 23
2.3.6 Lubrication system ................................................. 24
2.3.7 Lifting and moving loads ........................................ 24
2.3.8 Feed and jams ....................................................... 25
2.4 Emissions ........................................................................... 26
2.4.1 Dust........................................................................ 26
2.4.2 Noise...................................................................... 27
2.4.3 Radioactivity........................................................... 27

3. Basic maintenance instructions

3.1 General ............................................................................... 30
3.1.1 Routine inspection and care .................................. 30
3.1.2 Periodical maintenance.......................................... 30
3.2 Standard tool box................................................................ 30
3.3 Tightening threaded fasteners ............................................ 31
3.3.1 Required torque for threaded fasteners ................. 31
3.3.2 Requirements for joints with threaded fasteners.... 31
3.3.3 Locking fluid for threaded fasteners....................... 32
3.4 Welding............................................................................... 33
3.4.1 Lifting lugs for the mantle....................................... 33

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3.5 Backing with plastic composition ........................................ 35

3.5.1 General .................................................................. 35
3.5.2 Backing material..................................................... 35
3.5.3 Backing procedure ................................................. 36
3.5.4 Hygenic aspects and protective measures. ........... 37

4. Hydroset system
4.1 Flow diagram ...................................................................... 40
4.2 Adjust the setting ................................................................ 41
4.2.1 Decrease the setting .............................................. 41
4.2.2 Increase the setting................................................ 41
4.2.3 Correct setting........................................................ 42
4.2.4 Adjust the setting manually .................................... 42
4.2.5 Bleeding air from the Hydroset system .................. 43

5. Topshell assembly
5.1 Change the feed hopper ..................................................... 46
5.1.1 Remove the feed hopper........................................ 46
5.1.2 Inspect the feed hopper ......................................... 47
5.1.3 Install the feed hopper............................................ 48
5.2 Inspection of the crushing chamber .................................... 49
5.3 Checks prior to removal of the topshell............................... 50
5.4 General ............................................................................... 51
5.4.1 Spider bearing ........................................................ 51
5.4.2 Inspecting the spider bearing ................................. 51
5.4.3 Dust seal ring ......................................................... 52
5.4.4 Cleaning the return oil strainer and tank ................ 53
5.4.5 Grease for spider bearing lubrication ..................... 54
5.5 Change the spider cap........................................................ 57
5.5.1 Remove the spider cap .......................................... 57
5.5.2 Inspect the spider cap ............................................ 57
5.5.3 Install the spider cap .............................................. 58
5.6 Change the spider bushing and the seal ............................ 59
5.6.1 Remove the spider bushing and the seal .............. 59
5.6.2 Inspect the spider bushing and the seal................. 60
5.6.3 Install the spider bushing and the seal ................... 61

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5.7 Change the topshell............................................................ 63

5.7.1 Remove the topshell .............................................. 63
5.7.2 Inspect the topshell ................................................ 65
5.7.3 Install the topshell .................................................. 65
5.8 Change the concave ring.................................................... 68
5.8.1 Remove the concave ring ...................................... 69
5.8.2 Clean the topshell .................................................. 71
5.8.3 Install the concave ring .......................................... 71
5.9 Change the filler ring........................................................... 74
5.9.1 Remove the filler ring ............................................. 74
5.9.2 Inspect the filler ring............................................... 74
5.9.3 Install the filler ring ................................................. 75
5.10 Weld arm shields to the topshell ......................................... 76

6. Mainshaft and mantle

6.1 Change the mainshaft and the mantle................................ 78
6.1.1 Remove the mainshaft and the mantle .................. 79
6.1.2 Inspect the mainshaft and the mantle .................... 81
6.1.3 Install the mainshaft and the mantle ...................... 82
6.2 Change the head nut .......................................................... 84
6.2.1 Remove the head nut............................................. 84
6.2.2 Inspect the head nut .............................................. 85
6.2.3 Install the head nut................................................. 86
6.2.4 Remove the inner head nut.................................... 88
6.2.5 Install the inner head nut........................................ 88
6.3 Change the mantle ............................................................. 89
6.3.1 Remove the mantle................................................ 89
6.3.2 Inspect the mantle.................................................. 90
6.3.3 Install the mantle .................................................... 91
6.4 Change the mainshaft sleeve ............................................. 94
6.4.1 Inspect the mainshaft sleeve ................................. 94
6.4.2 Remove the mainshaft sleeve................................ 95
6.4.3 Install the mainshaft sleeve.................................... 96
6.5 Inspect the headcentre ....................................................... 98
6.6 Change the dust seal ring................................................... 99
6.6.1 Remove the dust seal ring ..................................... 99
6.6.2 Inspect the dust seal ring ..................................... 100
6.6.3 Install the dust seal ring ....................................... 100
6.7 Change the scraper .......................................................... 101
6.7.1 Inspect the scraper .............................................. 101

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7. Bottomshell assembly
7.1 Change the locating bar.................................................... 104
7.1.1 Remove the locating bar ...................................... 104
7.1.2 Check the locating bar clearance ......................... 104
7.1.3 Install the locating bar .......................................... 105
7.2 Change the step bearing components .............................. 106
7.2.1 Remove step bearing components....................... 107
7.2.2 Inspect the step bearing components .................. 109
7.2.3 Install the step bearing components..................... 110
7.3 Change the dust collar ...................................................... 113
7.3.1 Remove the dust collar ........................................ 113
7.3.2 Inspect the dust collar .......................................... 114
7.3.3 Install the dust collar ............................................ 115
7.4 Change the eccentric bushing .......................................... 116
7.4.1 Remove the eccentric bushing............................. 117
7.4.2 Remove the eccentric bushing - Alternative method 119
7.4.4 Install the eccentric bushing ................................. 121
7.5 Change the eccentric assembly........................................ 123
7.5.1 Remove the eccentric assembly .......................... 123
7.5.2 Inspect the eccentric assembly ............................ 125
7.5.3 Install the eccentric assembly .............................. 126
7.6 Change the gear carrier .................................................... 127
7.6.1 Remove the gear carrier ...................................... 127
7.6.2 Inspect the gear carrier ........................................ 128
7.6.3 Install the gear carrier/counterweight ................... 128
7.7 Change the eccentric gear................................................ 129
7.7.1 Remove the eccentric gear .................................. 129
7.7.2 Inspect the eccentric gear .................................... 129
7.7.3 Install the eccentric gear ...................................... 130
7.7.4 The eccentric gear / gear carrier joint .................. 130
7.8 Change the eccentric wearing plate.................................. 131
7.8.1 Inspect the eccentric wearing plate...................... 131
7.9 Change the bottomshell bushing ...................................... 132
7.9.1 Remove the bottomshell bushing ......................... 132
7.9.2 Inspect the bottomshell bushing........................... 133
7.9.3 Install the bottomshell bushing ............................. 134
7.10.1 Remove the Hydroset piston from above............. 135
7.10.2 Inspect the Hydroset piston.................................. 137
7.10.3 Install the Hydroset piston .................................... 137

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7.11 General – Hydroset cylinder ............................................. 138

7.12 Change the chevron packing ............................................ 139
7.12.1 Remove the chevron packing from below............ 139
7.12.2 Inspect the chevron packing ................................ 141
7.12.3 Install the chevron packing .................................. 142
7.13 Change the Hydroset cylinder bushing............................. 143
7.13.1 Remove the Hydroset cylinder bushing ............... 143
7.13.2 Inspect the Hydroset cylinder bushing ................. 144
7.13.3 Install the Hydroset cylinder bushing ................... 145
7.14 Change the mainshaft position probe ............................... 146
7.14.1 Remove the mainshaft position probe ................. 146
7.14.2 Install the mainshaft position probe...................... 147
7.15 Change bottomshell liners ................................................ 148

8. Pinionshaft assembly and bevel gears

8.1 General ............................................................................. 152
8.1.1 Oil for pinionshaft lubrication................................ 152
8.2 Change the pinionshaft assembly..................................... 153
8.2.1 Checks prior to removal ....................................... 153
8.2.2 Remove the pinionshaft housing assembly ......... 154
8.2.3 Inspect the pinionshaft housing assembly ........... 155
8.2.4 Install the pinionshaft housing assembly.............. 155
8.3 Change the pinionshaft and the pinion ............................. 157
8.3.1 Remove the pulley ............................................... 157
8.3.2 Remove the pinion ............................................... 158
8.3.3 Remove the pinionshaft ....................................... 160
8.3.4 Install the roller bearings and the spacers ........... 164
8.3.5 Install the pinionshaft ........................................... 166
8.3.6 Install the outer bearing cover.............................. 168
8.3.7 Install the level tube and the discharge tube........ 169
8.3.8 Install the inner bearing cover.............................. 171
8.3.9 Install the crusher pulley ...................................... 172
8.3.10 Preparation for the installation of a complete
pinionshaft assembly ........................................... 175
8.4 Bevel gears....................................................................... 177
8.4.1 Checking the gear backlash................................. 178
8.4.2 Adjustment of the backlash.................................. 181
8.4.3 Tooth bearing “footprint”....................................... 182

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9. Drive
9.1 V-belt drive ........................................................................ 188
9.2 General ............................................................................. 189
9.2.1 V-belt tension ....................................................... 189
9.3 Change V-belt guards ....................................................... 190
9.3.1 Remove V-belt guards.......................................... 190
9.3.2 Install V-belt guards.............................................. 190
9.4 Change V-belts ................................................................. 191
9.4.1 Remove V-belts .................................................... 191
9.4.2 Install V-belts ........................................................ 192
9.4.3 Remove V-belt drive motor................................... 193
9.4.4 Install V-belt drive motor....................................... 194

10. Start-up after maintenance

10.1 Check list for an overhauled cone crusher........................ 196

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 1. Introduction

MM Sandvik CH440:01 7
MM Sandvik CH440:01 1. Introduction

1.1 Equipment information

Purpose
The purpose of this Sandvik equipment is to be a crusher component in a
crushing and screening unit or plant within an aggregate or mining process.
The machine reduces the size of rocks, minerals and similar materials.
This crusher component has been exclusively designed for this application.
Unless the crusher is part of a complete plant delivery, Sandvik SRP AB is
not responsible for the complete aggregate or mining process.
Sandvik SRP AB will not accept any liability for damage to equipment or
injury to personnel caused by unauthorized or improper use or modification
of this equipment
Manufacturer
This equipment has been manufactured by:
Sandvik SRP AB
SE-233 81 Svedala
Sweden
www.sandvik.com
For maintenance
Contact the nearest Sandvik company, agent or representative, or contact the
factory directly:
Sandvik SRP AB
Service Department
SE-233 81 Svedala
Sweden
Telephone +46 (0)40 40 90 00
Telefax +46 (0)40 40 92 60

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MM Sandvik CH440:01 1. Introduction

Crusher identification
The figure below shows the location and an example of the cone crusher’s
identification plate. The identification plate contains the data needed when
contacting Sandvik concerning this specific equipment
The “type” designation is part of an identification.system that describes the
product.

Identification plate:
1 Type
2 Part number
3 Serial number
4 Mass (kg)
5 Order number
6 Manufacturer
7 Year of manufacture
8 CE mark

Type:
9 Type and size of crusher
10 Crushing chamber (concave
ring)
11 Mantle
12 Filler ring
13 Eccentric throw (mm)
14 Mark number

8
7

1 2 3 4 5 6

CH440-M/B/M-36/40/44/32:1

9 10 12 13 14
11

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MM Sandvik CH440:01 1. Introduction

Tank unit identification

The figure below shows the location and an example of the tank unit’s
identification plate. The identification plate contains the data needed when
contacting Sandvik concerning this specific equipment.

15 Type
16 Part number 22
17 Serial number
18 Mass (kg)
21
19 Order number
20 Manufacturer
21 Year of manufacture
22 CE mark 15 16 17 18 19 20

CE marking
This equipment complies with the basic health, environment and safety
regulations of the European Union and European Economic Area.
Sandvik will not take responsibility for this compliance when customers
modify any configuration of the cone crusher.

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MM Sandvik CH440:01 1. Introduction

1.1.1 Document information

Purpose of this maintenance manual
The purpose of this maintenance manual is to provide the maintenance
personnel with information on how to maintain and repair this Sandvik
equipment.
It is important to:
• keep the manual for the duration of the equipment
• pass the manual on to any subsequent holder or user of the equipment
• Some figures in the manual are based on other crushers, which are
similar to this crusher. Details of little or no importance for the text given
can therefore differ from this crusher’s design in some figures.
Document compliance
The instructions in this document are in accordance with the design and
construction of the equipment at the time it was delivered from the Sandvik
manufacturing plant.
Technical publications
• Installation manual (IM)
• Operator’s manual (OM)
When ordering technical publications, always specify the language and quote
the machine identity number.
Technical publications related to the maintenance of this equipment are:
• Maintenance manual (MM)
• Spare parts catalogue (SPC)

Feedback
If you have comments on this manual or problems connected to the crusher’s
documentation, send an e-mail to: manuals.srp@sandvik.com

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MM Sandvik CH440:01 1. Introduction

1.2 Operating principles of a cone crusher

In a cone crusher, the process material is crushed between two rigid surfaces.
The motion of the moving surface is independent of the load on the crusher.
The crushing action is achieved by an eccentric gyratory movement of the
manifest (6). Individual pieces of process material (e.g. rock or ore) are
nipped, compressed and crushed between the mantle (4) and the concave
ring (3).
The quality and the quantity of the crushed product depend on the interaction
between the crusher and the process material. The geometry of the crushing
chamber, the crusher dynamics and the properties of the process material are
the most important factors.
The concave ring (3), the mantle (4), the eccentric assembly (5) and the
location of the pivot point determine the chamber geometry of the cone
crusher. The crusher’s drive motor rotates the eccentric assembly at a
constant speed through a gear transmission. The rotation of the eccentric
assembly causes the lower end of the manifest to gyrate. At the top of the
manifest (6) is the spider bearing (1) that acts as the pivot point for this
gyrating motion. The mantle (4) is fixed to the manifest (6) and the concave
ring (3) is fixed to the topsail (2). The gyration of the manifest (6) means that
the distance between the mantle (4) and the concave ring (4) continually
varies. When this distance decreases the incoming process material will be
subjected to a compressing stress and will be crushed. When the mantle
moves away from the concave ring, the process material is able to flow down
through the chamber.
The mantle (4) and the concave ring (3) must be replaced regularly as they
are continuously worn. The rate at which this wear occurs depends on the
characteristics of the process material. Refer to Inspection of crushing
chamber in the Operator’s manual.

1
2
1 Spider bushing 3
2 Topshell 4
3 Concave ring
5
4 Mantle
5 Eccentric assembly 6
6 Mainshaft

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MM Sandvik CH440:01 1. Introduction

Setting adjustment
Due to the necessity to compensate for wear, and the requirement to produce
different product sizes, the crusher has a setting control system, called the
Hydroset system. Basically, it consists of a robust hydraulic jack, which
supports the mainshaft and adjusts its position.
By moving the Hydroset piston up and down, the discharge setting can be
changed, which in turn changes the size of the crushed material.
Read more in the OM, Setting measurement.

= =

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MM Sandvik CH440:01 1. Introduction

1.2.1 Description
The following figure shows an overview of the nomenclature and
components of this cone crusher. Grey areas indicate sectioned material.

Cone crusher - intersected view

1
1 Spider cap
2 Spider bushing 2
3 Head nut
4 Mantle
5 Concave ring
6 Mainshaft with 3
headcentre 4 20
7 Eccentric wearing plate 5
8 Bottomshell bushing
6 19
9 Eccentric 18
10 Eccentric bushing
11 Step bearing 17
12 Hydroset piston
7 16
13 Pinionshaft housing
14 Pinionshaft 8 15
15 Dust collar
16 Locating bar
17 Dust seal ring
18 Bottomshell
19 Topshell
20 Filler ring
9 14
10
13
11
12

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MM Sandvik CH440:01 1. Introduction

Cone crusher side view

21
22
23

21 Hole for level indicator

22 Inspection door
23 Feed hopper
24 Inspection hatch 24

Tank unit and auxiliary equipment

25

26
25 Over-pressure blower
26 Over-pressure air regulator
27 Tank unit
28 Water/oil heat exchanger 27
29 Air/oil heat exchanger
30 Charging kit for accumulator
(optional)
28

29

30

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This page is intentionally left blank

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

MM Sandvik CH440:01 17
MM Sandvik CH440:01 2. Safety precautions

2.1 Hazard information

2.1.1 Warning signs

General danger Dangerous voltage Risk of crushing

Hanging load Risk of crushing Flying fragments

2.1.2 Risk levels

Throughout the manual, risk levels are indicated with “DANGER”,
“WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels
are accompanied by a warning sign (see above).

Failure to observe information marked “DANGER!” can result in life-

threatening injuries!

DANGER!
Failure to observe information marked “WARNING!” can result in
personal injury and/or serious damage to, or destruction of,
equipment!
WARNING!
CAUTION! Failure to observe information marked “CAUTION!” can result in
damage to equipment!

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MM Sandvik CH440:01 2. Safety precautions

2.1.3 Prohibition signs

Do not remove
guards

2.1.4 Mandatory signs

Disconnect current Read the manual

2.2 Personnel
All work on the equipment is to be carried out only by trained or authorized
personnel.
– “Trained” means that the person in question has been given practical
instruction by an authorized person on how the various tasks are to be
carried out.
– “Authorized” means that a person has undergone a theoretical and
practical test of knowledge, organized by Sandvik SRP AB. He/she is
therefore judged to have the knowledge and competence to carry out
the tasks assigned to the appropriate role.
All expected work tasks on this production equipment have been defined by
Sandvik SRP AB as belonging to one of three categories – work roles –
based on different competence profiles. These three work roles are:
• Installation
• Operation
• Maintenance

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MM Sandvik CH440:01 2. Safety precautions

Sandvik SRP AB provides technical documentation appropriate to all three

work roles:
• Installation manual
• Operator’s manual
• Maintenance manual and Spare parts catalog
Sandvik SRP AB can provide adequate training for all three work roles and
can carry out authorization of trained personnel.
The technical documentation from Sandvik SRP AB covers only work on the
production equipment itself – it does not cover work tasks associated with
other equipment or routines at the site.
It is the responsibility of the plant management to assign responsibility for:
• The production equipment and the work area around the equipment
• All personnel in the vicinity of the equipment
• Compliance with national and local safety regulations
• Checking that all safety devices are fully operational
Sandvik SRP AB declines all responsibility for injury or damage resulting
from non-compliance with the instructions in this manual.

2.2.1 Personal protection

Sandvik SRP AB strongly recommends that personal protective equipment is
always worn when working in the vicinity of the equipment.
Sandvik SRP AB strongly recommends to use a safety harness when
working above, inside or under the equipment.
The Sandvik SRP AB recommendation for personal protective equipment
includes:

Ear protection Safety helmet Eye protection

Protective gloves Safety boots Mask or respirator

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MM Sandvik CH440:01 2. Safety precautions

2.3 General safety precautions

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

Always switch off power and lock out the equipment (so that it cannot
inadvertently be switched on) before any maintenance work is started. Also
ensure that it is not possible for anyone else to switch the power on while
maintenance work is being carried out.
Avoid staying on the equipment, unless necessary for maintenance work.

Risk of crushing
Never remain on the equipment while in operation. Moving parts
constitute a risk of crushing. Falling into the crusher implies danger of
DANGER! being crushed.

Risk of crushing
If the crusher is mounted on rubber dampers, there is a risk of
crushing between the oscillating parts of the crusher and the
WARNING! stationary frame.

Ejection
Never look into the crusher while in operation. Fragments and possibly
harmful matter fed to the crusher may be ejected. The bottomshell’s
WARNING! Inspection hatches must be closed during operation.

CAUTION! Sharp edges may appear on the equipment due to wear, please
consider sharp edges when handling worn parts. Remove any sharp
edges.

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MM Sandvik CH440:01 2. Safety precautions

2.3.1 Machine safety guards

Do not remove guards
Make sure that all guards are in place and functioning, to prevent
exposure to flying fragments and rotating parts. Never operate the
PROHIBITION! equipment unless guards are mounted.

Rotating parts
Exposure to rotating parts of the equipment must be prevented by
guards. Always attach guards after maintenance work.
WARNING!
Flying fragments
Fragments ejected upwards may fall down in the vicinity of the
equipment. Provide adequate guards and warning signs at appropriate
WARNING! places around the danger zone.

Upwardly ejected fragments may fall down in the vicinity of the crusher.
Therefore Sandvik SRP AB recommends additional protection.
Make sure all defective guards and dust sealing components are checked,
repaired and replaced before starting the equipment.

2.3.2 Machine access

Every machine requires access for personnel who carry out inspections and/
or maintenance work. Suitable access platforms and guard rails must be
installed. Walkways, stairs and ladders must be designed in accordance with
applicable regulations. (These parts are not included in the crusher’s standard
specification. For advice, contact Sandvik SRP AB.)
Areas where access is required are indicated on installations drawings, see
the Installation manual.

2.3.3 Electrical safety

CAUTION! Only personnel working according to European Standard EN 50110 or
equivalent are permitted to perform electrical operations on the
equipment.

Dangerous voltage
Personnel must regard all electrical equipment as live until it is proven
dead by proper testing procedures.
DANGER!
Make sure all broken or damaged electrical cables and connectors are
checked, repaired and replaced before starting the equipment.
Control cabinets must be lockable.

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MM Sandvik CH440:01 2. Safety precautions

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

CAUTION! Only welders qualified according to European Standard EN 287 or

equivalent are permitted to perform welding operations on the crusher.

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

Toxic gases
Inhalation of welding fumes is a health hazard. Always follow
instructions provided by the welding equipment supplier.
WARNING! Some parts of the crusher are made of manganese steel. Long-term
exposure to manganese oxide can affect the nervous system.

CAUTION! Drain oil before welding in an oil tank, to avoid the risk of explosion and
fire.

2.3.5 Hydraulic system

CAUTION! Only personnel certified in hydraulics are permitted to perform
maintenance on the hydraulic system (except bleeding air from the
Hydroset system).

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

CAUTION! Never adjust pressure relief valves beyond the recommended values.

Oil temperature
Hydraulic oil can become very hot during operation. Allow the oil to
cool before working on the hydraulic system. Equipment and hoses/
WARNING! pipes containing hydraulic oil may have hot surfaces.

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

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MM Sandvik CH440:01 2. Safety precautions

2.3.6 Lubrication system

CAUTION! Equipment and hoses/pipes containing lubrication oil may have hot
surfaces.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired
and replaced before starting the equipment.
CAUTION! Always remove oil stains to avoid skidding risk.

2.3.7 Lifting and moving loads

CAUTION! Only personnel with adequate lifting training are permitted to perform
lifting operations.
Hanging load
Never work or stand underneath a crane that is lifting material. Keep a
safe distance to hanging loads.
DANGER!
Make sure that the capacity of the lifting equipment is adequate and that it is
in good working order.
If lifting tackle has to be made up by joining separate components, make sure
that the joints are secure and have the same lifting capacity as the rest of the
tackle.
NOTE! Always use lifting tackle certified in accordance with local conditions.

Always engage the safety clips on lifting hooks to prevent the tackle from
slipping off.
Use ropes or poles to steady and maneuver loads. Do not use hands or feet.
Make sure that the route and the destination are free from obstacles before
moving a suspended load. It must be possible to lower the load to the ground
quickly and safely in case of an emergency.
When depositing loads, keep the lifting equipment in place until it has been
made sure that the load is stable.

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MM Sandvik CH440:01 2. Safety precautions

2.3.8 Feed and jams

CAUTION! When the crushing chamber is empty, avoid feeding solitary round
rocks.

CAUTION! Never feed combustible process material into the crusher.

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

Explosives
Never remove blocking boulders from the crusher by blasting.
Blasting may cause personal injury and seriously damage bearings or
WARNING! other parts. Sandvik SRP AB takes no responsibility for injury to
personnel or damage to the equipment when blasting is used.

