CJ615-01 MM S222.164.en-04

maintenance manual S 222.164.
en
SANDVIK CJ615:01
This document is valid for:
Serial no. / Machine no. Sign.
SANDVIK CJ615:01
© Copyright 2010 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: S222.164.en

Original instructions
Issue: 20110112
Version: 04
Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409060
www.sandvik.com
Table of contents
1. Introduction
1.1 Equipment information.......................................................... 6
1.1.1 Document information.............................................. 8
1.1.2 Description ............................................................... 9
2. Safety precautions
2.1 Hazard information ............................................................. 12
2.1.1 Warning signs ........................................................ 12
2.1.2 Risk levels.............................................................. 12
2.1.3 Prohibition signs..................................................... 13
2.1.4 Mandatory signs..................................................... 13
2.1.5 Personnel............................................................... 13
2.1.6 Personal protection ................................................ 14
2.2 General safety precautions................................................. 15
2.2.1 Machine safety guards........................................... 16
2.2.2 Machine access ..................................................... 16
2.2.3 Electrical safety...................................................... 17
2.2.4 Welding .................................................................. 17
2.2.5 Hydraulic systems.................................................. 18
2.2.6 Lubrication system ................................................. 18
2.2.7 Lifting and moving loads ........................................ 19
2.2.8 Feed and jams ....................................................... 20
2.3 Emissions ........................................................................... 21
2.3.1 Dust........................................................................ 21
2.3.2 Noise...................................................................... 22
2.3.3 Radioactivity........................................................... 22
3. Basic maintenance instruction

3.1 General ............................................................................... 24
3.2 Preventive maintenance ..................................................... 24
3.2.1 Routine inspection and care .................................. 24
3.2.2 Periodical maintenance.......................................... 24
3.3 Spare parts in this manual .................................................. 25
3.4 Recommended tool box...................................................... 26
3.5 Tightening threaded fasteners ............................................ 27
3.5.1 Requirements for joints with threaded fasteners.... 27
CJ615:01 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 3

Table of contents
4. Setting adjustment system

4.1 Exchanging spring retraction assembly .............................. 30
4.1.1 Remove spring retraction assembly ....................... 31
4.1.2 Install spring retraction assembly ........................... 31
4.2 Exchanging toggle plate and toggle seats .......................... 32
4.2.1 Remove toggle plate and toggle seats ................... 33
4.2.2 Install toggle plate and toggle seats ....................... 35
5. Flywheels
5.1 Exchanging flywheels ......................................................... 40
5.1.1 Removing flywheel ................................................. 41
5.1.2 Installing flywheel ................................................... 43
6. Bearings
6.1 Exchanging bearings .......................................................... 46
6.1.1 Removing moving jaw ............................................ 46
6.1.2 Installing moving jaw .............................................. 48
6.1.3 Removing frame bearings ...................................... 49
6.1.4 Installing frame bearings ........................................ 51
6.1.5 Removing moving jaw bearings ............................. 55
6.1.6 Installing moving jaw bearings ............................... 57
7. Setting hydraulics (option)

7.1 Exchanging spring retraction assembly .............................. 60
7.1.1 Remove spring retraction assembly ....................... 61
7.1.2 Install spring retraction assembly ........................... 62
7.2 Exchanging toggle plate and toggle seats .......................... 63
7.2.1 Remove toggle plate and toggle seats ................... 64
7.2.2 Install toggle plate and toggle seats ....................... 66
4 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 CJ615:01

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

1. Introduction
1.1 Equipment information

Purpose
The purpose of this Sandvik equipment is to be a crusher component in a
crushing and screening unit or site within an aggregate or mining process. It
can also be configured as a stand-alone machine complete with motor, motor
support, V-belts and pulley, and guards. The machine reduces the size of
rocks, minerals and similar materials. This jaw crusher component has been
exclusively designed for these applications. It is not the responsibility of
Sandvik SRP AB to secure the design and usage for the complete aggregate
or mining process. Sandvik SRP AB will not accept any liability for damage
to equipment or injury to personnel caused by unauthorized or improper use
or modification of this equipment.
Manufacturer
This Sandvik equipment has been manufactured by:
Sandvik SRP AB
Stationsplan
SE-233 81 Svedala
Sweden
www.sandvik.com
For maintenance
Contact the nearest Sandvik company, agent or representative, or the
manufacturer directly:
Sandvik SRP AB
Service department
SE-233 81 Svedala
Sweden.
Telephone +46 (0)40 40 90 00
Telefax +46 (0)40 40 92 60

1. Introduction
Identification
The figure below shows an example of the crusher’s identification plate. The
identification plate contains data needed when contacting Sandvik SRP AB
concerning this specific equipment.
Enter the serial number of the associated machine in the intended field on the
second page of this manual (the copyright page).
8
7
1 2 3 4 5 6
1 Machine type
2 Part number
3 Serial number
4 Mass (kg)
5 Order number
6 Manufacturer
7 Year of manufacture
8 CE mark
CE marking
This equipment complies with the basic health, environment and safety
regulations of the European Union and European Economic Area. Sandvik
SRP AB will not take responsibility for this compliance when a customer
modifies the jaw crusher in any way.

1. Introduction
1.1.1 Document information

Purpose of this Maintenance manual
The instructions in this manual are valid only for maintenance personnel
trained or authorized by Sandvik. The purpose of this Maintenance manual is
to provide maintenance personnel with:
• information on all scheduled maintenance procedures listed in the
checklists
• information for unscheduled maintenance such as:
– additional maintenance procedures
The structure, codes and descriptions of this manual are used in the Spare
parts catalog (SPC) and in the checklists.
It is important to:
• keep the manual for the lifetime of the equipment
• pass the manual on to any subsequent holder or user of the equipment
Document compliance
The instructions in this document are in accordance with the design and
construction of the equipment at the time it was delivered from the Sandvik
SRP AB manufacturing plant.
Technical publications
Technical publications related to installation and operation of this equipment
are:
• Installation manual (IM)
• Wear parts catalog (WPC)
• Operator’s manual (OM)
Technical publications related to maintenance of this equipment are:
• Maintenance manual (MM)
• Spare parts catalog (SPC)
These publications are only available to trained maintenance personnel.
Sandvik SRP AB can provide adequate training and authorize personnel.
Read more about the document structure and accompanying work roles in
section 2.2 Personnel.
When ordering technical publications, always specify the language and quote
the machine serial number.
Number of pages
This document contains a total of 66 numbered pages.
Feedback
If you have comments on this Maintenance manual or problems connected to
the jaw crusher’s documentation, send an e-mail to:
manuals.srp@sandvik.com

1. Introduction
1.1.2 Description
The following drawings show an overview of the jaw crusher’s nomenclature
and components.
Bottom view
1 Flywheel
2 Eccentric shaft
(concealed)
3 Frame 1
4 Front frame end
5 Fastening for cheek plate 2
6 Foot
7 Setting adjustment system
(concealed) 3
8 Support bar
9 Retraction rod 4
10 Back frame end
11 Retraction spring
5
12 Guard
7 8 9 10 11 12
Top view
13 Bearing housing 13
14 Moving jaw 14
15 Counterweight
16 Deflector plate
15
17 Clamping bar 16 17 18 19 20
18 Cheek plate
19 Jaw plate – moving
20 Jaw plate – stationary

1. Introduction
This page is intentionally left blank

To ensure maximum safety, always read this section carefully before carry-
ing out any work on the equipment or making any adjustments.

