5.
13 QA SERIES
SCREEN BOX BEARING CHANGE QA335
SAFETY FIRST
Sandvik‘s objective is zero harm to our
people, the environment we work in,
our customers and our suppliers.
PROTECTIVE FIRST AID
ALARM
EQUIPMENT KIT
EMERGENCY EMERGENCY ASSEMBLY
NUMBER EXIT POINT
PSYCHOLOGICAL
SAFETY
2
Company Confidential
GLOBAL INTERNAL CONTROLS
Control leads to
The Way We All Operate compliance !
Ensure
compliance
We all need to
with all relevant
be compliant
internal and
external rules
and regulation
Conducting
business with
‘Power of ethics and
Sandvik’ are integrity
the guidelines
for all
employees
QUALITY FOCUS
ZERO DEFECTS TO CUSTOMER
Sandvik aims to be THE preferred and
recurrent supplier in Mobile Crushing and
Screening
4
HEALTH AND SAFETY
5
USE THE MOBILE PORTAL MATERIAL SHARING POINT
All machine related materials can be downloaded at mobiles portal:
https://portal.sandvik
Here you can sign in and choose
Selection of materials
6
MOBILE UNIT HEALTH & SAFETY
MACHINE ISOLATION
Lockout & Tag Procedure
MOBILE UNIT HEALTH & SAFETY
MACHINE ISOLATION
Prior to performing any maintenance or adjustment on the
Sandvik Mobiles machine it is compulsory that the unit is
completely isolated.
Stop, lockout, tag and test must be performed.
1. Turn off the ignition (stopping the engine) and remove
1. the ignition key.
2. Locate the main battery isolator switch and turn armature
to the off position.
2.
MOBILE UNIT HEALTH & SAFETY
MACHINE ISOLATION
Multi Lock Place a lock on to the isolator to ensure no person can
Clasp remove or start the system while testing or maintenance is
taking place.
3. Fit lock to isolator (preventing contact movement).
If more than one person is required to carry out unit
maintenance or assist in the procedure, each person should
have their own individual lock attached to the isolator.
A multi lock clasp (pictured) should be used to allow this
ability.
Only remove individual locks once work has been completed
and person leaves the machine!
Individual
Locks
MOBILE UNIT HEALTH & SAFETY
MACHINE ISOLATION
Finally the isolation must be proven for its effectiveness
using a verified test meter.
4. Select an appropriate voltage testing device and using a
known energy source (permanent supply or battery),
prove the device is measuring voltage correctly.
5. Using the same test device, test the control isolation is
functional and the system is no able to be accidentally
activated or engine started.
6. Attach signage where possible in an easily visible
position to alert any person approaching the machine
that maintenance is being carried out.
PARTS REQUIREMENTS
11
SCREEN BOX BEARING CHANGE QA335
PARTS REQUIREMENTS
ITEM PART No. DESCRIPTION
1 HM1011/HM1026 DRIVE MOTOR (Dependent on engine option)
2 G5230000 MOTOR MOUNTING PLATE
3 BT8507 COMPLETE COUPLING
4 FAKS18X11X50 KEY STEEL 50mm
5 G5220000 DRIVE HOUSING
6 BT8008 SHAFT SEAL
7 BT8003 DISTANCE RING
8 BT3507 SCREEN BEARING TAPER LOCK
9 BT3010 OUTER BEARING
10 G4100000 BEARING HOUSING
12
DRIVE SIDE DISMANTLING
PROCEDURE
13
SCREEN BOX BEARING CHANGE QA335
DRIVE SIDE DISMANTLING PROCEDURE
• Remove the motor mounting plate by removing the 8 bolts
holding it in place. There is no need to remove the motor from
the motor mounting plate. Remove spider insert for coupling
also.
• Loosen grub screw and remove coupling and key from screen
box shaft.
• Remove drive housing by removing the 6 bolts fixing it to the
bearing housing. Use 2x M10 bolts to press the drive housing
from the bearing housing (and shaft seal) by screwing these
bolts into the two holes on the drive housing. Clean grease
from bearing and drive housings.
14
BEARING VISUAL INSPECTION
15
SCREEN BOX BEARING CHANGE QA335
BEARING VISUAL INSPECTION
At this point the bearing needs inspecting to determine if it is in good condition.
Simple visual checks can tell you a lot about the bearing health or why it has failed.
What to look out for:
Grease
• Colour: The colour of recommended Unirex N3 grease is
green and the Consistency is buttery. Usually fresh grease
can be found in grease nipple area.
