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Assembly and Operating Instructions

Gyratory crusher
KB 63 - 75
Iron ore
Shougang Hierro II
Shougang Hierro S.A.A.
San Juan de Marcona, Peru
2-492-20980

11/2013 Rev 0

Year of manufacture 2013

2-492-20980 (POS 01)

Revision level

Revision
status
0

Date

Changes

Made by

11/10/2013
22/11/2013

Original created (German)
Translation from original

Ritterbecks 
Ritterbecks

25/03/2014

Chapter 2.2 “Over-pressure ventilation of the dust sealing” Voltage: Capacity P: Speed n:

Ritterbecks

1

ThyssenKrupp Fördertechnik GmbH
Postfach 1463 – D - 59306 Ennigerloh
Schleebergstraße 12 – D - 59320 Ennigerloh
Telephone: +49 2524 30 0
Fax: +49 2524 2252
www.tk-processing.com
All parts protected by copyright. All rights reserved including those of translation into other languages. This document may not be processed, reproduced or distributed by any means, including electronic systems, in whole
or in part without our express permission in writing.

2-492-20980 (POS 01)

11/2013 Rev 0

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Table of Contents
1

2

11/2013 Rev 0

3

4

User's guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 1
1.1

User groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 1

1.2

Structure of the safety notes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 2

1.3

Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3

1.4

General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3

1.5

Liability and warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4

1.6

Copyright - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4

1.7

Technical modifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 4

1.8

Stocking of spare parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 5

Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 1
2.1

Oil circulating lubrication and hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 2

2.2

Over-pressure ventilation of the dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 2

2.3

Grease lubrication for spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 2

2.4

Drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 3

General safety instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 1
3.1

Principles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 1

3.2

Modifications and spare parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 2

3.3

Personnel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 2

3.4

Noise hazard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 3

3.5

Information regarding residual risks during daily operation - - - - - - - - - - - - - - - - - -3 - 3

3.6

Fire protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 4

3.7

Disposal of consumables and process materials - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 4

Design and operating principle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4 - 1
4.1

Scope of application and designated use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 1

4.2

Main components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 2

4.3

Operating principle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 4
2-492-20980 (POS 01)

TOC - 1

TOC- 2

Assembly groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 6

4.4.1

Crusher shells, concaves and wear parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 6

4.4.2

Main shaft with mantle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 10

4.4.3

Spider bearing with grease lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 12

4.4.4

Over-pressure ventilation of the dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 16

4.4.5

Eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 18

4.4.6

Base plate (with axial bearing ring) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 20

4.4.7

Lower main shaft bearing (axial step bearing) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 21

4.4.8

Hydraulic cylinder and balance unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 22

4.4.9

Crusher main drive motor and pinion assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 24

4.4.10

Measuring and monitoring equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 26

4.4.11

Oil circulating lubrication and hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 28

Transport, storage and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1
5.1

Transport instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1

5.2

Hoisting devices and slinging equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 4

5.2.1

Lifting gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 4

5.2.2

Lifting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 5

5.2.3

Lifting ropes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 7

5.2.4

Wire rope clamps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 10

5.2.5

Lifting chains - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 12

5.2.6

Hook - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 13

5.2.7

Screw-type lifting eyes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 13

5.2.8

Shackles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 16

5.2.9

Slinging equipment and load protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 18

5.2.10

Substructures for loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 19

5.3

Storage requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 20

5.3.1

General requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 20

5.3.2

Storage facilities & other details - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 21

5.3.3

Special requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 25

5.4

Handling of oil hydraulic systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29

5.4.1

General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29

5.4.2

Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29

5.4.3

Pipes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29

5.4.4

Hydraulic hose lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 30

5.4.5

Commission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31

5.4.6

Hydraulic fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31

5.4.7

Filling pumps and motors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31

2-492-20980 (POS 01)

11/2013 Rev 0

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4.4

11/2013 Rev 0

5.4.8

Pressure settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31

5.4.9

Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32

5.4.10

Cylinders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32

5.4.11

Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32

5.4.12

Fluid level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32

5.4.13

Filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.14

Oil temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.15

Oil change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.16

Accumulators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.17

Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.18

Pipework - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.19

Cooler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.20

Storage of hydraulic components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 34

5.4.21

Duration of storage and use of hydraulic hose lines - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 34

5.5

Installation planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 34

5.6

Preparation for installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 36

5.7

General information on assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 38

5.8

Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40

5.8.1

Pre-assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40

5.8.2

Weights: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40

5.8.3

Bottom shell - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 42

5.8.4

Base plate and eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 44

5.8.5

Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 46

5.8.6

Hydraulic cylinder and lower components of the main shaft bearing - - - - - - - - - - - - - - 5 - 50

5.8.7

Sealing housing of the dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 52

5.8.8

Mounting the concaves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 54

5.8.9

Installation of the liner plates in the upper shell - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 59

5.8.10

Spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 60

5.8.11

Main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 62

5.8.12

Sealing ring of the dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 64

5.8.13

Lower main shaft bearing section - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 65

5.9

Assembling the sub-assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 66

5.9.1

Bottom shell of the crusher, shells, main shaft, spider - - - - - - - - - - - - - - - - - - - - - - - - 5 - 66

5.9.2

Arm liners on spider - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 72

5.9.3

Direct drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 74

5.9.4

Compressor for over-pressure ventilation of dust sealing - - - - - - - - - - - - - - - - - - - - - - 5 - 76

5.9.5

Main shaft hydraulics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 77

2-492-20980 (POS 01)

TOC - 3

7

TOC - 4

Oil circulating lubrication and hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 78

5.9.7

Grease lubrication for spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 79

5.10

Prescribed tightening torques for all relevant bolts - - - - - - - - - - - - - - - - - - - - - - - 5 - 80

Commissioning and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1
6.1

General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1

6.2

Safety notes for operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1

6.3

Power supply and control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 3

6.4

Initial commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 5

6.5

Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6

6.5.1

Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6

6.5.2

Checks during operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6

6.6

Malfunctions, troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 7

6.6.1

Fault list / troubleshooting guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 8

6.6.2

Restart of the crusher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11

6.7

Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11

6.7.1

Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11

6.7.2

Emergency-stop system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 12

6.8

Handling of oil hydraulic systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 12

Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 1
7.1

Important information on maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 1

7.1.1

Information about cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 4

7.1.2

Information on maintenance and inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 5

7.1.3

Notes relating to repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 7

7.2

Maintenance intervals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 8

7.3

Special maintenance tasks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 12

7.3.1

Crusher shells and concaves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 12

7.3.2

Secure attachment of connecting bolts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 14

7.3.3

Main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 16

7.3.4

Spider bearing with grease lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 18

7.3.5

Dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 22

7.3.6

Eccentric bushing and axial step bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 26

7.3.7

Check the oil level and change the oil at the oil circulating lubrication unit - - - - - - - - - 7 - 28

7.3.8

Check the hydraulic oil level and change the hydraulic oil - - - - - - - - - - - - - - - - - - - - - 7 - 29

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5.9.6

Drive and pinion assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 30

7.3.10

Check of the torsional back lash - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 34

7.4

Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 38

7.4.1

Preparation for replacing the crushing jaws - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 40

7.4.2

Disassembly of the spider - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 40

7.4.3

Disassembly of the main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 42

7.4.4

Checks to be made with the spider, main shaft and dust sealing housing dismantled - - 7 - 44

7.4.5

Exchanging the concaves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 46

7.4.6

Wear parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 48

7.4.7

Main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 50

7.4.8

Spider bearing with grease lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 54

7.4.9

Dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 58

7.4.10

Axial step bearing of the main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 60

7.4.11

Exchanging the inner eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 62

7.4.12

Replacement of eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 64

7.4.13

Exchanging the outer eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 76

7.4.14

Crusher main drive motor and pinion assembly - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 78

7.5

Screw connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 86

7.5.1

Machine structures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 86

7.5.2

High-tensile bolted joints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 88

Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 1
8.1

Introduction and technical instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 - 1

8.2

Storage of lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 - 2

8.3

General information on lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 3

8.3.1

Oil groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 - 3

8.3.2

Open toothed gears - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 - 4

8.3.3

Lubricant lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 - 5

8.4

Table of lubricants (Index 8) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 6

8.4.1

Standard lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 6

8.4.2

Special lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 9

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7.3.9

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72& - 5

8.5

ANNEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 - 1
9.1

Drawings

9.2

Couplings

9.3

Clearance of teeth and bearings

9.4

Processing synthetic sealing compound

9.5

Compressor (over-pressure ventilation)

9.6

Monitoring devices

9.7

Distance sensor of main shaft setting unit

9.8

Central lubrication

9.9

Oil circulating lubrication and hydraulic unit

9.10

Shaft hydraulics (balance unit, hydraulic cylinder)

9.11

Tools

9.12

SUPERBOLT® Mechanical clamping elements

9.13

Gyramatic Version 2.4 - user manual / fault list

9.14

Fluid starter

9.15

Maintenance car with scissor-type elevating platform

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9

Lubricating instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 12

72& - 6

2-492-20980 (POS 01)

1

User's guide
The technical documentation (Assembly and Operating Instructions) is designed to familiarise the user with the machine / plant and its designated use.
The Assembly and Operating Instructions must always be available at the service location
of the machine / plant.

1.1

User groups
Necessary or expected user skills (competence):
Use personnel qualified for the machine / system with special knowledge of the machine/
plant and the processes.
Qualified personnel are persons who, on account of their training, experience and instruction as well their knowledge of the relevant standards, provisions, accident prevention
regulations and service conditions, are authorised to carry out the necessary tasks and
can recognise and avoid any potential hazards.
The operating personnel receive special instruction from the owner/operator of the
machine / plant. Operators must be conscious of the fact that they are in a hazardous area
during some manual tasks.
Two people always work temporarily on the machine/plant in accordance with the rules of
proper use. All operating, monitoring and servicing work is always carried out by at least
two people working together.
Those working on the machine / plant must be made familiar with the safety instructions
and layout of the emergency-stop systems as well as the related emergency-stop circuits.

11/2013 Rev 0

To exclude danger to other people, access to the machine / plant is prohibited for unauthorised people. These people are not familiar with the process workflow and cannot
recognise potential hazards.

2-492-20980 (POS 01)

1-1

1.2

Structure of the safety notes
The safety notes in the Assembly and Operating Instructions are highlighted as follows:

SIGNAL WORD
Type and source of danger
Possible consequence(s) of non-observance.
• Measure(s) for prevention of the danger.
The following table shows the classification and significance of the signal words for safety
notes.

Pictogram

Signal word

Significance

Consequences of non-observance

DANGER

Imminent danger

Death or severe bodily injuries

WARNING

Possible danger

Death or severe bodily injuries

CAUTION

Possible danger

Minor bodily injuries

CAUTION

Possible property damage

Damage to the machine / plant or
its environment

INFORMATION

Useful information or tip:
Simplifies the handling

!
!
General danger

!

11/2013 Rev 0

Special danger, e.g.
electrocution

1-2

2-492-20980 (POS 01)

1.3

1.4

Definitions
right

=

on the right-hand side looking in conveying direction

left

=

on the left-hand side looking in conveying direction

=

Instructions for action (in the stated order)

=

Listing in the text

/

=

or

General information
Dear Customer,
These Assembly and Operating Instructions are prepared by ThyssenKrupp Resource
Technologies and have to be observed in every detail by those responsible for the transport, installation, commissioning, operation, maintenance as well as the disposal of all
consumables and process materials. Only if the responsible individuals follow the instructions in these Assembly and Operating Instructions will errors in operating and servicing
the machine / plant be avoided and trouble-free operation ensured.
The Assembly and Operating Instructions contain important information on how to operate
the machine / plant safely, properly and efficiently. Observing this information helps to
avoid danger, to reduce repair costs and downtimes and to increase both the reliability and
the life of the machine / plant.
The Assembly and Operating Instructions include numerous instructions referring to possible hazards. The user is responsible for training the operating staff at the machine / plant
or on site and ensuring that the safety regulations are observed.
The Assembly and Operating Instructions do not include instructions and guidelines for
major repair work.

11/2013 Rev 0

ThyssenKrupp Resource Technologies can provide skilled and qualified personnel to carry out inspections and repairs if required.

2-492-20980 (POS 01)

1-3

1.5

Liability and warranty
ThyssenKrupp Resource Technologies explicitly exclude all liability and warranty claims
for damage or operational malfunctions originating from:

Non-compliance with instructions in the Assembly and Operating Instructions

Incorrect operation

Any use of the machine other than the specified use

Faulty maintenance

Use of consumables (in particular lubricants) not explicitly permitted by the manufacturer

Use of spare parts not approved by the manufacturer

Conversions and modifications not approved by the manufacturer.