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, levels of risk are indicated as “DANGER”,
“WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels
are accompanied by a warning sign (see above).
Failure to observe information marked “DANGER!” can result in 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!

2.1.3 Prohibition signs
Do not remove
guards
2.1.4 Mandatory signs
Disconnect current Read the manual

before any work
2.1.5 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. 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 as belonging to one of three categories – work roles – based on
different competence profiles. These three work roles are:
• Installation
• Operation
• Maintenance

Sandvik provides technical documentation appropriate to all three work

roles:
• Installation manual
• Operator’s manual
• Maintenance manual and Spare parts catalog
Sandvik can provide adequate training for all three work roles and can carry
out authorization of trained personnel.
The technical documentation from Sandvik 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 declines all responsibility for injury or damage resulting from non-
compliance with the instructions in this manual.
2.1.6 Personal protection

Sandvik strongly recommends that personal protective equipment is always
worn when working in the vicinity of the equipment.
The Sandvik recommendation for personal protective equipment includes:
Ear protection Safety helmet Eye protection
Protective gloves Safety boots Mask or breathing

apparatus

2.2 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 crusher, unless necessary for maintenance work.
Dangerous work
Never stand inside the crushing chamber when heavy parts (e.g. jaw
plates and cheek plates) are being lifted out or in.
WARNING!
Risk of crushing
Never remain on the crusher while crushing. Moving parts constitute a
risk of crushing. Falling into the crusher implies danger of being
DANGER! crushed.
Ejection
Never look into the crusher while crushing. Fragments and possibly
harmful matter fed to the crusher may be ejected.
WARNING!

2.2.1 Machine safety guards

Do not remove guards
Make sure that all guards are in place and functioning, to prevent
exposure to flying fragments and rotating parts. Never operate the
PROHIBITION! equipment unless guards are mounted.
Rotating parts
Exposure to rotating parts of the equipment shall be prevented by
guards. Always attach guards after maintenance work.
WARNING!
Flying fragments
Fragments ejected upwards may fall down in the vicinity of the
crusher. 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 recommends additional protection.
NOTE! To prevent the ejection of large stones the feed hopper should be equipped
with a pivoted stone guard. The stone guard must not be raised during
crushing.
Make sure all defective guards and dust sealing components are checked,
repaired and replaced before starting the equipment.
2.2.2 Machine access

Every machine requires access for personnel who carry out inspections and/
or maintenance work. Suitable access platforms and guard rails shall 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.)
Areas where access is required are indicated on installations drawings, see
the Installation manual.

2.2.3 Electrical safety

CAUTION! Only electrical personnel working according to European Standard
EN 50110 or similar are permitted to perform electrical operations on
the crusher.
Dangerous voltage
Personnel must regard all electrical equipment as live until it is proven
dead by proper testing procedures.
DANGER!
Make sure all broken or damaged electrical cables and connectors are
checked, repaired and replaced before starting the equipment.
Control cabinets must be lockable.
2.2.4 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 Sandvik
service personnel must be consulted.
CAUTION! Only welders qualified according to European Standard EN 287 or

similar are permitted to perform welding operations on the crusher.
If welding an item to the crusher, 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 can be dangerous to health. 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.

2.2.5 Hydraulic systems

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 get very hot in operation. Allow the oil to cool before
working on the hydraulic system. Equipment and hoses/pipes
WARNING! containing hydraulic oil may be hot on surface.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired
and replaced before starting the equipment.
Risk of crushing
Never touch or alter hydraulic cylinders when the equipment is in
operation. The hydraulic cylinders may suddenly change position.
WARNING! Always keep body parts away from hydraulic cylinders in operation.
2.2.6 Lubrication system

CAUTION! Equipment and hoses/pipes containing lubrication oil may be hot on
surface.
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.

2.2.7 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 from a hanging load.
DANGER!
Make sure that the capacity of the lifting equipment is adequate and that the
equipment itself 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 floor
quickly and safely in an emergency.
When depositing loads, keep the lifting equipment in place until the stability
of the load has been checked.

2.2.8 Feed and jams

CAUTION! When the crushing chamber is empty, avoid feeding solitary large
boulders into the upper part of the chamber. In unfavorable
circumstances the moving jaw may be pushed forward and bring the
toggle plate out of position.
CAUTION! Never feed combustible process material into the crusher.

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 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.
If it is possible, change the direction of rotation of the jaw crusher’s flywheel

for a while to clear a jam. Always return to the normal rotation direction
when the jam has been cleared.
In some cases it is also possible to increase the CSS (closed side setting)
temporarily to clear a jam.
CAUTION! If a hydraulic hammer is installed, never use it to fracture stones in the
crushing chamber. This may seriously damage bearings or other vital
components.
However, Sandvik recommends that a jam in the feed opening is cleared by

using a hydraulic hammer. If a blockage occurs, use the hydraulic hammer to
poke the stones to clear the blockage. A hydraulic hammer can also be used
to knock off corners and edges from slightly oversized stones so that they
can enter the crushing chamber.
Always follow local regulations when attempting to clear a jam.

2.3 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 for example specific regulation
applying to dust emission, asbestos, quartzite, radon etc.
2.3.1 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 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 declines all responsibility for any health hazards caused by dust,
generated when processing minerals in the crusher.

2.3.2 Noise
Health hazards
Crushing and processing material will create noise. Such noise can be
more or less dangerous to the hearing. Use ear protection.
WARNING!
Refer to OM - Technical specifications for measured noise levels and
measurement conditions.
Rubber compression mountings and dust encapsulation result in lower noise
levels.
2.3.3 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 declines all responsibility for any health hazards caused by the
release of radon or any other harmful substances when processing minerals
in the crusher.

3. Basic maintenance
instruction
This section describes the basic maintenance instruction for the jaw crusher.

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

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

This list is a complement to section 5. Inspection and care in the Operator’s
manual. All service intervals are based on estimations of average wear.
Section Intervals (oper- Instruction Note

ating hours)
4.1, 7.1 6 000 Exchange spring retraction arrange-
ment
4.2, 7.2 – Exchange toggle plate and toggle Worn 20 mma
seats and check the retraction cylin-
der and its bushings
6.1 > 15 000 Exchange frame bearings when unu- Must only be executed by
sual noise is heard certified personnel.
6.1 > 20 000 Exchange moving jaw bearings when Must only be executed by
unusual noise is heard certified personnel.
a. Compare with the original length in the Spare parts catalog

3.3 Spare parts in this manual

Description Cat. No. Quantity See section
Spring 7002-0 2 4.1, 7.1
Retraction rod 7001-0 2 4.1, 7.1
Nut M6M M56 7010-1 4 4.1, 7.1
Nut M6M M56 7008-1 4 4.1
Retraction cylinder bushing 7052-0 2 4.1
Toggle plate 5006-0 1 4.2, 7.2
Toggle seat, upper 5004-0 1 4.2, 7.2
Toggle seat, lower 5005-0 1 4.2, 7.2
Flywheel, flat 2205-0 1 5.1
Flywheel, grooved 2206-0 1 5.1
Roller bearing, frame 2006-0 2 6.1.4
Spiral pins 2201-1 6 6.1.4
V-ring 2010-1 2 6.1.4
V-ring 2007-1 2 6.1.4
Roller bearing, moving jaw 2101-0 2 6.1.6
V-ring 2104-1 2 6.1.6