Risk of crushing
Never stand inside the crusher when a blockage is removed. You might
be pulled forcefully and suddenly downwards together with the
DANGER! material in the crushing chamber and be crushed.

In some cases it is possible to increase the CSS (closed side setting)

temporarily to clear a jam.
Always follow local regulations when attempting to clear a jam.

© 2009 Sandvik SRP AB Doc. no. S 223.518 en Ver. 01 25

MM Sandvik CH440:01 2. Safety precautions

2.4 Emissions
Since Sandvik’s crushers are used for handling and/or processing of minerals
or other materials which can give rise to health risks for human beings and
animals, it is the responsibility of the user to follow the relevant rules and
regulations intended to prevent health risks. This includes specific
regulations applying to dust emission, asbestos, quartzite, radon etc.

2.4.1 Dust
Health hazard
Breathing or inhaling dust particles will cause death or severe injury.
Always wear approved respirator.
DANGER!
Always work with a respirator approved by the respirator manufacturer
for the job you are doing. It is essential that the respirator that you use
protects you from the tiny dust particles which cause silicosis and
which may cause other serious lung diseases. You should not use the
equipment until you are sure your respirator is working properly. This
means the respirator must be checked to make sure that it is clean,
that its filter has been changed, and to otherwise make sure the
respirator will protect you in the way it is meant to.

Make sure the dust suppression system in your equipment is working

properly. If the dust suppression system is not working properly, stop
working immediately.

Always make sure dust has been cleaned off your boots and clothes
when you leave your shift.

The smallest particles of dust are the most harmful. They may be so
fine that you can not see them.

Remember, you must protect yourself from the danger of breathing or

inhaling dust.

Sandvik SRP AB strongly recommends using additional equipment for dust

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

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MM Sandvik CH440:01 2. Safety precautions

2.4.2 Noise
Health hazards
Crushing and processing material result in noise. Such noise can be
dangerous to your hearing. Use adequate ear protection.
WARNING!
Refer to OM - Technical data for measured noise levels and measurement
conditions.
Rubber compression mountings and dust encapsulation result in lower noise
levels.

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

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

© 2009 Sandvik SRP AB Doc. no. S 223.518 en Ver. 01 27

MM Sandvik CH440:01 2. Safety precautions

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28 Doc. no. S 223.518 en Ver. 01 © 2009 Sandvik SRP AB

 3. Basic maintenance
instructions
This section describes the basic maintenance instructions for the CH440:01
cone crusher.

To ensure maximum safety, always read section 2. Safety precautions before

you do any work on the equipment, or make any adjustments.

MM Sandvik CH440:01 29
MM Sandvik CH440:01 3. Basic maintenance instructions

3.1 General
The instructions in this manual are limited to the components of the
CH440:01 cone crusher. Instructions for items not covered in the manual,
such as the drive motor, V-belts and so on, can be found in separate
documents.

3.1.1 Routine inspection and care

Instructions for daily and weekly attention necessary for the proper
maintenance of the CH440:01 cone crusher can be found in the Operator’s
manual. Refer to Inspection and care in the Operator’s manual.

3.1.2 Periodical maintenance

The instructions that are described in this manual, concern maintenance that
requires attention once a month or less. For a schedule on when the
maintenance should be carried out, refer to Inspection and care in the
Operator’s manual.
For an inspection checklist, refer to Appendix A in the Operator’s manual.
The instructions described in this manual are valid only for skilled Sandvik
personnel, specially trained partners or customers. All service intervals are
based on estimates of average wear.

3.2 Standard tool box

For a description of the contents of the standard tool box for the CH440:01
cone crusher, refer to Spare parts catalog/Wear parts catalog.

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MM Sandvik CH440:01 3. Basic maintenance instructions

3.3 Tightening threaded fasteners

3.3.1 Required torque for threaded fasteners
Unless otherwise specified, the threaded fasteners used in the CH440:01
cone crusher must be tightened to the torque specified in the table below.
The maximum permissible torque spread is +10%.
STRENGTH GRADE
(SS-ISO 898/1)
THREAD 8.8 10.9 12.9
mm Bright zinc-coated Bright zinc-coated Untreated
Nm (ft lbs) Nm (ft lbs) Nm (ft lbs)
8 21 (15) 28 (21) 40 (30)
10 40 (30) 56 (41) 79 (58)
12 70 (52) 98 (72) 136 (100)
16 169 (125) 238 (175) 333 (246)
20 331 (244) 465 (343) 649 (479)
24 572 (422) 804 (593) 1120 (826)
30 1130 (833) 1580 (1170) 2210 (1630)
36 1960 (1446) 2760 (2040) 3850 (2840)
42 3130 (2309) 4390 (3240) 6140 (4529)
48 4690 (3459) 6590 (4860) 9190 (6778)

3.3.2 Requirements for joints with threaded fasteners

Use the following materials for joints with threaded fasteners:
– Steel screws of grade 8.8 with bright zinc-coated finish.
– Nuts of grade 8 with bright zinc-coated finish.
– Hardened washers, at least HB200 (bright zinc-coated finish).
– Lightly oiled components.
– Cleaned threads in the castings.
Use a torque wrench that can be calibrated, or a bolt/nut runner with a torque
limiter, to torque the screws.

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MM Sandvik CH440:01 3. Basic maintenance instructions

3.3.3 Locking fluid for threaded fasteners

Unless otherwise specified, use Loctite 243 or an equivalent when locking
fluid is recommended in this manual, with the following exceptions:
– To seal pipe threads in the lubrication system,
use Loctite 577 or an equivalent.
– For pipes up to 3/4” in size, and in the Hydroset system,
use Loctite 542 or an equivalent.
If a previously used screw is to be installed, make sure that the threads are
cleaned of oil and locking fluid, before the screw is installed.
Follow the manufacturer’s instructions for the application of locking fluid.

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MM Sandvik CH440:01 3. Basic maintenance instructions

3.4 Welding
Some maintenance procedures require welding. For good results, it is
important that the welding is carried out by competent personnel, and that an
appropriate electrode is used.
Follow the welding instructions for the electrode you use, and ground as
close as possible to the working area. Make sure that the welding current
does not run through any sensitive crusher components, such as bushings and
bearings

3.4.1 Lifting lugs for the mantle

To remove the mantle (2) from the mainshaft, it is necessary to use lifting
lugs (1).

Warning
This instruction is valid only for welding Sandvik Manganese steel. For
instructions on welding other materials, consult your local supplier of
WARNING! welding equipment.

The lifting lugs (1) must comply with the following specifications:
– Comply with the dimensions shown in the figure below.
– Use grade S355J2G3 steel according to EN 10025-1, or similar steel
– Stamp each mantle lifting lug (1) with its S.W.L. (in 10 mm high
lettering): 1700 kg (3750 lbs).
– To attach the lifting lugs (1) to the mantle (2), use welding electrodes
according to standard EN 1600, E 18 8 Mn B42 or ISO 3581, E 18 8
Mn B. An example of an electrode that meets the requirements is the
ESAB OK 67.45.
(Continued)

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MM Sandvik CH440:01 3. Basic maintenance instructions

– The lifetime capacity of the mantle lifting lugs (1700 kg/3750 lbs
each) assumes that the appropriate slinging method is used, and that
the load directions are within the range shown in the drawing below.

1 Lifting lug
2 Mantle (4175-0) Allowable range of load directions

1 1

U Radius V
A
A W

X
a6
C

A-A R2 max.
Y

Type U V W X Y
(mm/inches) (mm/inches) (mm/inches) (mm/inches) (mm/inches)
CH440:01 lug 20/0.787 50/1.968 38/1.496 50/1.968 135/5.315

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MM Sandvik CH440:01 3. Basic maintenance instructions

3.5 Backing with plastic composition

3.5.1 General
To back mantles, concaves and concave rings in the cone crusher, use a
plastic composition that meets the requirements set by Sandvik.
There are two important requirements, after complete hardening and at 20°C
(68°F):
– Compressive strength at least 110 MPa (15950 psi)
– Shrinkage less than 0.01%.

The
NOTE! The backing material used by Sandvik is of the epoxy type. Sandvik urges
that you follow the safety guidelines in this manual, and those provided by
the manufacturer of the plastic backing composition.

3.5.2 Backing material

The plastic composition used is a 2-component epoxy-based composition
with no solvent.
The two components, the resin (component A) and the hardener (component
B), are mixed immediately before use. They have different colors, which
makes it easy to decide when the mix is homogenous.
The setting time for the plastic composition varies between 7 and 24 hours,
depending on the ambient temperature.
Unopened cans can be stored in a cool, dry place for about 12 months from
the date of manufacture. If the cans are stored at a temperature below 0°C
(32°F) the plastic will crystallize after some time. Heating to between 60°C
and 70°C (140°F to 158°F) for approximately two hours will restore the
plastic to its original characteristics.
In warm weather the cans must be protected from direct sunlight, or the
composition can set too rapidly. Keep the cans in the shade.

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MM Sandvik CH440:01 3. Basic maintenance instructions

3.5.3 Backing procedure

NOTE! When backing is carried out in cold weather, the cans 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 to 122°F) to shorten the setting time. If the components are very cold,
the plastic will not set.

NOTE! Do not heat the plastic composition with an open flame, as this can damage
the material.
To mix the plastic backing composition, and pour it into the cone crusher,
follow this procedure:
a) Thoroughly stir component A (which may have formed a sediment) so
that it is homogeneous and easy to pour.
b) Add the hardener (component B) and quickly and carefully mix the two
components with a low-speed electric drill fitted with a mixing
attachment. Make sure that no air bubbles are formed. Continue to mix
until the mixture is homogenous.
c) Immediately after mixing, pour the mix into the backing space in the
cone crusher.
d) Let the plastic backing set in the cone crusher. The setting time varies
from 7 to 24 hours, depending on the ambient temperature.

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MM Sandvik CH440:01 3. Basic maintenance instructions

3.5.4 Hygenic aspects and protective measures.

Risk for skin irritation
After setting, epoxy plastic is physiologically harmless. Unhardened
epoxy resin and hardener can, however, cause skin irritation and
WARNING! allergic contact eczema.

Carefully follow the recommendations below, to minimize the risks

associated with working with epoxy resin and hardener.
a) Provide good air ventilation for the room where the plastic composition
is mixed, and in other affected work-places.
b) The room in which the plastic composition is mixed must be kept clean,
so that spill is not spread.
c) Soap, water and paper towels must be available at the work-place.
d) Use PVC gloves to protect hands and wrists. A protective ointment
should be rubbed on unprotected skin that can come in contact with the
epoxy products. Protective ointment can also be rubbed on hands and
wrists before the putting on PVC gloves.
e) Use protective goggles. If any splashes reach the eyes, wash
immediately with water. If irritation persists, consult a physician.
If epoxy resin or hardener has come into contact with the skin,
immediately wash the affected area with soap and water. Do not use a
solvent.
f) Establish whether there are any applicable National standards covering
the handling and use of epoxy products or not. If so, follow the
prescribed procedures.
g) When you remove plastic-backed components using an oxy-acetylene
torch or a carbon-arc cutter, take safety precautions as always when
working with a torch.
h) Work of this kind requires the use of a mask with an air filter.

Flame cutting
When cutting manganese steel and plastic composition with a welding
torch, there is a risk of gases and dust which are dangerous to health.
WARNING! Use a breathing mask with a filter. Make sure that there is good
ventilation at the work-place.

The
NOTE! For further information regarding the health hazards and handling
recommendations for this product, refer to the Safety leaflet enclosed with
the plastic backing material.

© 2009 Sandvik SRP AB Doc. no. S 223.518 en Ver. 01 37

MM Sandvik CH440:01 3. Basic maintenance instructions

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38 Doc. no. S 223.518 en Ver. 01 © 2009 Sandvik SRP AB

 4. Hydroset system
This section gives further information about the Hydroset system.
To ensure maximum safety, always read section 2. Safety precautions before
you do any work on the equipment, or make any adjustments.

MM Sandvik CH440:01 39
MM Sandvik CH440:01 4. Hydroset system

4.1 Flow diagram

The hydraulic system in this cone crusher is called the Hydroset system. The
components of the Hydroset system enable quick and easy setting changes.

8 8

5 3 5 3

4 7.5MPa
4 7.5MPa
6 6

13 13

7
3.8MPa
7
3.8MPa

9 9

T R T R

2 2

1 1
Setting decrease Setting increase
1 Hydroset pump 8 Accumulator
2 Filter 9 Check valve
3 Control valve 13 Lowering anti-cavitation check
4 Damping valve valve
5 Pressure gauge A-C Ports
6 Pressure relief valve R+T Ports
7 Pressure limiting valve

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MM Sandvik CH440:01 4. Hydroset system

4.2 Adjust the setting

4.2.1 Decrease the setting
a) Start the Hydroset pump. Oil starts to flow from the tank, through port T
and port A in the valve.
b) The sleeve is pushed to the right, which increases the oil flow area.
c) The oil is pumped to port B, and the spindle is pushed to the right.
d) The oil flow pressure opens the pilot operated check valve, which allows
the oil to pass freely to the crusher.

4.2.2 Increase the setting

a) Start the Hydroset pump in reverse. Oil starts to flow from the tank
through port T, the check valve and port B.
b) The oil flow pressure at port A pushes the spindle to the left and opens
the pilot operated check valve. There is now a direct connection from the
crusher.
c) The check valve closes, and the pump draws oil from the crusher through
the valve.
d) The excess oil, which is pumped to port A, opens the pressure limiting
valve and flows through the filter, back to the tank.
Setting increase Setting decrease

P
2 Filter
6 2
6 Pressure relief valve
7 Pressure limiting valve 9
9 Check valve
10 Sleeve
11 Spindle
12 Pilot-operated check valve
R
13 Lowering anti-cavitation C B T
check valve
14 Cap A
15 Pin 1
A-C Ports
R+T Ports
1

12 7 11 13 10

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MM Sandvik CH440:01 4. Hydroset system

4.2.3 Correct setting

The Hydroset pump is stationary, and the pressure in the Hydroset system
keeps the check valve closed. An adjustable pressure limiting valve is
provided to protect the pump from overloads when the setting is being
decreased. This valve is set at the correct pressure before delivery.

4.2.4 Adjust the setting manually

If dirt has entered the control valve, it may be impossible to adjust the setting
as described in section 4.2 Adjust the setting. If so, the setting can be
adjusted manually as follows.
a) Remove the cap (14).
b) Push the pin (15). If the pin can not be pushed by hand, try the following
method:
– Place steel ball with a diameter of approximately 10 mm (0.4"), or
some other appropriately sized object, in the cap (14).
– Install the cap (14) so that the small added object pushes the pin (15).
c) Start the Hydroset pump.
d) Lower the main shaft to the applicable setting.
e) Stop the Hydroset pump.
f) If the valve still does not operate correctly, it must be removed and
cleaned.
g) Re-install the cap (14).
NOTE! To minimize the risk for dirt to enter the valve and affect its function, make
sure that the Hydroset lubrication system is always kept clean.

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MM Sandvik CH440:01 4. Hydroset system

4.2.5 Bleeding air from the Hydroset system

Air can be bled from the Hydroset system through a measuring nipple (1)
mounted on the throat of the accumulator.

1 Measuring nipple
2 Air bleed hose 3
3 L1 push button box

1 2

a) Raise the mainshaft a few millimetres (mm) by using the L1 push button
box (3), which is located in the vicinity of the cone crusher.
b) Prepare to connect the air bleed hose (2) to the nipple (1).
c) Position the free end of the air bleed hose in a suitable receptacle.
d) Screw the hose onto the nipple. The non-return valve in the nipple will
automatically open when the hose is screwed on.
e) When bubble-free oil comes out of the air bleed hose, raise the mainshaft
a few millimetres (mm) more.
f) Unscrew the hose from the nipple. The non-return valve in the nipple
will automatically close.
g) If necessary, repeat the air bleeding procedure until completely bubble-
free oil flows out.

© 2009 Sandvik SRP AB Doc. no. S 223.518 en Ver. 01 43

MM Sandvik CH440:01 4. Hydroset system

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44 Doc. no. S 223.518 en Ver. 01 © 2009 Sandvik SRP AB

 5. Topshell assembly
This section describes the maintenance instructions for the topshell
assembly.
To ensure maximum safety, always read section 2. Safety precautions before
you do any work on the equipment, or make any adjustments.

MM Sandvik CH440:01 45
MM Sandvik CH440:01 5. Topshell assembly

5.1 Change the feed hopper

The feed hopper has to be removed when the mantle is to be changed. The
feed distributor (if one is fitted) and the cone plates may have to be replaced
if they are worn or damaged.

5.1.1 Remove the feed hopper

a) Clean out all process material from the feed hopper (1). Use the
inspection door (2).
b) Remove the screws, the washers and the nuts (3, 4, 5, 6).
c) Install lifting eye bolts with a smallest recommended size M12 (8) with
shackles (9) on the upper flange (7).
– If lifting the whole feed hopper;
use at least three lifting eye bolts (preferably four) installed as shown
by (10) and (11).
– If lifting only one half of the feed hopper’s use two lifting eye bolts
installed as a pair at either (10) or (11).
d) Position the hook of a crane vertically above the feed hopper (1).
e) Attach suitable lifting slings to the lifting eye bolts (10-11) and to the
hook.
11
11
10
10
1 Feed hopper
2 Inspection door 7 9
3 Screw
4 Washer
2 8
5 Washer
6 Nut 1
7 Upper flange
8
9
Lifting eye bolt
Shackle
4
10 One pair of lifting eye bolts 3
with shackles 5
11 One pair of lifting eye bolts
with shackles 6

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MM Sandvik CH440:01 5. Topshell assembly

f) Take up the slack in the lifting tackle.

Hanging load
A feed hopper weighs up to 330 kg (720 lbs). Handle the feed hopper
with care. The tackle should now be tight but not lifting the feed
DANGER! hopper. Keep clear of hanging loads. See section 2. Safety precautions

g) Lift the feed hopper slowly and only a little above the crusher to check
that the feed hopper is well balanced when hanging in the lifting slings.
– If not, lower the feed hopper and slacken the slings.
Open the inspection door/doors, loop suitable lifting slings through
the opening/openings, and attach also these slings to the hook and
start lifting again from point f).
h) Carefully lift the feed hopper off the topshell and lay it down level on the
ground.

5.1.2 Inspect the feed hopper

Examine the feed hopper, the feed distributor and/or the cone plates for wear
and damage.

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MM Sandvik CH440:01 5. Topshell assembly

5.1.3 Install the feed hopper

a) Position the hook of a crane vertically above the feed hopper (1).
b) Attach the lifting slings to the lifting eye bolts (8) with shackles (9) on
the feed hopper and to the lifting hook.Take up the slack in the lifting
tackle.

Hanging load
A feed hopper weighs up to 330 kg (720 lbs). Handle the feed hopper
with care. The tackle should now be tight but not lifting the feed
DANGER! hopper. Keep clear of hanging loads. See section 2. Safety precautions

c) Make sure that the feed hopper is correctly orientated so that the cone
plates or feed distributor are/is correctly aligned.

Feed hopper with cone plates Feed hopper with distributor (splitter)

d) Install the screws, the washers and the nuts (3, 4, 5, 6)

e) Remove the lifting gear.
1 Feed hopper 11
11
2 Inspection door 10
3 Screw
4 Washer 10
5 Washer 7 9
6 Nut
2 8
7 Upper flange
8 Lifting eye bolt
1
9 Shackle
10 One pair of lifting eye bolts with 4
shackles
3
5
11 One pair of lifting eye bolts with
shackles 6

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MM Sandvik CH440:01 5. Topshell assembly

5.2 Inspection of the crushing chamber

Inspection of the liners must be carried out at the correct intervals. Refer to
Routine inspection and care in the Operator’s manual. 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 capacity drops off or 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.
The liners must also 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").
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 consists
primarily of fine material, the crushing is concentrated to the lower part of
the chamber.

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MM Sandvik CH440:01 5. Topshell assembly

5.3 Checks prior to removal of the topshell

NOTE! The checks that are described in this section must be carried out before the
topshell is removed, in order to determine how much the crusher must be
disassembled if, for instance, a liner change is planned.

a) Check the play between the mainshaft sleeve and the spider bushing.
Refer to section 5.4.1 Spider bearing.
b) Check the play between the dust seal ring and the dust collar. Refer to
section 5.4.3 Dust seal ring.
c) Check the backlash in the gears. Refer to section 8.4 Bevel gears.
d) Examine the return oil strainer for contamination. If an unusual amount
or type of contamination is found (metal particles for instance), the cause
must be investigated. Refer to section 5.4.4 Cleaning the return oil
strainer and tank.

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MM Sandvik CH440:01 5. Topshell assembly

5.4 General
5.4.1 Spider bearing
The spider bearing provides the pivot point for the gyratory movement of the
mainshaft. The spider bushing is hourglass-shaped with a tapered outer
surface.

5.4.2 Inspecting the spider bearing

Max. permissible play and distance above pivot point
S mm/(inches) L mm/(inches)
2.1/(0.083) 165/(6.5)

Check the play in the spider bearing (S) each time the liners are changed or at
least twice per year (1000 h). Check the play more frequently if the material
being crushed is abrasive.
If the play (S) is close to the maximum permissible, and it is decided to keep
running with the old bushing, the lubricant must be checked and topped up
more frequently than normal. See also section 5.4.5 Grease for spider
bearing lubrication.
When the play (S) is being measured, the mainshaft must be pushed in the
direction in which it is inclined and the measurement should then be made on
the opposite side with a feeler gauge. Measure on a level with the pivot point
(L). Feeler gauges are included in the tool kit supplied with the crusher.
NOTE! Avoid damaging the spider bearing seal and the scraper with the feeler
gauge.
(Continued)

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MM Sandvik CH440:01 5. Topshell assembly

If the play exceeds the maximum permissible value, the spider bushing and/
or the mainshaft sleeve must be replaced. When the bearing is dismantled,
the old components can be measured and compared with the measurements
obtained from new components to determine which item is most worn and
whether acceptable play can be obtained if just one item is replaced.
If the play considerably exceeds the maximum permissible value, the
mainshaft has been given an abnormal inclination during crushing and has
thus worn the eccentric bushing at an incorrect angle.
If this is the case, check the condition of the eccentric bushing, especially at
the top of the bore. If the bushing is worn unevenly - by an abnormal
indication of the mainshaft, for example - there is a risk of line contact
between the mainshaft and the bushing and there is thus a good chance of
seizure in the near future. Change the eccentric bushing! See section
7.4 Change the eccentric bushing.

5.4.3 Dust seal ring

The dust seal ring (3), which is supported beneath the headcentre, is free to
move and has an easy sliding fit on the dust collar (4). It is the most
important seal for the crusher’s oil system. The dust seal consists of the dust
seal ring (3) and a retaining ring (2). The retaining ring (2) is attached to the
headcentre with screws.

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

5 4 3 2

Use feeler gauges to check the play between the dust seal ring and the dust
collar.
Max. permissible play between dust seal ring and dust collar
mm/(inches)
1.5/(0.060)

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MM Sandvik CH440:01 5. Topshell assembly

5.4.4 Cleaning the return oil strainer and tank

a) Take off the cover over the lubrication oil tank.
b) Lift out the oil strainer (23).
c) Rinse contamination from the oil strainer with diesel oil or white spirit.
d) Blow the oil strainer clean with compressed air.
NOTE! Replace the oil strainer with a new one if it is damaged.
e) Check the bottom of the oil tank. If sediment is discovered, clean out
contamination from the bottom of the tank with diesel oil or white spirit.
f) Put the oil strainer back into place in the tank.