In addition, the conditions for liability and warranty as specified in the General Conditions
of Supply of ThyssenKrupp Resource Technologies are applicable.

1.6

Copyright
We reserve all rights in connection with this documentation, including those relating to patent registration or provisional patent registration. This documentation may not be disclosed to third parties or reproduced or used in any other way without our previous consent
in writing.

1.7

Technical modifications

11/2013 Rev 0

ThyssenKrupp Resource Technologies reserves the right to change designs in the course
of technical developments. Recent modifications may not yet have been included in the
drawings and texts of these Assembly and Operating Instructions.

1-4

2-492-20980 (POS 01)

1.8

Stocking of spare parts

CAUTION
The use of non-original spare parts
Damage to the machine/plant or its environment is possible
• Only use original spare parts that are approved by ThyssenKrupp ResourceTechnologies.
Damage caused by using products other than the original spare parts and accessories is excluded from the liability and warranty.
We expressly point out that we cannot assume any liability for spare parts and
accessories which have not been supplied by us. In some cases the installation of
such products may alter and negatively affect the structural characteristics of the
machine / plant and therefore impair safety.
Continuous operation and operational readiness of the machine / plant can only be ensured if important spare and wear parts are held in stock.
Please order spare parts using the information contained in the spare parts list. The spare
parts drawings listed in the spare parts list furnish additional information.
Our warranty only covers genuine spare parts supplied by us.

11/2013 Rev 0

Please note that parts manufactured by us and non-company products are often subject
to special production and delivery specifications.

2-492-20980 (POS 01)

1-5

11/2013 Rev 0

Blank page

1-6

2-492-20980 (POS 01)

Technical data

Crusher type:

Gyratory crusher KB 63 - 75

Max. particle size feed:

1200 mm ROM
80% < 450 mm

Crushing:

0 - 250 (X) mm
P80 ≤ 175 mm

Moisture content:

max. 2%

Hardness:

fmean = 150 MPa
fmax = 250 MPa

Bulk density:

2.3 t/m³

Crusher work index:

10 kWh/t

Crushing gap OSS (design):

approx. 175 mm

Crusher mouth opening:

approx. 1600 mm

Mantle diameter:

2030 mm

Stroke of the hydraulic cylinder:

max. 280 mm

Circumferential back lash between bevel gear/
bevel pinion:


suggested value +/- 15%

11/2013 Rev 0

2

Figure 0

2-492-20980 (POS 01)

2-1

2.1

Oil circulating lubrication and hydraulic unit
See ANNEX 9.8 "Oil circulating lubrication and hydraulic unit"

2.2

Oil tank:

separate tank

Tank capacity lubricating oil:

approx. 1500 litres

Tank capacity hydraulic oil:

approx. 250 litres

Over-pressure ventilation of the dust sealing
See ANNEX 9.5 "Compressor (over-pressure ventilation)"

2.3

Blower:

Gasring-compressor, single-stage 
G 200 2BH1500-7AC19G with intake filter 2BX2102

Excess pressure:

approx. 0.15 bar

Air flow rate:

approx. 100 m³/h

Electric motor

Voltage:
Capacity P:
Speed n:

Weight:

approx. 36 kg

460 V, 60 Hz
2.2 kW
1800 min-1

Grease lubrication for spider bearing
See ANNEX 9.7 "Central lubrication" and ANNEX 9.6.2 "Grease filling level sensor of the
top axle mounting"

200 litres

11/2013 Rev 0

Electric barrel pump:

2-2

2-492-20980 (POS 01)

2.4

Drive
See ANNEX 9.2 "Couplings" and Chapter 4.4.9 "Crusher main drive motor and pinion assembly"
750 kW, 60 Hz, 507 min-1

Safety coupling:

BWL 125 Spec.

Multiple-disc steel clutch:

MTF 514

11/2013 Rev 0

Motor:

2-492-20980 (POS 01)

2-3

11/2013 Rev 0

Blank page

2-4

2-492-20980 (POS 01)

3

General safety instructions

3.1

Principles
The machine/plant has been manufactured in accordance with the recognised safety
regulations. However, this does not preclude danger to life and limb for the user or others,
nor does it prevent harm to the machine/plant and/or other property.
– These safety instructions must be observed by all persons responsible for the transport, installation, commissioning, operation, maintenance as well as the dismantling
and disposal of consumables and process materials. We recommend that the owner
obtains a signed confirmation that the safety instructions have been read and understood by his personnel.
– The machine/ plant may only be used in a technically perfect condition in accordance
with its designated use and the instructions set out in the manual, and only by safetyconscious persons who are fully aware of the risks involved in operating the machine/
plant! Any malfunctions, especially those affecting the safety of the machine/plant,
should therefore be rectified immediately.
– In addition to the manual, observe and instruct the user in all other generally applicable
legal and other mandatory regulations relevant to accident prevention and environmental protection!

11/2013 Rev 0

These compulsory regulations may also deal with the handling of hazardous substances,
issuing and/or wearing personal protective equipment (safety helmet, safety boots, safety
goggles, hearing protection, respiratory protection).

Observe all safety instructions and warnings attached to the machine/ plant!

Ensure that safety instructions and warnings attached to the machine/plant are always
complete and perfectly legible!

In the event of safety-relevant modifications or changes in the behaviour of the
machine/ plant during operation, stop the machine/ plant immediately and report the
malfunction to the responsible department!

Never make any modifications, additions or conversions to the machine/ plant which
might affect safety without the supplier's approval! This also applies to the mounting
and adjustment of safety devices and safety valves as well as to welding work on loadbearing elements.

Replace hydraulic hoses within at appropriate intervals even if no safety-relevant
defects have been detected!

Comply with the prescribed intervals or those specified in the operating instructions for
routine checks and inspections!

For the execution of maintenance work, tools and workshop equipment adapted to the
task on hand are absolutely indispensable.

The personnel must be familiar with the location and operation of fire extinguishers!

Observe all fire-warning and fire-fighting procedures!

2-492-20980 (POS 01)

3-1

3.2

Modifications and spare parts
– For safety reasons, conversions and modifications are prohibited unless previously
approved by ThyssenKrupp Resource Technologies.
– Use of accessories and spare parts not approved by ThyssenKrupp Resource Technologies can lead to unforeseeable dangers.

3.3

Personnel
Personnel entrusted with work on the machine/ plant must have read the manual and in
particular the chapter on safety before beginning work. Reading the Instructions after work
has begun is too late. This applies especially to persons working only occasionally on the
machine/plant, e.g. during setting up or maintenance.
For reasons of security, long hair must be tied back or otherwise secured, garments must
be close-fitting and no jewellery - such as rings - may be worn. Injury may result from being
caught up in the machinery or from rings catching on moving parts.

Use protective equipment wherever required by the circumstances or by law!

Any work on and with the machine/plant may only be carried out by reliable personnel.
Statutory minimum age limits must be observed!
Employ only trained or instructed staff and set out clearly the individual responsibilities of
the personnel for operation, set-up, maintenance and repair!

Define the machine operator's responsibilities - also with regard to observing traffic
regulations - giving the operator the authority to refuse to carry out instructions by third
parties which compromise safety!

Work on the electrical system and equipment of the machine/plant may only be carried out
by a skilled electrician or by instructed persons under the supervision and guidance of a
skilled electrician and in accordance with electrical engineering rules and regulations.

11/2013 Rev 0

Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of hydraulic equipment!

3-2

2-492-20980 (POS 01)

3.4

Noise hazard
Information on the emissions level which is specific to the work station
No permanent work station has been assigned to the plant/machine.
Depending on the material to be processed, noise emissions will occur: these may only
be measured during operation. The user has to ensure the measurement of the sound
power level of all operation positions (e.g. for maintenance and checking, control station)
immediately after commissioning.

INFORMATION

Directive 2003/10/EC of the European Parliament and of the Council dated 6 February 2003 (17th individual directive in terms of Article 16 Paragraph 1 of the
Directive 89/391/EEC).
If other measures fail to prevent from risks due to noise hazards, a suitable and
properly adapted personal ear protection must be made available to the employee
and need be used by the employee.
Personal ear protection must be worn by the personnel if the noise hazard
reaches the threshold value (85 dB (A)).

3.5

Information regarding residual risks during daily operation
The safety requirements specified in the EC Machines Directive have been taken into account in the machine/plant.
Residual risks can nevertheless still occur during operation.
Residual risks, which remain even after careful shutting off and with platforms corresponding to the applicable safety requirements, are pointed out below.
Mechanical hazard/material
– Overcharging of the crushing area/ crusher discharge
Overcharging and discharge of crushing material on account of upstream conveying
equipment and/or congestion of material in the feed hopper.

11/2013 Rev 0

– Dusty operating conditions
on account of the type of feeding material, material feeding, the crushing procedure,
the material discharge.

2-492-20980 (POS 01)

3-3

3.6

Fire protection

The legal requirements regarding fire protection and fire prevention have to be complied with and supplemented with in-company regulations. The fire-fighting experts of
the insurance companies should also be consulted in this process.

Appoint supervisors who are in charge of all the matters related to fire prevention and
fire fighting and provide them with the knowledge required for this task.
The management staff and the engineers must support them in their task in an advisory
capacity.

The supervisor must check the fire extinguishing equipment at regular intervals, in order
to ensure that the equipment is always ready for use.
Areas which are easily flammable require particular attention in this context!
The persons commissioned with supervision and fire fighting must have attended a first
aid course. First aid stations must be provided.

The fire protection regulations must be posted at different locations in the plant.

The personnel must be informed about the fire protection measures. Any case of fire
must be reported immediately.

The units and the assembly groups which heat up more strongly during operation on
account of the electrical and/or mechanical stress to which they are exposed must be
monitored by the responsible personnel. This applies e.g. to compressors, gear units,
bearings, motors, oil/hydraulic units.

The fire extinguishers must be easily accessible and may not be obstructed by objects.
– The personnel must be familiarised with the use of the fire extinguishers to such a
degree that they are capable of fighting fire outbreaks with the appropriate fire extinguishers.
Fire-fighting rules
– Use fire-fighting water for burning wood, waste, fabric, jute, paper, belts, etc.
– In case of burning liquids (mineral oil, petrol, oil, petroleum, paints, tar, etc.), always
use CO2 extinguishers and powder type fire extinguishers.
– In case of burning cables, motors, electric plants, etc. only use powder type fire extinguishers or CO2 extinguishers.

Disposal of consumables and process materials

3-4

The safe and environment-friendly disposal of all consumables and process materials
should be ensured. You should also make sure that all respective national regulations
for the protection of the environment are complied with.

2-492-20980 (POS 01)

11/2013 Rev 0

3.7

4

Design and operating principle

4.1

Scope of application and designated use

DANGER
Risk of injury through operating the machine/plant with unauthorised modifications, conversions or spare parts
Imminent danger of death or severe bodily injuries
• ThyssenKrupp Resource Technologies explicitly excludes all liability and warranty claims if modifications/conversions are made without the express permission in writing of the manufacturer.
• Only operate the machine/plant in its original condition. Any deviations from the
original condition must be reported by the operator to the responsible department.

CAUTION
System damage through use of the machine/plant contrary to its designated
use
Damage to the machine/plant or its environment is possible
The intended use of the machine/plant is regulated by contract. Any other use contrary to its designated use is prohibited. ThyssenKrupp Resource Technologies
cannot be held liable for damage resulting from such misuse. The risk of such misuse lies entirely with the user.
• The gyratory crusher must be constantly fed with material to ensure that the
crushing chamber is always at least 80 % full.
• The machine/plant must be used exclusively for the intended purpose agreed
upon with the manufacturer.

11/2013 Rev 0

• Observe the Assembly and Operating Instructions.

The constant feeding ensures that the main shaft bearing is always uniformly loaded
("quiet load running").
At the same time a stable film of lubrication keeps wear to a minimum on all of the affected
bearing components.
This method also has a positive effect on the wear pattern of the crushing tools.

2-492-20980 (POS 01)

4-1

Frequent idle-running phases lead to uncontrolled movements of the main shaft in the spider head bearing and in the lower bearing bushing. At the same time, continuous re-filling
of the crushing chamber causes fluctuating loads and consequently uneven running under
load.
This impact-type method of operation destabilises the lubricating film between the bearing
components which can cause undesirable abrasion on the bearing positions.
This negative operating mode leads to an uneven wear patter with respect to the crushing
tools / wear parts.

INFORMATION

Prior to use of the machine/plant beyond this scope of application, consult the
after-sales service. Otherwise the warranty will lapse.