3.4 Recommended tool box

The following is a list of recommended tools for use during maintenance
work.
Tool Used for
85 mm Open end wrench Spring retraction arrangement
24 mm Open end wrench Spring retraction arrangement
4 mm Allen key Spring retraction arrangement (Setting hydraulics)
Bushing press Retraction cylinder bushing
Chain block Toggle plate and toggle seats
20 mm Round iron Toggle plate and toggle seats
18 mm Open end wrench Toggle plate and toggle seats
Wooden wedges Toggle plate and toggle seats
Chopping bit Flywheels
Hydraulic nut HMV 52 Flywheels
18 mm Combination wrench Flywheels
Extractor Flywheels
Hydraulic pump with manometer Flywheels
Deep gauge Flywheels
Dial indicator Flywheels
Hammer Flywheels / Frame bearings
Hook wrench Flywheels / Frame bearings
65 mm Open end wrench Moving jaw
Hydraulic nut HMV 80 Frame bearings
Hydraulic nut HMV 70 Frame bearings
Soft hammer Frame bearings
Feeler gauge Frame bearings
Gas torch Frame bearings
36 mm Open end wrench Frame bearings / Moving jaw bearings
Sledge hammer Moving jaw bearings
Copper punch Moving jaw bearings
Crow bar –
Lifting tackle and chain –
Lifting sling –
Mobile crane –

3.5 Tightening threaded fasteners

Unless otherwise specified, the threaded fasteners used in the crusher must
be tightened to the correct torque for the size in question.
STRENGTH GRADE (SS-ISO 898/1)
THREAD M 8.8 Bright zinc-coated
mm Nm ft lbs
8 21 15
10 40 30
12 70 52
16 169 125
20 331 244
24 572 422
30 1130 833
36 1960 1446
42 3130 2309
48 4690 3459
3.5.1 Requirements for joints with threaded fasteners

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


This section describes the scheduled maintenance work for the Setting
adjustment system.

NOTE! If the jaw crusher is equipped with the setting hydraulics option, this chapter
is replaced by section 7. Setting hydraulics (option).
4.1 Exchanging spring retraction assembly

The following spare parts are required:
Description Cat. No. Qty. Remarks

Spring 7002-0 2 L0 (spring’s length uncompressed) = 545 mm and
Smin (reduction of the spring’s length) = 80 mm
Retraction rod 7001-0 2

Nut M6M M56 7010-1 4
Nut M6M M56 7008-1 4
7200-0 Guard
7100-0 Hydraulic jack
7201-0 Screw
7008-1 Nut
7008-0 Yoke
7010-1 Nut
7003-0 Spring guide
7002-0 Spring 7201-0
7001-0 Retraction rod
7011-0 Retraction assembly
7200-0
frame 7008-1
7000-0 Pin
1 Bracket 7008-0
7100-0
7010-1
1 7000-0 7001-0 7011-0 7002-0 7003-0
Risk of crushing
Never stand behind or below the retraction system when work is
carried out. Due to fatigue the spring or retraction rod can be thrown
DANGER! backwards. If the guard is removed, always replace it when the work is
done.

4.1.1 Remove spring retraction assembly

Recommended tools a) Compress the springs (7002-0) with the hydraulic jack (7100-0) until it
Crow bar is possible to loosen the nuts (7010-1) that hold the springs.
Lifting tackle and chain b) Use an open end wrench to loosen the nuts.
Lifting sling
Mobile crane
c) Release pressure in the hydraulic jack (7100-0) until the springs are no
85 mm Open end wrench
longer compressed.
24 mm Open end wrench d) Remove the guard (7200-0) by unscrewing the screws (7201-0).
e) Remove the nuts (7008-1) and the yoke (7008-0) with the hydraulic
jack (7100-0).
f) Remove the nuts (7010-1), spring guide (7003-0) and springs (7002-0).
g) Remove the retraction rod (7001-0) by dismantling the pin (7000-0).
4.1.2 Install spring retraction assembly

a) Clean the retraction rod brackets (1)
b) Install the retraction rods (7001-0) by mounting the pins (7000-0).
NOTE! The retraction rod must not touch the retraction assembly frame (7011-0)
when the crusher is running.
c) Install the springs (7002-0), the spring guide (7003-0) and the
nuts (7010-1) on the retraction rod. Do not tighten the nuts yet.
d) Install the guard (7200-0) with the screws (7201-0).
e) Mount the yoke (7008-0) with the hydraulic jack (7100-0) on the
retraction rod and tighten with one nut (7008-1) on each side of the yoke.
f) Use the hydraulic jack with the spring guide (7003-0) to compress the
springs to the recommended initial length (see table above).
g) Tighten the nuts (7010-1).
h) Release pressure in the hydraulic jack.
CAUTION! The pressure in the hydraulic jack must be released before starting the
crusher.
CAUTION! Make a performance test of the setting adjustment system by running

the crusher without load. Listen for abnormal noises. A clattering noise
can indicate that the springs are not sufficiently tightened. Tighten the
springs further according to the instructions above until the noise
disappears.

4.2 Exchanging toggle plate and toggle seats

Description Cat. No. Qty. Remark
Toggle plate 5006-0 1 weight 800 kg
Toggle seat, upper 5004-0 1 weight 130 kg
Toggle seat, lower 5005-0 1 weight 130 kg
NOTE! There are toggle plates of different lengths to choose from. The chosen length
depends on what setting the crusher will be operated at and if the crusher is
equipped with a jaw shim plate. Also, if a crusher is equipped with a
hydraulic setting adjustment system this will have affect on which toggle
plate should be chosen.
NOTE! Adjust to maximum CSS before releasing the retraction springs to facilitate
removal of the toggle plate and toggle seats. If the crusher is equipped with
shims these must be removed before exchanging the toggle plate and toggle
seats. See section 8. Setting adjustment system in the Operator’s manual.
CAUTION! The crusher must be stopped and the retraction assembly must be
removed when exchanging the toggle plate and toggle seats.
5013-0
5013-0 Toggle seat retainer 5014-0
5014-0 Screw 5003-0
5003-0 Toggle seat holder 5004-0
5004-0 Upper toggle seat
7002-0 Springs
5006-0 Toggle plate
5005-0 Lower toggle seat
3000-0 Moving jaw
7100-0
7002-0
3000-0 5005-0 7001-0 5006-0

4.2.1 Remove toggle plate and toggle seats

a) Position the hook of a mobile crane vertically above the toggle
Recommended tools plate (5006-0).
Crow bar
Lifting tackle and chain
b) Connect the lifting device to the toggle plate (5006-0) from above. Use
Lifting sling the two elliptical holes (4) for the lifting sling (2).
Mobile crane c) Take up the slack in the lifting tackle.
20 mm Round iron
Wooden wedges
Chain block
2
1 Bracket
2 Lifting sling
3 Wooden wedge
4 Holes in toggle plate
4
1
Hanging load
Be aware of the weight of the toggle plate, see table above. Handle the
toggle plate with care. The tackle should now be tight but not lifting the
DANGER! toggle plate. Keep clear of hanging loads, see section 2. Safety
precautions.
d) Loosen the spring retraction arrangement as described in section

4.1.1 Remove spring retraction assembly.
e) Attach a chain block to the retraction rod bracket (1). Let the chain pass
under the jaw crusher’s discharge opening and tighten it to a position in
front of the jaw crusher.
f) Place two wooden wedges (3) between the moving jaw and back frame
end to prevent the moving jaw from falling back.
(Continued)

g) To prevent the toggle seat holder from falling down insert a round
iron (5) through the hole (6) in the frame and under the toggle plate so
that the toggle seat holder can rest on the iron.
h) Pull the jaw forward using the chain.
5 Round iron
6 Hole
5006-0 Toggle plate
5
5006-0
i) Lower the toggle plate (5006-0) to the surface.