20
20 Float
21 Weir
21
22 Adjustable lower outlet 22
23 Oil strainer 23
24 Return oil chamber

24

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MM Sandvik CH440:01 5. Topshell assembly

5.4.5 Grease for spider bearing lubrication

The motion of the mainshaft in the spider bearing is both gyratory and rotary.
The speed is relatively low and the pressure is high. It is important that the
correct grade of lubricant is used so that the grease can penetrate to the
bearing surfaces.
Requirement specification
The grease must comply with the demands in the table below in order to
guarantee lubrication of the spider bearing for long periods, under conditions
of vibration and extremely high loads. In addition, the grease must provide
good protection against corrosion. The spider bearing contains components
of alloyed steel, cast iron and nitrile rubber. The grease must therefore be
harmless to these materials.
Requirements for spider bearing grease
Properties Requirements Test method
Consistency 0 or 00 NLGI
Base oil viscosity at 40°C ≥ 400
(104°F) in mm2/s (cSt)
Thickening agent Lithium or sodium
Drop point ≥ 140°C (284°F) DIN ISO 2176
Corrosion protection Approved DIN 51 802 SKF Emcor

Other properties:
– Must contain EP additives
– Must be pumpable
The recommended operating temperature range is –10°C to +100°C (14°F to
212°F). For operation under extreme ambient temperatures, contact the
lubricant supplier.
(Continued)

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MM Sandvik CH440:01 5. Topshell assembly

Examples of greases
The examples listed below are greases which – according to the respective
manufacturer – comply with Sandvik’s requirements.
Local variations can occur in different countries. For safety’s sake, check
with your supplier that the selected grease complies with the requirements in
question.
In addition to the greases listed, a number of other brands and qualities meet
Sandvik’s requirements and are accordingly also usable.
Mobil Mobilith SHC 007 (643569) Statoil GreaseWay LiCaX90
Molub-Alloy Tribol 3020/1000-00 Texaco Marfak 00 (01907)
Grease quantity
Grease quantity
Spider bearing 6–8 kg / (13.2-17.6 lbs.)

The spider bearing must be filled with grease up to the correct level (2). This
corresponds to approximately the amount given in the table above. When the
spider bearing is being greased, the mainshaft must be in its lowest position.
Grease can be pumped in through a pipe (1) inside one of the topshell spider
arms.

1 Grease pipe
2 Grease level
3 Observation hole 1 5
4 Spider bearing seal
5 Air vent line
2 4
3

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MM Sandvik CH440:01 5. Topshell assembly

Checking and changing the grease

During the first few weeks of operation, the grease level should be checked
daily by unscrewing the plug in the spider cap.
Checking the grease level in the spider cap:
a) Stop the crusher.
b) Unscrew and remove the plug in the spider cap.
c) Examine the grease level by sticking a finger into the observation hole
and feeling the grease level or alternatively by shining a flashlight into
the hole and observing the level.
If an unusually large quantity of grease is observed on the mainshaft beneath
the spider bearing, it is possible that the spider bearing seal has been
damaged. It is important to keep the mainshaft free of grease and stone dust
accumulations to prevent such contamination being pressed into the spider
bearing through the spider bearing seal (4) each time the mainshaft is raised.
The grease level (2) should be checked frequently and new grease should be
added when necessary. If it is damaged, the spider bearing seal (4) must be
replaced as quickly as possible. See section 5.6 Change the spider bushing
and the seal.
Alongside the grease nipple on one of the topshell arms there is a decal
which shows the type of grease pumped into the spider bearing before
delivery. Do not mix greases of different types.
When a new mantle and/or concave is fitted, the spider bearing and seal
should be carefully cleaned and then filled with new grease. To avoid
unscheduled stoppages, it is recommended that the spider bearing seal (4) is
changed each time the liners are changed.

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5.5 Change the spider cap

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

5.5.1 Remove the spider cap

a) Clean off all process material from the spider cap.
b) Remove the four screws and the washers that hold the spider cap to the
topshell.
c) Position the hook of a crane vertically above the spider cap.
d) Attach a sling to the lifting eye bolt on the spider cap.
e) Attach the sling to the hook.
f) Take up the slack in the lifting tackle.

Hanging load
A spider cap weighs up to 160 kg (350 lbs). Handle the spider cap with
care. The tackle should now be tight but not lifting the spider cap.
DANGER! Keep clear of hanging loads. Refer to section 2. Safety precautions.

g) Carefully lift the spider cap from the topshell.

h) Remove the O-ring from the spider cap.
i) Place the spider cap on the ground.
j) Clean out all grease from the spider bearing.

5.5.2 Inspect the spider cap

a) Measure the play at the pivot point. Refer to section 5.4.1 Spider
bearing.
b) Clean the O-ring. Examine the O-ring and the rim of the spider cap and
the topshell where the O-ring fits. If the O-ring is damaged it must be
replaced.
c) Examine the spider cap for wear. If it is worn, weld on wear protection or
change the spider cap.
d) Clean the air vent passages in the spider cap and the topshell. Make sure
that they are not clogged.
e) Check that the lubrication passage through the topshell is unobstructed.

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MM Sandvik CH440:01 5. Topshell assembly

5.5.3 Install the spider cap

a) Position the hook of a crane vertically above the spider cap.
b) Attach a sling to the lifting eye bolt on the spider cap.
c) Attach the sling to the hook.
d) Take up the slack in the lifting tackle.

Hanging load
A spider cap weighs up to 160 kg (350 lbs). Handle the spider cap with
care. The tackle should now be tight but not lifting the spider cap.
DANGER! Keep clear of hanging loads. Refer to section 2. Safety precautions.

e) Carefully lift the spider cap from the ground.

f) Grease the O-ring and install it on the spider cap.
g) Place the spider cap on the topshell.
h) Install the four screws and the washers.
i) Fill with grease. Refer to section 5.4.5 Grease for spider bearing
lubrication.

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5.6 Change the spider bushing and the seal

The spider bushing and the seal can be changed without removing the
topshell.
However, it is recommended that a change is carried out in connection with
liner replacement since accessibility is better and it is easier to clean the
components when the topshell is removed.
If the spider bushing and the seal are changed without removing the topshell,
it is important to lubricate the outer diameter and the sealing lip of the seal,
to reduce the risk of the seal not seating properly. It is also important that the
space between the spider and the mainshaft sleeve is properly cleaned out.

5.6.1 Remove the spider bushing and the seal

NOTE! Before starting these procedures, it is necessary to remove the spider cap.
Refer to section 5.5.1 Remove the spider cap.

a) Remove the screws and the washers that hold the spider bushing.
b) Press the spider bushing up and out of the spider. For jacking screws, use
the screws that were removed in a). Follow this procedure:
– Put the screws into the threaded holes in the top flange of the bushing.
– Tighten the screws in diagonal rotation, with gradually increasing
torque.
– The spider bushing seal ring is removed with the bushing.
c) Install three lifting eye bolts in the empty threaded holes in the spider
bushing.
d) Position the hook of a crane vertically above the spider bushing.
e) Attach three lifting slings to the lifting eye bolts.
f) Attach the lifting slings to the hook.
(Continued)

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MM Sandvik CH440:01 5. Topshell assembly

g) Take up the slack in the lifting slings.

Hanging load
A spider bushing weighs up to 70 kg (150 lbs). Handle the spider
bushing with care. The tackle should now be tight but not lifting the
DANGER! spider bushing. Keep clear of hanging loads.
Refer to section 2. Safety precautions.

h) Carefully lift out the spider bushing.

i) Remove the spider bushing seal ring from the spider bushing.
j) Lower the spider bushing carefully down onto a clean area on the
ground.

2 1
1 Circulation hole
2 O-ring
3 Air vent
4 Lubricant pipe
5 Spider bearing seal (5705-0)
6 Pivot point

4 3
5 6

5.6.2 Inspect the spider bushing and the seal

a) Clean the seating for the O-ring between the spider cap and the topshell.
Examine for wear or damage.
b) Clean the seatings in the topshell for the spider bushing and the seal ring.
Examine for wear or damage.
c) Clean the spider bushing. Make sure that the circulation holes in the
spider bushing are clean and unobstructed.
d) Make sure that the lubrication and air vent passages in the topshell are
not blocked, and that grease can reach the bushing.
e) Make sure that the air vent in the topshell is clean.

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5.6.3 Install the spider bushing and the seal

a) Screw three lifting eye bolts into the threaded holes in the top flange of
the spider bushing.
b) Snap the seal ring onto the locating tongue at the bottom of the spider
bushing and make sure that the sealing lip points upward.

7 Spider bushing (5675-0)

8 Spider bearing seal (5705-0)
7

8
c) Position the hook of a crane vertically above the spider bushing.
d) Attach three lifting slings to the lifting eye bolts.
e) Attach the lifting slings to the hook.
f) Take up the slack in the lifting slings.

Hanging load
A spider bushing weighs up to 70 kg (150 lbs). Handle the spider
bushing with care. The tackle should now be tight but not lifting the
DANGER! spider bushing. Keep clear of hanging loads.
Refer to section 2. Safety precautions.

g) Grease the inner surface of the spider bushing well, so that it is coated
with a thick layer of grease.
h) Carefully lift the spider bushing above the topshell and carefully lower it
into place.
NOTE! When the bushing is in position in the topshell, the gap between the flange of
the bushing and the topshell is approximately 3 mm (0.12").

(Continued)

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MM Sandvik CH440:01 5. Topshell assembly

i) Install the screws and washers.

j) Tighten the screws all around counter-clockwise as shown below,
gradually increasing the torque. The flange on the spider bushing should
be flush against the topshell. Tighten the screws to the appropriate
torque. Refer to section 3.3 Tightening threaded fasteners.
Remove the lifting eye bolts.
1

k) Fill the spider bushing with grease to the top edge of the spider bushing.
Refer to section 5.4.5 Grease for spider bearing lubrication.
l) Grease the O-ring and place it in its seating on the spider cap.
m) Install the spider cap. Refer to section 5.5.3 Install the spider cap.

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5.7 Change the topshell

5.7.1 Remove the topshell
a) Remove the protective caps (4 and 5).
b) Remove the screws that hold the topshell to the bottomshell. There are
four jacking screws in the topshell flange to facilitate splitting the joint.

1 Lifting sling
2 Spider arm
1
3 Topshell (5005-0)
4 Clamping screw (1540-0) 2
Nut (1540-1)
Washers (1540-2, 1540-3)
Protective cap (1540-5)
5 Jacking screw (1550-0), 3
Protective cap (1550-5)
6 Bottomshell (1005-0) 5

6
c) Remove the spider cap. Refer to section 5.5.1 Remove the spider cap.
d) Position the hook of a crane vertically above the topshell.
e) Put suitable lifting slings around the spider arms.
f) Attach the lifting slings to the hook.
(Continued)

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MM Sandvik CH440:01 5. Topshell assembly

g) Take up the slack in the lifting tackle.

Hanging load
A topshell assembly with filler ring and concave ring weighs up to 4
700 kg (10 350 lbs). Handle the topshell assembly with care. The tackle
DANGER! should now be tight but not lifting the topshell assembly.
Keep clear of hanging loads. Refer to section 2. Safety precautions.

NOTE! Be very careful when you lift the topshell to avoid damage to the mainshaft,
the spider bushing or any other machined surfaces.

h) Carefully lift the topshell from the bottomshell.

i) Place the topshell on planks so that the machined surfaces are not
damaged.

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5.7.2 Inspect the topshell

a) Clean the tapered mating surfaces on the topshell and the bottomshell.
b) Examine the tapered mating surfaces for rust and damage.
6 Bottomshell (1005-0
8 9
7 Mainshaft (4005-0) 7
8 Tapered surface
9 Contact surface 8
9

5.7.3 Install the topshell

a) Coat the tapered mating surfaces and the contact surfaces of the flanges
with thick oil. or grease
NOTE! Oil containing molybdenum disulphide will reduce the risk of corrosion.

b) Lubricate the spider bushing, the spider bearing seal and the mainshaft
sleeve with ordinary spider bushing grease. Refer to section 5.4.5 Grease
for spider bearing lubrication.
c) Position the hook of a crane vertically above the topshell.
d) Put suitable lifting slings around the spider arms.
e) Attach the slings to the hook.
(Continued)

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MM Sandvik CH440:01 5. Topshell assembly

f) Take up the slack in the lifting tackle.

Hanging load
A topshell assembly weighs up to 4 700 kg (10 350 lbs). Handle the
topshell assembly with care. The tackle should now be tight but not
DANGER! lifting the topshell assembly. Keep clear of hanging loads. Refer to
section 2. Safety precautions.

g) Carefully lift the topshell off the planks and lower it onto the bottomshell
with the flanges as parallel as possible to each other.
CAUTION! It is very important that the topshell is kept level to protect the tapered
bore from damage.
Make sure that the mainshaft does not damage the spider bushing seal
as the topshell is lowered onto the bottomshell.
3
A
2

3
B

6
6
2 Spider arm 6 Bottomshell (1005-0)
3 Topshell (5005-0)

h) When the topshell is resting horizontally on the bottomshell, measure the

gap between the flanges of the topshell and the bottomshell.
– Make four measurements around the periphery, with 90° between
them.
– Calculate the average and compare with the table below.
Topshell and bottomshell taper (A-B above)
Minimum Normal Maximum
2.7mm/(0.11") 3.5mm/(0.14") 4.3mm/(0.17")

If the gap is smaller than the minimum 2.7 mm (0.11"), consult Sandvik for
instructions.
(Continued)

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MM Sandvik CH440:01 5. Topshell assembly

NOTE! Wear and damage between the topshell and the bottomshell can cause the
joint 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 and built up by
welding and remachined. Consult Sandvik for instructions.

i) Use clamping screws to adjust the position of the topshell. Put

chamfered, hardened washers (200 HB) beneath the nuts.
j) Retract the jacking screws before the topshell is pulled down.
k) Tighten the clamping screws circular, in stages, until the flanges are tight
against each other.
l) Torque the screws until there is no play between the flanges.
Refer to section 3.3.1 Required torque for threaded fasteners.Lower the
mainshaft to its lowest position, with the Hydroset piston resting on the
Hydroset cylinder cover.
m) Fill the spider bearing with grease, to the top edge of the spider hub. This
requires between 6 and 8 kg (13 to 18 lbs) of grease. Refer to section
5.4.5 Grease for spider bearing lubrication.
n) Grease the contact surfaces of the spider cap and its seating.
o) Install the spider cap. Refer to section 5.5.3 Install the spider cap.
p) After the machine has been crushing for a few hours, torque the screws
that clamp the bottomshell and the topshell again. Refer to m) above.

11
12

10 Spider cap (5650-0) 10

11 Screws (5655-0), Washers (5655-2) 11
12 Lifting eye

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MM Sandvik CH440:01 5. Topshell assembly

5.8 Change the concave ring

The design of the CH440:01 cone crusher is such that all concave rings, from
EF to EC, can be fitted into a single topshell. This is possible, despite the
differences in shape of the various concave rings, by using filler rings.
No filler ring 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 topshell by a support ring with six
clamping screws. The concave ring has locating bosses which fit into
recesses in the support ring, while the ring itself is positioned against the
topshell by locating dowels.

1 Concave ring (6005-0) 5

2 Plastic backing (6005-8) 6
3 Filler ring (6006-0) 4
4 Washer (6007-1)
5 Screw (6007-0)
6 Shim (6007-2) 13 7
7 Screw (6020-0)
3 8
8 Sleeve (6020-2) 9
9 Disc spring (6020-8)
10
11
Support ring (6050-0)
Plank 2 T
12 Gap between the support ring and the topshell
13 Lifting hole/plastic backing level hole
1
11
12
10
If lifting lugs are to be welded to the concave ring, make sure that the lugs
are amply dimensioned. Use a welding electrode suitable for manganese,
according to standard EN 1600, E 18 8 Mn B42 or ISO 3581, E 18 8 Mn B.
An example of an electrode that meet the requirements is the ESAB OK
67.45. Refer to section 2. Safety precautions for information about welding,
and to section 3.4.1 Lifting lugs for the mantle for dimensions of suitable
lifting lugs.

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MM Sandvik CH440:01 5. Topshell assembly

5.8.1 Remove the concave ring

a) Remove the topshell. Refer to section 5.7.1 Remove the topshell. Place
the topshell on timber supports, so that the machined surfaces are not
damaged and the concave ring is accessible.
b) Remove the screws that hold the concave ring in the topshell. Make a
note of the way the disc springs are arranged.
NOTE! The screws in the top of the topshell hold the filler ring and should not be
removed during a normal liner change.

Risk of crushing
Do not stand inside the crusher when the concave ring is removed.
A concave ring weighs up to 860 kg (1 890 lbs).
WARNING! See section 2. Safety precautions

Warsdf

Warning
We advise against using explosives in the crusher. This would cause
risks of injury to personnel and damage to the equipment. The cost of
WARNING! the resultant damage can far outweigh any time-saving during liner
replacement.

(Continued)

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MM Sandvik CH440:01 5. Topshell assembly

c) Remove the concave ring from the topshell. Since the concave ring is
backed with plastic backing, it may remain in the tophell and must then
be driven out of the topshell. Use one of the following methods:
– Hit the top rim of the concave ring with a sledge hammer.
– If the concave ring does not come loose, two jacks can be positioned
between the top rim of the concave ring and the topshell arms.
Hit the concave ring around its top rim at the same time as the jacks
are operated.
– If the concave ring does not come loose when these methods are used,
it must be split with a cutting torch.
Take great care to avoid damage to the topshell and filler ring.

Toxic gases
Use a breathing mask when cutting concave rings and plastic backing.
Make sure that the work-place is well ventilated.
WARNING! See section 2. Safety precautions

1
1 Jack
2 Concave ring (6005-0)
2

Distance between underside of spider arms and top of concave ring:

110mm (4.33").
Jack capacity:
2 x 50 tons (110 231 lb)

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5.8.2 Clean the topshell

a) Position the hook of a crane vertically above the topshell.
b) Put suitable lifting slings around the spider arms.
c) Attach the lifting slings to the hook.
d) Take up the slack in the lifting tackle.

Hanging load
A topshell assembly weighs up to 3 900 kg (8 600 lbs). Handle the
topshell assembly with care. The tackle should now be tight but not
DANGER! lifting the topshell assembly.
Keep clear of hanging loads. Refer to section 2. Safety precautions.

e) Carefully lift the topshell.

f) Clean the contact surfaces in the topshell and examine for damage and
irregularities caused by the machined surfaces of the concave ring, such
as ridges, marks, indentations etcetera.
– If there are irregularities in the topshell, these must be removed by
grinding.
– If there is serious wear, or if the concave ring has worn deep grooves
in the topshell, consult Sandvik for instructions.
g) Make sure that the filler ring is securely installed in the topshell. If the
filler ring has come loose, it must be removed for inspection of the
contact surfaces and the retaining screws. Refer to section 5.9 Change
the filler ring.

5.8.3 Install the concave ring

a) Place the support ring on planks, with the six clamping screws installed
in their holes.
b) Position the concave ring on the support ring. Make sure that the locating
bosses on the concave ring fit into the corresponding recesses in the
support ring.
c) Make sure that the locating dowels are securely installed in the lower
edge of the topshell.
d) Lightly lubricate the surfaces of the topshell that will be in contact with
the plastic backing with a thin layer of grease (apply with a paint roller)
or silicone spray. Never lubricate the corresponding surface of the
concave ring.
(Continued)

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MM Sandvik CH440:01 5. Topshell assembly

e) Lower the topshell 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.
Tp
NOTE! In order to increase the life of the support ring, it can be rotated relative to
the topshell (6 x 60°).

f) Install the washers, the disc springs, the sleeves and the nuts.
g) Remember to arrange the disc springs the way they were before the
topshell was removed. Refer to the note of how the disc springs were
arranged in b) under section 5.8.1 Remove the concave ring.
h) Measure dimension "T". Refer to the figure below.

1 Concave ring (6005-0)

2 Plastic backing (6005-8) 5
3 Filler ring (6006-0)
6
4 Washer (6007-1) 4
5 Screw (6007-0)
6 Shim (6007-2)
7 Screw (6020-0) 13 7
8 Sleeve (6020-2)
3 8
9
10
Disc spring (6020-8)
Support ring (6050-0)
9
11 Plank
12 Gap between the support 2 T T
ring and the topshell
13 Lifting hole/plastic backing
level hole
1
11
12
10
i) Make sure that there is an even fit all around the topshell, by tightening
the screws in diagonal rotation until the dimension T – 4.5 mm
(T – 0.18" is reached). This corresponds to approximately 460° rotation
of the nut.
(Continued)

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MM Sandvik CH440:01 5. Topshell assembly

j) Torque the nuts. Refer to section 3.3 Tightening threaded fasteners.

k) After all the screws have been tightened, make sure that there is no play
between the topshell and the lower part of the concave, or between the
filler ring and the lower part of the concave. Use a feeler gauge.
Tp
NOTE! There are holes in the support ring to facilitate this check.

l) Fill the space between the concave ring and the topshell or filler ring
with plastic backing, refer to section section 3.5 Backing with plastic
composition.
m) Check the tightness of the clamping screws after a short period of
operation. If necessary, tighten the screws again.

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MM Sandvik CH440:01 5. Topshell assembly

5.9 Change the filler ring

The filler ring in the cone crusher acts as a spacer with metal-to-metal
contact against both the topshell and the concave ring.
Two types of filler ring are used for this cone crusher.
• The MF filler ring is intended for MF and F concave rings.
• The MC filler ring is intended for MC, M and EF concave rings.
The EC concave ring is installed directly in the topshell, without a filler ring.
NOTE! If a filler ring backed with plastic composition comes loose during
operation, it should be removed, inspected, reinstalled and backed with
plastic composition again.
iIf a solid filler ring comed loose during operation, it should be removed and
its contact surfaces inspected before it is reinstalled.

5.9.1 Remove the filler ring

NOTE! If the intention is to change to a coarser crushing chamber, the filler may
have to be removed. Refer to the Spare Parts Catalog to determine which
filler ring is used with which concave ring.

a) Remove the screws that hold the locking ring and the filler ring in the
topshell.
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 tons (80,000 lbs), as follows:
– Position the jacks between the top edge of the filler ring and the
topshell arms.
– Press out the filler ring.
– If the filler ring still does not come free, it may be necessary to heat
the topshell while the jacks are operated.

5.9.2 Inspect the filler ring

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

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MM Sandvik CH440:01 5. Topshell assembly

5.9.3 Install the filler ring

c) Put a small amount of grease into each threaded hole in the filler ring.

1 Concave ring (6005-0)

2 Plastic backing (6005-8) 5
3 Filler ring (6006-0) 6
4 Washer (6007-1) 4
5 Screw (6007-0)
6 Shim (6007-2)
7 Screw (6020-0) 13 7
8 Sleeve (6020-2) 3 8
9 Disc spring (6020-8) 9
10 Support ring (6050-0)
11 Plank
2 T
12 Gap between the support ring and the topshell
13 Lifting hole/plastic backing level hole

1
11
12
10

d) Install the screws, the washers and the shims in the filler ring.
e) 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.
f) Pull the filler ring up into position in the topshell by tightening the six
screws in diagonal rotation until they are tight.
g) For MF filler: When an MF filler has been properly seated, back it with
plastic composition. Refer to section 3.5 Backing with plastic
composition.
h) Check the tightness of the screws after a few days of operation.
If necessary, tighten the screws again.

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MM Sandvik CH440:01 5. Topshell assembly

5.10 Weld arm shields to the topshell

To weld arm shields to the topshell arms it is necessary to use an electrode
that meets the requirements of SS-EN ISO 2560: E19 12 3 L B 2 2, AWS
A5.4 (for example ESAB OK 63.35 electrode).
Make a continuous weld around the attachment slots. Use an
a-dimension of 6 to 8 mm (0.24 to 0.32").

a-dimension:
4-6mm (0.18 - 0.24")

76 Doc. no. S 223.518 en Ver. 01 © 2009 Sandvik SRP AB

 6. Mainshaft and mantle
This section describes the maintenance instructions for the mainshaft and the
mantle.
To ensure maximum safety, always read section 2. Safety precautions before
you do any work on the equipment, or make any adjustments.