4.2

Main components
See Illustration 2

1

2

3

4

5

6

7

8

9

Crusher shells

(1)

Concaves

(2)

Wear parts

(3)

Base plate

(4)

Main shaft with mantle

(5)

Dust sealing

(6)

Eccentric bushing with bevel gear

(7)

Connection of main shaft hydraulics

(8)

Spider bearing

(9)

10

11

12

13

14

15

16

17

18

19

4-2

Lower main shaft bearing (axial step bearing)

(10)

Pinion assembly with pinion

(11)

Crusher main drive motor

(12)

Speed monitor

(13)

Connection for the oil circulating lubrication

(14)

Connection for the hydraulic unit

(15)

Connection for grease lubrication

(16)

Grease filling level sensor

(17)

Distance sensor (position of main shaft/gap width)

(18)

Main shaft hydraulics

(19)

Overpressure-ventilation

attached to the steel
structure

Grease lubrication pump with control

on the sub-structure

2-492-20980 (POS 01)

11/2013 Rev 0

The gyratory crusher basically consists of the following assembly groups:

Balance unit for main shaft hydraulics

attached to the steel
structure

11/2013 Rev 0

Oil circulating lubrication and hydraulic unit (main shaft adju- attached to the steel
stment)
structure

Figure 1

2-492-20980 (POS 01)

4-3

4.3

Operating principle
See Illustration 2
The material fed into the crusher is crushed between the fixed concaves (2) of the crusher
shells (1) and the wobbling mantle of the main shaft (5) .
The tumbling movement of the mains shaft (5) is driven by the eccentric bushing (7) . This
causes the gap between the concaves and the mantle to vary continuously at the circumference. The material is broken up by crushing and impact effects until it can leave the
crusher through the crushing gap.
The main shaft (5) is radially guided in the upper spider bearing (9) in the spider bushing
and in the lower eccentric bushing (7). Axial support of the main shaft (5) is provided by a
hydraulic cylinder (19) which can be used to adjust the crushing gap by moving the piston
and thus the main shaft (5).

11/2013 Rev 0

A hydraulic unit (for vertical adjustment of the main shaft/setting the crushing gap and protecting against overload) is integrated the unit for the oil circulating lubrication of the eccentric bushing and the axial bearing (= internal lubrication circuit) as well as the eccentric
bushing (= external lubrication circuit). The units are combined for reasons of accessibility
and maintenance but form separate circuits.

4-4

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 1

2-492-20980 (POS 01)

4-5

4.4

Assembly groups

4.4.1

Crusher shells, concaves and wear parts
See Figure 3 and Figure 4
The crusher shells (a cast structure) consist of the following:
– the conical upper and lower shell (1, 2)
– the spider mounted on these (3)
– the three-arm bottom shell, which is located under the lower shell (4),

11/2013 Rev 0

– the spider cap (5).

Figure 2

4-6

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 3

2-492-20980 (POS 01)

4-7

The inside of the shells are lined with concaves (9).
The top of the upper shell is also lined with rim liners (6).
The arms of the spider are protected from wear by arm liners (26).
The crusher axle (7) is supported and centred by the top axle mounting (8) within the spider (7). The spider bearing is protected by the spider cap (5).
Bowls (1, 2) and bottom part (4) are positioned via conical seats and screwed to the external flanges.
The bottom shell is lined with liner plates (10). It is connected to the internal hub via three
arms (11). One of the arms is designed for the installation of the pinion assembly (12)
(pinion assembly tunnel). The compressed air piping (13) for the dust sealing (14) and the
lubrication oil piping (15) are installed in one arm and passed to the outer eccentric
bushing of the external lubrication circuit (16). The arms are protected against damage
from impacting material by liner plates (17) and (27).
The hub in the centre accommodates the outer eccentric bushing (16). The eccentric
bushing (18) is arranged in the outer eccentric bushing. The dust sealing (14) is mounted
on top of the hub.
The base plate (19) (including axial step bearing ring) is bolted to the bottom shell, which
supports the eccentric bushing in the axial direction. The hydraulic cylinder (20) supports
the axial step bearing (21) and is arranged under the base plate. The hydraulic cylinder is
also bolted to the bottom shell.
There is an inspection opening cover (22) provided on the bottom part. An inspection opening with a cover (23) is arranged on the bottom shell of the hub for checking the bevel
gear (24) and the pinion (25).

11/2013 Rev 0

The bottom flange of the bottom shell is used to mount the bottom shell on the
substructure/foundation.

4-8

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 1

2-492-20980 (POS 01)

4-9

4.4.2

Main shaft with mantle
The main shaft (1) consists of forged steel. A fire protection ring (3) is bolted to the main
shaft.
The mantle (2) is attached to the shaft cone. The mantle (2) is clamped by the outer ring
nut (6) and an intermediate ring (4) and held on the shaft cone.
The intermediate ring (4) with the outer ring nut (6) and the mantle (2) are secured against
twisting by a welded seam (w1, w2). The outer ring nut (6) is protected from wear by a cap
(5) and hard facing.
The eye bolt (9) is used to assemble/disassemble the main shaft.
The mantle is back-filled with a special sealing compound (7) (see ANNEX 9.4).
The sealing ring of the dust sealing (8) is screwed to the underside of the main shaft (1).
The upper shaft of the main shaft is protected by the main shaft sleeve (10).

11/2013 Rev 0

The step bearing upper part (11) of the axial step bearing is mounted on the bottom front
face of the main shaft.

4 - 10

2-492-20980 (POS 01)

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Figure 4

2-492-20980 (POS 01)

4 - 11

4.4.3

Spider bearing with grease lubrication
See Figure 6 and Figure 7
The top main shaft bearing is designed as a slide bearing. The top shaft of the main shaft
is surrounded by the main shaft sleeve (1a) and guided in the spider bush (1c) with insert
(1b).
The top main shaft bearing is lubricated with grease by a separately arranged lubrication
unit.
The spider bushing is sealed against the crushing chamber by a sealing ring (4) with shaft
sealing rings (2) and the leather packing (3).
A pneumatically operated grease lubrication pump (7) supplies the top axle mounting with
grease via the lubricant connection (5).
A filling level sensor (6) is installed in the head of the spider. It is used to monitor the
grease level of the spider bearing and automatically activates the grease lubrication pump
if necessary.
The grease reservoir is provided with a filling level sensor with low level indication.

11/2013 Rev 0

Figure 5

4 - 12

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 6

2-492-20980 (POS 01)

4 - 13

A flow meter (8) is installed in the grease lubrication line.
The following components are installed on the control plate (9) to control the grease lubrication pump (7):
– Pressure relief valve to regulate the operating pressure of the grease lubrication pump
– Pressure gauge to indicate the operating pressure of the grease lubrication pump
– 3/2 way valve to activate the grease lubrication pump
– Grease filter
– Check valve

11/2013 Rev 0

In the event of a failure, the crusher main drive motor can be switched off depending on
the interlocking system.

4 - 14

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 2

2-492-20980 (POS 01)

4 - 15

4.4.4

Over-pressure ventilation of the dust sealing
See Figure 9 and Figure 10
The dust sealing protects the section of the oil circulating lubrication inside the gyratory
crusher against the ingress of dust from the crushing chamber (A).
The internal space (B) is sealed by means of a plastic ring (1) which is mounted between
the top and bottom sealing rings (2) and (3) with a clearance. A low radial clearance is provided between the plastic ring (1) and the sealing housing (4). The plastic ring (1) follows
the wobbling motion of the main shaft.
A separately arranged blower also generates a slight over-pressure inside the gyratory
crusher (B).
As a result, there is a continuous air flow from the interior of the crusher (B) to the crushing
chamber (B). This prevents the ingress of dust and other pollutants.
The sealing effect is also maintained if the pressure inside the crusher drops due to the
operating conditions. This is the case e.g. when the main shaft is lifted or the lubrication
oil flows backwards when the crusher is switched off.
The oil seal (5) prevents splash oil from leaking into the space above the plastic ring (1).

11/2013 Rev 0

The lubricating oil is passed via a duct (6) in the sealing housing and bottom part and is
returned to the tank.

Figure 7

4 - 16

2-492-20980 (POS 01)

Starting from the compressor (1), the compressed air is passed to the hollow space of the
dust sealing via a hose/pipe system (2), the pressure transducer (3) (adjustable from 70 150 mbar) and the air ducts (4) in the hub of the bottom shell and in the dust sealing
housing.
The compressor is provided with an intake filter (5) and a pressure relief valve (6) and
mounted on a bracket on the steel structure.
In the event of a failure, the crusher main drive motor can be switched off depending on
the interlocking system.

11/2013 Rev 0

After the crusher has been switched off, the blower decelerates with a time delay.

Figure 8

2-492-20980 (POS 01)

4 - 17

4.4.5

Eccentric bushing
The eccentric bushing is driven by the pinion assembly. It guides the main shaft in the
inner eccentric bushing (4) and generates its wobbling (rotary/oscillating) motion.
The eccentric bushing consists of the eccentric bushing body (1) on which the bevel gear
(2) is mounted by means of a feather key (3) and bolts (7).
The inner eccentric bushing (4) is made of bearing metal and is secured against rotation
by a feather key (5).
The eccentric bushing is lubricated by the oil circulating lubrication internally (between the
inner eccentric bushing and the main shaft), externally (between the eccentric bushing
and the outer eccentric bushing) and on the underside (between the eccentric bushing and
the axial step bearing ring).
The circulating lubrication also supplies the teeth of the bevel gear.

11/2013 Rev 0

The top device for compensating unbalance (6) fixes the inner eccentric bushing in a vertical (axial) direction.

4 - 18

2-492-20980 (POS 01)

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Figure 9

2-492-20980 (POS 01)

4 - 19

4.4.6

Base plate (with axial bearing ring)
The base plate is arranged between the bottom shell of the crusher (3) and the hydraulic
cylinder (2).
The hydraulic cylinder (2) is bolted to the bottom shell (3) via through holes in the base
plate (1).
The turning flank clearance between the bevel gear of the eccentric bush and the pinion
assembly can be set using slotted spacer plates(74) arranged between the base and the
bottom shell.
The axial step bearing ring (5) is provided with lubrication grooves and is arranged on the
base plate. The eccentric bushing slides on the axial step bearing ring. The cylindrical pin
(6) secures the axial step bearing ring against twisting.

11/2013 Rev 0

The sealing cord (7) prevents oil losses (lubrication space - external bearing) and the ingress of pollutants into the interior of the crusher.

Figure 3

4 - 20

2-492-20980 (POS 01)

4.4.7

Lower main shaft bearing (axial step bearing)
The lower main shaft bearing (axial step bearing) axially supports the main shaft on the
piston of the hydraulic cylinder and takes up its wobbling motion.
The hydraulic cylinder for adjustment of the crushing gap (main shaft adjustment) and protection against overload is located below the axial step bearing.
The axial step bearing is designed as a slide bearing. The step bearing upper part (1) is
bolted to the main shaft; the slide bearing plate (2) is arranged on the hydraulic cylinder
and secured against sliding/torsion by the cylindrical pin (3). The bottom spherical disk (4)
moves between them. Lubrication grooves are provided in the step bearing upper part and
the slide bearing plate.

11/2013 Rev 0

The boundaries of the bearing components are supplied with lubrication oil by the internal
lubrication oil circuit.

Figure 10

2-492-20980 (POS 01)

4 - 21

4.4.8

Hydraulic cylinder and balance unit
The main shaft hydraulic unit consists of the hydraulic cylinder (1) and the balance unit (2).
It is used to adjust the crushing gap, especially if the crushing tools are worn, and to protect against overload.
The separately arranged balance unit is used for vertical guidance of the piston, especially
if the main shaft is sudden relieved of load during operation of the crusher. Lifting of the
main shaft off the main shaft bearing is thereby prevented.
The balance unit consists of a compressed air tank (3) and a compensation cylinder (4)
with an integrated check valve and an adjustable throttle valve. The cylinder of the balance
unit is connected to the hydraulic cylinder (1) of the main shaft adjustment system via pipe
systems.
The compressed air tank (3) of the balance unit is only filled with enough compressed air
to prevent the pressure from lifting the piston and thus the main shaft via the compensation cylinder (4) when the crushing chamber is empty.
As soon as the main shaft is lifted, the oil pressure in the hydraulic cylinder (5) drops
because the piston is relieved of the load of the main shaft. The pressure in the compressed air tank presses the oil from the compensation cylinder into the cylinder (5) and
causes the piston with the axial bearing (6) to follow the main shaft.
As soon as the main shaft is lowered, the oil pressure in the cylinder (5) rises and the oil
is pressed back into the compensation cylinder.
A check valve with an adjustable throttle upstream of the compensation cylinder prevents
the oil from rushing into the balance unit (1) when the main shaft is lowered.
The position of the piston and/or the main shaft (i.e. the size of the crushing gap) is determined by the distance sensor (7).