NOTE! Apply a crow bar or wedges if the toggle plate (5006-0) gets stuck. Never use
arms or feet.
j) Release the lifting device from the toggle plate and remove the toggle
plate from the jaw crusher.
k) Use the round iron as a guide and pull out the toggle seat holder (5003-0)
half way through the hole (6).
l) Connect the toggle seat holder to a lifting sling and withdraw it from the
crusher.
m) Unscrew the toggle seat retainers (5013-0), (5013-1) on both ends of the
toggle seat holder with an open end wrench.
n) Remove the toggle seat from the toggle seat holder.
o) Remove the lower toggle seat (5005-0).
p) Note the position of the lower toggle seat’s thicker flange (top or bottom)
so that it comes in the same position when it is reinstalled.

4.2.2 Install toggle plate and toggle seats

NOTE! Before starting this procedure, it is necessary to secure the moving jaw as
described in section 4.2.1 Remove toggle plate and toggle seats items e–f and
to remove the springs (7002-0) and retraction rod (7001-0) as described in
section 4.1.1 Remove spring retraction assembly.
a) Wash the new toggle plate (5006-0) and the new toggle
seats (50040), (5005-0).
b) Clean the slots where the upper and lower toggle seats fit.
c) Install the lower toggle seat (5005-0). Make sure the thicker flange of the
lower toggle seat is in the same place as when it was removed.
5013-0
5013-0 Toggle seat retainer 5014-0
5014-0 Screw 5003-0
5003-0 Toggle seat holder 5004-0
7002-0 Springs
5006-0 Toggle plate
3000-0 Moving jaw
7100-0
7002-0
3000-0 5005-0 7001-0 5006-0

d) Push the upper toggle seat (5004-0) into the toggle seat holder (5003-0).
e) Fasten the toggle seat retainers (5013-0), (5013-1) on both ends with
screws (5014-0) and washers (5014-2).
f) Connect the toggle seat holder to a lifting sling.
g) Insert a round iron into the hole (6) in the frame.
(Continued)

h) Use the round iron as a guide and insert the toggle seat holder into
correct position.
i) Disconnect the lifting sling from the toggle seat holder.
j) Connect the lifting device to the toggle plate (5006-0). Use the two
elliptical holes (4) for the lifting sling (2).
Hanging load
precautions.
k) Carefully lift the toggle plate (5006-0) below the back frame end.
l) Lower the toggle plate to the surface.
m) Release the lifting sling (2) from the hook.
n) Reconnect the lifting sling (2) to the hook, this time through the back
end frame.
o) Lift and drag the toggle plate (5006-0) so it comes in position under the
back frame end.
p) Lift the toggle plate (5006-0) gently.
5003-0 Toggle seat holder

5006-0 Toggle plate
2
2 Lifting sling
5003-0
5004-0
5005-0 5006-0
(Continued)

q) Position the back of the toggle plate (5006-0) in the upper toggle
seat (5004-0).
r) Lift up the lower end of the toggle plate in line with the lower toggle
seat (5005-0).
NOTE! Use a crow bar if the toggle plate gets stuck. Never use arms or feet.
s) Adjust the dust curtain.
t) Remove the wooden wedges (3).
u) Move the moving jaw slowly backward and make sure that the toggle
plate fits in the toggle seat (5005-0).
v) Check that the toggle plate (5006-0) and dust curtain are seated correctly.
NOTE! Pull the jaw slightly backwards if needed to adjust the toggle plate or dust
curtain into correct position.
w) Slacken off the chain used to lock the moving jaw (3000-0) and remove
it.
x) Slacken off the lifting tackle and remove the lifting sling (2).
y) Install the spring retraction arrangement as described in section
4.1.2 Install spring retraction assembly.


5. Flywheels
This section describes the scheduled maintenance work for the flywheels and
the tools to use.

5. Flywheels
5.1 Exchanging flywheels

Flywheel, flat 2205-0 1 weight 3000 kg
Flywheel, grooved 2206-0 1 weight 3000 kg
The jaw crusher has a flywheel (2205-0), (2206-0) on each side of the frame.
One of these is used for the drive and this flywheel is grooved for V-belts
(2206-0). The dimensions of the flywheels are chosen to ensure that the jaw
crusher runs smoothly and evenly, even under heavy loads. The two
flywheels can switch places with each other. The jaw crusher is balanced and
tested before shipping.
NOTE! The following instructions are for exchange on one side. Repeat the
procedure for the other side.
CAUTION! If the flywheels are to switch places with each other it is important to
change also the counterweights (2212-0). These are mounted inside the
flywheel rim at an angle ahead of the flywheel’s line of symmetry, in the
direction of rotation (see figure below). With the counterweights in the
wrong position there will be vibrations in the jaw crusher.
26
2206-0
1
2212-0
2212-0 Counterweight (concealed)

2206-0 Flywheel grooved for V-belts
1 Lightening holes
NOTE! The hydraulic nut and the extractor mentioned in the following instruction
can be hired from Sandvik.
NOTE! Never grease the flywheels’s V-belt grooves. If lubricant comes in contact
with the flywheel, clean it off with a degreasing agent.
Risk of crushing
Always use the appropriate tools for exchanging flywheels. If the
flywheel is mounted incorrectly, there is a risk that the flywheel can
WARNING! come off unintentionally.

5. Flywheels
5.1.1 Removing flywheel

Recommended tools a) Remove the guards over the V-belt drive and/or flywheel.
Hammer b) Remove the V-belts, if applicable.
Chopping bit
Hydraulic nut HMV 52
c) Remove the screws (2211-0) and washers (2211-2) that hold the end
18 mm Combination wrench
cover (2210-0) in place.
Extractor d) Position the hook of a mobile crane vertically above the flywheel.
Crow bar
e) Connect the lifting gear to the flywheel. Use a lightening hole (1) for the
Hydraulic pump
lifting sling.
Lifting sling f) Take up the slack in the lifting tackle.
Mobile crane g) Connect a second adjustable lifting gear to the flywheel and the lifting
hook. Use the lightening hole (1) on the other side of the counterweight
to balance the flywheel.
h) Take up the slack in the second lifting tackle.
Hanging load
Be aware of the weight of the flywheel, se table above. Handle the
flywheel with care. The tackle should now be tight. Keep clear of
DANGER! hanging loads, see section 2. Safety precautions.
i) Use a hammer to loosen the locking nut (2209-1) and remove the lug of
the locking washer (2209-4) that locks it.
2211-0 Screw
2211-2 Washer
2210-0 Cover
2209-1 Shaft nut 2211-0
2209-4 Tab washer 2211-2 2209-1 2208-0
2208-0 Spacer ring
2 Key way
3 Screw holes
2210-0 2209-4
2
3
(Continued)