MM Sandvik CH440:01 77
MM Sandvik CH440:01 6. Mainshaft and mantle

6.1 Change the mainshaft and the mantle

NOTE! If a wear part is worn out, replace it.

Before
NOTE! Before starting these procedures, it is necessary to remove the topshell. Refer
to section 5.7.1 Remove the topshell.

When the topshell assembly is removed, the mainshaft assembly remains in

the bottomshell. At this stage, it is wise to carry out various inspection and
maintenance procedures, for example, to change the mantle and examine the
play between the dust collar and the dust seal ring.
Even if the mantle is changed without removing the mainshaft from the
crusher, the mainshaft must be lifted out so that the step bearing can be
inspected. Refer to section 7. Bottomshell assembly.

2
1 Mainshaft (4005-0)
3
2 Tapered surface
3 Bottomshell (1005-0)

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.1.1 Remove the mainshaft and the mantle

a) Carefully clean the mainshaft (1), the flange of the bottomshell (3), the
arms of the bottomshell and around the dust seal ring retainer, to prevent
dirt from entering the bearings when the mainshaft is removed.
b) Position the hook of a crane vertically above the mainshaft.
c) Install a lifting eye bolt (4) in the top of the mainshaft.
d) Attach a suitable lifting sling to the lifting eye bolt and to the hook.
e) Take up the slack in the lifting tackle.

Hanging load
A mainshaft assembly with mantle weighs up to 3 500 kg (7 700 lbs).
Handle the mainshaft assembly with care. The tackle should now be
DANGER! tight but not lifting the mainshaft assembly.
Keep clear of hanging loads. Refer to section 2. Safety precautions.

f) Lift the mainshaft approximately 20 mm (0.8").

NOTE! The step washer can fall off the mainshaft at once, but sometimes it sticks to
the mainshaft, depending on the temperature and viscosity of the oil. Wait for
5 to 10 minutes before you continue, to make sure that the step washer has
fallen off the mainshaft.

(Continued)

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MM Sandvik CH440:01 6. Mainshaft and mantle

g) Carefully lift out the mainshaft and make sure that the step washer (10)
has dropped off.
h) Make sure that the step washer (10) has not landed upside down (the
concave surface should face upward).
i) When the mainshaft is removed, the inner seal ring usually remains
inside the dust collar (9). Remove the inner seal ring (6) from the inside
of the dust collar.
j) Put a cover on the dust collar (9), to prevent dirt from contaminating the
oil and the bearings.
k) Lower the mainshaft (1) onto a trestle (5) at working height, next to the
bottomshell.

1 Mainshaft (4005-0)
4 Lifting eye bolt 6
5 Trestle 4 7
6 Inner seal ring (1450-0) 8
7 Seating ring (1401-0) 1 9
8 Bushing retaining ring (1816-0)
9 Dust collar (1400-0)
10 Step washer (2280-0)

10
5

If the shaft seized in the eccentric bushing do following:

– If the mainshaft and the mantle have rotated at the same speed as the
eccentric during operation, the eccentric bushing may have seized on
the mainshaft. If so, the dust collar must be loosened so that the
mainshaft and the 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 neither one of the two methods above work, then the dust collar
must be destroyed. The eccentric can then be removed from the shaft
and the bushing.

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.1.2 Inspect the mainshaft and the mantle

Mainshaft diameter Maximum play between the mainshaft and
the eccentric bushing
mm (inches)
340 mm (13.4") 1,2 mm (0.047")

a) Use micrometers to measure the shaft diameter and the bore of the
eccentric bushing. These measurements will give the play between the
mainshaft and the eccentric bushing. The maximum play is given in the
table above. Even if a re-machined mainshaft has been installed, the play
must not exceed 1.2 mm (0.047").
NOTE! A larger play is permissible, if the bearing surfaces are evenly worn, and
neither part is to be repaired (i.e., 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. Refer to section
5.3 Checks prior to removal of the topshell and to section 5.6.2 Inspect the
spider bushing and the seal.

b) Examine the mainshaft sleeve for wear. If the surface wear exceeds
0.4 mm (0.016"), the mainshaft sleeve must be replaced. Refer to section
6.4.1 Inspect the mainshaft sleeve.
c) If a seizure has occurred between the mainshaft and the eccentric
bushing, refer to section 7.4 Change the eccentric bushing.
d) Check that the inner seal ring rests flat on the dust collar.
e) Measure the play between the inner seal ring and the shaft with a
micrometer. The play must not exceed 2.5 mm (0.10").
f) Check the step bearing components for wear. Refer to section
7.2.2 Inspect the step bearing components.
g) If there is more dirt than is to be expected on the inside of the dust collar,
refer to Faults and suggested corrective actions in the Operator’s
manual.
h) Examine the lower bearing surface of the mainshaft. A dull surface is a
sign of contaminated oil. A shiny surface usually indicates clean oil.
(Continued)

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MM Sandvik CH440:01 6. Mainshaft and mantle

i) Clean and inspect the dust seal ring, and make sure that the drain holes in
the dust collar are free from obstructions. Refer to section 6.6 Change
the dust seal ring.

1
1 Mainshaft sleeve (4025-0) 2
2 Inner head nut (4205-1)
3 Head nut (4205-0) 3
4 Burning ring (4205-2) 4
5 Mantle (4175-0)
6 Headcentre (4160-0) 5
7 Dust seal ring (4305-0)
6
8 Retaining ring (4350-0)
9 Scraper (4355-1) 7
10 Mainshaft (4005-0) 8
11 Mainshaft step (4075-0)
9
10
11

6.1.3 Install the mainshaft and the mantle

a) Position the hook of a crane vertically above the mainshaft.
b) Install a lifting eye bolt in the top of the mainshaft.
c) Attach a suitable lifting sling to the lifting eye bolt.
d) Attach the lifting sling to the hook.
e) Align the step washer so that it is centred on the piston wearing plate.
Make sure that the concave surface is facing upwards.
f) Coat the lower part of the mainshaft with oil.
(Continued)

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MM Sandvik CH440:01 6. Mainshaft and mantle

g) Take up the slack in the lifting tackle.

Hanging load
A mainshaft assembly with mantle weighs up to 3 500 kg 7 700 lbs).
Handle the mainshaft assembly with care. The tackle should now be
DANGER! tight but not lifting the mainshaft assembly.
Keep clear of hanging loads. Refer to section 2. Safety precautions.

CAUTION! Be very careful when you install the mainshaft and the inner seal. Make
sure that the bearing surfaces of the mainshaft, and the mainshaft step,
are not damaged by impact with the bottomshell. Make sure that the
dust seal ring moves correctly over the dust collar, otherwise the dust
seal ring may be damaged when the shaft is lowered.

h) Fix the inner seal ring on the mainshaft by placing it askew. When the
mainshaft has entered the eccentric bushing, the ring will be released
from the mainshaft inside the dust collar.
i) Lower the mainshaft into the bottomshell. Be very careful when you
lower it into the eccentric bushing.
j) Lower the inner seal ring inside the dust collar.
k) Rotate the mainshaft by hand, and lower it while you move the crane
slightly, to keep the mainshaft aligned with the eccentric bushing.
l) Move the dust seal ring to the centre and rotate the mainshaft when the
ring is properly centred and approaches the dust collar.
NOTE! Use the inspection holes in the bottomshell to make sure that the dust seal
ring is properly centred, and moves correctly over the dust collar.

m) As soon as the dust seal ring has ridden up onto the dust collar, stop the
rotation of the mainshaft.
1

2
1 Dust seal ring (4305-0)
2 Inner seal ring (1450-0) 3
3 Mainshaft (4005-0)
4 Mainshaft step (4075-0)
5 Dust collar (4305-0)
4
5

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.2 Change the head nut

NOTE! If the head nut is damaged or worn out, replace it.

6.2.1 Remove the head nut

Hot surface
The heated components are hot. Handle the heated components with
care. Use protective gloves.
WARNING!
NOTE! The weld between the mantle and the burning ring 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 welding first. This procedure also minimizes the
heat input to the inner head nut, which reduces the risk that the adhesion of
the locking fluid to the mainshaft is destroyed.

a) Cut free the burning ring between the mantle and the head nut.
b) Use a grinder to grind off the welds between the burning ring and the
mantle.

Toxic gases
Inhalation of fumes can be dangerous to your health.
When using a cutting torch, make sure that there is good ventilation
WARNING! and use a breathing mask. Refer to section 2.3.4 Welding

c) Use a cutting torch to cut through the welds between the burning ring
and the head nut.
CAUTION! Make sure you keep the flame away from the mainshaft.
Remove the head nut by hitting the lugs with a sledgehammer and
unscrewing the nu.
6
5

1 Mantle (4175-0)
4
2 Headcentre (4160-0)
3 Burning ring (4205-2) 3
4 Head nut (4205-0)
5 Inner head nut (4205-1) 2
6 Mainshaft sleeve (4025-0)
1

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.2.2 Inspect the head nut

a) Carefully clean the threads on the head nut and on the inner head nut
(which remains installed on the crusher). Use a wire brush.
NOTE! The inner head nut should be removed only if its outer threads have been
damaged. Refer to section 6.2.4 Remove the inner head nut.

b) Lubricate the threads on the inner head nut and on the head nut with
molybdenum disulphide paste (or an equivalent anti-seize paste).
c) Examine the surface of the mainshaft below the threads of the inner head
nut. Polish any damaged areas until a smooth surface is obtained.
d) To check the fit of the headcentre, measure the distance from the top of
the headcentre to the top of the shaft. Compare this dimension to the
larger of the two values that are stamped on the top of the shaft. Refer to
section 6.5 Inspect the headcentre.

6
5
1 Mantle (4175-0)
4
2 Headcentre (4160-0)
3 Burning ring (4205-2)
4 Head nut (4205-0) 3
5 Inner head nut (4205-1)
6 Mainshaft sleeve (4025-0) 2

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.2.3 Install the head nut

NOTE! If a new mantle is to be installed, install the mantle before installing the head
nut.
Apart from the instructions in this section, also refer to section 6.3 Change
the mantle before you install the mainshaft and the mantle.

a) Install the head nut and tighten it hard by using a sledgehammer to hit
the lugs.
b) Weld a burning ring to the head nut and the mantle as follows:
– Begin welding between the ring and the nut and make welds that are
approximately 80 mm (3") long, with gaps of approximately 130 mm
(5") between them.
– Align the welds to the mantle with the gaps between the welds to the
head nut.
– The weld size (a-dimension) should be between 6 and 7 mm (0.25 to
0.30").
1
1 Mainshaft sleeve (4025-0) 2
2 Inner head nut (4502-1)
3 Head nut (4205-0)
3
4 Burning ring (4205-2) 4
5 Headcentre (4160-0)
6 Mantle (4175-0) 5

Toxic gases
Inhalation of welding fumes can be dangerous to your health. Always
follow instructions provided by the supplier of the welding equipment.
WARNING! Make sure that there is good ventilation and use a breathing mask.

CAUTION! Always ground close to the welding area. Always connect the ground
to the head nut/mantle.
(Continued)

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MM Sandvik CH440:01 6. Mainshaft and mantle

NOTE! Avoid welding immediately below the lugs on the heat nut. A welding in this
area makes it more difficult to remove the head nut.

The electrode that is used to weld between the burning ring and the mantle
must meet the requirements of EN 1600; E 18 8 Mn B 42, AWS A5.4-92
(E307-15). An example of a suitable electrode is ESAB's OK 67.45.
For the welding between the burning ring and the head nut, the electrode
must meet the requirements of EN 499; E42 4 B 42 H10, AWS A5.1; E 7018.
An example of a suitable electrode is ESAB’s OK 48.00 electrode.
NOTE! In some cases, when moist material is crushed for example, it can be
necessary to weld all the way around the burning ring.

NOTE! In order to prevent fine material from entering through the opening in the
burning ring, the opening can be closed by a weld. Use an OK 48.00
electrode, or an equivalent.

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.2.4 Remove the inner head nut

NOTE! Remove the inner head nut only if its outer threads have been damaged.

a) Carefully grind or chisel a groove in the inner head nut.

CAUTION! Be very careful when you grind or chisel. Make sure that you do not
damage the mainshaft threads.

b) Split the inner head nut with a wedge.

c) Remove the inner head nut.

6.2.5 Install the inner head nut

a) Clean the threads of the mainshaft and of the inner head nut with a
degreasing fluid.
b) Check that the inner head nut can be run down to the end of the thread.
c) Remove the inner head nut again.
d) Apply Loctite 270, or an equivalent, to the mainshaft threads.
e) Install the inner head nut and make sure it is tight against the mainshaft.

1
2
3
1 Mainshaft (4005-0)
2 Mainshaft sleeve (4025-0)
3 Inner head nut (4205-1)

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.3 Change the mantle

NOTE! If the mantle is worn out, replace it.

6.3.1 Remove the mantle

NOTE! Remove the mainshaft and the head nut before you remove the mantle.
Refer to section 6.1.1 Remove the mainshaft and the mantle, and to section
6.2.1 Remove the head nut.

a) Weld two lifting lugs on the mantle. The lifting lugs must be amply
dimensioned and must be welded with an electrode suitable for
manganese. Refer tosection 3.4.1 Lifting lugs for the mantle.

1
1 Lifting lugs
2 Mantle (4175-0) 2
3 Mainshaft (4005-0)

Toxic gases
Inhalation of welding fumes can be dangerous to your health. Always
follow instructions provided by the supplier of the welding equipment.
WARNING! Make sure that there is good ventilation and use a breathing mask.

CAUTION! Always ground close to the welding area. Always connect the ground
to the head nut/mantle.

b) Position the hook of a crane vertically above the mantle.

c) Attach suitable lifting slings to the lifting lugs on the mantle.
d) Attach the lifting slings to the hook
(Continued)

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MM Sandvik CH440:01 6. Mainshaft and mantle

e) Take up the slack in the lifting tackle.

Hanging load
A mantle weighs up to 775 kg (1 700 lbs). Handle the mantle with care.
The tackle should now be tight but not lifting the mantle. Keep clear of
DANGER! hanging loads. Refer to section 2. Safety precautions.

f) Lift the mantle off the headcentre. The mantle can be difficult to remove.
If the mantle can not be lifted off, hit it around the bottom edge with a
sledgehammer while you lift it. If necessary, heat the mantle.

CAUTION! If the mantle is to be heated, make sure that the working area is well
ventilated. Take care to avoid damaging the bearing surfaces and the
threads of the mainshaft with the mantle.

6.3.2 Inspect the mantle

Manganese flow in the mantle can cause a gap between the headcentre 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
headcentre. If this occurs, the fit must be restored by grinding and polishing.
If the wear is severe, consult Sandvik for advice.

6
5
1 Mantle (4175-0) 4
2 Headcentre (4160-0)
3 Burning ring (4205-2)
4 Head nut (4205-0) 3
5 Inner head nut (4205-1)
6 Mainshaft sleeve (4025-0) 2

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.3.3 Install the mantle

a) Thoroughly clean the headcentre and the mantle.
b) Weld two lifting lugs on the mantle. The lifting lugs must be amply
dimensioned and must be welded with an electrode suitable for
manganese. Refer to section 3.4.1 Lifting lugs for the mantle.

CAUTION! Always ground close to the welding area. Always connect the ground
to the head nut/ mantle.

c) Position the hook of a crane vertically above the mantle.

d) Attach suitable lifting slings to the lifting lugs on the mantle and to the
hook

1
1 Lifting lugs 2
2 Mantle (4175-0)
3 Mainshaft (4005-0)

e) Take up the slack in the lifting tackle.

Hanging load
A mantle weighs up to 775 kg (1 700 lbs). Handle the mantle with care.
The tackle should now be tight but not lifting the mantle.
DANGER! Keep clear of hanging loads. Refer to section 2. Safety precautions.

f) Lift the mantle.

g) Position the mantle on the headcentre.
h) Install the head nut and the burning ring on top of the mantle.
i) Tighten the head nut so that the bottom edge of the mantle touches the
headcentre.
(Continued)

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MM Sandvik CH440:01 6. Mainshaft and mantle

j) Check with a feeler gauge as shown by the arrows, all around the
periphery, that there is contact between the lower part of the mantle and
the headcentre.

4
3

1 Mantle (4175-0)
2 Headcentre (4160-0) 1
3 Head nut (4205-0)
4 Inner head nut (4205-1)
2

k) Remove the head nut.

l) Lubricate the outer threads of the inner head nut with lubricating paste,
to protect it from the plastic backing that is to be poured in.
(Continued)

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MM Sandvik CH440:01 6. Mainshaft and mantle

m) Fill the space between the mantle and the headcentre with well-mixed
plastic composition.
n) Do not let the level of the plastic composition rise above the shoulder of
the headcentre, i.e. leave the space “P” (see below) empty.
Refer to section 3.5 Backing with plastic composition.

EF mantle Other mantles

P P

Mantle Space “P”

mm (inches)
EF 270 mm (10.6")
Other mantles 130 mm (5.1")

Risk for skin irritation

After setting, epoxi plastic is physiologically harmless. Before setting,
however epoxi resin and hardener can cause skin irritation and
WARNING! allergic contact eczema.

o) Install and tighten the head nut as soon as the plastic composition has
been poured in, refer to section 6.2.3 Install the head nut.
p) Weld the burning ring to the mantle and to the head nut. Refer to section
6.2.3 Install the head nut.

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.4 Change the mainshaft sleeve

NOTE! If the mainshaft sleeve is worn out, replace it.

The top end of the mainshaft is fitted with a protective sleeve, which can be
replaced if the bearing surface becomes worn or damaged. Refer to section
6.1.2 Inspect the mainshaft and the mantle.

6.4.1 Inspect the mainshaft sleeve

a) Examine the bearing surface of the mainshaft sleeve. Wear on the
bearing surface of the mainshaft sleeve can form a regular pattern. The
lip of the spider bearing seal can cause similar wear. Usually, this does
not necessitate replacement of the sleeve, as long as the maximum play
does not exceed the value given in section 5.4.2 Inspecting the spider
bearing.
b) Examine the machined surfaces on the mainshaft for damage and rust.
Remove scratches and rust by polishing, and clean thoroughly.
c) The lower part of the mainshaft sleeve 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).

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.4.2 Remove the mainshaft sleeve

a) Grind a longitudinal groove along the full length of the mainshaft sleeve.

CAUTION! Grind very carefully, to avoid damaging the mainshaft.

NOTE! An alternative method is to shock-heat the sleeve and pull it off.

b) Split the mainshaft sleeve (2) with a wedge.

c) Attach lifting eye bolts (5) into the holes on the rim of the mainshaft
sleeve.
d) Position the lifting hook vertically above the mainshaft sleeve.
e) Attach the lifting slings to the lifting eye bolts and to the lifting hook.
f) Take up the slack in the lifting tackle.

Hanging load
A mainshaft sleeve weighs up to 45 kg (95 lbs). Handle the mainshaft
sleeve with care. The tackle should now be tight but not lifting the
DANGER! mainshaft sleeve.
Keep clear of hanging loads. Refer to section 2. Safety precautions.

g) Lift the mainshaft sleeve off the mainshaft (1).

1 1 5
2
1 Mainshaft (4005-0)
2 Mainshaft sleeve (4025-0) 2
3 Inner head nut (4205-1)
4 Trestle 3
5 Lifting eye bolts 1

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.4.3 Install the mainshaft sleeve

The mainshaft sleeve (2) has a shrink fit on the mainshaft (1).
a) Make sure that all surfaces are clean and smooth.
b) Attach lifting eye bolts (5) into the holes on the rim of the mainshaft
sleeve.
c) Heat the mainshaft sleeve to about 150°C (302°F). Make sure that you
do not overheat the sleeve. Heating can be carried out in an oil bath, or, if
that is not available, by using an L.P.G. torch on the inside of the sleeve.
If a torch is used, heat the mainshaft sleeve in two stages:
– Heat the mainshaft sleeve to 150°C (302°F).
– Allow the heat to spread evenly through the sleeve, for about five
minutes.

Hot surface
The heated mainshaft sleeve is hot. Handle the heated mainshaft
sleeve with care. Use protective gloves.
WARNING! Refer to section 2. Safety precautions.

CAUTION! Check the temperature and, if necessary, reheat the sleeve to the
correct temperature.

(Continued)

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MM Sandvik CH440:01 6. Mainshaft and mantle

d) Position the lifting hook vertically above the mainshaft sleeve.

e) Attach the lifting slings to the lifting eye bolts and to the lifting hook.
f) Take up the slack in the lifting tackle.

Hanging load
A mainshaft sleeve weighs up to 45 kg (95 lbs). Handle the mainshaft
sleeve with care. The tackle should now be tight but not lifting the
DANGER! mainshaft sleeve.
Keep clear of hanging loads. Refer to section 2. Safety precautions.

g) Lift and lower the mainshaft sleeve into position above the mainshaft
and then lower it until it seats against the radius on the shaft.

1 1 5
2

1 Mainshaft (4005-0) 6 2
2 Mainshaft sleeve (4025-0)
3 Inner head nut (4205-1) 3 1
4 Trestle
5 Lifting eyes 6
6 Mainshaft radius 4

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.5 Inspect the headcentre

NOTE! Before making repairs on the headcentre, consult Sandvik.

The headcentre is installed with a shrink fit on the mainshaft at the factory.
To confirm that the shrink fit is still sound, check the position of the
headcentre by measuring from the top of the headcentre to the top of the
shaft. Refer to dimension “B” in the figure below. The measured dimension
“B” must correspond to the larger value that is stamped on the top end of the
shaft.
Also, check the fit at the larger end of the headcentre and mainshaft. No play
is permitted.
If dimension “B” does not correspond to the stamped value, or if there are
other signs that the headcentre has come loose, consult Sandvik.

.
B

1 Headcentre (4160-0)
2 Mainshaft (4005-0)

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.6 Change the dust seal ring

NOTE! If the dust seal ring is worn out, replace it.

The dust seal consists of the dust seal ring and a retaining ring.
– The dust seal ring, which is supported below the headcentre, has a
sliding fit on the dust collar. It is the most important seal for the
crusher’s oil system.
– The retaining ring is secured to the headcentre with screws.
The crusher also has an inner seal ring. See section 6.1 Change the mainshaft
and the mantle

6.6.1 Remove the dust seal ring

NOTE! Remove the mainshaft and the mantle before removing the dust seal ring.
Refer tosection 6.1.1 Remove the mainshaft and the mantle.

a) Place the mainshaft on suitable supports (planks or similar) on its side,

so that the retaining ring is accessible.
b) Protect the bearing surfaces on the mainshaft and mainshaft step.
c) Remove the screws from the retaining ring.
d) Put four screws back into the threaded jacking holes in the retaining ring.
e) Tighten the screws to press the retaining ring out from the headcentre.
f) Support the retaining ring so that it does not fall and damage the
mainshaft.
g) The dust seal ring can now be lifted off.

1 Headcentre(4160-0)
1
2 Dust seal ring (4305-0)
3 Retaining ring (4350-0) 2
4 Mainshaft step (4075-0)
with bearing surfaces 3
5 Jacking hole

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.6.2 Inspect the dust seal ring

a) Examine the machined surfaces on the retaining ring for damage and
rust. Remove scratches and rust by polishing.
b) Examine the fit between the retaining ring and the headcentre. No
movement is permitted between these two components.
c) Make sure that the dust seal ring (1) moves easily on the dust collar
under its own weight. If it does not, the hole in the dust seal ring may be
deformed. Adjust the ring so that it can easily be moved up and down on
the dust collar.
d) Measure the play between the dust seal ring and the dust collar. The
maximum permissible play is 1.5 mm (0.060").

6.6.3 Install the dust seal ring

a) Lift the dust seal ring into place in the recess at the bottom of the
headcentre. Use a suitable lifting appliance.
b) Lift the retaining ring into place. Use a suitable lifting appliance.