11/2013 Rev 0

The three adjustable pressure relief valves (8) are used to limit the working pressure and
thus serve as an overload protection.

4 - 22

2-492-20980 (POS 01)

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Figure 11

2-492-20980 (POS 01)

4 - 23

4.4.9

Crusher main drive motor and pinion assembly
See Figure 15
The drive refers to the connection between the electric motor and pinion assembly.
It consists of:
– the multi-plate couplings (1) between the pinion assembly and the electric motor,
– with intermediate piece/ spacer tube (2),
– the safety coupling (3) between the multi-plate coupling and spacer tube,
– Speed sensor (14)
– Protection box (15) and
– Motor bracket (16).
The multiple-disc steel clutch is used to compensate for minor alignment faults between
the motor shaft journal and the pinion assembly shaft(4).
The distance tube allows the pinion assembly to be removed without shifting the drive
motor.
The safety coupling is provided with a torque limiter with hydraulic torque setting. The necessary releasing torque is set by varying the hydraulic pressure. See Chapter 5.8.5
"Transmission" and ANNEX 9.2 "Couplings".
Transmission
The pinion assembly is arranged in the pinion assembly tunnel of the bottom shell of the
crusher.
The shaft of the pinion assembly (4) with a pinion (5) to drive the bevel gear of the eccentric bushing is supported in the pinion assembly housing (6) by roller bearings (7) and (8).
The bearings are lubricated by the oil filling in the pinion assembly housing (stand oil lubrication).
The contact pattern of the teeth of the bevel gear set and the backlash can be adjusted by
changing the thickness of the disks (9) (see Chapter 7.3.9 "Drive and pinion assembly").
Resistance thermometers (10) and (11) are installed in the pinion assembly housing to
monitor the temperature of the pinion assembly bearings.

max. 85 °C

Warning

max. 92 °C

Depletion of crusher

The fluid switch (12) monitors the oil level of the pinion assembly housing.

11/2013 Rev 0

Accelerometers (optional) (13) (including evaluation unit) monitor the condition of the roller
bearings of the pinion assembly.

4 - 24

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 12

(similar illustration)

2-492-20980 (POS 01)

4 - 25

4.4.10

Measuring and monitoring equipment
Monitoring of the oil circulating lubrication and hydraulic unit:

Filling levels of lubricating oil tank and hydraulic oil tank

Temperatures of lubricating oil tank and hydraulic tank

Operating pressures in lubrication circuits and the hydraulic system

Filter clogging

Lubricating oil temperature (return flow)

Lubricating oil temperature in cooling circuit

Monitoring of lubricating oil flow rate (flow meters for supply and return flow)

Shaft position via distance sensor, see Chapter 4.2 "Main components".

See also ANNEX "9.9 Oil circulating lubrication and hydraulic unit".
Grease lubrication unit for spider bearing

Filling level of reservoir, see Chapter 4.4.3 "Spider bearing with grease lubrication"

Grease filling level of the spider bearing, see Chapter 4.4.3

Flow function via a pulse counter in the grease lubrication line of the top axle mounting,
see Chapter 4.4.3.

See also ANNEX "9.8 Central lubrication".
Transmission
See also Chapter 4.4.9 "Crusher main drive motor and pinion assembly"

Filling level monitoring unit of oil filling of pinion assembly housing

Temperature of the pinion assembly bearings

Monitoring of the torque

Accelerometer (optional).

11/2013 Rev 0

The speed monitor (1) is arranged on a bracket (2) which is screwed to the flange of the
transmission. Two diametrically opposite sheet metal strips (3) and (4) which function as
cam switches are mounted on the flange of the multiple-disc clutch.

4 - 26

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 13

2-492-20980 (POS 01)

4 - 27

4.4.11

Oil circulating lubrication and hydraulic unit
See Figure 17 and ANNEX 9
The oil circulation lubrication unit for the lower main shaft bearing (axial step bearing and
eccentric bearing) and the hydraulic unit for setting the crushing gap/main shaft adjustment and overload protection are combined in one unit.
Function of the oil circulating lubrication
The lubricating oil is drawn from the tank and supplied to the lower main shaft bearing via
two separate oil lines (internal and external lubrication circuits).
The oil for the internal circuit (1) (axial step bearing and inner eccentric bushing) is conducted to the bearing points through the hydraulic cylinder (2).
The oil for the external circuit (3) (outer eccentric bushing) is conducted to the bearing
point via a separate pipe system.
After the bevel gear and pinion have been lubricated, the two oil flows return to the tank
via a common return line (4).
Function of the hydraulic system
The hydraulic cylinder (2) is a plunger cylinder with an internal duct for conveying the lubricating oil from the internal circuit and the hydraulic oil connection (5).
During operation of the crusher, the main shaft is axially supported on the piston (7) of the
hydraulic cylinder via the axial step bearing (6).
The main shaft can be lifted/lowered by regulating the oil volume, thereby adjusting the
crushing gap.
The position of the piston, and thus the position of the main shaft, is measured by the integrated distance sensor (8).
The cylinder is protected against overload caused by feeding material which cannot be
crushed by two pressure relief valves (9) in the cylinder bottom.

11/2013 Rev 0

The separately arranged balance unit (10) is connected to the hydraulic cylinder (2) via
pipes. It consists of a compressed air tank and a compensation cylinder and prevents the
main shaft from lifting off the axial step bearing under particular conditions of operation.
See also Chapter 4.4.8.

4 - 28

2-492-20980 (POS 01)

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Figure 14

2-492-20980 (POS 01)

4 - 29

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Blank page

4 - 30

2-492-20980 (POS 01)

5

Transport, storage and installation

5.1

Transport instructions
The machine/plant is transported in component parts or as assembly groups. Make sure
that suitable lifting tackle is used to unload the parts from the transport vehicles and move
them to the storage location.
The machine/plant must be transported with adequate care in order to prevent damage
and not endanger staff. In addition to the following information, the general and local
safety and accident prevention regulations must be observed. Overhead gantries and
mobile cranes or lifting tackle with a sufficient load bearing capacity must be available to
carry out the unloading, transport/loading safely and correctly.

11/2013 Rev 0

The transport and storage symbols on the machine packaging must be heeded.

Keep away from heat

Keep dry

Caution! Glass!

This way up

Sling here

Centre of gravity

Do not use hand
hooks

No hand truck here

Stacking limitation

Clamp here

Permitted temperature range

Do not use fork lift
truck here

Electrostatic sensitive
device

Do not destroy barrier

Tear off here

Do not roll

2-492-20980 (POS 01)

5-1

When transporting the machine by crane, only use suitable loading devices.
When packing the machine, loading devices may only be attached at the marked points.

DANGER
Risk of injury due to the improper transport of the machine/plant
Imminent danger of death or severe bodily injuries
• Only transport the machine/plant on the designated slinging devices (lugs) and
slinging points.
• The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
• Make sure to use proper transportation equipment.
• Do not walk under suspended loads.
• Secure moveable components.

CAUTION
System damage from improper transport of the machine/plant
Damage to the machine/plant or its environment is possible
• Do not attach any additional slinging points to the machine through welding,
torching or drilling (notching effects and the corresponding risk of crack formation).
• Do not push together the side walls or the attachment parts of the machine by
pulling lifting gear at an angle!

11/2013 Rev 0

• If transport securing devices have been furnished do not remove them until
installation has been completed.

5-2

2-492-20980 (POS 01)

CAUTION
System damage from improper storage/assembly of the machine/plant
Damage to the machine/plant or its environment is possible
• If the machine/plant is to be stored, it has to be left in the delivery condition. The
manufacturer is not liable for damage caused by improper repeated assembly of
the machine/plant.

11/2013 Rev 0

Check all components for transport damage after delivery to the site.

2-492-20980 (POS 01)

5-3

5.2

Hoisting devices and slinging equipment

WARNING
Risk of injury through components that are improperly secured during
installation
Death or severe bodily injuries are possible
• Make sure that moveable components are properly secured during installation

5.2.1

Lifting gear
Usually, cranes and lifting gear is used for transporting heavy assembly groups and components. Slinging equipment such as ropes and hooks are critical elements between the
load and lifting equipment.
Safe lifting requires adequately dimensioned and suitably designed lifting gear and slinging equipment to be used, as well as correct attachment and fixing to the load.
The weight of assembly groups and components is specified in the spare parts catalogue
/ in the Operating Instructions, so that equipment such as e. g. hoisting devices, winches,
cranes, lifting chains can be selected accordingly.
Check hydraulic winches for proper function before use. Only use winches with adjustment ring. This allows loads to be supported mechanically and prevents their lowering.

INFORMATION

11/2013 Rev 0

Before lifting heavy loads, attach a load cell to check the load.

5-4

2-492-20980 (POS 01)

5.2.2

Lifting

Before lifting, determine the weight of the load.

Determine the size and shape of the load; two criteria which determine the following:
– the type of load securing, e. g. with slings, baskets or slings with special fixtures,
– the slinging equipment / load securing fixtures, e. g. lifting rope, lifting chain, screw
eyes, yokes (see following sections),
– the load angle of the slinging equipment.

Determine the thickness of the slinging equipment to be used. Do not exceed the permissible load bearing capacity of the slinging equipment.

If any of the following points are unclear, consult the assembly supervisor responsible:
– correct attachment method,
– selected thickness of slinging equipment,
– type of slinging equipment.

Check the slinging equipment for damage / faults. Make sure that any faulty slinging
equipment is discarded immediately.

Do not overload slinging equipment and protect it against sharp corners and edges of
the load e. g. through edge/corner protection made of sacking or metal, boards etc.

Protect high-gloss/finished surfaces of the load against damage caused by the slinging
equipment. Protective material that is intended to prevent the load/lifting means slipping must be attached in such a way that it cannot slip if the slinging equipment becomes loose.

When attaching slinging equipment at great heights:
– Use the climbing aids provided. If no climbing aids have been provided or these are
not available, use an approved ladder.
– Secure the ladder to prevent it slipping or falling over.
– Use both hands for climbing. Have the slinging equipment to be attached brought
up by lifting tackle (e. g. crane).
After attaching the slinging equipment, tighten it as far as possible by hand. If the slinging equipment has to be tightened by crane, make sure that no body parts get between the load and the slinging equipment, and keep hands and fingers safe.

11/2013 Rev 0

2-492-20980 (POS 01)

5-5

Give the crane driver fixed/agreed clear signals for moving the load.

Before lifting the load:

Remove any material lying loosely on the load.

Secure unused rope/chain ends, e. g. by hooking them to the main ring/collecting them
in the shackle.

Instruct staff to leave the hazard area.

Check that the load is secured symmetrically at all points.

Make sure that the slinging equipment cannot damage the load (and vice versa).

After the weight of the load has been picked up completely by the lifting tackle and
the load has been lifted a little:

Check the load brake.

Check again whether the load is secured at all points.

Transport the load over free areas as far as possible.

Warning signals must be given if there is anyone in the hazard zone.

Setting the load down:
Set the load down slowly on a respectively sturdy base. Align the base again before
the load is set down.

Remove slinging equipment from the load and check both for damage.

11/2013 Rev 0

5-6

2-492-20980 (POS 01)

5.2.3

Lifting ropes
The number of sling points is equal to the number of rope strands connecting the crane
hook with the load. A load angle i. e. an angle between the horizontal surface of the load
and the lifting ropes is formed by several strands. The smaller the load angle, the smaller
the permissible load bearing capacity of the lifting ropes and thus the effectiveness.
Effectiveness of the load angle

Effectiveness
Load angle

Load bearing capacity
%

max. permissible load per strand in relation to 1000 kg

50,0

(500 kg)

45°

70,7

(707 kg)

60°

86,6

(866 kg)

90°

100,0

(1000 kg)

11/2013 Rev 0

30°

2-492-20980 (POS 01)

5-7

The load bearing capacity/wire rope strength is reduced by:
– Splitting rope loops in the lifting ropes and splitting lifting ropes into continual
strands
– Bending round corners
– Using lifting ropes for clamping
– Acceleration and slowing during lifting and lowering operation
– General wear
– High and low temperatures
– Vibration
– Corrosion
Use:
Although the weight of lifting ropes is lower than that of lifting chains of the same load bearing capacity, they have a few disadvantages. They can become damaged more easily
and are more difficult to handle since their bending radius is smaller.
Lifting ropes are suitable for vertical lifting operation or for lifting operation where ropes
must be routed in a large radius around corners.
The thickness of a wire rope is given in relation to its outer diameter.

Protect lifting ropes from the influences of the weather, solvents, high temperatures
and chemicals.