5. Flywheels
j) Remove the locking nut (2209-1) and locking washer (2209-4) from the
threaded shaft.
k) Loosen the spacer ring (2208-0).
l) Fit the hydraulic nut (5) on the shaft, with the piston on the outside,
leaving a gap of 5 mm to the spacer ring (2208-0).
NOTE! The extractor has a lifting eye bolt (4). Use it for lifting.
m) Screw the extractor’s (6) studs into the threaded holes (3) in the
flywheel.
n) Loosen the flywheel’s fit on the shaft with the pump and hydraulic nut.
o) Disconnect the lifting gear from the flywheel and connect it to the
extractor plate.
p) Remove the extractor (6) from the shaft and place it on the ground.
q) Disconnect the lifting gear from the extractor plate and reconnect it to
the flywheel.
r) Remove the hydraulic nut (5).
s) Remove the spacer ring (2208-0).
t) Gently remove the flywheel from the shaft and place it horizontally on
the ground.
5
4 Lifting eye bolt
5 Hydraulic nut
6
6 Extractor

5. Flywheels
5.1.2 Installing flywheel

NOTE! Lock the other flywheel to prevent the eccentric shaft from rotating.
Recommended tools
Hammer a) Inspect and clean the key way (2), the key (2207-0) and the bore of the
Chopping bit flywheel.
b) Clean the seating on the shaft.
18 mm Combination wrench
Crow bar c) Lightly lubricate the sides of the key way on the flywheel.
Deep gauge NOTE! Do not lubricate the whole bore.
Dial indicator
Hydraulic pump with manometer d) Position the hook of a mobile crane vertically above the flywheel.
e) Connect two lifting gears to the flywheel. Use lightening holes (1) for
Lifting sling
Mobile crane
the lifting slings on both sides of the counterweight (2212-0). The
Hook wrench
second lifting gear must be adjustable so that the flywheel can be aligned
with the key in the shaft.
f) Lift the flywheel and slide it into position on the shaft with the key
(2207-0) in the key way (2).
Hanging load
Be aware of the weight of the flywheel, see table above. Handle the
flywheel with care. The tackle should now be tight. Keep clear of
DANGER! hanging loads, see section 2. Safety precautions.
g) Push the flywheel up onto its seating and install the spacer ring (2208-0).
2211-0
2211-2 2209-1 2208-0
2211-0 Screw
2211-2 Washer
2210-0 Cover
2209-1 Shaft nut
2209-4 Tab washer
2208-0 Spacer ring
2 Key way
3 Screw holes
2210-0 2209-4
2
3
(Continued)

5. Flywheels
NOTE! To ensure full metallic contact it is necessary to adjust the vertical position of
the flywheel.
h) Fit a hydraulic nut (5) on the shaft, with the piston on the inside.
i) Tighten the hydraulic nut manually so the bore of the flywheel comes in
full metallic contact with the taper on the shaft.
j) Slacken off the lifting tackle.
k) Pump the hydraulic nut to 6 MPa.
l) Install a dial indicator.
m) Measure with a depth gauge as well.
n) Pump up the hydraulic nut to push up the flywheel 1.4–1.6 mm on the
taper.
o) Leave the hydraulic nut in place under pressure for 30 minutes.
p) Remove the hydraulic nut (5) from the shaft.
q) Ensure correct axial displacement by measuring with a depth gauge
again.
r) Fit the tab washer (2209-4) and shaft nut (2209-1).
s) Tighten the shaft nut (2209-1) with a hook wrench.
t) Bend down a lug on the tab washer (2209-4) into the slot on the shaft
nut.
u) Grease the parts to prevent corrosion.
v) Fit the end cover (2210-0) with the screws (2211-0) and washers
(2211-2).
w) Remove the lifting gear.
x) Install the V-belts, if applicable.
Risk of crushing
Exposure to rotating parts of the equipment shall be prevented by
guards. Always attach guards after maintenance work.
WARNING!
y) Install the guards over the V-belt drive and/or flywheel.
NOTE! Remove the lock from the other flywheel.
z) Run the jaw crusher without load for a while to test the function before
crushing.

6. Bearings
This section describes the scheduled maintenance work for the bearings and
the tools to use.

6. Bearings
6.1 Exchanging bearings

The crusher has four spherical roller bearings on the eccentric shaft. The
moving jaw bearings have cylindrical bores while the frame bearings have
tapered bores and are consequently installed on tapered withdrawal sleeves.
If trouble occurs in an eccentric shaft bearing, try to determine if it’s in the
frame (outer) bearing or in the moving jaw (inner) bearing. The bearing
temperature or unusual noise from the bearing gives an idea of the situation.
CAUTION! The exchange of the bearings must be executed by certified personnel.
CAUTION! It is important that correct tools are used when maintenance work is
being executed on the bearings.
NOTE! The hydraulic nuts mentioned in the following instructions can be hired from
Sandvik.
6.1.1 Removing moving jaw

a) Remove the spring retraction arrangement and toggle plate. See section
4.1.1 Remove spring retraction assembly and section 4.2.1 Remove
Recommended tools toggle plate and toggle seats.
Crow bar
b) Remove the flywheels. See section 5.1.1 Removing flywheel.
65 mm Open end wrench c) Remove the screws (2004-0), washer and twin nuts (2004-7) that clamp
the bearing housings to the frame.
d) Position the hook of a mobile crane vertically above the moving jaw
(3000-0).
e) Connect the lifting gear to the lifting lug (1) on the moving jaw (3000-0)
and take up the slack in the lifting tackle.
Hanging load
A moving jaw weighs up to 22500 kg. Handle the moving jaw with care.
The tackle should now be tight. Keep clear of hanging loads, see
DANGER! section 2. Safety precautions.
(Continued)

6. Bearings
f) Lift out the moving jaw (3000-0) with eccentric shaft (2200-0) and
bearings.
3000-0 1
3000-0 Moving jaw
2200-0 Eccentric shaft
2004-0 Screw
2004-7 Twin nut
1 Lifting lug
2200-0
2004-0
2004-7
g) Place the jaw horizontally on the ground with the flat side where the
deflector plate normally is fastened downwards.
h) If applicable, continue to dismantle the frame bearing and/or moving jaw
bearing according to section 6.1.3 Removing frame bearings and section
6.1.5 Removing moving jaw bearings.

6. Bearings
6.1.2 Installing moving jaw

a) Clean the contact surfaces on the frame sides, and the bearing seating in
the lower bearing housings.
b) Remove any corrosion.
c) Position the hook of a mobile crane vertically above the moving jaw
(3000-0).
d) Connect the lifting gear to the lifting lug (1) on the moving jaw (3000-0).
Hanging load
A moving jaw weighs up to 22500 kg. Handle the moving jaw with care.
The tackle should now be tight. Keep clear of hanging loads, see
DANGER! section 2. Safety precautions.
e) Lift the moving jaw (3000-0) and lower it into the frame.
f) Make sure that the eccentric shaft (2200-0) and frame bearing housings
are correctly aligned so that the V-rings do not jam in an incorrect
position.
g) Install the screws (2004-0), washer and twin nuts (2004-7).
h) Tighten to the correct torque, 3900 Nm, with a torque wrench.
NOTE! The torque above applies for bolts treated with Dacromet. Do not use bolts
treated with molybdenum disulphide.
NOTE! Lubricate the nuts with one string of oil.
Flying fragments
Never lubricate screws, washers or other contact surfaces. Do not
exceed the torque value stated above or the bolts could stretch and
WARNING! break due to excessive prestressing force.
i) Fit the flywheels. See section 5.1.2 Installing flywheel.

j) Clean and install the toggle plate. See section 4.2.2 Install toggle plate
and toggle seats.
k) Install the spring retraction arrangement. See section 4.1.2 Install spring
retraction assembly.
l) Adjust the discharge setting to the desired value. See section 5.6 Setting
measurement in the Operator’s manual.
m) Start up the crusher and press in grease as if the crusher was new. See
section 6. Lubrication of roller bearings in the Operator’s manual.