Risk for crushing

A dust seal ring weighs about 15 kg (30 lbs) and the retaining ring
weighs about 70 kg (150 lbs), together about 85 kg (185 lbs).
WARNING! Be careful when you handle the dust seal ring and the retaining ring.
Refer to section 2. Safety precautions.

c) Lift the retaining ring into place. Use a suitable lifting appliance.
d) Install the washers and the screws in the retaining ring and tighten them.
e) Make sure that the dust seal ring can move freely between the headcentre
and the retaining ring.
f) Make sure that there is no movement between the retaining ring and the
headcentre.
1 2 3 4

1 Dust seal ring (4305-0)

2 Retaining ring (4350-0)
3 Scraper (4355-1)
4 Retaining plate (4355-0)
5 Jacking hole
6 Screw (4365-0), Washer (4365-2)
6

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MM Sandvik CH440:01 6. Mainshaft and mantle

6.7 Change the scraper

NOTE! If the scraper is worn out, replace it.

The scraper consists of a rubber flap and a retaining plate, which is bolted to
the bottom of the retaining ring in the dust seal.
The purpose of the scraper is to keep the dust collar clean and to ensure that
there is always room for the downward movement of the mainshaft
assembly, e.g. if tramp iron enters the crusher.
The inspection holes in the bottomshell can be used to inspect the scraper
before it is removed.

6.7.1 Inspect the scraper

a) Examine the scraper for wear and damage. Use the inspection holes in
the bottomshell. If necessary, remove the scraper.
b) Measure the length of the hanging scraper. If the length of the hanging
scraper is less than 130 mm (5.1") it must be replaced.

1 2 3 4

1 Dust seal ring (4305-0)

2 Retaining ring (4350-0)
3 Scraper (4355-1)
4 Retaining plate (4355-0)
5 Jacking hole
6 Screw (4365-0), Washer (4365-2)

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MM Sandvik CH440:01 6. Mainshaft and mantle

This page is intentionally left blank

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 7. Bottomshell assembly
This section describes the maintenance instructions for the bottomshell
assembly.
Work on components and assemblies inside the bottomshell normally
requires the prior removal of the topshell assembly and the mainshaft assem-
bly. See section 5. Topshell assembly and section 6. Mainshaft and mantle
respectively.
To ensure maximum safety, always read section 2. Safety precautions before
you do any work on the equipment, or make any adjustments.

MM Sandvik CH440:01 103

MM Sandvik CH440:01 7. Bottomshell assembly

7.1 Change the locating bar

The locating bar (5) is attached to the underside of the dust collar (4). It
functions as a stop for the gear carrier (hub)(6), to prevent upward movement
caused by forces in the bevel gears.
If the gear backlash is adjusted, the clearance of the locating bar must be
checked.

7.1.1 Remove the locating bar

a) Remove the screws that hold the locating bar (5) to the underside of the
dust collar (4).
b) Remove the locating bar (5).

7.1.2 Check the locating bar clearance

a) Remove the inner seal ring (1), the seating ring and the bushing retaining
ring (3). Refer to section 6.6 Change the dust seal ring.
b) Measure the clearance “S” between the locating bar (5) and the gear
carrier (6) with a feeler gauge. Refer to the figure below.
– The clearance “S” is normally 0.2 mm (0.008").
– The maximum permissible clearance is 0.4 mm (0.016").
(Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

c) If necessary, adjust the clearance “S” by removing or adding shims (T)

between the locating bar and the dust collar.
1
2
3 5
4 T 4
5

S 7

6
6

1 Inner seal ring (1450-0) 5 Locating bar (1410-0)

2 Seating ring (1401-0) 6 Eccentric bushing (1810-0)
3 Bushing retaining ring (1816-0) 7 Gear carrier(1815-0)
4 Dust collar (1400-0)

7.1.3 Install the locating bar

a) Position the locating bar (5) on the underside of the dust collar (4).
Make sure that the holes in the locating bar are aligned with the
corresponding holes in the dust collar and remember to fit the shims (T).
See section 7.1.2 Check the locating bar clearance.
b) Apply Loctite 270 (or an equivalent) to the threads of the retaining
screws.
c) Install the screws that hold the locating bar (4) to the dust collar.
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 taken into
consideration, and is independent of what grade of screw is used.)

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MM Sandvik CH440:01 7. Bottomshell assembly

7.2 Change the step bearing components

Sandvik recommends inspecting the step bearing components in conjunction
with liner changes and renewing the bearing components at regular intervals.
NOTE! If wear on the step bearing components is severe, refer to Faults and
suggested corrective actions in the Operator’s manual.

The step bearing assembly consists of a kit with three components. Refer to
the figure below:
– The step washer (3) rests on the piston wearing plate (4) and can
move freely between the mainshaft step (2) and the piston wearing
plate (4).
– The piston wearing plate (4) rests on the Hydroset piston (5).
A dowel prevents it from rotating on the piston.
– The mainshaft step (2) is retained at the bottom end of the mainshaft
(1).

The step bearing components carries the entire axial load from the mainshaft
assembly and the crushing forces in the crushing chamber. The step washer is
made of steel whilst the piston wearing plate and step washer are of bronze.
Even though the step washer normally wears less then the other two
components, all three must be changed at the same time to ensure that the
geometry of the bearing is correct.
The maximum play between the step bearing components is 0.03 mm
(0.0012").
The step bearing components should be removed from the crusher at regular
intervals, for inspection of the oil grooves.

1
1 Mainshaft (4005-0)
2
2 Mainshaft step (4075-0)
3 Step washer (2280-0) 3
4 Piston wearing plate (2260-0)
5 Hydroset piston (2005-0) 4
5

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7.2.1 Remove step bearing components

The step bearing components can be lifted up through the eccentric bushing
with the help of the special lifting tool in the tool kit which is supplied with
the crusher.
CAUTION! Normally the step bearing components are covered in oil and they may
stick together and to the top of the Hydroset piston. Lift carefully and
check that no sticking occurs.

NOTE! Be careful not to scratch or damage the eccentric bushing when the
stepwasher is removed.
Do not jerk when using the lifting tool, only do slow moves when lifting.

a) Use the special lifting tool to lift both the step washer (3) and the piston
wearing plate (4) at the same time.
10
11 9
3 Step washer (2280-0) 8
4 Piston wearing plate (2260-0)
6 Lifting claw 7 3
7 Guide ring 4
8 Holding ring
9 Central shaft
6
10 Lifting eye
6
11 Chain

3
4

b) Lift the tool, well balanced in the chain (11) and lower it through the
holes in the washer (3) and the wearing plate (4). Make sure that the
upper part of the claws (6) are below the bottom of the wearing plate (4).
c) Still holding the chain (11), lift the central shaft (9) to press the three
claws (6) outwards.
d) When all three claws (6) are stuck underneath the bottom of the piston
wearing plate (4), slacken the chain (11) and let the guide ring (7) drop
down and lock the tool in position.
NOTE! The chain is preferably held above the tool throughout the lifting procedure.

e) Attach a suitable lifting sling to the lifting eye (10).

(Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

f) Position the hook of a crane vertically above the lifting tool.

g) Attach the lifting sling to the hook.
h) Take up the slack in the lifting tackle.
Risk of crushing
A piston wearing plate weighs up to 25 kg (55 lbs) and a step washer
up to 25 kg (55 lbs). Handle the step bearing components with care.
DANGER! The tackle should now be tight but not lifting the the bearing
components. Keep clear of hanging loads. Refer to section 2. Safety
precautions.

Before lifting, check that the claws (6) are correctly positioned and
attached to the piston wearing plate (4).
i) Lift out the step washer (3) and piston wearing plate (4). Take up the
slack in the chain (11) and lower them on to timber supports on the
ground.
j) To free the lifting tool, lower the central shaft (9) and the guide ring (7).
Lift up the entire tool with the chain (11).

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7.2.2 Inspect the step bearing components

The mainshaft step and the piston wearing plate are made of bronze with a
high lead content, which sometimes causes a temporary blackening of the
rubbing surfaces. The step washer is made of steel.
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.
a) 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.

1 2

1 Mainshaft step (4075.0)

2 Step washer (2280-0)
3 Piston wearing plate (2260-0)

Measure both from the outside and the inside at four points 90° apart.
1 2 This means totally 16 measurements. The maximum permitted play is
0.03 mm (0.0012").
b) Examine the oil grooves in the rubbing surfaces of the mainshaft step
and the piston wearing plate, that are in contact with the step washer.
If the grooves have sharp edges, chamfer them 1 to 2 mm (0.04 to 0.08")
with a belt grinder.
1 Chamfers
2 Oil grooves (Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

c) 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 (4.3").
When the total thickness of the step bearing has been reduced to 95 mm
(3.7"), all three step bearing components must be replaced.

1
1 Mainshaft step (4075.0)
2 Step washer (2280-0) H 2
3 Piston wearing plate (2260-0)
3

7.2.3 Install the step bearing components

a) Clean and degrease the step bearing components.
b) Lightly lubricate the bearing upper surfaces with a thin layer of
molybdenum disulphide grease. Make sure you keep the grease out of
the oil grooves, to avoid obstructing the oil circulation.
c) Apply a thin coat of lubrication oil underneath the step washer (3) and
the piston wearing plate (4).
a) Use the special lifting tool to lift both the step washer (3) and the piston
wearing plate (4) at the same time. .
10
11 9
8
3 Step washer (2280-0)
7 3
4 Piston wearing plate (2260-0)
6 Lifting claw
4
7 Guide ring 6
8 Holding ring 6
9 Central shaft
10 Lifting eye
11 Chain 3
4

(Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

b) Lift the tool, well balanced in the chain (11) and lower it through the
holes in the washer (3) and the wearing plate (4). Make sure that the
upper part of the claws (6) are below the bottom of the wearing plate (4).
c) Still holding the chain (11), lift the central shaft (9) to press the three
claws (6) outwards.
d) When all three claws (6) are stuck underneath the bottom of the piston
wearing plate (4), slacken the chain (11) and let the guide ring (7) drop
down and lock the tool in position.
NOTE! The chain is preferably held above the tool throughout the lifting procedure.

e) Attach a suitable lifting sling to the lifting eye (10).

f) Position the hook of a crane vertically above the lifting tool.
g) Attach the lifting sling to the hook.
h) Take up the slack in the lifting tackle.

Risk of crushing
A piston wearing plate weighs up to 25 kg (55 lbs) and a step washer
up to 25 kg (55 lbs). Handle the step bearing components with care.
DANGER! The tackle should now be tight but not lifting the the bearing
components. Keep clear of hanging loads. Refer to section 2. Safety
precautions.

NOTE! Avoid damaging or scratching the eccentric bushing.

i) Before lifting, check that the claws (6) are correctly positioned and
attached to the piston wearing plate (4).
j) Lift the step washer (3) and piston wearing plate (4) and lower them into
position at the centre of the bottomshell. Make sure that the dowel in the
Hydroset piston (5) enters the corresponding hole in the piston wearing
plate, and does not reach the bottom of the hole
k) To free the lifting tool, lower the central shaft (9) and the guide ring (7).
Use the chain (11) to lift up the entire tool.
(Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

l) Install the mainshaft step on the bottom end of the mainshaft with a
circlip. Use snap ring pliers.

Risk of crushing
A mainshaft step weighs up to 25 kg (55 lbs). Handle the mainshaft
step with care. Keep clear of hanging loads. Refer to section 2. Safety
DANGER! precautions.

T
NOTE! When the mainshaft step is in place, it should be possible to move it slightly
on the end of the mainshaft. The degree of movement is very small, and is
limited to the difference between the diameters of the dowel and the hole in
the mainshaft step.

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7.3 Change the dust collar

Normally, it is necessary to remove the dust collar only if the eccentric
assembly is to be removed.

7.3.1 Remove the dust collar

NOTE! Be very careful when the dust collar is removed, so that you do not damage
the underlying gasket.

Refer to the figure below.

a) Remove the screws (1) and the washers (1) from the dust collar (2).
b) Use full-length threaded screws to press the dust collar off the
bottomshell.
c) Install four lifting eye bolts (4) in the threaded holes.
d) Position the hook of a crane vertically above the dust collar.
Use a four-part lifting sling.
e) Attach the lifting sling (3) to the lifting eye bolts and the hook.

3
4
5
2
1 Screw (1405-0), Washer (1405-2) 4 Lifting eye bolt
2 Dust collar (1400-0) 5 Hole
3 Lifting sling

(Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

f) Take up the slack in the lifting tackle.

Hanging load
A dust collar weighs up to 110 kg (242 lbs). Handle the dust collar with
care. The tackle should now be tight but not lifting the dust collar. Keep
DANGER! clear of hanging loads. Refer to section 2. Safety precautions.

g) Lift the dust collar from the bottomshellInspect the dust collar

7.3.2 Inspect the dust collar

a) Examine the fit of the dust collar against the bottomshell. If the dust
collar has come loose and the fit against the bottomshell has been lost,
consult Sandvik.
b) Examine the outer surface of the dust collar. Make sure that wear or
damage has not made it possible for dust to enter the crusher between the
dust collar and the dust seal ring.

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7.3.3 Install the dust collar

Refer to the figure below.
a) Position the hook of a crane vertically above the dust collar (3).
b) Attach the lifting slings to the lifting eye bolts (2) and to the hook.
c) Take up the slack in the lifting tackle.

Hanging load
A dust collar weighs up to 180 kg (390 lbs). Handle the dust collar with
care. The tackle should now be tight but not lifting the dust collar.
DANGER! Keep clear of hanging loads. Refer to section 2. Safety precautions.

d) Lift the dust collar and position it above the bottomshell.

e) Grease the gasket (4) and place it on the dust collar.
f) Align the holes in the gasket with the corresponding holes in the dust
collar.
g) Align the locating dowel (1) in the bottomshell with the corresponding
hole in the dust collar.
h) Lower the dust collar, with the gasket, onto the bottomshell.
i) Remove the lifting equipment and the lifting eye bolts.
j) Install the screws and the washers in the dust collar.
k) Torque the screws in diagonal rotation in several stages until the
specified torque is reached. Refer to section 3.3 Tightening threaded
fasteners.

2
3 1
1 Locating dowel (1404-0)
2 Lifting eye bolt
3 Dust collar (1400-0)
4 Gasket (1430-0)
1

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MM Sandvik CH440:01 7. Bottomshell assembly

7.4 Change 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 changed
by changing the eccentric bushing or by lifting up the bushing and moving
the key to another keyway in the eccentric.
NOTE! The throw (in mm) is stamped into the top edge of the bushing near the
relevant key way together with the letter H for an H-type Hydrocone. An
arrow stamped into the top of the eccentric in line with the key way indicates
which eccentric throw has been set.

1
Eccentric throw combinations
2 HX
X
mm inches
3

X
HX
13 0.51

HXX
16 0.63 4
20 0.79

HXX
24 0.94
24 0.94
28 1.10
32 1.26
32 1.26
36 1.42 3
40 1.57
44 1.73

1 Lifting eye bolt hole

2 Oil groove
3 Key way
4 Machine type and throw

For details of the play between the mainshaft and the eccentric bushing, refer
to section 6.1.2 Inspect the mainshaft and the mantle.
If the bushing is a tight fit, the whole eccentric assembly can be removed.
Refer to section 7.5 Change the eccentric assembly.
There are two ways to remove the eccentric bushing from the CH440:01
cone crusher. First, refer to section 7.4.1 Remove the eccentric bushing.
If that method does not work, then try the alternative method, refer to section
7.4.2 Remove the eccentric bushing - Alternative method.

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7.4.1 Remove the eccentric bushing

NOTE! Before starting these procedures it is necessary to remove the mainshaft,
the inner seal ring and the seating ring.
Refer to section 6.1 Change the mainshaft and the mantle.
NOTE! If the ambient air temperature is higher than 30°C (86°F), the eccentric
bushing should be cooled with a bag of dry ice placed inside the bushing for
30 minutes before removal is started.

Refer to the figure below.

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 to be removed.
b) Use the special lifting tool (5) in the tool kit that is supplied with the cone
crusher to pull the eccentric bushing (4) from the eccentric.
c) Position the hook of a crane vertically above the eccentric.
d) Attach a suitable lifting sling to the lifting tool and to the hook.

2 3
4
1 5

1 Bushing retaining ring (1816-0) 4 Eccentric bushing (1810-0)

2 Gear carrier (1815-0) 5 Lifting tool
3 Eccentric (1805-0)

(Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

e) Take up the slack in the lifting tackle.

Hanging load
An eccentric bushing weighs up to 130 kg (280 lbs). Handle the
eccentric bushing with care.The tackle should now be tight but not
DANGER! lifting the eccentric bushing. Keep clear of hanging loads.
Refer to section 2. Safety precautions.

f) Lift the eccentric bushing approximately 10 mm (0.4").

g) Install lifting eye bolts in the threaded holes in the top of the eccentric
bushing.
h) Attach lifting slings to the lifting eye bolts.
i) Attach the lifting slings to the hook of the crane.
j) Lift out the bushing.

CAUTION! Always start the removal by using the special lifting tool. If the eccentric
is jammed, the threads may be damaged if you start to lift with the lifting
eye bolts threaded into the top of the eccentric bushing.

NOTE! The switch to the use of the eye bolts is to ensure stability during the lift out
of the crusher.

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7.4.2 Remove the eccentric bushing - Alternative method

If the eccentric bushing cannot be removed with the procedure described in
section 7.4.1 Remove the eccentric bushing, the eccentric assembly must be
taken out of the bottomshell. See section 7.5.1 Remove the eccentric
assembly.
NOTE! If the ambient air temperature is higher than 30°C (86°F), the eccentric
bushing should be cooled with a bag of dry ice placed inside the bushing for
30 minutes before removal is started.
Refer to the figure below.
a) Drive out the eccentric bushing (3) from the eccentric (4) with a wooden
block and a hammer.

CAUTION! Protect the bearing surface on the upper side of the gear carrier from
damage.

b) If the bushing can not be removed as described in a),

– Place the eccentric assembly on a surface to which a reaction beam
can be anchored. Position a 50-ton jack (6) between the reaction beam
and a thick steel plate placed on top of the eccentric bushing.
Operate the jack to press the eccentric bushing out of the eccentric.

1
2 6
3
1 Reaction beam
2 Plate 4
3 Eccentric bushing (1810-0)
4 Eccentric (1805-0)
5 Wooden blocks
6 Jack

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7.4.3 Inspect the eccentric bushing

a) Examine the bore of the eccentric. It must be smooth and not oval or
conical. Any ovality or conicity must be corrected by scraping or
grinding with a belt grinder.
b) Measure the play between the eccentric bushing and the eccentric. The
maximum permitted play is 0.22 mm (0.009").
c) Examine the bearing surface of the mainshaft for wear and damage.
d) Examine the bore of the bushing to make sure that it is not deformed.

NOTE! If a serious seizure occurs between the mainshaft and the eccentric bushing,
the resulting high temperature can lead to so-called heat cracks (reminiscent
of fish scales) on the bearing surface of the mainshaft. These heat cracks are
narrow vertical lines, between 3 and 5 mm (0.12 – 0.2") 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 new failure. Consult Sandvik
for information on corrective measures.

1
2 HX
X

3
X
HX
HXX

4
HXX

1 Lifting eye hole

2 Oil groove
3 Key way
4 Machine type and throw
3

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7.4.4 Install the eccentric bushing

Refer to the figure below.
a) Make sure that the key is correctly installed in the eccentric bushing (4)
before the bushing is installed in the eccentric (3).

2 3
4
1

1 Bushing retaining ring (1816-0) 3 Eccentric (1805-0)

2 Gear carrier (1815-0) 4 Eccentric bushing (1810-0)

b) Install lifting eye bolts in the threaded holes in the top of the bushing.
c) Position the hook of a crane vertically above the eccentric.
d) Attach suitable slings to the lifting eye bolts and to the hook.
e) Take up the slack in the lifting tackle.

Hanging load
An eccentric bushing weighs up to 130 kg (280 lbs). Handle the
eccentric bushing with care.The tackle should now be tight but
DANGER! not lifting the eccentric bushing. Keep clear of hanging loads.
Refer to section 2. Safety precautions.

(Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

f) Coat the outer surface of the eccentric bushing with oil.

g) Lift the eccentric bushing into position above the bore of the eccentric.
h) Carefully lower the eccentric bushing into place in the eccentric.
NOTE! Under certain circumstances, for instance if the temperature exceeds 35°C
(95°F) the bushing may 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.
i) Make sure that the top flange of the bushing seats properly in the recess
at the top of the eccentric.
j) Measure the bore of the bushing to check that it is not deformed.
k) Install the eccentric bushing retaining ring (1) which locks the eccentric
bushing in the eccentric.
l) Apply locking fluid to the screws. Refer to section 3.3.3 Locking fluid
for threaded fasteners.
m) Tighten the screws to the correct torque. Refer to section 3.3 Tightening
threaded fasteners.
n) If the eccentric throw has been changed, stamp the new eccentric throw
into the bottomshell flange above the pinionshaft

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7.5 Change the eccentric assembly

The eccentric assembly consists of the eccentric, the gear carrier (hub) and
counterweight, the eccentric bushing and the eccentric gear. The assembly is
supported by the wearing plate which is mounted on the bottomshell.

7.5.1 Remove the eccentric assembly

Refer to the figure below.
a) Remove the dust collar. Refer to section 7.3.1 Remove the dust collar.
b) Install lifting eye bolts (3) in the threaded holes in the top of the gear
carrier (2).
NOTE! The bushing retaining ring (4) must still be in place.
c) Position the hook of a crane vertically above the eccentric assembly.
d) Attach suitable lifting slings to the lifting eye bolts and to the hook
.
3
2
1

1 Inspection hole 4
2 Gear carrier (1815-0)
3 Lifting eye bolt
4 Bushing retaining ring (1816-0)

e) Take up the slack in the lifting tackle

Hanging load
An eccentric assembly weighs up to 700 kg (1 540 lbs). Handle the
eccentric assembly with care. The tackle should now be tight but not
DANGER! lifting the eccentric assembly.
Keep clear of hanging loads. Refer to section 2. Safety precautions.

(Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

f) Lift the eccentric assembly approximately 10 mm (0.4").

g) Use a screwdriver through the inspection hole (1) in the gear carrier to
make sure that the wearing plate has not been lifted with the eccentric
assembly, but remains in the bottomshell.
h) Carefully lift out the eccentric assembly. Make sure that you do not
damage the bottomshell bushing.
NOTE! If the eccentric has seized in the bottomshell bushing, the bottomshell
bushing and the wearing plate will also be removed when the eccentric
assembly is lifted out.

NOTE! If there is severe damage to the bearing surface of the bottomshell bushing,
the bushing must sometimes be split in order to remove it.

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7.5.2 Inspect the eccentric assembly

Refer to the figure below.
a) Examine the wearing surfaces of the eccentric (3) for scratches and signs
of heavy wear or excessive temperature, such as dark spots or patterns of
thin cracks.
NOTE! If a serious seizure occurs between the mainshaft and the eccentric bushing
(6), the resulting high temperature can lead to so-called heat cracks
(reminiscent of fish scales) on the bearing surface of the mainshaft. These
heat cracks are narrow vertical lines, between 3 and 5 mm (0.12 – 0.2") 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 on corrective measures.

b) Examine the wearing plate (5). Refer to section section 7.8.1 Inspect the
eccentric wearing plate.
c) Examine the inner surface of the eccentric bushing (6) for wear,
scratches or dark spots, which can indicate that the bushing has been
subjected to high temperatures.

1
1 Bushing retaining ring (1816-0) 2
2 Gear carrier (1815-0)
3 Eccentric (1805-0) 3
4 Gear (1850-0) 4
5 Wearing plate (1880-0)
6 Eccentric bushing (1810-0) 5
7 Pinion (1850-2) 6
7

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7.5.3 Install the eccentric assembly

Refer to the figure below.
a) Coat the outer surface of the eccentric with oil.
b) Position the hook of a crane vertically above the eccentric assembly.
c) Attach suitable lifting slings to the lifting eye bolts and the hook.
d) Take up the slack in the lifting tackle.