Avoid knots forming in wire ropes. In the event of a knot, do not use the rope again.

Protect ropes against sharp-edged corners by enlarging the corner radius. This can be
by means of metallic corner protection devices or blocks. Sacking and wooden boards
can also be used.

The correct procedure for securing lifting ropes to the hook is as follows:
– Secure each individual strand on the hook to prevent hitching at the hook.

11/2013 Rev 0

– Never use one single slinging rope strand since this could lead to the load rotating.
The wire rope could be untwisted and thus the splice pulled out.

5-8

2-492-20980 (POS 01)

Never wind the wire rope completely around the crane hook (i. e. by 360 degrees). The
low bending radius would damage the rope.

Check the lifting ropes for:
– broken or cut strands,
– rust and corrosion,
– knots and kinked spots,
– damaged eyes
Do not bend the eyes of lifting ropes over corners.

When securing loads by winding the lifting ropes around the load, use shackles (1).

11/2013 Rev 0

2-492-20980 (POS 01)

5-9

5.2.4

Wire rope clamps
Attach wire rope clips in such a way that the lower part of the clip (6) is pushed against the
long end (5) of the rope, and the yoke of the clip (2) against the dead end (4) of the rope.
Always attach a rope thimble (1). The correct number of clips and distance (3) between
them is given in the following table.
Tighten clamping nuts using the given torques.

11/2013 Rev 0

Once the rope has been put into operation and is tensioned, tighten the clamping nuts
again. Check the clamping nuts regularly and tighten if necessary. This compensates rope
expansion and the related reduction of rope radius.

5 - 10

2-492-20980 (POS 01)

Rope diameter

Diameter of the clamping yoke

Distance between clips

Required minimum
number of clips

mm

Inches

mm

Inches

mm

3/16

4,76

11/32

8,73

3

76

2

1/4

6,35

7/16

11,11

3-1/4

83

2

5/16

7,94

1/2

12,70

3-1/4

83

2

3/8

9,53

9/16

14,29

4

102

2

7/16

11,11

5/8

15,88

4-1/2

114

2

1/2

12,70

11/16

17,46

5

127

3

5/8

15,88

3/4

19,05

5-3/4

146

3

3/4

19,05

7/8

22,23

6-3/4

172

4

7/8

22,23

1

25,40

8

203

4

1

25,40

1-1/8

28,58

8-3/4

222

4

1-1/8

28,58

1-1/4

31,75

9-3/4

248

5

1-1/4

31,75

1-5/16

36,51

10-3/4

273

5

1-3/8

34,93

1-1/2

38,10

11-1/2

292

6

1-1/2

38,10

1-23/32

43,66

12-1/2

318

6

1-5/8

41,28

1-3/4

44,45

13-1/4

337

6

1-3/4

44,45

1-15/16

49,21

14-1/2

368

7

2

50,80

2-1/8

53,98

16-1/2

419

8

2-1/4

57,15

2-5/8

66,68

16-1/2

419

8

2-1/2

63,50

2-7/8

69,85

17-3/4

451

8

11/2013 Rev 0

Inches

2-492-20980 (POS 01)

5 - 11

5.2.5

Lifting chains
Use:
Lifting chains are made of alloyed steel and are sturdier and more flexible than lifting
ropes, but they are not as resistant to impact loads as ropes are. The thickness of a chain
is determined in relation to the diameter (1) of a chain link.

Avoid knots forming in lifting chains. They weaken the chain strand and can lead to
deformation or other damage to the chain links.

Shorten lifting chains by hooking them back into the chain or into the main line with the
aid of a gripper hook. Never shorten a chain by twisting, knotting or bolting.

Protect lifting chains against sharp corners and edges that could deform the chain
links. Use suitable flexible boards or metallic corner protection devices.

11/2013 Rev 0

5 - 12

2-492-20980 (POS 01)

If the chain for lifting operation is to be wound around the load to be lifted, always turn
the hook opening away from the direction in which the slings are to be pulled. This prevents the hook slipping out when the slings are tightened.

Check lifting chains for:
– notches, cracks, exact dimensions and wear
– deformed chain links, welding burr, bent or open hooks, elongation
– rust and corrosion

5.2.6

If all the strands of a lifting chain can be hooked back into the main line, the permissible
load bearing capacity of the whole sling can be increased by 50 %.

Hook
The load bearing capacity is usually stamped into the hook.

11/2013 Rev 0

5.2.7

If possible, use a hook with spring-loaded snap-in locking devices. If such hooks are
not available, the hook has to be secured temporarily as shown in the diagram.

Screw-type lifting eyes
The size of screw-type lifting eyes is determined in relation to the diameter of the shank of
the threaded section. A distinction is made between simple screw-type eyes and screwtype eyes with shoulder.

For vertical lifting operation, use simple screw-type eyes (without shoulder).

Screw-type eyes with shoulder are used when loads are to be lifted at certain angles
(e. g. lifting operation with several lifting ropes).
2-492-20980 (POS 01)

5 - 13

The permissible load bearing capacity that has already been reduced by the load angle,
is reduced even further by the use of screw-type eyes.
A screw-type eye with shoulder that is used e. g. at an angle of 45°, can only used for up
to a load of about 10 % of the permissible load for vertical lifting operation.
Permissible loads for eye bolts with shoulders:

Shank diameter

Vertical lifting operation

Tension at 60° to
the shoulder level

Tension at 45° to
the shoulder level

Tension at 90° or
loose side pull

per screw-type eye

per screw-type eye

per screw-type eye

per screw-type eye

Inches

mm

Pounds

kg

Pounds

kg

Pounds

kg

Pounds

kg

1/4

6,4

300

136

50

23

30

14

40

18

1/2

12,7

1300

590

200

91

140

64

150

68

3/4

19,3

3000

1361

400

181

250

113

300

136

1

25,4

6000

2722

800

363

500

227

600

272

1-1/4

31,8

9000

4082

1300

590

800

363

900

408

1-1/2

38,1

13000

5897

1800

816

1200

544

1300

590

2

50,8

23000

10433

3300

1497

2100

953

2300

1043

2-1/2

63,5

37000

16783

6000

2722

3500

1724

4300

1950

5 - 14

Use screw-type eyes of a suitable size.

Check the condition of the thread to make sure the screw-type eye fits tightly and that
there is flush and complete contact between the shoulder and the load. Never use
screw-type eyes with cracked or flawed threads.

2-492-20980 (POS 01)

11/2013 Rev 0

Eyes must be screwed fully in, this ensures the shaft cannot be bent.

Only use screw-type eyes the load bearing capacity of which is suitable for the load,
i. e. shanks with threads that fit exactly in standard boring holes.

Check shanks of the screw-type eyes for deformation or crack formation.

Use hardened washers to make sure the edges of the screw-type eye are a tight fit.
The washers must not be thicker than two threads.

11/2013 Rev 0

2-492-20980 (POS 01)

5 - 15

5.2.8

Shackles

DANGER
Danger caused through the use of improper slinging equipment
Imminent danger of death or severe bodily injuries
• Never replace shackle bolts with standard bolts. Danger of breaking!
Shackles are closed safety devices that cannot be hooked out. Their size is determined in
relation to the diameter of the main part (1) and not in relation to the diameter of the bolt.
A distinction is made between anchor load shackles (on the left of the diagram) and chain
load shackles (on the right).

Do not expose the main part of the shackle to side tensile loads.

Ensure the shackle bolt is a perfect fit.

The permissible load for anchor load and chain load shackles as well as for screw-type
or socket pin is always the same.

If shackles are used at load angles other than 90°, the permissible load bearing capacity is reduced; see table:

11/2013 Rev 0

5 - 16

2-492-20980 (POS 01)

Diameter

Single shackle vertical

Two shackles 60°

Two shackles 45°

Two shackles 30°

mm

Americ.
tonnes

tonnes

Americ.
tonnes

tonnes

Americ.
tonnes

tonnes

Americ.
tonnes

tonnes

1/4

6,4

1/3

0,3

3/4

0,7

1/2

0,5

1/3

0,3

5/16

7,9

1/2

0,5

1

0,9

¾

0,7

1/2

0,5

3/8

9,5

3/4

0,7

1-1/4

1,1

1

0,9

3/4

0,7

7/16

11,1

1

0,9

1-3/4

1,6

1-1/2

1,4

1

0,9

1/2

12,7

1-1/2

1,4

2-1/2

2,3

2

1,8

1-1/2

1,4

5/8

15,9

2

1,8

3-3/4

3,4

3

2,7

2

1,8

3/4

19,3

3

2,7

5-1/2

5

4-1/2

4,1

3

2,7

7/8

22,2

4

3

6

7

6

3

5-1/2

5

1

25,4

5-1/2

5

10

9

8

7,2

6

5,4

1-1/8

28,6

6-1/2

5,9

11-1/2

10,5

9-1/2

8,5

6-1/2

5,9

1-1/4

31,8

8

7,2

14

12,7

12

10,8

8

7,2

1-3/8

24,9

10

9

17

15,4

14

12,7

10

9

1-1/2

38,1

12

10,8

20

18,1

17

15,4

12

10,8

1-3/4

44,5

16

14,5

28

25,4

23

20,9

16

14,5

2

50,8

21

19

36

32,6

30

27,1

21

19

2-1/4

57,2

27

24,5

46

41,7

38

34,5

27

24,5

2-1/2

63,5

34

31

58

52,6

48

44

34

31

2-3/4

70,1

40

36,2

69

62,9

57

51,9

40

36,2

3

76,2

80

45,3

87

78,8

71

64,4

50

45,3

4

101,6

100

90,7

173

156,9

142

128,7

100

90,7

11/2013 Rev 0

Inches

2-492-20980 (POS 01)

5 - 17

Slinging equipment and load protection

Protect lifting ropes against sharp edges/corners. Use materials to enlarge the radius,
e. g. metallic corner protection devices (left and right), belts, wooden blocks, sacking,
steel bushings/sleeves. This protects finished load surfaces from the wire rope too.

Protect lifting chains against sharp edges/corners. Use materials to enlarge the radius,
e. g. metallic corner protection devices (left and right), belts, wooden blocks, sacking,
steel bushings/sleeves. This protects finished load surfaces from the chain too.

11/2013 Rev 0

5.2.9

5 - 18

2-492-20980 (POS 01)

Substructures for loads

Make sure that the base has a sturdy and level surface and can bear the whole weight
of the load. Only use hard wood with (approx.) square cross-section as a base.

Protect finished surfaces by cushioning the base, e. g. with sacking, pressboard, belts.

Use wedges to prevent the load rolling away or moving (e. g. handles, round forged
parts and rings). When using wedges be careful with your hands and make sure they
do not get crushed if the load moves.

When using several supports as substructures, only use supports of the same height.
Place supports under the load so that they are stable and level. Do not use supports
that have rounded edges, are fragile or damaged.

Compensate unevenness under the supports.

Use the supports to create a cavity under the load, enabling the slinging equipment to
be attached and removed easily.

11/2013 Rev 0

5.2.10

2-492-20980 (POS 01)

5 - 19

5.3

Storage requirements

5.3.1

General requirements

CAUTION
System damage from improper storage of the machine/plant
Damage to the machine/plant or its environment is possible
• All the delivered machine and plant components must be stored on suitable supports to keep them dry. The storage place must be free from vibration.
• The stored machine and plant components must be protected from water, sea
water, aggressive vapour or gas and increased ozone concentration.
If the storage time is exceeded by a lengthy period (i.e. more than 2 months), all the bearings of the machine and plant components must be completely filled with suitable grease.
The shafts in the bearings must be turned several times once a month. They must be subsequently topped up with grease. The bearings and housings are thereby protected from
condensation water and rust. After storage, i.e. before the plant component is commissioned, the grease must be removed and the bearings cleaned and regreased (approx. 1/3
of the volume of bearing and housing).
All the machine and plant components must be stored at temperatures between + 5 °C
and + 45 °C. Electrical equipment is to be stored dry and frost-free, temperatures between
minimum + 5 °C and maximum + 45 °C.
All unpainted surfaces must be provided with suitable protection against corrosion.
The storage location must be dry. If equipment is stored in a shipping container, a "desiccant material" must be placed in the container prior to storage. The equipment must be
covered and good ventilation provided in the storage place.

11/2013 Rev 0

The packing climate must be protected from environmental influences, in order to maintain
rust prevention and the effectiveness of siccatives.