6. Bearings
6.1.3 Removing frame bearings

NOTE! The frame bearing housing is either locating or non-locating. The
instructions are valid for both locating and non-locating bearing housings.
The pictures describe the non-locating bearing housing.
NOTE! Lift out the moving jaw before removing the frame bearing. See section
6.1.1 Removing moving jaw.
NOTE! Sandvik recommends exchanging both frame bearings at the same time.
CAUTION! The work described in the instructions below requires experience and
special training from SKF. The exchange of the bearings must be
Recommended tools executed by certified personnel.
Crow bar
Lifting tackle and chain a) Clean all surfaces around the bearing housing. This is particularly
Hydraulic nut HMV 80 important if the bearing is to be re-used.
36 mm Open end wrench b) Remove the locking tab (2201-4) and shaft nut (2201-0).
Hammer
Hook wrench
c) Remove the screws (2009-0) that hold the labyrinth cover (2008-0).
Soft hammer d) Warm the labyrinth ring (2010-0) slightly with a gas torch.
Feeler gauge
e) Remove the labyrinth cover (2008-0) with the labyrinth ring (2010-0) by
Gas torch
levering carefully with a crowbar.
f) Remove the V-ring (2010-1) from the labyrinth ring (2010-0).
2006-0 2006-1 2009-0 2010-0 2201-4
2000-0 Bearing housing (non-locating)

2006-0 Roller bearing, frame
2006-1 Withdrawal sleeve
2009-0 Screw
2010-0 Labyrinth ring
2201-4 Locking tab
2008-0 Labyrinth cover
2010-1 V-ring
2011-0 Key 2000-0
2201-0 Shaft nut
2200-0 2008-0 2010-1 2011-0 2201-0
g) Remove the key (2011-0).

h) Measure the bearing play if the bearing is to be re-used.
(Continued)

6. Bearings
i) Connect the lifting device to the lifting eye (1) on the bearing housing
and take up the slack in the lifting tackle.
1
1 Lifting eye
2006-0 Roller bearing, frame 2006-0
2200-0 Eccentric shaft 2006-1
2200-0
2000-0
j) Remove the withdrawal sleeve (2006-1) with the hydraulic nut.
High pressure
Oil that sprays out with high pressure is very dangerous. Any leakage
in the hydraulic system must immediately be repaired.
DANGER!
NOTE! The removal of a large bearing fitted on a tapered seating or a withdrawal
sleeve can also be carried out with the oil injection method. When oil has
been pumped in between the mating surfaces the bearing slides off its
tapered seating very rapidly. You must therefore limit the axial movement of
the bearing or sleeve by screwing a nut onto the shaft.
k) Lift off the bearing housing with the bearing from the eccentric shaft
(2200-0) and place it on the ground.
l) Remove the bearing (2006-0) from the bearing housing.
m) Warm the inner labyrinth ring (2007-0) slightly with a gas torch and
remove it from the eccentric shaft.
n) Remove the V-ring (2007-1) from the inner labyrinth ring (2007-0).
2200-0 Eccentric shaft 2007-0

2007-1 V-ring
2007-1
2200-0
o) If the moving jaw bearings are to be exchanged, proceed to section

6.1.5 Removing moving jaw bearings.

6. Bearings
6.1.4 Installing frame bearings

Roller bearing, frame 2006-0 2
Spiral pin 2201-1 6
V-ring 2010-1 2
V-ring 2007-1 2
NOTE! The frame bearing housing is either locating or non-locating. The

instructions are valid for both locating and non-locating bearing housings.
The pictures describe the non-locating bearing housing.
NOTE! The moving jaw must be lifted out of the crusher and placed on the ground
before proceeding with this instruction.
executed by certified personnel.

2006-0 2006-1 2009-0 2010-0 2201-4
2009-0 Screw
2201-4 Locking tab
2010-1 V-ring
2011-0 Key
2201-0 Shaft nut
2000-0
2200-0 2008-0 2010-1 2011-0 2201-0
Recommended tools
Crow bar a) Clean the bearing housing (2000-0), labyrinth ring (2010-0), labyrinth
Lifting tackle and chain cover (2008-0) and eccentric shaft (2200-0). Remove any burrs.
b) Measure the inside diameter of the bearing housing to check that it is
Hook wrench
correct. For diameter tolerance, please consult Sandvik.
Hammer c) Lubricate the shaft (2200-0), bearing (2206-0) and withdrawal sleeve
Soft hammer (2206-1). Use SKF Mounting fluid LHMF 300/5 or similar.
Feeler gauge
(Continued)

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

2007-0
2007-1 V-ring
2007-1
2200-0
NOTE! Always replace used V-rings with new ones when exchanging bearings.
h) Connect the lifting device to the lifting eye on the bearing housing and
raise the bearing housing to the vertical position.
i) Grease the inner labyrinth ring (2007-0) slightly.
j) Lift the bearing housing onto the eccentric shaft (2200-0). Make sure the
bearing has metallic contact with the inner labyrinth ring (2007-0).
(Continued)

6. Bearings
k) Adjust the crane if necessary and push in the withdrawal sleeve (2206-1)
until it is tight against the shaft (2200-0) and the bearing (2006-0).
1
1 Lifting eye
2006-0 Roller bearing, frame 2006-0
2000-0 Bearing housing (non-locating) 2006-1
2200-0
2000-0
NOTE! The inner ring of a tapered bore bearing is always installed with a firm fit.
The tightness of the fit does not depend on the shaft tolerance (as with a
parallel-bore bearing) but on how far the bearing is driven up on the
withdrawal sleeve. The original play in the bearing is reduced when the
bearing is driven up and this reduction in play is a measure of the bearing
interference fit.
l) Install the hydraulic nut on the shaft (2200-0) and ensure metallic
contact.
m) Reduce the clearance according to table below.
Assemblage of bearings
Item Reduction of clearance Axial displacement Min. residual clearance
Min. Max. Min. Max.
Frame bearing 0.170 mm 0.230 mm 2.6 mm 3.6 mm 0.190 mm
NOTE! When spherical roller bearings with tapered bore are being fitted it is either
the reduction in the original radial play or the axial displacement on the
taper, which is used to measure the bearing interference fit.
n) Leave the hydraulic nut in place under pressure for 30 minutes.
o) Remove the hydraulic nut.
p) Fill the bearing with grease.
(Continued)

6. Bearings
q) Install the key (2011-0) into the key way on the shaft.
r) Install the labyrinth cover (2008-0) and fill it with grease.
s) Mount the V-ring (2010-1) in the labyrinth ring (2010-0).
t) Warm the labyrinth ring (2010-0) slightly and install it on the shaft
(2200-0).
2006-0 2006-1 2009-0 2010-0 2201-4
2009-0 Screw
2201-4 Locking tab
2010-1 V-ring
2011-0 Key
2201-0 Shaft nut
2000-0
2200-0 2008-0 2010-1 2011-0 2201-0
u) Fit the shaft nut (2201-0) on the shaft and tighten it with a hook wrench.
v) Drill two holes in the labyrinth ring and one hole in the shaft nut.
w) Fit the locking tab (2201-4) and fasten it with the spiral pins.
x) Install the moving jaw with eccentric shaft and bearings in the crusher.
See section 6.1.2 Installing moving jaw.