• The example hear is showing a bearing packed with
incorrect grease. The Colour and consistency Does not
match SANDVIK recommended Unirex N3 grease.
Check with operators that the correct grease is being used
as per the daily maintenance.
16
SCREEN BOX BEARING CHANGE QA335
BEARING VISUAL INSPECTION
Grease:
• Grade: to ensure that correct grease is used it´s
recommended to take a grease sample for analysis. This
can be easily taken of from bearing cover.
• Contaminants: check that bearing housing seals are
healthy and grease is not contaminated by water, dust or
any other particles.
• Amount: the correct amount can be checked by the grease
that remains on the bearing cover after removing it and
looking at the bearing itself. The photo besides showing a
greased bearing.
17
SCREEN BOX BEARING CHANGE QA335
BEARING VISUAL INSPECTION
Bearing condition:
• Clearance: The correct bearing clearance Is 0.003”
(0.07mm). The photo besides is showing a clearance of
0,10mm and therefore out of specification and can cause
noise whilst running.
18
SCREEN BOX BEARING CHANGE QA335
BEARING VISUAL INSPECTION
Bearing condition:
• Check for damage to rollers and the inner or outer race of
the bearing. The pictures beside showing corrugation on
rollers and outer race caused by using incorrect grease
and contamination.
• Check for high bearing temperatures whilst running
dependant on the Ambient temperatures the average
bearing temperature range can vary. Log these on the
sheet provided.
19
DRIVE SIDE DISMANTLING
PROCEDURE
20
SCREEN BOX BEARING CHANGE QA335
DRIVE SIDE DISMANTLING PROCEDURE
• Remove distance ring and undo lock tab on star washer.
Unscrew lock nut to end of threads and tap gently to
loosen taper lock sleeve. Remove nuts holding bearing
housing to screen box side. Remove bearing housing and
bearing. It may be necessary to screw two M20 bolts into
the threaded holes on the bearing housing to press it off
from the screen box side.
• Remove grub screws and press out bearing using 4x M12
Bolts.
21
SCREEN BOX BEARING CHANGE QA335
DRIVE SIDE INSPECTION PROCEDURE
• The bearing housings need to be inspected, there
are 10 measurements required to ensure the
bores are within tolerance and also the housing
are not out of round. Dimensions need to be
recorded. If unsure, contact Sandvik Service
support. The surface quality can be taken if
possible.
1 2 3 diff
A
B
C
Surface
quality
22
SCREEN BOX BEARING CHANGE QA335
DRIVE SIDE INSPECTION PROCEDURE
• Driveshaft dimensions need to be checked.
Each dimension need to be checked crosswise
and bearing seat at two axial points. 11
measurements need to be recorded. The
surface quality can be taken if possible.
A B C D E
Surface
23
DRIVE SIDE ASSEMBLY
PROCEDURE
24
SCREEN BOX BEARING CHANGE QA335
DRIVE SIDE ASSEMBLY PROCEDURE
• Thoroughly clean the inside of bearing and drive housing
and refit the grub screws, using thread lock. There may be
some paint flecks or burrs on the screen box side as a
result of the removal of the bearing housing, clean any
dirt/debris from mating surfaces of the screen box side and
the bearing before refitting the bearing housing.
• Replace shaft seal. Lubricate by applying a small amount
of grease to the lips of the seal. Then, press seal into the
recess on the drive housing.
Note: Mount bearings in a clean environment. Housings, shaft and other
components of the bearing should be cleaned before fitting new bearings. Bearings
should be left in their original packaging until immediately before mounting
25
SCREEN BOX BEARING CHANGE QA335
DRIVE SIDE ASSEMBLY PROCEDURE
• Remove new bearing BT3010 from packaging and pack
bearing full of grease on both sides . Fill with roughly
100gr of grease Unirex N3 per side.
Fill all space between
bearing rollers and roller
faces
Note: Only use N3 UNIREX grease when greasing bearings. NEVER use
grease containing Molybdenum. Doing so may cause damage to machine
parts and WILL invalidate any warranty.
26
SCREEN BOX BEARING CHANGE QA335
DRIVE SIDE ASSEMBLY PROCEDURE
• Fit sleeve into the bearing and press bearing into the
bearing housing, with greased face on the inside. Tap the
bearing into the housing and press fully into the bearing
housing.