5 - 20

2-492-20980 (POS 01)

The storage area must be clean and free from dust and other contaminants.
Equipment must be stored in the original crates or on the original transport skids provided
by ThyssenKrupp Resource Technologies. Equipment on transport skids must be loosely
covered with tarpaulins, in order to keep it clean and to allow the air to circulate.
Stored equipment may not be exposed to direct sunlight.
Plant components made of plastic or rubber may not be exposed to direct sunlight. The
storage temperature must be + 5 °C minimum and + 45 °C maximum. It must be protected
from contamination by grease or oil. Rubber parts, such as the belts of troughed belt conveyors and the filter belts of vacuum belt filters, are normally delivered on coils. The coils
must be stored vertically and not horizontally. Furthermore, the coils may not be stored
directly on the floor. They must be stored vertically on a firm base surface. Pallets or similar must be used for moisture protection. The coils may not be stacked.
The stored equipment must be secured against damage and loss. Secured storage areas
may only be accessed by authorised personnel.
Insurance with sufficient coverage for damage caused by third parties, transport and
weather damage (lightning, flooding, and storms) and theft must be concluded for the entire handling/storage period until the machine/plant has been accepted.

5.3.2

Storage facilities & other details

5.3.2.1

"Open-air" storage

11/2013 Rev 0

Please note that roofed storage (Chapter 5.3.2.2 "Storage in "covered areas"") is to be
preferred, however large-volume, painted plant components showing a small proportion
of mechanically machined surface compared to the volume as well as wear-out parts,
where surface corrosion does not affect the function, could be stored in the open air (provided that there is no indication to the contrary on the packing, as e.g. “protect from heat”,
“protect from moisture” or similar.) See Chapter 5.1 "Transport instructions".

2-492-20980 (POS 01)

5 - 21

Examples: "Large-volume plant components"
– Mills (mechanically machined parts such as bearings, retaining flanges on the gear rim
must be provided with protection against corrosion and mechanical damage e.g. by
anti-corrosive grease, plastic foil and wooden banding)
– Gear rim cover
– Mill outlet case
– Chutes
– Ducts for material transport and dedusting
– Crusher frame
– Apron conveyor supporting frame/chain conveyor supporting frame (without drive
units)
– Supporting frame for troughed belt conveyor
– Bed plates
– Structural steelwork elements
Examples: "Wear parts whose surface has no effect on the functional capability"
– Grinding media, rods and balls
– Mill and shell lining
– Slotted plates and rear panel plates for intermediate and discharge diaphragms
– Crusher rolls for RollSizer
Systematic organisation of the material warehouse is strongly recommended, i.e. storage
should correspond to the assembly planning (Example: bed plates and base plates should
be placed at the outer edge of the storage area, etc…). Route plans must be provided in
the store. The store must also be accessible to heavy trucks, mobile cranes and forklifts.
Drainage systems for discharge of surface water must be present.
Items must always be stored on a support such as timber planks, pallets, or similar, preferably on a level, drained and gravelled base surface. Contact with surface water and the
ground must be avoided. All parts must be stored in such a way that no water can accumulate.
The effectiveness of the protection of machined surfaces (protection against corrosion
and mechanical damage) must be checked and repaired or renewed if necessary.

11/2013 Rev 0

Markings on plant components must be readable without the part having to be moved. If
water accumulates on a plant component through visible markings, the component must
be provided with new visible markings at suitable points.

5 - 22

2-492-20980 (POS 01)

5.3.2.2

Storage in "covered areas"
Plant components which have to be protected from direct sunlight as well as those which
have to be protected from rain as a result of mechanically machined surfaces, rubber or
plastic seals, ventilation holes, or similar.
Examples:
– Rubber belts for troughed belt conveyors. Please note that the belts are delivered on
coils and must be stored in a vertical position.
– Rubber and plastic seals (e.g. for gear rim protection cover, mill outlet casing, material
guide bar of troughed belt conveyors, etc.).
– Components with a high proportion of mechanically machined surfaces, e.g. gear rims,
pinions with bearings, gear units, gear motors, motors, fans, parts of filter plant
housings, rotary gate valves, control and shut-off valves, large-volume couplings, bearing housings and bearing segments for the slide shoe bearings.
– Idlers for troughed belt conveyors, drive stations and pulleys, mechanical parts of belt
weighers.
– Plant components with ventilation holes e.g. gear units, gear motors and bearings
equipped with openings for air pressure compensation.
– All compact hydraulic units and compressors which have to be protected against dirt
by plastic foil. The covering on the bottom must remain open, in order to prevent the
accumulation of condensation water.
– Operating fluids such as lubricants, grease and oil as well as sealants such as silicone,
paints, thinners and cleansers.

11/2013 Rev 0

Items must always be stored on a support such as timber planks, pallets, or similar, preferably on a level, drained and gravelled base surface. Contact with surface water and the
ground must be avoided.

2-492-20980 (POS 01)

5 - 23

5.3.2.3

Storage “in enclosed inside areas with partial air conditioning”
“Partially air-conditioned” means reduction of air humidity and temperature limit. All components whose functional capability is adversely affected by high temperatures and high
air humidity, especially electrical equipment, but also other components.
Examples:
– Bolts/nuts for mounting the gear rim
– Anchor bolts
– All types of instruments/measuring instruments
– Hydraulic pipes, gear rim lubrication
– Switches, control centres (MCC = motor control centre)
– Transmitters, frequency control
– Separators for hydraulic and lubricating units
– Filter bags for dust collectors and the corresponding solenoid valves
– Measuring instruments for the belt weigher and misalignment monitoring
– Filter cloth for bag filter installations

5.3.2.4

Storage in “closed lockable rooms”
High-quality, sensitive and valuable components.
Examples:
– Measuring instruments
– Sensors
– PCs
– Screens

11/2013 Rev 0

– Laboratory equipment e.g. test screens, scales, etc. …

5 - 24

2-492-20980 (POS 01)

5.3.3

Special requirements

5.3.3.1

Electric motors
Motors must be stored in the original crates if they are not mounted on the equipment.
The storage area must be free of vibration.
Bearings:
– Balls and rollers (regreasable roller bearings). Bearings going into extended storage
must be completely greased beforehand. Motor shafts must be manually rotated once
a month and bearing grease must be topped up. Rotate the shaft by hand before putting it into service.
– Balls (roller bearings, regreasing not possible). No other provisions are necessary for
the bearings.
All drain openings must be operable and the drain plugs removed during storage. The
motors must be stored so that the drain opening is at the lowest point. All breathers and
automatic drains must be operable via T-safety screws, so that breathing can take place
at a different location from the bearing seats.
Windings must be measured when they are put into storage. When they are removed from
storage, the resistance reading may not be more than 50 % below the original value. Any
values below this value necessitate electrical or mechanical drying. Where a large quantity
of motors is stored, an inspection or sampling should be made by removing the end brakkets and visually inspecting for the presence of water in the grease or rust on the bearing.
If present, replace the bearings and relubricate.
All external parts and motors subjected to corrosion to be protected by corrosive resistant
coating.

11/2013 Rev 0

Where motors are not stored in the original containers, but are removed and mounted on
other pieces of machinery, the mounting must be such that the drains and breathers are
fully operable. In this respect, the drains must be located at the lowest point of the motor
and the drain plugs removed, so that condensation water can drain out by itself. All other
storage conditions apply, including rotation of the motor shafts. If such conditions cannot
be complied with, the equipment must be treated as if it were mounted in its normal position and all protective devices such as heaters, breathers and drains were fully operable.

2-492-20980 (POS 01)

5 - 25

5.3.3.2

Gear unit
Oil and grease lubrication:
The oil recommended by the manufacturer must be used for the oil change.
All gear openings such as flanges for oil lubrication, openings for holding thermometers
and pressure and flow sensors must be checked for proper sealing. Replace the sealing
if necessary. Breathing or venting: Pressure compensation between the pressure inside
the gear unit and the atmosphere must be provided. The inside of the gear must be protected against humidity and/or nesting insects or birds.

5.3.3.3

Gear motors
If gear motors, e.g. SEW, are placed in storage, a volatile corrosion inhibitor (VCI) is added to the lubricant of these gear units.
Some of the gear units are delivered with a higher oil level for long-term storage.
The storage period is a maximum of 3 years in compliance with the documentation supplied by the manufacturer.

CAUTION
Gear damage from improper storage of the machine/plant
Damage to the machine/plant or its environment is possible
• Gear units must be kept sealed until commissioning, in order to prevent volatilisation of the VCI corrosion inhibitor.

11/2013 Rev 0

• Before these gear motors are commissioned, the operating oil level must be
restored using dipstick/oil-inspection glass/oil-level plug.

5 - 26

2-492-20980 (POS 01)

5.3.3.4

Electrical control systems
Control centres (MCC):
– Cover the motor control centre with heavy duty plastic or similar material to prevent the
ingress of foreign matter.
– Motor control centres which are not installed and used immediately must be stored in
a clean dry area. The storage temperature should be constant and between + 5 °C and
+ 45 °C. If the storage temperature fluctuates or if humidity exceeds 60 %, space heaters must be used to prevent condensation. Control centres must be stored in an airconditioned building with adequate air circulation and be protected from dirt and water.
– Control centres which are designed for indoor applications do not have packaging
which is suitable for outdoor storage. They should therefore be provided with additional
packaging for protection from outside elements and a temporary electric heater to prevent condensation. A space heater rated at 200 watts per section is adequate for the
average control centre. All loose packaging or flammable material must be removed
before switching on space heaters.
Control centres which are for outdoor use and are not being used must be kept dry internally by installing temporary heaters or by means of self-contained space heaters.
DC drives:
– Drive motors are enclosed. Ensure that all covers are tightly fitted.
Keep the temperature between +5 °C and +45 °C.
– Drive housing and operator's station -- Keep the housing and the operator's station dry
by means of siccatives. Ensure that both are closed. If any openings are cut, they must
be sealed with duct sealant or duct tape.
Keep the temperature between +5 °C and +45 °C.
Process control equipment:
Process control equipment should be stored indoors in a heated/air-conditioned room.

11/2013 Rev 0

Control valves:
The normal storage conditions are valid for all products. "Normal" is defined as conditions
free from heat or cold (+ 5 °C to + 45 °C storage temperature), and where the products
are kept dry and protected from dust. Other products may not be stacked on them.

2-492-20980 (POS 01)

5 - 27

5.3.3.5

Other mechanical equipment
Belts and seals
These components must be protected from moisture and stored in a dry environment. The
environment must be ozone free and the belts and seals kept out of direct sunlight, in order
not to adversely affect the performance characteristics.
Bare metal components (e.g. pistons, bushes or the sealing surfaces of valves) must be
rust-proofed by rubbing them with a VCI corrosion inhibitor such as rust-inhibiting oil or
wrapped in oiled paper (these additives are referred to internally as VCI = volatile corrosion inhibitors). Volatile corrosion inhibitors permanently emit small amounts of protective
additives. Rust-inhibiting oil or oiled paper therefore protect surfaces with or without metal
contact and are particularly suitable for irregular shapes such as hollow parts, tapped holes, pipes and machines.

11/2013 Rev 0

VCI additives can be used for steel, iron, chrome, cast iron and aluminium. There are also
special VCI additives for copper and copper alloys and for both materials. The VCI method
is not applicable for the conservation of zinc, tin, cadmium, magnesium, lead and alloys of
these metals.

5 - 28

2-492-20980 (POS 01)

5.4

Handling of oil hydraulic systems

5.4.1

General
The reliable functioning of oil hydraulic systems is primarily dependent on careful maintenance. The service life of the hydraulic components is generally longer than that of mechanical components (e.g. ball bearings).
The following general instructions may were appropriate be replaced by special instructions.

5.4.2

Installation
At assembly particular attention is to be paid to utmost cleanliness.

5.4.3

Pipes
The pipes must be sawn off square. Cutting the pipes with cutting rollers is not permissible. Special instructions apply to the welding of pipes.
During all welding operations, it must be ensured that the welding current does not flow
through any hydraulic devices, otherwise internal components may be welded together.
The pipes must be cleaned of dirt before mounting.
The pipes must be laid in such a way that they are unstressed.
Sealants such as hemp and putty are not permitted.

11/2013 Rev 0

Pump suction lines must be carefully sealed against the ingress of air. Leak oil lines are
to be laid in a manner that the pumps and motor housing always remain filled with oil. They
must not have any connection to pressure lines and drain lines.

2-492-20980 (POS 01)

5 - 29

5.4.4

Hydraulic hose lines

WARNING
Risk of injury through leakage or fractures of the hose lines and leaking
pressure medium
Death or severe bodily injuries are possible
• Stop the machine/ plant using the emergency-stop switch.
• Shield the machine/ plant in such a way that the pressure medium cannot injury
any persons or cause a fire hazard.