6. Bearings
6.1.5 Removing moving jaw bearings

NOTE! Lift out the moving jaw and remove the frame bearing before removing the
moving jaw bearing. See section 6.1.1 Removing moving jaw and section
6.1.3 Removing frame bearings.
NOTE! Sandvik recommends exchanging both moving jaw bearings at the same
time.
2104-1 V-ring 2104-1

2101-0 Roller bearing, moving jaw 2104-0
2103-0 Screw
2200-0
2101-0 2102-0 2103-0

Recommended tools a) Remove the screws (2103-0) that hold the labyrinth cover (2102-0).
Crow bar
b) Slightly heat the labyrinth ring (2104-0).
Lifting sling c) Remove the labyrinth cover (2102-0) with the labyrinth ring (2104-0)
36 mm Open end wrench and V-ring (2104-1) by levering carefully with a crowbar.
Sledge hammer
d) Repeat items a-c on the labyrinth on the other end of the shaft.
Copper punch
(Continued)

6. Bearings
2101-0 Moving jaw bearing

1 Lifting sling
2 Lifting eye
2101-0 1 2200-0 2
e) Connect a lifting eye (2) to the end of the eccentric shaft (2200-0).
f) Connect a tackle to the eye and secure it to a point straight in front of the
shaft.
g) Pull out the shaft slightly with the tackle.
h) Connect a lifting sling (1) to the eccentric shaft (2200-0) and take up the
slack in the lifting tackle so that the shaft doesn’t fall to the ground.
i) Continue to pull the shaft out of the moving jaw. Secure it with another
lifting sling.
j) Remove the rollers from the bearing.
NOTE! If the bearing is not to be re-used it can be more convenient to cut the outer
ring in two and remove the rollers.
k) Raise up the shaft vertically.
l) Warm the inner ring quickly until it comes off the shaft.
m) Turn the eccentric shaft upside-down and heat the other inner ring until it
comes off.

6. Bearings
6.1.6 Installing moving jaw bearings

Roller bearing, moving jaw 2101-0 2
V-ring 2104-1 2
NOTE! The moving jaw must be lifted out of the crusher and placed on the ground
before proceeding with this instruction.
Recommended tools a) Clean the eccentric shaft (2200-0), labyrinth cover (2102-0) and
Crow bar labyrinth ring (2104-0). Remove any burrs.
Lifting sling
b) Heat the bearing to maximum 125 °C. Use an inductive heater, oven or
oil bath.
Sledge hammer c) Lubricate the shaft (2200-0). Use SKF Mounting fluid LHMF 300/5 or
Copper punch similar.
d) Mount the bearing on the shaft and let it cool down.
e) Fill the bearing with grease.
f) Connect a lifting eye to the end of the eccentric shaft (2200-0)
g) Connect a tackle through the bore of the moving jaw to the eye and
secure it on the other side of the jaw.
h) Connect a lifting sling to the eccentric shaft (2200-0) and take up the
slack in the lifting tackle.
i) Lift the shaft up into alignment with the jaw.
j) Pull the eccentric shaft into the jaw with the tackle.
2104-1 V-ring 2104-1

2101-0 Roller bearing, moving jaw 2104-0
2103-0 Screw
2200-0
2101-0 2102-0 2103-0

(Continued)

6. Bearings
k) Install the labyrinth cover (2102-0) and use Loctite on the screws
(2103-0).
l) Fill the labyrinth cover (2102-0) with grease.
m) Mount the V-ring (2104-1) in the labyrinth ring (2104-0).
n) Warm the labyrinth ring (2104-0) slightly and install it on the shaft.
o) Install the frame bearings. See section 6.1.4 Installing frame bearings.
p) Install the moving jaw with eccentric shaft and bearings in the crusher.
See section 6.1.2 Installing moving jaw.

This section describes the scheduled maintenance work for the Setting
adjustment system for a jaw crusher equipped with the setting hydraulics
option.

NOTE! If the jaw crusher is equipped with the setting hydraulics option, this chapter
replaces section 4. Setting adjustment system.
7.1 Exchanging spring retraction assembly

Spring 7002-0 2
Retraction rod 7001-0 2
Nut M6M M56 7008-1 4
7201-0 Screw
7200-0 Guard
7008-1 Nut
7008-0 Yoke
7005-0 Hydraulic cylinder
7003-0 Spring guide
7002-0 Spring
7011-0 Retraction assembly
frame
7000-0 Pin 7201-0
1 Bracket
7200-0
7008-1
7008-0
7005-0
1 7000-0 7001-0 7011-0 7002-0 7003-0

Risk of crushing
Never stand behind or below the retraction system when work is
carried out. Due to fatigue the spring or retraction rod can be thrown
DANGER! backwards. If the guard is removed, always replace it when work is
done.
Risk of crushing
Release pressure in the hydraulic cylinder and move nuts only when
the crusher is shut off. Forces in springs or retraction rods can cause
WARNING! severe injuries when the crusher is running, see section 2. Safety
precautions.

7.1.1 Remove spring retraction assembly

q) Press the OFF button on the pre-load control box (2) to release pressure
in the hydraulic cylinder (7005-0).
NOTE! Press the OFF button only briefly. If it is pressed longer the jaw will be
pushed forward.
Recommended tools r) Unscrew the caps on the flow control valves (3) on the hydraulic unit.
Crow bar s) Loosen both locking nuts (3).
t) Open both valves (3) by unscrewing them 4 turns each with an Allen key
Lifting sling
to depressurize the system.
Mobile crane
4 mm Allen key u) Switch off the power to the hydraulic pump.
24 mm open end wrench v) Remove the guard (7200-0) by unscrewing the screws (7201-0).
85 mm open end wrench
w) Remove the nuts (7008-1) and the yoke (7008-0) with the hydraulic
cylinder (7005-0).
x) Remove spring guide (7003-0) and springs (7002-0).
y) Remove the retraction rod (7001-0) by dismantling the pin (7000-0).
3
2
2 Pre-load control box

3 Flow control valves

7.1.2 Install spring retraction assembly

a) Clean the retraction rod brackets (1).
b) Install the retraction rods (7001-0) by mounting the pins (7000-0).
NOTE! The retraction rod must not touch the retraction assembly frame (7011-0)
when the crusher is running.
c) Install the springs (7002-0) and the spring guide (7003-0) on the
retraction rod.
d) Install the guard (7200-0) with the screws (7201-0).
e) Mount the yoke (7008-0) with the hydraulic cylinder (7005-0) on the
retraction rod and tighten with one nut (7008-1) on each side of the yoke.
f) Close both flow control valves (3) with an Allen key.
g) Lock them with the locking nut and put on the caps (3).
h) Switch on the power to the hydraulic pump.
i) Press the ON button on the pre-load control box (2) to apply pressure in
the hydraulic cylinder.
j) Adjust the nuts (7010-1) and tighten them, so that the distance L
(between the end of the hydraulic cylinder and the spring guide) will be
155 mm when pressure is applied in the hydraulic cylinder (7005-0).
(Release pressure, adjust the nuts, apply pressure again and measure to
check.)
CAUTION! Always apply pressure in the hydraulic cylinder before starting the
crusher.
CAUTION! Make a performance test of the setting adjustment system by running

the crusher without load. Listen for abnormal noises. A clattering noise
can indicate that the springs are not sufficiently tightened. Increase the
pressure until the noise disappears.