• Refit bearing housing, with the bearing in place, onto the
screen box side. Align holes and bolt in place using 6x
M20x110(10.9) bolts and torque with 570 Nm
• Check end of shaft is 90mm from the bearing housing
face. It may be necessary to tap shaft back and forth to
achieve 90mm distance.
.
Measured shaft distance:
27
SCREEN BOX BEARING CHANGE QA335
DRIVE SIDE ASSEMBLY PROCEDURE
• Set bearing clearance by tightening locking nut until 0.003”
(0.07mm) clearance is achieved between roller and outer
bearing ring. Locate lock washer tab to lock up nut.
28
SCREEN BOX BEARING CHANGE QA335
DRIVE SIDE ASSEMBLY PROCEDURE
• Grease the bearing via the grease nipple situated on the underside of the bearing
housing until the grease starts to come out of the front face of the bearing. Pack the
front of the bearing by hand. It is recommended that a total of 60 grams of grease,
per bearing, is packed into the bearing as an initial fill.
• Offer up the bearing housing end cap to the bearing housing. Care must be taken to
avoid damaging the shaft seal when doing so. Using the 6x bolts and 6x Nord lock
washers, fix end cap to the housing. Apply thread lock to all bolts when fitting
29
SCREEN BOX BEARING CHANGE QA335
DRIVE SIDE ASSEMBLY PROCEDURE
• Fit the shaft side of the coupling onto the shaft along with the key. The
face of the coupling should be flush with the face of the shaft. Apply
thread lock to the grub screw and lock the coupling in place by
tightening the grub screw.
• Refit motor mounting plate (along with motor and coupling attached),
to the drive housing in such a way that the drive side of the coupling
inserts correctly into the shaft side of the coupling, with the
polyurethane spider in place. The gap between the two halves of the
coupling should be 3-4mm.
This completes bearing replacement for drive side ONLY.
30
PARTS REQUIREMENTS
31
SCREEN BOX BEARING CHANGE QA335
PARTS REQUIREMENTS
ITEM PART No. DESCRIPTION
1 G4110000 NON DRIVE END CAP
2 BT8008 SHAFT SEAL
3 BT3507 BEARING TAPER LOCK
4 BT3010 BEARING
5 G4100000 BEARING HOUSING
32
NON DRIVE SIDE
DISMANTLING PROCEDURE
33
SCREEN BOX BEARING CHANGE QA335
NON DRIVE SIDE DISMANTLING PROCEDURE
1. Remove bearing housing end cap (and shaft seal) by
unscrewing 6x M12 bolts fixing it to the bearing housing. It may
be necessary to screw 2x M10 bolts into the holes in the end
cap to press away from the bearing housing. Clean grease
from bearing housing cap and bearing.
2. Undo lock tab on star washer. Unscrew locking nut to end of
threads and tap gently to loosen taper lock sleeve.
3. Remove bearing housing by unscrewing the 6x M20 nuts fixing
it to the screen box side. It may be necessary to screw 2x M20
bolts into the holes on the bearing housing to press the bearing
housing away from the screen box side.
34
BEARING VISUAL INSPECTION
35
SCREEN BOX BEARING CHANGE QA335
BEARING VISUAL INSPECTION
At this point the bearing needs inspecting to determine if it is in good condition.
Simple visual checks can tell you a lot about the bearing health or why it has failed.
What to look out for:
Grease
• Colour: The colour of recommended Unirex N3 grease is
green and the Consistency is buttery. Usually fresh grease
can be found in grease nipple area.
• The example hear is showing a bearing packed with
incorrect grease. The Colour and consistency Does not
match SANDVIK recommended Unirex N3 grease.
Check with operators that the correct grease is being used
as per the daily maintenance.
36
SCREEN BOX BEARING CHANGE QA335
BEARING VISUAL INSPECTION
Grease:
• Grade: to ensure that correct grease is used it´s
recommended to take a grease sample for analysis. This
can be easily taken of from bearing cover.
• Contaminants: check that bearing housing seals are
healthy and grease is not contaminated by water, dust or
any other particles.
• Amount: the correct amount can be checked by the grease
that remains on the bearing cover after removing it and
looking at the bearing itself. The photo besides showing a
greased bearing.
37
SCREEN BOX BEARING CHANGE QA335
BEARING VISUAL INSPECTION
Bearing condition:
• Clearance: The correct bearing clearance Is 0.003”
(0.07mm). The photo besides is showing a clearance of
0,10mm and therefore out of specification and can cause
noise whilst running.