Hanging load
An eccentric assembly weighs up to 700 kg (1 540 lbs). Handle the
eccentric assembly with care. The tackle should now be tight but not
DANGER! lifting the eccentric assembly. Keep clear of hanging loads. Refer to
section 2. Safety precautions.

e) Lift the eccentric assembly.

f) Carefully lower the eccentric assembly into the bottomshell bushing.
Make sure that you do not damage the bottomshell bushing.
g) 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 (1815-0)
3 Lifting eye bolt
4
4 Bushing retaining ring (1816-0)

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7.6 Change the gear carrier

7.6.1 Remove the gear carrier
The gear carrier (4) is an interference fit on the eccentric (5). To remove it
from the eccentric it must be pressed off. See section 7.4.1 Remove the
eccentric bushing for a similar instruction.

Hanging load
An eccentric assembly weighs up to 700 kg (1 540 lbs).
Handle the assembly with care. Keep clear of hanging loads.
DANGER! See section 2. Safety precautions.

a) Place the eccentric assembly on wooden blocks as shown in the figure

below.
b) Put a plate (9) on top of the eccentric assembly as shown in the figure
below.
c) Use a jack and a reaction beam to push out the eccentric from the gear
carrier.
11
10
4 Gear carrier (1815-0) 5 9
5 Eccentric (1805-0) 13
8 Wooden blocks 12
9 Plate 4
10 Jack
11 Reaction beam 8
12 Key (1820-0)
13 Screw (1825-0)

Risk of crushing
A gear carrier weighs up to 300 kg (660 lbs). Handle the gear carrier
with care. Keep clear of hanging loads.
DANGER! Refer to section 2. Safety precautions.

(Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

7.6.2 Inspect the gear carrier

Examine the bearing surfaces for wear and damage.

7.6.3 Install the gear carrier/counterweight

a) Heat the gear carrier to approximately 50°C (90°F) above the
temperature of the eccentric.
b) Install the gear carrier on the eccentric.

Hanging load
An eccentric assembly weighs up to 700 kg (1 540 lbs).
Handle the assembly with care. Keep clear of hanging loads.
DANGER! See section 2. Safety precautions.

c) When the components have cooled, make sure that the key is properly
installed and that the gear carrier fits against the shoulder of the
eccentric.

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7.7 Change the eccentric gear

7.7.1 Remove the eccentric gear
Refer to the figure below.
a) Install jacking screws in the threaded holes (2) in the gear carrier(1).
b) Tighten the jacking screws to remove the gear (3). See below.

2 1
1 Gear carrier (1815-0)
2 Threaded holes

7.7.2 Inspect the eccentric gear

Examine the tooth “footprint” for signs of wear. Refer to section 8.4.3 Tooth
bearing “footprint”.

1 Gear carrier (1815-0)

3 Gear (1850-0)

1
3

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7.7.3 Install the eccentric gear

Refer to the figure above.
a) Install the gear (3) on the gear carrier (1) with the attachment screws.
b) Make sure that the gear fits flush against the seating on the gear carrier.
c) Torque the screws. The screws must be adequately tightened, since there
is no key in the assembly.

7.7.4 The eccentric gear / gear carrier joint

a) Use untreated grade 12.9 steel screws and hardened washers, at least HB
400 to 470.
b) Lightly coat the screws with Loctite 270.
c) Clean the threads in the eccentric gear.
d) Torque the screws in stages, in diagonal rotation, refer to section
3.3.1 Required torque for threaded fasteners. Use a torque wrench that
can be calibrated, or a bolt/nut runner with a torque limiter.

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7.8 Change the eccentric wearing plate

The eccentric wearing plate, on which the eccentric assembly is supported, is
designed to absorb the rotating moment from the bottomshell bushing. The
wearing plate is locked to the bottomshell with dowels.

7.8.1 Inspect the eccentric wearing plate

Refer to the figure below.
a) Examine the protrusions (1) that lock the bottomshell bushing. Any
deformations of the protrusions must be taken care of by grinding, to
ensure good contact with the indentations at the top of the bushing.

1 Protrusions
2 Wearing plate (1880-0)
3 Dowel (1885-0) 1
2 3

b) Examine the dowels (3) that lock the eccentric wearing plate to the
bottomshell. If the dowels are damaged, replace them.

2
3

2 Wearing plate (1880-0)

3 Dowel (1885-0)

c) Measure the thickness of the eccentric wearing plate. If the thickness is

less than 25 mm (0.98"), the wearing plate must be replaced.

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7.9 Change the bottomshell bushing

7.9.1 Remove the bottomshell bushing
NOTE! There must be enough space for the bottomshell bushing to expand due to
friction heat.

Normally, the fit between the bottomshell (1) and the bottomshell bushing
(3) is such that the bushing can be removed easily.
Refer to the figure below.
a) Position the hook of a crane vertically above the bottomshell bushing.
b) Place a lifting tool (4) under the bottom edge of the bottomshell.
bushing (3). Use the lifting tool in the tool kit supplied with the crusher.
c) Attach a suitable lifting sling to the lifting tool and to the hook.
d) Lift the bushing slightly from its seating in the bottomshell (1)..

Hanging load
A bottomshell bushing weighs up to 60kg (132 lbs). Handle the
bottomshell bushing with care. The tackle should now be tight but not
DANGER! lifting the bottomshell bushing. Keep clear of hanging loads. Refer to
section 2. Safety precautions.

NOTE! Do not use the lifting tool to lift the bushing out of the bottomshell.

1
1 Bottomshell (1005-0)
2 Hole for the lifting eye bolt 2
3 Bottomshell bushing (1200-0)
4 Lifting tool

3
4

e) Remove the special lifting tool.

f) Install lifting eye bolts in the holes (2) in the bottomshell bushing (3).
Use the lifting eye bolts in the tool kit supplied with the crusher.
(Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

g) Attach suitable lifting slings to the lifting eye bolts and to the hook.
h) Take up the slack in the lifting tackle.

Hanging load
A bottomshell bushing weighs up to 100 kg (220 lbs). Handle the
bottomshell bushing with care. The tackle should now be tight but not
DANGER! lifting the bottomshell bushing.
Keep clear of hanging loads. Refer to section 2. Safety precautions.

Lift the bottomshell bushing out of the bottomshell.

NOTE! To switch to the use of the eye bolts is to ensure stability during the lift out of
the crusher.

7.9.2 Inspect the bottomshell bushing

a) Examine the bore of the bottomshell. It must be smooth and circular.
Elevated temperature can cause the bore to become oval or conical. Any
deformation must be taken care of by scraping or grinding with a belt
grinder.
b) Measure the bore diameter of the bottomshell bushing. Make a note of
the diameter. The nominal bore diameter is 510 mm (20.1").
c) Measure the diameter of the eccentric. Use the measured bore diameter
from b) to calculate the play between the eccentric and the bottomshell
bushing. If the eccentric is remachined, the maximum play between the
eccentric and the bottomshell bushing is 1.7 mm (0.067").
d) Measure the play between the bottomshell and the bottomshell bushing.
The maximum permitted play is 0.22 mm (0.009").

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7.9.3 Install the bottomshell bushing

Refer to the figure below.
a) Install lifting eye bolts in the holes (2) in the bottomshell bushing (3).
Use the lifting eye bolts in the tool kit that is supplied with this cone
crusher.
b) Position the hook of a crane vertically above the bottomshell bushing.
c) Attach suitable lifting slings to the lifting eye bolts and to the hook.
d) Take up the slack in the lifting tackle.

Hanging load
A bottomshell bushing weighs up to 100 kg (220 lbs). Handle the
bottomshell bushing with care. The tackle should now be tight but not
DANGER! lifting the bottomshell bushing. Keep clear of hanging loads. Refer to
section 2. Safety precautions.

e) Lift the bottomshell bushing and lower it into the bottomshell.

– If the bore of the bottomshell is not circular, it can be difficult to
install the bottomshell bushing. Any ovality and conicity of the
bottomshell bore must be removed by scraping or grinding.
– If the bottomshell bore is circular, a slightly oval bushing can be
carefully pressed down into place.
NOTE! The lugs on the wearing plate are fixed in relation to the bottomshell, so that
the bottomshell bushing must be rotated to a position where its indentations
match the wearing plate protrusions. The flange around the top of the
bushing must be in contact with the top of the bottomshell gear carrier.

1 Bottomshell (1005-0)
2
2 Hole for lifting eye bolt
3 Bottomshell bushing (1200-0)
3
4

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7.10 Change the Hydroset piston

Lubricating oil enters the crusher through the wall of the Hydroset cylinder,
flows through the Hydroset piston and up through the step bearing.Narrow
oil channels on the outside of the piston 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.
The chevron packing is attached to the bottom of the piston with a clamping
ring.

7.10.1 Remove the Hydroset piston from above

The Hydroset piston can be removed from above or below. This section
describes how to remove it from above. If the piston is to be removed from
below, refer to section 7.12 Change the chevron packing.
Refer to the figure below.
a) Disconnect the supply line for the lubricating oil.
b) Raise the piston far enough for the oil inside the piston to drain.
c) Lower the piston to its lowest position

1
1 Bottomshell (1005-0)
2 Lubrication oil inlet
3 Chevron packing (2305-0)
4 Hydroset piston (2205-0)

2
4
3

(Continued).

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MM Sandvik CH440:01 7. Bottomshell assembly

NOTE! Do not remove the Hydroset oil hoses, the oil can be drained from the
Hydroset hoses by removing the drain plug (6). This will also ensure that
there is no vacuum when the piston is lifted. Refer to the figure below and
section 7.11 General – Hydroset cylinder.

5 Hydroset cylinder cover (2505-0)

6 Plug (2530-0) 5
6

d) Drain the Hydroset line by disconnecting the hose from the back of the
Hydroset tank unit.
NOTE! The oil volume to be drained is approximately 8litres (2.11 US gallons).

e) Remove the piston wearing plate. Refer to section 7.2.1 Remove step
bearing components
f) Install lifting eye bolts in the holes in the Hydroset piston (4).
g) Position the hook of a crane vertically above the bottomshell.
h) Attach suitable lifting slings to the lifting eye bolts and to the hook.
i) Take up the slack in the lifting tackle.

Hanging load
A Hydroset piston weighs up to 185 kg (405 lbs). Handle the Hydroset
piston with care. The tackle should now be tight but not lifting the
DANGER! Hydroset piston. Keep clear of hanging loads. Refer to section
2. Safety precautions.

NOTE! A small quantity of oil may remain inside the Hydroset piston.

j) Lift the Hydroset piston (4) out of the bottomshell (1)

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7.10.2 Inspect the Hydroset piston

a) Clean the piston.
b) Examine the outer surface of the piston for wear and damage.
c) Examine the chevron packing. Refer to section 7.12.2 Inspect the
chevron packing.
d) Examine the bore of the Hydroset cylinder bushing. Refer to section
7.13.2 Inspect the Hydroset cylinder bushing.

7.10.3 Install the Hydroset piston

a) If the crusher is fitted with an ASRi system remove the position sensor to
avoid damage when the piston is lowered.
b) Coat the rubbing surfaces of the piston and the Hydroset cylinder
bushing with molybdenum disulphide.
c) Carefully lubricate the sealing lips of the chevron packing.
d) Install lifting eye bolts in the holes in the Hydroset piston.
e) Position the hook of a crane vertically above the Hydroset piston.
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.

Hanging load
A Hydroset piston weighs up to 185 kg (405 lbs). Handle the Hydroset
piston with care. The tackle should now be tight but not lifting the
DANGER! Hydroset piston. Keep clear of hanging loads. Refer to section
2. Safety precautions.

CAUTION! Make sure that you do not damage the sealing lips of the chevron
packing when the piston is lowered into the Hydroset cylinder and into
the Hydroset cylinder bushing.

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 mainshaft as a
weight to carefully press the piston into the bushing.

i) Lift the Hydroset piston and carefully lower it into the bottomshell.
j) If the crusher is fitted with an ASRi system, reinstall the position sensor.
k) Fill the Hydroset system with oil and bleed out all air. Refer to section
4.2.5 Bleeding air from the Hydroset system.

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7.11 General – Hydroset cylinder

Normally, it is not necessary to remove the Hydroset cylinder from the
bottomshell.
The joint between the Hydroset cylinder and the bottomshell is sealed with
an O-ring. Unless there is severe leakage, it does not need to be replaced.
NOTE! If the Hydroset cylinder is to be removed, use the lowering rods in the tool kit
that is supplied with the cone crusher. The procedure is similar to the
procedure described in section 7.12.1 Remove the chevron packing from
below.

Hydroset cylinder cover / Hydroset cylinder and

Hydroset cylinder / bottomshell joints
– Use Grade 8.8 steel screws.
– Lightly lubricate the screws with oil.
– Clean the threads in the bottomshell.
– Torque the screws in stages, and in diagonal rotation, see section
3.3.1 Required torque for threaded fasteners.
Use a torque wrench that can be calibrated, or a bolt/nut runner with a
torque limiter.

1 Bottomshell (1005-0)
2 Screw (2020-0)
Washer (2020-2)
3 Hydroset cylinder (2005-0)
4 Screw (2515-0)
Washer (2515-2)

1
2
3
4

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7.12 Change the chevron packing

If only the chevron packing is to be changed, it is convenient to do so from
below.

7.12.1 Remove the chevron packing from below

If
NOTE! If only the chevron packing (4) is to be changed, it is more convenient to do
so from below.

Refer to the figure below.

a) Disconnect the lubricating oil supply line.
b) Raise the Hydroset piston (2) far enough for the oil inside the piston to
drain.
c) If the mainshaft has not been removed, then follow this procedure:
– Lower the mainshaft to the bottom and then raise it slightly.
– Put timber blocks under the headcentre, on top of the arms in the
bottomshell.
– Lower the mainshaft onto the timber blocks. Make sure that the shaft
rests securely on the blocks.
CAUTION! The mainshaft must not rest on the dust collar or on the dust seal ring.
This is prevented by the timber blocks. The timber blocks also eliminate
the risk of oil remaining under pressure when the Hydroset line is
disconnected.

1 Lubricating oil inlet

2
3
Hydroset piston (2205-0)
Hydroset cylinder bushing (2050-0)
1
4
5
Chevron packing (2305-0)
Packing clamp plate (2400-0)
2
6 O-ring 3
7 Hydroset cylinder cover (2505-0)
8 Drain plug (2530-0) 4
5
6
7
8
(Continued)

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d) Remove the drain plug to drain the Hydroset hose of oil.

e) Disconnect the hose from the back of the Hydroset tank unit.
NOTE! The oil volume to be drained is approximately 8 litres (2.11 US gallons).

f) Disconnect the Hydroset oil supply line. Drain any remaining oil
g) Remove the position sensor probe. Refer to section 7.14 Change the
mainshaft position probe.
h) Remove three of the screws from the Hydroset cylinder cover.
i) Install instead the threaded lowering rods (9) that are included in the tool
kit supplied with the crusher. Make sure to place two of the lowering
rods so that there is enough space between them for the piston to be
removed, if necessary.
j) Run the nuts up the threaded rods.
k) Remove the remaining screws that hold the Hydroset cylinder cover to
the Hydroset cylinder.
l) Lower the Hydroset cylinder cover (7) by running the nuts down the
lowering rods.
m) Approximately 100 mm (3.9") from the bottom of the piston, there is a
circumferential groove in the piston. Use the nuts on the threaded rods to
lower the Hydroset cylinder cover so far that the groove becomes visible
and the piston retainer (8) can be installed.
Make sure that the piston retainer is correctly aligned and securely
engaged in the groove on the piston.
Most of the piston will remain in the Hydroset cylinder with the chevron
packing accessible outside.
(Continued)

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n) Lower the Hydroset cylinder cover (7) so far that there is enough space
for the packing clamp plate to be removed.
o) Remove and discard the O-ring (6) between the Hydroset cylinder and
the Hydroset cylinder cover.

4 Chevron packing (2305-0)

5 Packing clamp plate (2400-0)
6 O-ring
7 Hydroset cylinder cover
8 Piston retainer 8
9 Lowering rod
10 Plug/cylinder cover cap (2460-0)
4
9 5

6
7

10
.
NOTE! If the piston is to be removed lower the Hydroset cylinder cover so far that
the piston comes completely out of the Hydroset cylinder.
The piston has a boss which fits into an indentation in the Hydroset cylinder
cover, when the piston is at its lowest position. For this reason it is necessary
to lower in stages and use timber blocks, if the piston is to be removed.

7.12.2 Inspect the chevron packing

Refer to the figures above.
a) Examine the chevron packing (4) for damage. If there is damage to the
surface that seals against the cylinder bushing, the Hydroset piston (2)
must be removed and the bushing must be examined. Refer to the Note at
the end of section 7.12.1 Remove the chevron packing from below.
b) If the piston has been removed, examine the step bearing components
and the bore of the Hydroset cylinder. Refer to section 7.2.2 Inspect the
step bearing components.

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7.12.3 Install the chevron packing

Refer to the figure below.
a) Lubricate each ring of the chevron packing (4), the piston (2) and the
cylinder bushing with oil.
b) Carefully lubricate the sealing lips of the chevron packing.
c) Install the chevron packing on the piston. Make sure that the sealing lips
point downwards.
d) Make sure that the clamp plate (5) is pulled up tight against the piston, so
that the packing is compressed slightly.
NOTE! The chevron packing will be correctly clamped once it, and the piston, are
installed in the Hydroset cylinder bushing.

e) Raise the piston and the chevron packing into the Hydroset cylinder
bushing using the nuts on the lowering rods.
NOTE! Take care not to damage the sealing lips when the chevron packing enters the
Hydroset cylinder bushing.

f) Install a new O-ring (6) between the Hydroset cylinder and the cylinder
cover.
g) Install cover plate screws in the holes not occupied by lowering rods.
h) Remove the lowering rods.
i) Install the remaining cover plate screws.
j) Torque the cover plate screws. Refer to section 3.3 Tightening threaded
fasteners.

1 Lubrication oil inlet

2 Hydroset piston (2205-0) 1
3 Hydroset cylinder bushing (2050-0)
4
4 Chevron packing (2305-0) 9 2
5 Packing clamp plate (2400-0) 8
3
6 O-ring
7 Screw (2401-0) 5
8 Inner sealing lip 4
9 Outer sealing lip 7
5
6

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7.13 Change the Hydroset cylinder bushing

The Hydroset cylinder bushing sits in the lower section of the Hydroset
cylinder, where the chevron packing seals.
The Hydroset cylinder bushing provides a sealing surface in the lower part of
the Hydroset cylinder. Together with the Hydroset piston, the chevron
packing and the Hydroset cylinder cover, it functions as a hydraulic cylinder.

7.13.1 Remove the Hydroset cylinder bushing

Refer to the figure below.
a) Remove the Hydroset piston (2). This can be done from above or below
the crusher. Refer to section 7.10.1 Remove the Hydroset piston from
above or section 7.12.1 Remove the chevron packing from below.
– If the Hydroset piston has been removed from below the crusher, the
Hydroset cylinder cover will be hanging on the lowering rods,
beneath the Hydroset cylinder. Continue as described below, from b).
– If the Hydroset piston has been removed from above the crusher, the
Hydroset cylinder cover will be in place at the bottom of the crusher.
Follow the applicable instructions given in section 7.12.1 Remove the
chevron packing from below, and lower the Hydroset cylinder cover
(3). Then continue as described below from instruction b).
b) Place wooden blocks on the Hydroset cylinder cover (3).
c) Remove the screw (6) and the washer (6) below the Hydroset cylinder
bushing (1).

1
1
1 Hydroset cylinder bushing (2050-0)
2 Lowering rod
3 Hydroset cylinder cover (2505-0)
4 Plug (2530-0)
5 O-ring (2540-0) 5 2
6 Screw (2055-0)
Washer (2055-2)
6
3
4
(Continued)

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NOTE! If the bushing does not slide downwards, carefully lever with a bar on the top
edge of the bushing, through the lubrication oil opening on the side of the
Hydroset cylinder.
d) Lower the Hydroset cylinder cover until the Hydroset bushing can be
slid out sideways.

7.13.2 Inspect the Hydroset cylinder bushing

Refer to the figure above.
a) Examine the inner surface of the Hydroset cylinder bushing (1) for
damage, such as scratches or unevenness. No damage is permitted.
(Scratches or unevenness can allow oil to leak past the chevron packing
and cause the Closed Side Setting (CSS) to increase.)
b) Examine 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.

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7.13.3 Install the Hydroset cylinder bushing

Refer to the figure below.
a) Install a new O-ring (6) on the Hydroset cylinder bushing (1).
b) Coat the contact faces of the Hydroset cylinder and the bushing with
molybdenum disulphide.
c) Use the Hydroset cylinder cover, the lowering rods and the nuts to press
the bushing into the cylinder. Lock it in position at the bottom of the
Hydroset cylinder with a washer (7) and a screw (7).
d) Install the piston, the O-rings and the Hydroset cylinder cover.
Remember to install a new O-ring (3) on the Hydroset cylinder cover.
Refer to section 7.12.3 Install the chevron packing.
NOTE! The piston wearing plate can be fitted to the Hydroset piston and the step
washer can be placed in position on top of the piston wearing plate before
the piston is installed.

1 1
1 Hydroset cylinder bushing (2050-0)
2 Lowering rod
3 O-ring (2540-1)
4 Hydroset cylinder cover (2505-0)
5 Plug (2530-0)
6 O-ring (2540-0) 6 2
7 Screw (2055-0)
Washer (2055-2)
7 3
4

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7.14 Change the mainshaft position probe

The mainshaft position probe is optional for this cone crusher and is fitted if
the crusher is equipped with an ASRi system.
The mainshaft position sensor assembly consists of the probe and the
measuring tube (mounted in the Hydroset piston).

7.14.1 Remove the mainshaft position probe

Refer to the figure below.
a) Lower the mainshaft to its lowest position.
b) Place a suitable receptacle under the Hydroset cylinder.
NOTE! The oil volume to be drained is approximately 8 litres (2.11 US gallons).

c) Open the drain plug (5) and disconnect the hose at the back of the
Hydroset tank, to drain the crusher of oil.
d) Remove the probe cover from the Hydroset cylinder cover.
e) Disconnect the signal cable plug from the connector socket (4) on the
probe.
f) Remove the screws (3).
g) Carefully remove the probe (2).

1 O-ring (2606-8)
2 Probe (2601-1)
3 Screw (2510-2)
4 Connector socket
5 Hydroset drain plug (2530-0)

5
1
2 4
3

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MM Sandvik CH440:01 7. Bottomshell assembly

7.14.2 Install the mainshaft position probe

Refer to the figure above.
a) Lubricate the O-ring (1) and its seating with oil.
b) Install the probe (2) and the O-ring.
c) Install the probe attachment screws. Torque the screws, refer to section
3.3.1 Required torque for threaded fasteners.
d) Connect the signal cable plug to the socket on the probe.
e) Install the probe cover on the Hydroset cylinder cover.
f) Install the drain plugs.
g) Bleed the Hydroset system of air before operation. Refer to Bleeding air
from the Hydroset system in the Operator’s manual.