7.2 Exchanging toggle plate and toggle seats

Toggle plate 5006-0 1 pc weight 800 kg
Toggle seat, upper 5004-0 1 pc weight 130 kg
Toggle seat, lower 5005-0 1 pc weight 130 kg
NOTE! There are toggle plates of different lengths to choose from. The chosen length
depends on what setting the crusher will be operated at and if the crusher is
equipped with a jaw shim plate. Also, if a crusher is equipped with hydraulic
setting this will have affect on which toggle plate should be chosen.
NOTE! Adjust to maximum CSS before releasing the retraction springs to facilitate
removal of the toggle plate and toggle seats. If the crusher is equipped with
shims these must be removed before exchanging the toggle plate and toggle
seats. See section 8. Setting adjustment system in the Operator’s manual.
CAUTION! The crusher must be stopped and the retraction assembly must be
removed when exchanging the toggle plate and toggle seats.

7002-0 Spring
5006-0 Toggle plate
7001-0
7002-0
5005-0 5006-0 5004-0 5003-0

7.2.1 Remove toggle plate and toggle seats

a) Position the hook of a mobile crane vertically above the toggle plate
(5006-0).
b) Connect the lifting device to the toggle plate (5006-0) from above. Use
the two elliptical holes (4) for the lifting sling (2).
c) Take up the slack in the lifting tackle.
1 Bracket
2 Lifting sling 4
3 Wooden wedge
4 Holes in toggle plate 1
Hanging load
precautions.
d) Loosen the spring retraction arrangement as described in section

Recommended tools 7.1.1 Remove spring retraction assembly.
Crow bar
e) Attach a chain block to the retraction rod bracket (1). Let the chain pass
Lifting sling under the jaw crusher’s discharge opening and tighten it to a position in
Mobile crane front of the jaw crusher
20 mm Round iron f) Place two wooden wedges (3) between the moving jaw and back frame
end to prevent the moving jaw from falling back.
Wooden wedges
(Continued)

g) To prevent the toggle seat holder from falling down insert a round iron
through the hole and under the toggle plate so that the toggle seat holder
can rest on the iron.
h) Pull the jaw forward using the chain.
5 Round iron
6 Hole
5006-0 Toggle plate
5006-0
i) Lower the toggle plate (5006-0) to the surface.

NOTE! Apply a crow bar or wedges if the toggle plate (5006-0) gets stuck. Never use
arms or feet.
j) Release the lifting device from the toggle plate and remove the toggle
plate from the jaw crusher.
k) Use the round iron as a guide and pull out the toggle seat holder (5003-0)
half way.
l) Connect the toggle seat holder to a lifting sling and withdraw it from the
crusher.
m) Unscrew the toggle seat retainers (5013-0), (5013-1) on both ends of the
toggle seat holder.
n) Remove the toggle seat from the toggle seat holder.
o) Remove the lower toggle seat (5005-0).
p) Note the position of the lower toggle seat’s thicker flange (top or bottom)
so that it comes in the same position when it is reinstalled.

7.2.2 Install toggle plate and toggle seats

NOTE! Before starting this procedure, it is necessary to secure the moving jaw as
described in section 7.2.1 Remove toggle plate and toggle seats items e–f and
to remove the springs (7002-0) and retraction rod (7001-0) as described in
section 7.1.1 Remove spring retraction assembly.
a) Wash the new toggle plate (5006-0) and the new toggle seats (5004-0),
(5005-0).
b) Clean the slots where the upper and lower toggle seats fit.
c) Install the lower toggle seat (5005-0). Make sure the thicker flange of the
lower toggle seat is situated the same way as when removing it.

7002-0 Spring 7001-0
7002-0
5006-0 Toggle plate
5005-0 5006-0 5004-0 5003-0
d) Push the upper toggle seat (5004-0) into the toggle seat holder (5003-0).
e) Fasten the toggle seat retainers (5013-0), (5013-1) on both ends with the
screws (5014-0) and washers (5014-2).
f) Connect the toggle seat holder to a lifting sling.
g) Insert a round iron into the hole (6).
h) Use the round iron as a guide and insert the toggle seat holder into
correct position.
(Continued)

i) Disconnect the lifting sling from the toggle seat holder.

j) Connect the lifting gear to the toggle plate (5006-0). Use the two
elliptical holes (4) for the lifting sling (2).
Hanging load
precautions.
k) Carefully lift the toggle plate (5006-0) below the back frame end.
l) Lower the toggle plate to the surface.
m) Release the lifting sling (2) from the hook.
n) Reconnect the lifting sling (2) to the hook, this time through the back end
frame.
o) Lift and drag the toggle plate (5006-0) so it comes in position under the
back end frame.
p) Lift the toggle plate (5006-0) gently.
5003-0
2 Lifting sling
5004-0
5006-0 Toggle plate
5005-0 Lower toggle seat 5005-0 5006-0
(Continued)

q) Position the back of the toggle plate (5006-0) in the upper toggle seat
(5004-0).
r) Lift up the lower end of the toggle plate in line with the lower toggle seat
(5005-0).
NOTE! Use a crow bar if the toggle plate gets stuck. Never use arms or feet.
s) Adjust the dust curtain.
t) Remove the wooden wedges.
u) Move the moving jaw slowly backward and make sure that the toggle
plate fit in the toggle seat (5005-0).
v) Check that the toggle plate (5006-0) and dust curtain is seated correctly.
NOTE! Pull the jaw slightly backwards if needed to adjust the toggle plate or dust
curtain into correct position.
w) Slacken off the chain used to lock the moving jaw (3000-0) and remove
it.
x) Slacken off the lifting tackle and remove the lifting sling (2).
y) Install the spring retraction arrangement as described in section
7.1.2 Install spring retraction assembly.

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maintenance manual S 222.164.

Serial no. / Machine no. Sign.

Document number: S222.164.en

3. Basic maintenance instruction

CJ615:01 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 3

4. Setting adjustment system

7. Setting hydraulics (option)

4 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 CJ615:01

CJ615:01 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 5

1.1 Equipment information

6 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 CJ615:01

CJ615:01 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 7

1.1.1 Document information

8 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 CJ615:01

CJ615:01 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 9

This page is intentionally left blank

10 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 CJ615:01

CJ615:01 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 11

2.1 Hazard information

General danger Dangerous voltage Risk of crushing

Hanging load Risk of crushing Flying fragments

2.1.2 Risk levels

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

12 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 CJ615:01

2.1.3 Prohibition signs

2.1.4 Mandatory signs

Disconnect current Read the manual

CJ615:01 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 13

Sandvik provides technical documentation appropriate to all three work

2.1.6 Personal protection

Ear protection Safety helmet Eye protection

Protective gloves Safety boots Mask or breathing

14 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 CJ615:01

2.2 General safety precautions

CJ615:01 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 15

2.2.1 Machine safety guards

2.2.2 Machine access

16 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 CJ615:01

2.2.3 Electrical safety

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

CJ615:01 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 17

2.2.5 Hydraulic systems

2.2.6 Lubrication system

18 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 CJ615:01

2.2.7 Lifting and moving loads

CJ615:01 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 19

2.2.8 Feed and jams

CAUTION! Never feed combustible process material into the crusher.

If it is possible, change the direction of rotation of the jaw crusher’s flywheel

However, Sandvik recommends that a jam in the feed opening is cleared by

20 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 CJ615:01

Make sure the dust suppression system in your equipment is working

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

Sandvik strongly recommends using additional equipment for dust control.

CJ615:01 © Sandvik SRP AB – Doc. no. S 222.164 en Ver. 04 21