CAUTION
Plant damage through fluttering hose lines during pressure build-up
Damage to the machine/plant or its environment is possible
• Fix the hose in place
The hydraulic hose lines must be mounted in such a way that
the length required to prevent kinking and tensile load of the hose is provided during
operation;

the prescribed minimum bending radius is adhered to;

twisting of the hose caused by faulty installation or occurring during operation (e.g.
through the blocking of a rotary joint or unfavourable movements of the connecting
points) is reduced to a minimum;

it is positioned or protected so as to minimise the abrasion of the outer layer of the
hose;

it is properly fixed in place should the weight of the hose line potentially cause an
impermissible loading.

11/2013 Rev 0

5 - 30

2-492-20980 (POS 01)

5.4.5

Commission
Before filling with hydraulic fluid, check the tank and pipes once again for cleanliness. The
test must be made directly prior to filling.
Faulty pipework or incorrect wiring is generally not noticed until the plant is being commissioned and the required functions are not available.
Any modification at this stage normally proves to be extremely difficult.
Careful checking of the pipings and the wiring on basis of the circuit diagram is therefore
urgently recommended before filling the pressure fluid into the tank.
Solenoid-operated valves and pressure switches must be checked for the type of current
and voltage.
Pumps and the associated electric motors must be aligned with each other. Any misalignment between the motor and the pump may cause premature destruction of the pump.
Pumps and their motors must not be distorted by any incorrect pipe connection.
Unless they have been delivered ready for operation, accumulators must be properly provided with the specified nitrogen charge before they are installed in the plant. It is advisable to mark the gas precharge pressure on the accumulator (e.g. with a sticker) and also in
the circuit diagram, so that an easy comparative check can subsequently be made if required.

5.4.6

Hydraulic fluid
HLP oils or HVLP oils selected to meet the respective climatic conditions or ambient temperatures are to be used.
The hydraulic oil must always be filtered when being filled.

5.4.7

Filling pumps and motors
Pumps and motors must be filled through the leak oil connection before their initial startup.

5.4.8

Pressure settings

11/2013 Rev 0

The pressure setting of the limit valves must initially be kept low at start-up. Type-tested
pressure relief valves for hydraulic accumulator systems which do not permit any variation
because of their fixed-value adjustment are an exception.

2-492-20980 (POS 01)

5 - 31

5.4.9

Start-up

DANGER
Risk of injury through faults in the control system or operating errors
Imminent danger of death or severe bodily injuries
• Ensure that no unauthorised persons are located in the danger zone
Wherever practical, variable-delivery pumps and motors should be set to a small swivelling angle, in order to facilitate the initial priming.
The electric motors can now be switched on for a short time (approx. 5 to 10 sec.). Check
the direction of rotation in the process. At the same time it need be checked whether couplings or other connection parts have become loose.
Before the operating pressure setting can gradually be increased, check whether the
pump discharges quietly and steadily. Any leaks must be remedied immediately. The plant
must be vented when it is operated at a low-pressure setting. The fluid level in the tank
must be monitored and fluid (of the same type) must be added if necessary.
After the operating pressure has been reached and the functional test has been successfully passed, pressure switches, level switches, thermostats, etc. must be adjusted.

5.4.10

Cylinders
Cylinders must be mounted in such a way that they are unstressed and above all free of
transverse forces, otherwise malfunctions and premature wear may occur.

5.4.11

Maintenance
The frequency of maintenance cannot be specified. It is a pure matter of experience. Only
the regularity with which it is performed is important. The following points must be regularly
checked at intervals recommended by the manufacturer or gained from experience.

5.4.12

Fluid level

11/2013 Rev 0

The fluid level must be checked constantly during the commissioning period; after commissioning it must be initially checked daily and then weekly.

5 - 32

2-492-20980 (POS 01)

5.4.13

Filters
During the commissioning period, the filters must be checked at intervals of 2 to 3 hours
and must be exchanged if necessary. In the initial 150 - 250 operating hours, the filters
must be serviced considerably more frequently than afterwards. If visual or electrical clogging indicators are provided, the filter elements must be exchanged according to these
indicators. Actuation of the clogging indicators at cold start is insignificant and is terminated after a short time if the filter elements are clean.
Breathers must be regularly checked and the filter element exchanged if necessary.

5.4.14

Oil temperature
The operating temperature must not only be measured in the oil tank but also at the bearing points of the pumps, amongst other places. A temperature rise indicates wear. (Growing friction and leakage by converting hydraulic energy into heat).

5.4.15

Oil change
The frequency of the system fluid change depends on several operating factors and is
governed by the degree of ageing and pollution.
Regular laboratory tests of the hydraulic oil must be carried out, especially in case of large
oil quantities of oil.

5.4.16

Accumulators
If necessary, the precharge pressure of the nitrogen side of accumulators must be chekked at regular intervals. When doing so, the oil side of the accumulator must be absolutely
unpressurised.

5.4.17

Alignment
At adequate intervals we recommend to check the correct alignment of the energy converters (pumps, motors, cylinders etc.) at operating temperature and, as far as possible,
under operating pressure. This includes erection bolts, screws, connections, pipes, couplings, etc.

5.4.18

Pipework

11/2013 Rev 0

The hydraulic pipe system must be checked for leaks at regular intervals. Bolted joints
must be retightened when the plant is unpressurised.

5.4.19

Cooler
The fins of oil/air coolers must be cleaned at regular intervals depending on the environmental conditions.
Oil/water coolers must be descaled from time to time.
The frequency depends on the hardness of the cooling water used.
2-492-20980 (POS 01)

5 - 33

5.4.20

Storage of hydraulic components
Store pumps, valves, cylinders, etc. in a dry place in the absence of air humidity.
The storage rooms must be free of corrosives and fumes. Filling with an anti-corrosion oil
is recommended in any case. This oil must be compatible with the subsequent oil grade.
The oil film remaining after draining the anti-corrosion oil may not have an adverse effect
on subsequent use.

5.4.21

Duration of storage and use of hydraulic hose lines
The term 'duration of use' refers to the total period of use and storage of a hose line starting from the date of manufacture of the hose line (the assembly date).
With respect to storage, a distinction must be made between the storage of bulk hose and
the storage of hose lines (assembled hoses), as different storage times apply for each
type.
Even if properly stored, hoses and hose lines are subject to natural ageing. This limits the
duration of use of hydraulic hose lines.
When manufacturing (assembling) a hose line, the hose (bulk hose) should not be older
than your years.
This means that the bulk hose should not have been stored for longer than a maximum
four years at the time of the hose assembly (assembly date).
The duration of use of a hose line including the storage duration of the hose line should
not exceed six years, and the storage duration of the hose line (of the assembled hose)
should not exceed two years.
In summary, this means the following:
4 years

Maximum storage duration of hose line
(assembled hoses):

2 years

Maximum duration of use of hose line
(incl. storage time of the hose line):

6 years

11/2013 Rev 0

Maximum storage duration of bulk hose:

5 - 34

2-492-20980 (POS 01)

5.5

Installation planning
When planning the installation, please note the following:
– Please refer to the relevant foundation and installation drawings for the main dimensions of the machine/plant and the associated secondary units.
See ANNEX 9.1 "Drawings".
– Provide additional ladders, walkways, platforms and safety railings for maintenance
work and indicate the permissible traffic loads.
– Provide sufficient space to accommodate the periphery equipment as well as to
arrange the feeding units and conveyors to unload the material to be crushed.
– Provide suitable lifting gear for the installation and for the exchange of spare and wear
parts. It should be possible to position the lifting tackle/load hook vertically on top of the
machine/plant.
– Comply with the specified loading values for the design of foundations and the calculation of the girder/platform structures.
– The movement of the machine/plant generates horizontal and vertical forces which
must be absorbed by suitable shear braces.
– Ensure that the machine is accessible for cleaning.
– Initiate measures against dangerous environmental influences, e.g. dangerous dusts,
uncontrolled oil leaks, noise.
– Integrate the machine/plant in the existing/planned control system, including interlokking system, protective and monitoring devices, e.g. emergency stop switches, local
switches, speed monitors, filling level monitors. Integrate optical and acoustic starting
alarms in the control system.
If the conditions at the place of installation vary from those in the installation drawing, please consult ThyssenKrupp Resource Technologies.

INFORMATION

The construction contractor is responsible for the correct dimensioning of foundations, steel platforms, load-bearing ceilings and their supports as well as for the
execution of the construction work and compliance with the official regulations,
even if an erecting engineer of ThyssenKrupp Resource Technologies erects the
machine/plant.
Align the machine / plant with a level.

11/2013 Rev 0

For installation on a concrete foundation, grout the foundation bolts and the base
frame by concrete mortar 1:2 (1 portion cement; 2 portions sand) after alignment.
Prior to this, carefully clean the surface of the foundation and saturate it with
water.

2-492-20980 (POS 01)

5 - 35

5.6

Preparation for installation

WARNING
The use of untrained personnel or equipment that does not comply with
safety standards poses additional danger
Death or severe bodily injuries are possible
• The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
• When carrying out overbelt assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms. Never use machine
parts as a climbing aid! Wear fall protection when carrying out maintenance work
at a higher level.

WARNING
Risk of injury through components that are improperly secured during
installation
Death or severe bodily injuries are possible
• Make sure that moveable components are properly secured during installation.

WARNING
Danger from working on electrical systems without proper technical knowledge

• Work on the electrical systems or equipment may only be carried out by a skilled
electrician or by specially trained personnel under the supervision of an electrician and in compliance with the applicable regulations required for electricians.

5 - 36

2-492-20980 (POS 01)

11/2013 Rev 0

Death or severe bodily injuries are possible

INFORMATION

The manufacturer accepts no liability for damage resulting from incorrect installation of the machine!
A careful selection of the tools and appliances used and the assembly personnel
employed is important for the correct execution of the assembly work.
It is recommendable to have the assembly work supervised from start to finish by
assembly specialists from ThyssenKrupp Resource Technologies.

11/2013 Rev 0

Our warranty is based on the assumption that an assembly specialist from ThyssenKrupp Resource Technologies will carry out the assembly and assembly
inspection.

2-492-20980 (POS 01)

5 - 37

5.7

General information on assembly

WARNING
Risk of injury through improper assembly and transport
Death or severe bodily injuries are possible
• Make sure that moveable components are secured, also during installation
• Use proper transportation equipment
• Do not walk under suspended loads
• Fasten and lift components properly
• Only transport the machine/plant on the designated slinging devices (lugs) and
slinging points.

WARNING
Risk of injury through assembly work at a higher level
Death or severe bodily injuries are possible
• When carrying out overbelt assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms.
• Never use machine parts as a climbing aid!
• Wear fall protection when carrying out maintenance work at a higher level.

WARNING
Risk of injury through work on electrical systems

Work on electrical systems or equipment may only be carried out by a skilled electrician or by specially instructed personnel under the control and supervision of a
skilled electrician and in accordance with the applicable electrical engineering
rules.

5 - 38

2-492-20980 (POS 01)

11/2013 Rev 0

Death or severe bodily injuries are possible

CAUTION
System damage through improperly executed welding work
Damage to the machine/plant or its environment is possible
• Always take note of the pre-heating temperature of all components to be welded
and tack-welded. The pre-heating temperatures specified for welding work to be
performed on the individual materials can be found in the respective assembly
drawings in ANNEX 9.1.
• Never conduct welding current through slide or roller bearings or other moveable
connections or measuring equipment.
• Carry out welding work on individual machine components prior to their installation.

INFORMATION

The manufacturer accepts no liability for damage resulting from incorrect installation of the machine!
A careful selection of the tools and appliances used and the assembly personnel
employed is important for the correct execution of the assembly work.
It is recommendable to have the assembly work supervised from start to finish by
assembly specialists from ThyssenKrupp Resource Technologies.
Our warranty is based on the assumption that an assembly specialist from ThyssenKrupp Resource Technologies will carry out the assembly and assembly
inspection.

Initial assembly must be carried out by trained personnel.

11/2013 Rev 0

The respective layout plan and assembly drawings must be carefully studied, see
ANNEX 9.1 "Drawings". All guidelines and notes must be observed.

2-492-20980 (POS 01)

5 - 39

5.8

Installation
See ANNEX 9.1 "Drawings"

INFORMATION

Tightening torques for all relevant bolts, see Chapter 5.10 and Chapter 7.5 "Screw connections".

5.8.1

Pre-assembly
The gyratory crusher is delivered in sub-assemblies and component parts.
The assembly groups and individual components can be assembled and adapted to the
relevant crane capacities at the place of installation.
Suspension points and drawings, see drawings in ANNEX 9.1.