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MM Sandvik CH440:01 7. Bottomshell assembly

7.15 Change bottomshell 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.
Liner plates on the inside of the bottomshell
a) Clean the new plates.
b) Weld lifting lugs to the liners. The electrode must meet the requirements
of SS-EN ISO 2560: E42 4 B 42 H5, AWS A5.1; E 7018 (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").
Bottomshell arm liners
a) Clean the new arm liners.
b) Position the arm liners on the bottomshell arms.
c) Use pieces of round bar to fill the gaps between the manganese liners
and the bottomshell.
d) Weld between the round bar and the bottomshell. The electrode must
meet the requirements of SS-EN ISO 2560: E42 4 B 42 H5, AWS A5.1;
E 7018 (for example ESAB OK 48.00 electrode).
Use an A-dimension of 6 mm (0.24").
e) Weld between the round bar and the manganese liners. The electrode
must meet the requirements of SS-EN ISO 2560: E19 12 3 L B 2 2, AWS
A5.4 (for example ESAB OK 63.35 electrode).
Use an A-dimension of 6 mm (0.24").
(Continued)

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MM Sandvik CH440:01 7. Bottomshell assembly

6 5 5 2 9 4

5 4 3 1
1 Liner -pin shaft arm (1010-1)
2 Liner - narrow arm (1010-2)
3 Wearing plates (1320-1)
4 Wearing plates (1320-2)
5 Wearing plates (1320-3)
6 Wearing plates (1320-4)
7 Wearing plates (1320-5)
8 Wearing plates (1320-6)
a6
9 Wearing plates (1320-7) WD

a6
WD

a6 75
WD

C
a6 a6 75
WD WD

a6 75
WD

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MM Sandvik CH440:01 7. Bottomshell assembly

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 8. Pinionshaft assembly and
bevel gears
This section describes the maintenance instructions for the pinionshaft and
the bevel gears.
To ensure maximum safety, always read section 2. Safety precautions before
you do any work on the equipment, or make any adjustments.

MM Sandvik CH440:01 151

MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

8.1 General
8.1.1 Oil for pinionshaft lubrication
The pinionshaft bearings are lubricated by a separate circulatory system. A
small flow of oil is bled off from the main lubrication system and is pumped
to the oil inlet in the top of the pinionshaft housing.
Oil quantity
Oil quantity
Pinionshaft housing 1.3 litres/(0.34 US gal.)

The volume in the pinionshaft housing is limited by a level tube and excess
oil returns to the main lubrication tank by gravity.

1
2
1 Oil inlet
2 Oil level
3 Level tube
4 Drain plug

3
4

Cleaning
Remove the drain plug (magnetic plug) and clean it at least twice a year. This
will also drain out any sediment from the pinionshaft housing.

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

8.2 Change the pinionshaft assembly

The following replaceable parts are mentioned in this instruction
NOTE! If a wear part is worn out, replace it.

The pinionshaft housing assembly forms a complete unit with separate

lubrication.
The cone crusher has a circulatory lubrication system, which is designed so
that a constant flow of oil is pumped from the tank unit to the pinionshaft
housing. A level tube maintains a constant level in the pinionshaft housing,
while excess oil flows back to the tank through the main return hose.

8.2.1 Checks prior to removal

a) Measure the gear backlash. See section 8.4.1 Checking the gear
backlash.
b) Measure the distance between the flange of the pinionshaft housing and
the bottomshell with a feeler gauge. There is a recess (6) in the edge of
the gasket to facilitate this. Make a note of the measured distance.
c) Examine the axial play in the bearings by pulling the crusher pulley
outward. Measure the play with a dial gauge. A play that is larger than is
to be expected can be an indication that a bearing needs to be replaced.

Reduce backlash
5

4
Increase backlash

6 3 1 7
1 Pinionshaft (3505-0) 5 Hole for jacking screw
3 Screw (1505-0) 6 Recess for measurement with feeler gauge
Washer (1505-2) 7 Adjustment screw (3710-0)
4 Oil inlet hose

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

8.2.2 Remove the pinionshaft housing assembly

NOTE! It is necessary to remove parts before proceeding with this instruction, refer
to section section 9.4 Change V-belts. To get a better balance, leave the
pulley on the pinionshaft when lifting and moving the pinionshaft housing.

a) Remove the oil hoses (4) from the pinionshaft housing.

b) Make sure that the lock nut on the upper backlash adjustment screw (7)
is tight.
c) Loosen the lock nut on the lower backlash adjustment screw (7).
d) Remove the lower backlash adjustment screw.
e) Remove the screws and the washers (3) that attach the pinionshaft
housing assembly to the bottomshell.
f) Rotate the pinionshaft housing assembly so that the protrusion on the
flange rests against the bracket of the lower adjustment screw.
g) Position the hook of a crane vertically above the pinionshaft (1).
h) Place a lifting sling around the end of the pinionshaft housing assembly
and attach the sling to the lifting hook.
i) Install two jacking screws in the holes (5), at 180° spacing.
j) Tighten the jacking screws to raise the pinionshaft housing assembly
from its seating in the bottomshell. Let the assembly hang in the opening
in the bottomshell.
k) Move the lifting sling to the opposite side of the housing flange.

2 8 9
2 Pinionshaft housing (3005-0)
8 Oil inlet
9 Flange
10 Drain plug

10

(Continued)

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

l) Raise the pinionshaft housing assembly further and move the lifting
sling inwards until the assembly is in balance.

Hanging load
A pinionshaft housing assembly with pulley weighs up to 380 kg
(830 lbs). Handle the pinionshaft housing assembly with care.
DANGER! The tackle should now be tight but not lifting the pinionshaft housing
assembly. Keep clear of hanging loads. See section 2. Safety
precautions.

m) Lift the pinionshaft housing assembly out of the bottomshell and place it
on a pair of trestles.

8.2.3 Inspect the pinionshaft housing assembly

If a new pinionshaft housing assembly is to be installed, or if the pinionshaft
(1), the gears or the inner spacer have been replaced, then the gear backlash
and the tooth bearing “footprint” must be inspected. See
section 8.4.1 Checking the gear backlash and to section 8.4.3 Tooth bearing
“footprint”.
If no components have been replaced and the pinionshaft housing assembly
is to be re-installed, fit a gasket of appropriate thickness between the
pinionshaft flange and the bottomshell. Use the measurement noted during
the removal. See b) in section 8.2.1 Checks prior to removal.

8.2.4 Install the pinionshaft housing assembly

a) Place a lifting sling around the pinionshaft housing, on the pinion side of
the flange.
b) Position the hook of a crane vertically above the pinionshaft housing
assembly.
c) Attach the lifting sling to the hook.
d) Take up the slack in the lifting tackle.

Hanging load
A pinionshaft housing assembly with pulley weighs up to 380 kg
(830 lbs). Handle the pinionshaft housing assembly with care.
DANGER! The tackle should now be tight but not lifting the pinionshaft housing
assembly.
Keep clear of hanging loads. See section 2. Safety precautions.

(Continued)

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

e) Adjust the position of the sling to keep the assembly in balance.

NOTE! When the pinionshaft assembly is to be put back into the bottomshell, make
sure that the protrusion in the housing flange is in the correct position
relative to the bracket for the lower adjustment screw.

1 Pinionshaft (3505-0) 5
3 Screw (1505-0)
Washer (1505-2)
4 Oil inlet hose
5 Hole for jacking screw
6 Recess for measurement
with feeler gauge
4
7 Adjustment screw (3710-0)

6 3 1 7

f) Lift the pinionshaft housing assembly and position it in line with the hole
in the bottomshell.
g) Push the pinionshaft housing assembly into the bottomshell. This may
require moving the lifting sling outwards as the assembly moves into the
bottomshell.
h) When the pinionshaft housing assembly gets closer to its correct position
in the bottomshell, slowly turn the shaft (1) backwards and forwards to
make sure that the pinion meshes correctly with the eccentric gear.
i) Install the retaining screws and the washers (3) in the bottomshell.
j) Install the lower backlash adjustment screw (7) and its lock nut.
k) Torque the screws that clamp the pinionshaft housing assembly to the
bottomshell. See section 3.3 Tightening threaded fasteners.
l) Make sure that the distance between the flange of the pinionshaft
housing and the bottomshell is the same as before the pinionshaft
assembly was removed. See b) in section 8.2.1 Checks prior to removal.
m) Examine the backlash in the gears. See section 8.4.1 Checking the gear
backlash.
n) Install all the components of the circulatory pinionshaft lubrication
system.
o) Fill the pinionshaft housing with oil to the correct level. Refer to section
10.1 Check list for an overhauled cone crusher.

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

8.3 Change the pinionshaft and the pinion

8.3.1 Remove the pulley
Health hazard
The cone crusher has seal rings made from fluorinated rubber. If these
have been exposed to extreme heat (i.e. they are burnt), they must be
WARNING! treated in the same way as corrosive acid. See the safety leaflet.

a) Remove the screw (10), the washer (9) and the retaining washer (8).
b) Remove the screw between the crusher pulley (6) and the tapered
bushing (4).
c) Place a lifting sling into one of the grooves near the middle of the
crusher pulley.
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 tapered bushing
(4) and tighten them, so that the crusher pulley is pushed slightly
outwards.
f) Take up the slack in the lifting tackle.

Hanging load
A crusher pulley weighs up to 100 kg (220 lbs). Handle the crusher
pulley with care. The tackle should now be tight but not lifting the
DANGER! crusher pulley. Keep clear of hanging loads. See section 2. Safety
precautions.

g) Pull the crusher pulley (6) off the pinionshaft and lower it to the ground.
h) Remove the tapered bushing (4) and the key (3).
2 3 1 4 5 6 7 8 9 10

1 Pinionshaft (3505-0) 4 Tapered bushing 8 Retaining washer

2 Pinionshaft housing 5 Spacer 9 Washer
(3005-0) 6 Crusher pulley 10 Screw
3 Key (3515-0) 7 Screw

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

8.3.2 Remove the pinion

CAUTION! Carry out this procedure indoors, in a clean environment.
a) Place the pinionshaft housing (2) on the ground on a sheet of plywood.
b) Unscrew the oil inlet (11).
c) Place a lifting sling around the middle of the pinionshaft housing
(2).

2 8 9
2 Pinionshaft housing (3005-0)
8 Oil inlet
9 Flange
10 Drain plug

10

d) Position the hook of a crane vertically above the pinionshaft housing and
attach the sling to the hook.
e) Take up the slack in the lifting tackle.

Hanging load
A pinionshaft housing assembly weighs up to 280 kg (610 lbs). Handle
the pinionshaft housing assembly with care. The tackle should now be
DANGER! tight but not lifting the pinionshaft housing assembly.
Keep clear of hanging loads. See section 2. Safety precautions.

(Continued)

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

f) Lift the pinionshaft housing assembly, then lower it with the outer
(drive) end downwards, onto a suitable support (16) for example a cable
drum.
g) Remove the lifting sling from the pinonshaft housing.
h) Remove the retaining ring (15) from the inner (pinion) end of the
pinionshaft.
i) Remove the screws from the inner bearing cover (14).
j) Mount a robust extractor (17) on the end of the pinionshaft, to remove
the pinion (13). The inner bearing cover has a lip (18) for an
extractor (17).
15
3
1 Pinionshaft (3505-0) 17
13
2 Pinionshaft housing (3005-0) 14
3 Key (3515-0) 1
13 Pinion (1850-2)
14 Inner bearing cover (3190-1)
18
15 Retaining ring (3650-0)
16 Support (drum) 2
17 Extractor
18 Lip

16

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 (3) and make sure that there are no burrs on the end of
the shaft.

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

8.3.3 Remove the pinionshaft

a) Place a lifting sling close to the middle of the pinionshaft housing.
b) Position the hook of a crane vertically above the pinionshaft housing.
c) Attach the lifting sling to the hook.
d) Take up the slack in the lifting tackle.

Hanging load
A pinionshaft housing assembly weighs up to 280 kg (610 lbs). Handle
the pinionshaft housing assembly with care. The tackle should now be
DANGER! tight but not lifting the pinionshaft housing assembly. Keep clear of
hanging loads. See section 2. Safety precautions.

e) Lift the pinionshaft housing assembly, then lower it horizontally onto

wooden blocks.

20
1 Pinionshaft housing (3005-0)
3 Pinionshaft (3505-0)
19 Plate/outer bearing cover (3190-2)
20 Lifting eye bolt

3 1 19

f) Remove the lifting sling from the pinionshaft housing.

g) Remove the screws and the washers from the plate/outer bearing
cover (19).
h) Remove the plate/outer bearing cover.
i) Install lifting eye bolts (20) in the outer end of the pinionshaft housing.
(Continued)

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

j) Position the hook of a crane vertically above the pinionshaft housing.

k) Attach suitable lifting slings to the lifting eye bolts.
l) Attach the lifting slings to the hook.
m) Take up the slack in the lifting tackle.

Hanging load
A pinionshaft housing assembly weighs up to 280 kg (610 lbs). Handle
the pinionshaft housing assembly with care. The tackle should now be
DANGER! tight but not lifting the pinionshaft housing assembly. Keep clear of
hanging loads. See section 2. Safety precautions.

n) Lift the pinionshaft housing until it hangs vertically.

o) Position two suitable trestles below opposite sides of the pinionshaft
flange.
p) Lower the pinionshaft housing onto the trestles.
q) Pull out the short discharge tube (31) and remove the level tube.
The level tube has a threaded hole at the bottom for an M8 extractor
screw (33).
The level tube must be taken out before the shaft can be pulled out in the
directions of the arrow.

26
1 Pinionshaft (3505-0)
1 27
21 Trestles
26 Lifting eye bolt
27 Outer bearing (3070-2)
28 O-ring
29 Steel wire hook
21
30 Hole in discharge tube for removal
31 Discharge tube
32 O-rings
33 Extractor screw
34 32 33
34 Level tube
31
30
28 29

(Continued)

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

r) Attach a lifting eye bolt (26) to the outer end of the pinionshaft.

21 Trestle
26 25
22 Inner bearing (3070-1)
23 Inner spacer (3090-1)
24 Key (3515-0)
25 Outer spacer (3090-2)
27
26 Lifting eye bolt
27 Outer bearing (3070-2) 21

22
23
24

s) Position the hook of a crane vertically above the pinionshaft (1) end.
t) Attach the a sling to the lifting eye bolt and to the hook.
u) Take up the slack in the lifting tackle.

Hanging load
A pinionshaft assembly weighs up to 95 kg (210 lbs). Handle the
pinionshaft assembly with care. The tackle should now be tight but not
DANGER! lifting the pinionshaft assembly.
Keep clear of hanging loads. See section 2. Safety precautions.

v) Lift out the pinionshaft, complete with both bearings (22 and 27) and
both spacers (23 and 25).
CAUTION! Great care must be taken, and cleanliness is very important, when work
is carried out on the bearings. Keep the bearing components protected.
w) Cut the outer ring of the inner bearing (22) at two diametrically opposite
points so that the outer ring and the rollers drops off.
x) Carefully heat the inner spacer (23) and remove it.
y) Heat the inner ring of the inner bearing (22) until it drops off the shaft.
(Continued)

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

z) Lower the pinionshaft, with the outer bearing and spacer still in place,
onto wooden blocks on the ground.
aa) Remove the lifting sling from the lifting eye bolt.
ab) Loop a lifting sling around the pinionshaft near the inner end.
ac) Take up the slack in the lifting tackle.

Hanging load
A pinionshaft assembly weighs up to 95 kg (210 lbs). Handle the
pinionshaft assembly with care. The tackle should now be tight but not
DANGER! lifting the pinionshaft assembly. Keep clear of hanging loads. See
section 2. Safety precautions.

ad) Attach the other end of the sling to the lifting hook and raise the
pinionshaft (1) to the vertical position.
ae) With the pinionshaft hanging vertically, remove the outer bearing (27) in
the following way:
– Cut the outer ring at two diametrically opposite points so that the
outer ring and the rollers drop off.
– Carefully heat the outer spacer (25) and remove it.
– Heat the inner ring of the outer bearing until it drops off the shaft.
4 13 3/24 14 2 5 19

6 7 9 10 11 12 8
23 17 22 1 27 15 25

1 Pinionshaft (3505-0) 8 Screw (3220-0) 15 O-ring (3120-2)

2 Pinionshaft housing 9 Oil seal (3170-1) 17 O-ring (3120-1)
(3005-0) 10 Oil level plug (3590-0) 19 Outer bearing cover
3 Key (3515-0) 11 Drain plug (3585-0) (3190-2)
4 Retaining ring (3650-0) 12 Washer (3220-2) 22 Inner bearing (3070-1)
5 Oil seal (3170-2) 13 Pinion (1850-2) 23 Inner spacer (3090-1)
6 Screw (3210-0) 14 Inner bearing cover 25 Outer spacer (3090-2)
7 Washer (3210-1) (3190-1) 27 Outer bearing (3070-2)

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

8.3.4 Install the roller bearings and the spacers

CAUTION! Carry out this procedure indoors, in a clean environment. Use an oil
bath, an induction heater or an oven to heat components that are to be
shrunk into place. Avoid using an open flame, since there is an obvious
risk of overheating or localized heating.
a) Position the pinionshaft (1) horizontally on a stand with wooden inserts
so that both ends of the pinionshaft are free.Use an overhead crane.
1
1 Pinionshaft (3505-0)

b) Clean the pinionshaft:

– Spray the pinionshaft with degreasing fluid. Clean it with a cloth.
– Remove shavings, grinding or dirt from the key ways at both ends of
the pinionshaft.
– Use compressed air to clean the pinionshaft ends.
c) Remove any grease from the inner roller bearing with a cloth.
d) Position the roller bearing up end. Measure the gap between the rolls and
outer ring in the upper part of the roller bearing.

Make sure that the gap is within the accepted limits. These limits are
listed in the manufacture´s documentation. If the gap in the bearing is
outside the limits, the roller bearing must not be used.
e) Heat the inner bearing to 90 °C (194 °F) above the ambient air
temperature. To 110 °C in an ambient air temperature of 20 °C.

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

CAUTION! When heating bearing components, check the temperature with a

thermometer, or use another technique recommended by the bearing
manufacturer.

Hot surface
The heated bearing components are hot. Handle the bearing
component with protective gloves.
WARNING!
f) Install the inner bearing with a push fit on the shaft with a suitable drive.
Push until the roller bearing is flush against the inner ring while it
shrinks against the pinionshaft.

g) Install the outer bearing at the outer end of the pinionshaft the same way.
h) Let the bearings cool down.
i) Measure the play again. Use a feeler gauge. Since the roller bearing
hangs on the pinionshaft, measure the gap between the bearing and the
outer ring at the lower part of the bearing.
j) Heat the spacer to 90 °C (194 °F) above the ambient air temperature.
CAUTION! When heating bearing components, check the temperature with a
thermometer, or use another technique recommended by the bearing
manufacturer.
Hot surface
The heated bearing components are hot. Handle the bearing
component with protective gloves.
WARNING!
NOTE! If the roller bearings have recently been installed, the temperature of the
pinionshaft can be increased due to the heating of the roller bearings.

CAUTION! To avoid damage to the O-ring, remove all sharp edges from the key
ways and the spacer grooves.

k) Grease the pinionshaft end next to the inner bearing with molybdenum
disulphide paste.Use a brush to apply the grease.
(Continued)

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

l) Lubricate an O-ring with oil.

m) Position the O-ring (28) in the groove inside the spacer (25).
n) Lubricate the surfaces over which the O-rings are to be fitted with oil.

23 Inner spacer (3090-1) 23 17

17 O-ring (3120-1) 28
28 Groove

o) Install the spacer on the inner shaft end with a suitable drift. Push until
the spacer is flush against the roller bearing while it shrinks against the
pinionshaft
p) Install the O-ring and the outer spacer ring on the outer end of the
pinionshaft the same way.
q) Let the pinionshaft cool.

8.3.5 Install the pinionshaft

a) Position the pinionshaft housing with the outer end upward between two
boards that are mounted on trestles, so that the flange rests on the boards.

Hanging load
A pinionshaft housing weighs up to 185 kg (410 lbs). Handle the
pinionshaft housing with care.
DANGER! Keep clear of hanging loads. See section 2. Safety precautions.

b) Clean the pinionshaft housing:

– Clean the inside of the pinionshaft housing with a cloth.
– Carefully grind off any burrs that remain from the turning.
– Clean the screw holes for the holes for the locking tubes and magnetic
plugs. Make sure that you remove all paint and dirt. Use compressed
air.
c) Apply thread seal on the threads of the magnetic plug and the angle.
d) Install the magnetic plug in the corresponding hole on the side of the
pinionshaft housing.
e) Install a protection plug in the angle to protect it from dirt.
f) Lubricate the inside of the pinionshaft housing with oil.
(Continued)

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g) Attach a lifting eye bolt to the outer end of the pinionshaft.

h) Position the hook of a crane vertically above the outer end of the
pinionshaft.
i) Attach a lifting sling to the lifting eye bolt and to the hook.
j) Take up the slack in the lifting tackle.
Hang

Hanging load
A pinionshaft weighs up to 95 kg (210 lbs). Handle the pinionshaft with
care. The tackle should now be tight but not lifting the pinionshaft.
DANGER! Keep clear of hanging loads. See section 2. Safety precautions.

k) Lift the pinionshaft so that it hangs vertically with the inner end at
normal working height. Place a board under the inner end of the
pinionshaft for support and lift at the outer end.
l) Make sure that the outer rings of the roller bearings are aligned with the
inner ring.
m) Carefully lower the pinionshaft into the pinionshaft housing until the
outer bearing rest in position.
n) If the pinionshaft does not glide into place by its own weight, do the
following until it is in place:
– Carefully tap the outer ring down to the outer roller bearing.
– Lightly tap the outside of the pinionshaft housing at the level of the
inner roller bearing. Use a rubber mallet.
o) Carefully tap the spiral pin into the corresponding hole.

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8.3.6 Install the outer bearing cover

a) Clean the inside of the outer bearing cover (19) with a cloth.
b) Lubricate the inside of the bearing cover with oil.
c) Install the oil seal (5) to the bearing cover with a suitable tool. Preferably
push the oil seal inside the bearing cover to avoid damage.

5 8,12
3 Key (3515-0) 19
5 Oil seal ring (3170-2) 3
8 Screw (3220-0) 29
12 Washer (3220-2) 30
19 Outer bearing cover (3190-2)
21 Trestle
27
27 Outer bearing (3070-2) 21
29 Gasket (3240-2)
30 Spiral pin (3330-0)

d) Make sure that the sealing ring is flush against the bearing cover all the
way around.
e) Install a gasket (29) in the bearing cover.
f) Prepare the inner bearing cover in the same way.
g) Position the outer bearing cover on the outer end of the pinionshaft
housing so that the spiral pin enters the corresponding hole in the bearing
cover.
h) Apply a medium strong locking fluid to the threads of the six screws.
i) Install washers on the screws. Tighten the screws in diagonal rotation to
fasten the bearing cover. Torque the screws to 169Nm (124.6 ft lbs).
j) Grind the keys so that they fit into the key ways at each end of the
pinionshaft.
k) Install the outer key (3) in the key way at the outer end of the
pinionshaft.
l) Install the bushing on the journal pin.
m) Install the shim on top of the bushing.
n) Apply a medium strong locking fluid to the screw.
o) Tighten the screw to fasten the retaining washer.

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8.3.7 Install the level tube and the discharge tube

a) Loop a lifting sling around the pinionshaft housing near the inner end.
b) Attach the lifting sling to the hook of the crane.
c) Take up the slack in the lifting tackle.

Hanging load
A pinionshaft housing assembly weighs up to 280 kg (610 lbs). Handle
the pinionshaft housing assembly with care. The tackle should now be
DANGER! tight but not lifting the pinionshaft housing assembly. Keep clear of
hanging loads. See section 2. Safety precautions.

d) Position the pinionshaft housing on it side on sheets of plywood or

wooden trestles on the floor.

1 Pinionshaft (3505-0)
2 Pinionshaft housing (3005-0)

1 2
e) Install lifting eye bolts in the inner end of the pinionshaft.
f) Attach lifting slings to the lifting eye bolts and the pinionshaft.
(Continued)

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g) Take up the slack in the lifting tackle.