38
SCREEN BOX BEARING CHANGE QA335
BEARING VISUAL INSPECTION
Bearing condition:
• Check for damage to rollers and the inner or outer race of
the bearing. The pictures beside showing corrugation on
rollers and outer race caused by using incorrect grease
and contamination.
• Check for high bearing temperatures whilst running
dependant on the Ambient temperatures the average
bearing temperature range can vary. Log these on the
sheet provided.
39
NON DRIVE SIDE
DISMANTLING PROCEDURE
40
SCREEN BOX BEARING CHANGE QA335
NON DRIVE SIDE DISMANTLING PROCEDURE
• Remove grub screws and press out bearing using 4x
M12 bolts.
• Thoroughly clean inside the bearing housing and refit
grub screws using thread lock. There may be some
paint flecks or burrs on the screen box side as a result
of the removal of the bearing housing, clean any
dirt/debris from mating surfaces between the screen
box side and the bearing housing before refitting the
bearing housing
41
SCREEN BOX BEARING CHANGE QA335
NON DRIVE SIDE INSPECTION PROCEDURE
• The bearing housings need to be inspected, there
are 10 measurements required to ensure the
bores are within tolerance and also the housing
are not out of round. Dimensions need to be
recorded. If unsure, contact Sandvik Service
support. The surface quality can be taken if
possible
1 2 3 diff
A
B
C
Surface
quality
42
SCREEN BOX BEARING CHANGE QA335
NON DRIVE SIDE INSPECTION PROCEDURE
• Driveshaft dimensions need to be checked.
Each dimension need to be checked crosswise
and bearing seat at two axial points. 9
measurements need to be recorded. The
surface quality can be taken if possible
A B C
1
2
3
surface
43
NON DRIVE SIDE ASSEMBLY
PROCEDURE
44
ASSEMBLING NON-DRIVE SIDE
• Replace shaft seals on the bearing housing and end cap
by firstly lubricating the lips of the seals with a small
amount of grease and pressing them into the recesses in
the housing and the end cap.
Note: Mount bearings in a clean environment. Housings, shafts and other components of the
bearing should be cleaned before fitting new bearings. Bearings should be left in their original
packaging until immediately before mounting.
45
SCREEN BOX BEARING CHANGE QA335
NON DRIVE SIDE ASSEMBLY PROCEDURE
• Remove new bearing BT3010 from packaging and pack
bearing full of grease on both sides . Fill with roughly
100gr of grease Unirex N3 per side.
Fill all space between
bearing rollers and roller
faces
Note: Only use N3 UNIREX grease when greasing bearings. NEVER use
grease containing Molybdenum. Doing so may cause damage to machine
parts and WILL invalidate any warranty.
46
SCREEN BOX BEARING CHANGE QA335
NON DRIVE SIDE ASSEMBLY PROCEDURE
• Press the bearing into the bearing housing, with greased face on the inside. Level the bearing and tap the bearing
into the housing and press it fully into the bearing housing.
• Refit the bearing housing, with the bearing in place, onto the screen box side whilst taking care to avoid damaging
the shaft seal while doing so. Ensure that the shoulder of the bearing housing is engaged into the recess in the
screen box side. Align the holes and bolt in place.
• Set the bearing clearance by tightening the locking nut until 0.003” (0.07mm) clearance is achieved between roller
and outer bearing ring. Locate lock washer tab to lock up nut.
• Grease bearing via the grease nipple on the underside of bearing housing until grease comes out through face of the
bearing. Pack the front of bearing with grease by hand. It is recommended that 180 grams of grease, per bearing, is
required.
47
SCREEN BOX BEARING CHANGE QA335
NON DRIVE SIDE ASSEMBLY PROCEDURE
• Offer up the bearing housing end cap to the bearing housing. Ensure
breather hole on end cap is above the shaft in the position shown below.
Care must be taken to avoid damaging the shaft seal when fitting end cap.
Fix end cap to the housing.
48
SCREEN BOX BEARING CHANGE QA335
MEASUREMENT CHECK SHEET
49
SCREEN BOX BEARING CHANGE QA335
BEARING OPERATING TEMPERATURE LOG
After completes bearing replacement are a 3 hour test run required. Temperatures need to be logged at
sheet below. High bearing temperatures whilst running dependant on the Ambient temperatures the
average bearing temperature range can vary.
50
SUPPORTING MATERIAL
UNIREX N3
51
ROCKTECHNOLOGY.SANDVIK