Hanging load
A pinionshaft housing assembly weighs up to 280 kg (610 lbs). Handle
the pinionshaft housing assembly with care. The tackle should now be
DANGER! tight but not lifting the pinionshaft housing assembly. Keep clear of
hanging loads. See section 2. Safety precautions.

h) Raise the pinionshaft housing and turn it around to the vertical position.
a) Position the pinionshaft housing onto a suitable support (16) for example
a cable drum.
a) Clean the level tube and the discharge tube. Make sure that there are no
remaining burrs from the turning. Use compressed air to remove all
loose dirt.
b) Attach two O-rings in the grooves in the level tube.
c) Apply grease to the level tube and its O-rings. Use a brush to apply the
grease.
d) Install the level tube in the corresponding hole on the outside of the
pinionshaft housing.
e) Install the discharge tube (31) in the hole in the middle on the edge of the
pinionshaft housing. Make sure that the small hole (30) on the discharge
tube is upward.
f) Carefully tap the level tube (34) until the level tube falls into place
between the O-rings (32).
1 Pinionshaft (3505-0)
16 Support (drum) 29
28 O-ring 30
28
29 Steel wire hook
30 Hole in discharge tube for removal
31
31 Discharge tube
32 O-rings 1
33 Extractor screw
34 Level tube

36 32 34

16

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8.3.8 Install the inner bearing cover

a) Lubricate the inner spacer ring with oil. Pour oil down into the inner
roller bearing.
b) Position the inner bearing cover on the inner 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 to the figure below.

c) Apply locking fluid to the threads of the six screws.

d) Install washers on the screws. Tighten the screws alternately to fasten the
bearing cover. Use a torque the screws alternately to 40 Nm (29.5 ft lbs).
e) Make sure that the key fits properly into the key ways in the pinion and
on the pinionshaft.
f) Heat the pinion to 150 °C (266 °F) above the ambient air temperature. To
302 °C in an ambient air temperature of 20 °C. Use an oil bath, an
induction heater or an oven.

Hot surface
The heated bearing components are hot. Handle the bearing
components with protective gloves.
WARNING!
g) Mount the pinion, with the key, on the inner end of the pinionshaft.
h) Install the retaining ring on the inner end of the pinionshaft. Make sure
that it fits into the groove.

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8.3.9 Install 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.

Hanging load
A pinionshaft housing assembly weighs up to 280 kg (610 lbs). Handle
the pinionshaft housing assembly with care. The tackle should now be
DANGER! tight but not lifting the pinionshaft housing assembly. Keep clear of
hanging loads. See section 2. Safety precautions.

c) Position the pinionshaft housing on it side on sheets of plywood or

wooden trestles on the floor.

1 Pinionshaft (3505-0)
2 Pinionshaft housing (3005-0)

1 2
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.

Hanging load
A pinionshaft housing assembly weighs up to 280 kg (610 lbs). Handle
the pinionshaft housing assembly with care. The tackle should now be
DANGER! tight but not lifting the pinionshaft housing assembly. Keep clear of
hanging loads. See section 2. Safety precautions.

(Continued)

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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.

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)

2 3 1 4 5 6 7 8 9 10

1 Pinionshaft (3505-0) 4 Tapered bushing 8 Retaining washer

2 Pinionshaft housing 5 Spacer 9 Washer
(3005-0) 6 Crusher pulley 10 Screw
3 Key (3515-0) 7 Screw

(Continued)

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

n) Attach two lifting eyes on the pulley (6).

o) Position the hook of a crane vertically above the pulley.
p) Attach a lifting sling to the hook.
q) Attach the lifting sling to the lifting eye on the pulley.
r) Take up the slack in the lifting tackle.
s) Lift the pulley.

Hanging load
A pulley weighs up to 100 kg (220 lbs). Handle the pulley with care. The
tackle should now be tight but not lifting the pulley. Keep clear of
WARNING! hanging loads. See section 2. Safety precautions.

t) Install the pulley on the pinionshaft.

u) Install the two screws (7).
v) Torque the screws alternately, refer to section 3.3.1 Required torque for
threaded fasteners.

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8.3.10 Preparation for the installation of a complete

pinionshaft assembly
If the gear and pinion, pinionshaft housing etcetera are to be replaced, or
when a check was not made on the thickness of the gasket between the
pinionshaft housing flange and the bottomshell during removal, the tooth
bearing “footprint” and the backlash must be adjusted. The thickness of the
gasket can be calculated as follows.
a) Measure dimension (A) with a rod-type micrometer. See the figure
below. Make a note of the measurement.

1 wedge
A

C
b) Position the pinionshaft assembly upright, resting on the crusher pulley.
c) To compensate for the axial play in the bearings, put a wooden wedge (1)
between the crusher pulley and the outer bearing cover.
d) Measure the distance between the contact face of the pinionshaft flange,
which seats against the bottomshell, and the machined surface on the
small end of the pinion.
e) Make a note of dimension (B), which is stamped into the small end of the
pinion.
f) Make a note of dimension (C) which is stamped into the machined outer
surface of the bottomshell.
g) Calculate the gasket thickness using this formula:

A + B - C = Gasket thickness

NOTE! The calculated gasket thickness applies for compressed gaskets.

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h) Use the calculated gasket thickness and the table below to determine the
required thickness of the gasket to be installed.

Gasket thickness, uncompressed Gasket thickness, compressed

mm (inches) mm (inches)

0.5 (0.05) approximately 0.3 (0.012)

0.8 (0.03) approximately 0.5 (0.020)
1.5 (0.06) approximately 0.9 (0.035)

i) Fit gaskets of the correct thickness, as determined above.

j) Install the pinionshaft assembly and rotate the shaft slowly backwards
and forwards as the pinion comes into mesh with the eccentric gear. See
section 8.2.4 Install the pinionshaft housing assembly.
k) Tighten the screws that hold the pinionshaft housing to the bottomshell.
l) Check the backlash and the tooth bearing “footprint”. Adjust if
necessary. Refer to section 8.4.3 Tooth bearing “footprint”.
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.

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8.4 Bevel gears

The cone crusher has spiral bevel gears. Under normal conditions this type of
transmission requires very little maintenance.
The gear backlash can be checked without removing the pinionshaft housing
assembly from the bottomshell. This check must be carried out at regular
intervals - refer to Routine Inspection and Care in the Operator's Manual.
The gear backlash must also be checked whenever the pinionshaft housing
assembly has been removed and put back into the bottomshell. See section
8.4.1 Checking the gear backlash.
If the gear backlash is not within the range specified in the table in See
section 8.4.1 Checking the gear backlash, it must be adjusted.
See section 8.4.2 Adjustment of the backlash.
If components have been changed, or if no record was kept of the gasket
thickness when the pinionshaft housing assembly was removed, the gasket
thickness must be determined. See section 8.3.10 Preparation for the
installation of a complete pinionshaft assembly.
The tooth bearing “footprint” must be checked whenever certain components
in the pinionshaft assembly have been changed: the gear set, the pinionshaft,
the pinionshaft housing or the bottomshell.
See section 8.4.3 Tooth bearing “footprint”.

NOTE! 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.

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8.4.1 Checking the gear backlash

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 below 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.
The backlash cannot be measured directly between the pinion and the
eccentric gear. Instead the movement of the crusher pulley is measured to
calculate the backlash.
Use a dial gauge for these measurements. If a dial gauge is not available, a
set square can be used. In this case, make marks on the pulley and measure
the distance between the marks.
Since there is play between the eccentric and the bottomshell 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 pinionshaft.
NOTE! Due to the play in the pinionshaft 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 pinionshaft housing flange are tight.

The correct values for the backlash in the cone crusher are presented in the
table below.
Crusher Pinion pitch Backlash on Crusher pulley Movement on outer
circle diameter pitch circle outer diameter diameter of pulley
mm (inches) diameter mm (inches) with correct play
mm (inches) mm (inches)
CH440 192 (7.6) 0.80 – 1.00 385 (15) 1.60-2.00
(0.031 – 0.039) (0.063 - 0.079)

NOTE! The values in the table above are theoretically calculated for reference
during manufacture and installation of the gears.

(Continued)

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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.
250mm

1 Dial gauge
2 Lever
3 Set square

3 1 1 2
With V-belt pulley installed With removed V-belt pulley

The following formula is used to check the backlash:

Crusher pulley
movement =Play in gears on pitch line x Crusher pulley outer dia
on outer diameter Pinion pitch circle diameter
Example:
The CH440:01 cone crusher has a crusher pulley with 385 mm (15 inches)
outer diameter. What movement should be found on the outer diameter of the
crusher pulley (with a 50 Hz gear set)
Refer to the table below for the correct backlash, and then use the formula to
calculate the movement as follows:

Min. movement
on crusher pulley =0.8 x 385 = 1.6 mm or 0.031 x 15 = 0.063"
outer diameter. 192 7.6
Max. movement
on crusher pulley =1.0 x 385 = 2.0 mm or 0.039 x 15 = 0.079"
outer diameter. 192 7.6

(Continued)

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MM Sandvik CH440:01 8. Pinionshaft assembly and bevel gears

When the V-belt pulley has been removed,:

Movement
shown on = Play in gears on pitch line x 2R
dial gauge Pinion pitch circle diameter
Example:
The dial gauge is placed 250 mm (9.84") from the centre. What movement
should be found at this radius, to achieve the correct backlash in the gears on
the pitch line?
See the table for the correct backlash, and then use the formula to calculate
the movement as follows:

Minimum = 0.80 x 2 x 250 = 2.08 mm or 0.031 x 2 x 9.84 = 0.082"

movement 192 7.6

Maximum = 1.0 x 2 x 250 = 2.60 mm or 0.039 x 2 x 9.84 = 0.102"

movement 192 7.6

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8.4.2 Adjustment of the backlash

Since the pinionshaft housing is eccentrically mounted, the backlash in the
gears can be adjusted by rotating the pinionshaft housing.
a) Use a feeler gauge to measure the thickness of the gasket between the
flange on the pinionshaft housing and the bottomshell. Record this
measurement. There is an indentation in the edge of the gasket to
facilitate measurement. New gaskets may be needed.
b) Loosen the screws that hold the pinionshaft assembly.
c) Carefully release the gasket from the flange on the pinionshaft housing,
to avoid damage. The gear backlash can then be adjusted:
– Increase the gear backlash by moving the adjusting screws
downwards (= clockwise).
– Reduce the gear backlash by moving the adjusting screws upwards
(= anti-clockwise)
Reduce backlash
5

4
Increase backlash
6 3 1 7
1 Hole for jacking screw 5 Screw (1505-0), Washer (1505-2)
2 Upper and lower adjustment 6 Recess for measurement with a feeler
screws (3710-0) gauge
3 Pinionshaft (3505-0) 7 Filter plug (3305-0)
4 Drain plug (3340-0)

d) When the backlash is correct, tighten the retaining screws and lock the
adjusting screws.
e) Check the backlash again. See section 8.4.1 Checking the gear backlash.
Adjust if necessary.
NOTE! If the pinionshaft assembly is to be removed, and the backlash is correct,
remove only one of the adjusting screws. See section 8.2 Change the
pinionshaft assembly.

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8.4.3 Tooth bearing “footprint”

The tooth bearing “footprint” is a visual representation of the way in which
the teeth of the gear wheel and the pinion mesh together.
The gear installation is correct only when the correct backlash and the
correct tooth bearing “footprint” have been obtained.
It is normally necessary to check the tooth bearing “footprint” only if it is
impossible to determine the correct gasket thickness in any other way.
Instead, it is usually sufficient to check the thickness of the old gasket and
follow the directions given in section 8.3.10 Preparation for the installation
of a complete pinionshaft assembly.
Checking the tooth bearing “footprint”
If the gear set, the pinionshaft, the pinionshaft housing or the bottomshell has
been replaced, the correct gasket thickness must be determined by checking
the tooth bearing “footprint”.
a) Start with the complete pinionshaft assembly and the mainshaft
assembly removed from the crusher.
b) Apply marking blue to the teeth of the pinion.
c) Install the pinionshaft assembly in the bottomshell, using gaskets giving
an uncompressed total gasket thickness of 1.8mm. Use two 0.5mm
gaskets and one 0.8mm gasket.
d) Tighten the attachment screws to the specified torque. See section
3.3.1 Required torque for threaded fasteners.
e) Install the eccentric assembly. See the appropriate parts of section
7.5.3 Install the eccentric assembly.
f) Rotate the pinionshaft (anti-clockwise, seen from outside) through 5 - 6
revolutions.
NOTE! This will be difficult to accomplish unless a bar is fitted at the outer end of
the pinionshaft to provide leverage.

g) Use a crane to lift the eccentric assembly far enough for an inspection to
be made of the teeth on the gear wheel and the pinion.
(Continued)

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The ideal tooth bearing “footprint” is obtained when the contact mark is
slightly high on the pinion and slightly low on the eccentric gear.
Under light load, the length of the “footprint” is usually half the length of the
teeth.
Under heavy load, the “footprint” usually moves towards the large end (the
“heel”, 4) of the tooth. The gears should therefore be adjusted so that the
“footprint” is nearer the small end (the “toe”, 5) of the tooth

1 Eccentric gear (1850-1)

1
2 Pinion (1850-2)
3 “Footprint”
4 Heel
5 Toe
2
3
4
5
Adjustment of the “footprint”
If the tooth bearing “footprint” (3) differs from the ideal, the meshing
between the teeth on the gear wheel and the teeth on the pinion can be
adjusted by moving the entire pinionshaft assembly inwards or outwards in
its seating in the bottomshell. This is accomplished by using gasket packages
of different thicknesses.
(Continued)

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If the tooth bearing “footprint” is at the large end of the pinion (near the
outside of the gear wheel), move the pinion outwards from the centre of the
eccentric gear. To do this, increase the thickness of the gasket package
between the pinionshaft housing flange and the bottomshell

Footprint at the larger end

If the tooth bearing “footprint” is at the small end of the pinion (toward the
inside of the gear wheel), move the pinion inwards towards the centre of the
eccentric gear. To do this, reduce the thickness of the gasket package
between the pinionshaft housing flange and the bottomshell.

Footprint at the smaller end

.
NOTE! When adding or removing gaskets, it is normally not necessary to take the
pinionshaft assembly completely out of the bottomshell. Remove the
attachment screws and pull the pinionshaft assembly a few mm outwards, so
that the gaskets are free.

(Continued)

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A gasket can be added by making a cut in the top of the new gasket and
carefully placing it between two of the gaskets already fitted.
A gasket can be removed by tearing it.
When the new gasket package thickness has been arranged, push the
pinionshaft assembly into position in the bottomshell and tighten the
attachment screws to the correct torque. Apply marking blue to the pinion
again. This can be done inside the bottomshell gear carrier if the eccentric
assembly is still lifted up.
Carefully lower the eccentric assembly into the correct position and check
the tooth bearing “footprint” again, as described in section 8.4.3 Tooth
bearing “footprint”.
If the tooth bearing “footprint” is still not correct, adjust the thickness of the
gasket package again, as described above.
If the tooth bearing “footprint” is correct, continue with the installation of the
pinionshaft assembly., as described in the relevant parts of section
8.2.4 Install the pinionshaft housing assembly.

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 9. Drive
This cone crusher normally has a V-belt drive. This section describes the
maintenance instructions for the V-belt drive.
To ensure maximum safety, always read section 2. Safety precautions before
you do any work on the equipment, or make any adjustments.

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MM Sandvik CH440:01 9. Drive

9.1 V-belt drive

Fixed guarding must be installed around the moving parts of the crusher’s
drive system of the crusher. This cone crusher has a V-belt drive, and it must
be possible to check the tension in the belts. The guarding must be designed
to comply with the applicable safety guarding regulations.
A V-belt drive, consisting of crusher pulley, motor pulley and a set of V-
belts, is supplied as standard with this cone crusher.
See the product manual for further maintenance instruction for the crusher
motor.

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MM Sandvik CH440:01 9. Drive

9.2 General
9.2.1 V-belt tension
During the first few days of operation, the belt tension must be checked
frequently since new belts stretch. If the belts are not tensioned sufficiently,
slipping can occur and the life time of the belt will be reduced considerably.
Proper belt tension can be determined with the help of the deflection load.
Check the deflection load with a spring balance or a special instrument, a
tensiometer or its equivalent.

Recommended deflection load (F)

F, kp/belt (lbf/belt)
Belt profile Normal Max. (newly fitted belts)
SPC 7 (15.4) 12.0 (26.5)
8V 9 (19.8) 14.0 (30.9)

Checking the deflection load with a tensiometer:

a) Measure the belt span (W) in meters, as shown below.
b) Multiply the span by 1.5, to give the belt deflection (D) in cm.
c) 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 belt in the middle of the span and press
sufficiently hard to bring the top side of the lower O-ring level with the
belt alongside.
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 belts, tighten or slacken
them.

F
2

1
6

1 F-scale
6 14 12 10 8

W
2 D-scale
D = deflection D
5

W = belt span F
4

F = deflection load 2
3
2

D
1

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9.3 Change V-belt guards

9.3.1 Remove V-belt guards
a) Remove the screws, the washers and the nuts from the guard sections (3).
b) Remove the guard sections.

3 4
3 V-belt guard
4 Inspection hatch 3

V-belt drive, right-hand layout.

The entire drive assembly can also be mounted on the left.

9.3.2 Install V-belt guards

When all adjustments are finished install the guards.
a) Position the guard sections (3) over the V-belt drive.
a) Install the screws, the washers and the nuts.

CAUTION! Do not start the motor/crusher before the V-belt guards have
been correctly installed.

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9.4 Change V-belts

The V-belts are subjected to wear. Worn V-belts may slip on the pulleys. This
can be taken care of by tightening the V-belts; refer to section 9.2.1 V-belt
tension for further information.
Occasionally a V-belt breaks or wears out and then Sandvik recommends
changing all V-belts at the same time.

9.4.1 Remove V-belts

a) Make sure the drive motor is properly locked out.
b) Remove the guard from the V-belt drive.
c) Slacken the nuts on the screws (4) that fasten the motor to the motor
beams.

4 Fastening screws
5 Adjusting screws

4 5

d) Push the motor (7) with the motor pulley (9) towards the crusher pulley
(8) on the motor beams (6).
e) Remove the worn V-belts (10) from the pulleys (9).

8
10 9
11
6 Motor beams 6
7 Motor 8
8 Crusher pulley
9 Motor pulley 7
10 V-belt
11 Spacer 6

V-belt drive, right-hand layout. The entire drive

assembly can also be mounted on the left.

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MM Sandvik CH440:01 9. Drive

9.4.2 Install V-belts

a) Clean both pulleys.
b) Make sure that the fastening screws have been loosened.
c) Install the V-belts (10) on the pulleys (8 and 9).
d) Push the motor (7) away from the crusher to tension the belts (10).
e) Check the alignment of the crusher pulley and the motor pulley with a
ruler/straight-edge (12). 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.
12

8 Crusher pulley
9 Motor pulley
12 Ruler/straight-edge

9 8

f) Check the tension of the V-belts (10). Refer to section 9.2.1 V-belt
tension.
g) Use the adjusting screws (5) to move the motor sideways to obtain
correct belt tension.

5 Screws

5 5

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. refer to section section 9.3.2 Install V-belt guards

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MM Sandvik CH440:01 9. Drive

9.4.3 Remove V-belt drive motor

a) Remove the screws (4) from the T-nuts.

4 Screws
6 Motor beams 6
7 Motor
8 Crusher
7

b) Position the hook of a crane vertically above the electric motor (7)
c) Attach suitable lifting slings and to the lifting eye bolts on the motor (7).
d) Attach the lifting slings to the hook.
e) Take up the slack in the lifting tackle.

Hanging load
The drive motor weighs up to 1 700 kg (3 800 lbs) if 50Hz/400V.
For different frequencies/valtages, refer to the machine label or the
DANGER! manufacturer’s documentation.
Handle the motor with care.
The tackle should now be tight but not lifting the motor.
Keep clear of hanging loads, see section 2. Safety precautions.

f) Lift the motor (7) away from the motor beams (6).
g) Mount the washers and the screws on the T-nuts. Do not tighten.

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MM Sandvik CH440:01 9. Drive

9.4.4 Install V-belt drive motor

a) Position the hook of a crane vertically above the electric motor (7)
b) Attach suitable lifting slings and to the lifting eye bolts on the motor (7).
c) Attach the lifting slings to the hook.
d) Take up the slack in the lifting tackle.

Hanging load
The drive motor weighs up to 1 700 kg (3 700 lbs)if 50Hz/400V.
For different frequencies/valtages, refer to the machine label or the
DANGER! manufacturer’s documentation.
Handle the motor with care.
The tackle should now be tight but not lifting the motor.
Keep clear of hanging loads, see section 2. Safety precautions.

e) Lower the motor (7) on to the motor beams(6).

f) Mount the washers and the screws on the T-nuts. Do not tighten.
g) Install the V-belts, align the motor (7), tension the V-belts (8), refer to
section 9.4.2 Install V-belts and tighten the screws and T-nuts.

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 10. Start-up after maintenance
This section describes instructions for an overhauled cone crusher.
To ensure maximum safety, always read section 2. Safety precautions before
you do any work on the equipment, or make any adjustments.

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MM Sandvik CH440:01 10. Start-up after maintenance

10.1 Check list for an overhauled cone 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. Refer to
Mechanical installation and connections in the Installation manual.
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.
d) Fill the lubrication tank and the Hydroset tank with oil. Refer to
Lubrication in the Operator’s manual, for oil quality and oil quantity.

Oil products
Oil products present environmental and fire risks and can cause injury
if inhaled or brought into contact with the skin. Follow your lubricant
WARNING! supplier’s instructions and safety directions when handling oils and
greases.

NOTE! Use the same type of oil in the Hydroset tank and the lubrication tank, but
with different viscosity.

e) Switch on the oil heaters.

NOTE! Before starting an overhauled crusher, fill the pinionshaft housing with oil.

f) Check that the spider bearing is filled with grease to the top of the
bushing, when the mainshaft is in its lowest position. Refer to
Lubrication in the Operator’s manual, for grease recommendations.
g) Check that the spider bearing seal does not leak.
h) Check the direction of rotation of the motor on the lubrication oil pump.
Refer to Oil pump in the Operator’s manual.
i) If the crusher is fitted with an air/oil heat exchanger, check the direction
of rotation of the fan motor and the air flow direction. Air should be
drawn through the cooler matrix.
j) If the crusher is fitted with a water/oil heat exchanger, check that there is
a sufficient flow of cooling water.
k) Start the crusher's main lubrication oil pump and check that there is no
leakage in the oil lines. Run the pump for about 30 minutes, then clean it
from any contaminants (e.g. remnants of sealing compound etc.) that
have collected on the return oil strainer. Start the pump again.
(Continued)

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MM Sandvik CH440:01 10. Start-up after maintenance

l) Slightly raise and lower the mainshaft several times, and check that the
electrical setting control circuits are correctly connected.
m) Bleed all air out of the Hydroset system. Refer to section 4.2.5 Bleeding
air from the Hydroset system.
n) Lower the mainshaft 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.
o) Raise the mainshaft between 10 and 15 mm (0.4 to 0.6") from its lowest
position.
p) Check that the crusher’s drive is correctly aligned. Check that the V-belts
are correctly tensioned. Refer to section 9.2.1 V-belt tension.
q) Start the crusher's drive motor and check that the direction of rotation is
correct. Refer to section 9. Drive. Run the crusher without load until the
return oil temperature reaches about 40°C (104°F).
r) Check the operation of the return oil flow switch and, if necessary, make
an adjustment. Refer to Return oil flow switch in the Operator’s manual.
s) Bleed the Hydroset system again. Refer to section 4.2.5 Bleeding air
from the Hydroset system.
t) Depress the float on the return oil flow switch (-OG1). The crusher's
drive motor must stop.
u) The crusher's drive motor must also stop if there is a high temperature
alarm from the protective thermostat (-TG1). 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 Hydroset
and lubrication system in the Operator’s manual.
v) Stop the crusher's drive motor and the lubrication pump.

CAUTION! The lubrication pump must never be stopped until the crusher has
stopped completely.

w) Clean the return oil strainer.

x) Check that material cannot be fed to the crusher unless both the crusher
and the discharge system are running.

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