5.8.2

Weights:

INFORMATION

5 - 40

Bottom shell with pinion assembly, eccentric bushing, base
plate and wear liners (without hydraulic cylinder):

approx. 52.000 kg

Lower shell:

approx. 26.600 kg

Upper shell:

approx. 46.500 kg

Spider, cpl., with top axle mounting and arm liners:

approx. 38.500 kg

Crusher axle with dust sealing, crushing mantle and upper
part of the step bearing:

approx. 49.780 kg

Hydraulic cylinder:

10000 kg

Base plate, complete:

1800 kg

Dust sealing, complete:

2000 kg

Top axle mounting:

1150 kg

Lower main shaft bearing (axial step bearing):

550 kg

Pinion assembly, complete:

2600 kg

Drive:

878 kg without motor

2-492-20980 (POS 01)

11/2013 Rev 0

Since casting parts have higher manufacturing tolerances, their weight may deviate by +/- 15% from the specified value.

10800 kg

Outer ring nut:

185 kg

Protective nut:

131 kg

Wear insert of main shaft:

385 kg

Eccentric bush, complete (with bevel gear):

approx. 7.600 kg

Spider cap:

4670 kg

Outer eccentric bushing (bottom shell):

652 kg

Wear parts (bottom shell):

approx. 3.400 kg

Wear parts for upper shell:

approx. 9.000 kg

Wear parts for spider (liner arms):

approx. 13.500 kg

Upper crushing jaw upper crusher ring:

345 kg each, 16 pcs

Lower crushing jaw lower crusher ring:

366 kg each, 16 pcs

Upper crushing jaw lower crusher ring:

291 kg each, 16 pcs

Lower crushing jaw OSS 240:

481 kg each, 16 pcs

11/2013 Rev 0

Mantle:

2-492-20980 (POS 01)

5 - 41

5.8.3

Bottom shell
Also see drawings in the ANNEX 9.1

Clean and slightly oil all contact surfaces.

Install, align, tack-weld and weld liner plates (5) on to the bottom shell. The instructions
provided in the drawing 4609235 in ANNEX 9.1 must be followed.

Align, tack-weld and weld the liner plates (6) on to the conical part of the hub. The
instructions provided in the drawing 4609235 in ANNEX 9.1 must be followed.

Place wearing caps (7) on the arms of the bottom shell and tack-weld.

INFORMATION

Since casting parts have higher manufacturing tolerances, it might be necessary
to adjust the relevant arm liners before their installation.

Align the protective cap (8) with the through bore for mounting the base plate and weld
oil-tight.

Check welded disk (9) in the bore (over-pressure ventilation) for oil-tightness.

Screw the retaining ring (10) at bottom part of hub.

CAUTION
System damage from improper tightening of screws
Damage to the machine/plant or its environment is possible
• Take the clearance of bolts in the through holes into account!

Mark the position of the retaining ring in relation to the hub for subsequent assembly
and disassembly work.

Lower the outer eccentric bushing (11) into the hub and turn it until the bottom recesses
of the outer eccentric bushing rest on the retaining ring (10).

Jack up the bottom shell (1) in such a way that the eccentric bushing (2), the base plate
(3) and the hydraulic cylinder (4) can be mounted from below.

11/2013 Rev 0

5 - 42

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 18

2-492-20980 (POS 01)

5 - 43

5.8.4

Base plate and eccentric bushing
See Figure 19, drawing 4350085 and drawing 4609204 in the ANNEX 9.1
Prepare the base plate (1) and place on jacks.

Place the spacer plate (2) (1, 2, 3 and 5 mm - to set the backlash of the gears of the
bevel pinion and bevel gear) onto the bottom plate.

Insert cylindrical pin (3) and position the axial bearing ring (4).

Prepare the eccentric bushing (5) for assembly.

Thoroughly oil all the running surfaces of the axial step bearing ring (4), the outer
eccentric bushing in the bottom shell and the eccentric bushing.

Place the complete eccentric bushing on the axial step bearing ring (4) of the base
plate (1).

Fix the bottom shell and carefully allow the outer eccentric bushing to slide on to the
eccentric bushing, then continue lowering to the base plate.

Ensure that the sealing cord (6) is not damaged when lowering into the bottom seat.

Bolt the base plate to the bottom shell.

11/2013 Rev 0

5 - 44

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 19

2-492-20980 (POS 01)

5 - 45

5.8.5

Transmission
See drawing 4521963 Sheets 1 + 2 in ANNEX 9.1

Clean and slightly oil the contact surfaces of the pinion assembly tunnel/pinion assembly.

Insert the complete pinion assembly (1) with sealing cord (2) in the pinion assembly
tunnel (3) of the bottom shell (4).

Sequence of assembly steps:
– Secure the lifting strap (17) to the crane at the centre of gravity of the entire pinion
assembly (1).
– Insert the pinion assembly (1) into the pinion assembly tunnel (3) as far as possible.
– Support (18) the back of the pinion assembly (1) and move the lifting strap (17)
further back.
– Insert the pinion assembly (1) further into the pinion assembly tunnel (3) and support at the back (18).
– If the pinion assembly cannot be further inserted this way, use the lifting belt (17) as
a replacement for the supports (18). The pinion assembly (1) must remain supported during relocation.
– Screw in four threaded rods M30 (13), evenly distributed around the circumference,
into the mounting holes (19) of the pinion assembly tunnel (3) through the bore
holes of the pinion assembly.
– Using nuts (14), pull the pinion assembly (1) evenly into the bearing seat (15) via
the pull-in aids (16).
– Slightly turn the pinion assembly shaft so that the pinion can engage in the bevel
gear.
– Remove the threaded rods (13) and the lifting belt (17).

Arrange disks (5) (5 mm thickness; for correct backlash) between the pinion assembly
flange and tunnel and screw the pinion assembly to the bottom shell.

Check the torsional backlash. To do that:
– check the backlash (punched-in value +/- 15 %) (see Chapter 7.3.10 "Check of the
torsional back lash" and ANNEX 9)
– If necessary, change the thickness of the disks (5) and the thickness of the filler plates (6) between the base plate and the bottom shell.

INFORMATION

11/2013 Rev 0

The final check of the torsional backlash can be made after the hydraulic cylinder
has been installed and the main shaft inserted.

5 - 46

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 20

2-492-20980 (POS 01)

5 - 47

Install resistance thermometers (7) and (8).
max. 85 °C
max.max. 92 °C

Warning
Depletion of crusher

Install an oil level indicator (9) with fluid switch (10).

Install accelerometers (11) and (12) (optional).

11/2013 Rev 0

5 - 48

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 20

2-492-20980 (POS 01)

5 - 49

5.8.6

Hydraulic cylinder and lower components of the main shaft bearing
See ANNEX 9.11 "Tools"

Clean and slightly oil all contact surfaces.

Position hydraulic cylinder on the scissors lift of the maintenance car and secure in
place.

Insert sealing cord (1) in the cylinder flange of hydraulic cylinder (2).

Place oil ring (3) on the piston of the hydraulic cylinder and bolt on.

Insert cylindrical pin (4) in the piston surface to prevent rotation.

Place the sliding ring (5) and the lower part (6) of the step bearing on the piston.

Position the hydraulic cylinder with the maintenance car below the hub of the bottom
shell.
For the operation of the maintenance car see separate documentation.

WARNING
Danger of crushing due to maintenance car moving
Death or severe bodily injuries are possible
• Make sure no unauthorised persons are near the maintenance car.
• Leave the area of danger!

With the maintenance car at a standstill, raise the hydraulic cylinder using the scissors
lift.
Pay attention to the correct position of the oil connections. Do not damage the sealing
cord (1).
Mount the hydraulic cylinder on the bottom shell.

INFORMATION

11/2013 Rev 0

The final check of the torsional backlash can be made after the hydraulic cylinder
has been installed and the main shaft inserted.

5 - 50

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 21

2-492-20980 (POS 01)

5 - 51

5.8.7

Sealing housing of the dust sealing
See drawing 4609197 and drawing 4470280 in the ANNEX 9.1

Insert O-ring (1) in the bottom shell to seal the air duct.

INFORMATION

Use additional sealing agent to enhance the flange sealing effect, e.g. Hylomar©.

Insert sealing cord (2), glue the ends together.

Attach the seal housing (3) to lifting gear, lower to the bottom shell and align the oil and
air ducts with each other.

Place the seal housing on the hub of the bottom shell and bolt on.

Insert disk (oil seal) (4) in the seal housing.

Mount the inspection cover (5) on the bottom shell.

Mount the air (6) and oil lines (7) in the bottom shell, so that they are oil- and air-tight.
During the further assembly process, seal the lines with caps to prevent dust from entering. Further important assembly instructions provided in drawing 4609197 in
ANNEX 9.1 must be followed.

Cover the opening of the seal housing.

Pay attention to the clearance between the housing (1) and the bearing bush (8), follow
the instructions in drawing 4350716 in ANNEX 9.1.

11/2013 Rev 0

5 - 52

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 22

2-492-20980 (POS 01)

5 - 53

5.8.8

Mounting the concaves
See Figure 23, Figure 24 and Figure 25
For the assembly of the concaves, refer to drawing 4609240 in ANNEX 9.1.

Attach and connect the lower shell to the prepared bottom shell.
See Chapter 5.9.

Place the upper shell on the lower shell and connect them.

Longitudinally align the receiving pockets for the spider in the direction of loading (pay
attention to the position of the grease lubrication connection for the spider bearing).
Tightening torques of bolts see Chapter 5.10.

Clean and remove the grease from the contact surfaces of the shells and concaves.
When back-filling synthetic resin and cement-bonded Betec sealing compound, do not
apply separating agent to the concaves and the internal surfaces of the crusher shells.

For preparation and processing of the sealing compound see ANNEX 9.4.

Insert and align the shims (1) in the lower shell.

Weld round steel bars (2; spacer bars for horizontal joint) to the lower concaves (3).

Put the lower row of concaves (3) into the lifting gear using the transport lugs, insert
and distribute evenly across the circumference. Comply with the vertical distances.
Check that all bearing points of each concave are close-fitting. If necessary, insert
shims.

INFORMATION

11/2013 Rev 0

Since casting parts have higher manufacturing tolerances, it might be necessary
to adjust the relevant crushing jaws before their installation.

5 - 54

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 23

2-492-20980 (POS 01)

5 - 55

Use assembly rings for securing and as assembly aids where necessary.

Drive in wooden wedges (10) between the concaves and the auxiliary assembly ring
(14).

Insert and drive in the conical holding pins (6).
If the holding pins protrude above the top edge of the concaves, shorten them to the
exact height of the concaves.

Figure 24

System damage from improper tightening of screws
Damage to the machine/plant or its environment is possible
• Drive in the conical holding pins diametrically opposite in a clockwise direction
in several steps.

5 - 56

2-492-20980 (POS 01)

11/2013 Rev 0

CAUTION

Seal all horizontal and vertical joints of the concaves (3, 8, 9, 5) with hemp ropes (4) or
plaster of Paris.

Backfill the row of concaves (3) by inserting synthetic resin sealing compound(7) in the
openings provided for each concave. Ensure that all the concaves are backfilled completely. See ANNEX 9.4.

Put the next rows of concaves (8, 9, 5) into the lifting gear using the transport lugs, centre and align them. Pay attention to the vertical joints.
Weld the round steel bars (2) to the upper sides of the concaves (8,9) beforehand.

Possibility (see Figure 24): Insert the next auxiliary assembly rings (11) and secure the
concaves with wooden wedges (12).

11/2013 Rev 0

Figure 25

2-492-20980 (POS 01)

5 - 57

Backfill each row of concaves (8, 9, 5) with synthetic resin sealing compound (7).

After hardening, remove the transport lugs, sealants, wooden wedges and auxiliary
assembly rings.

11/2013 Rev 0

Figure 25

5 - 58

2-492-20980 (POS 01)

5.8.9

Installation of the liner plates in the upper shell
See Figure 26
For installation of the liner plates, refer to drawing 4609235 in ANNEX 9.1.

Insert liner plates (1) on the transport lugs (2) into the upper shell, align and bolt into
place. Tightening torques of bolts see Chapter 5.10.

Remove the transport lugs (2) after installation.

Figure 26

INFORMATION

11/2013 Rev 0

Since casting parts have higher manufacturing tolerances, it might be necessary
to adjust the relevant liner plates before their installation.

2-492-20980 (POS 01)

5 - 59

5.8.10

Spider bearing
See Figure 27 and drawing 4609216 in ANNEX 9.1

Clean all the contact surfaces, prepare the conical spider bushing (1a) and wear insert
(1b) for installation.

Further important assembly instructions provided in drawing no. 4609216 in
ANNEX 9.1 must be followed.

INFORMATION

The spider bushing must slide into the seat of the spider without force.
Do not press in or cool the bushing under any circumstance: rework the spider
bushing if necessary.

Pre-mount the sealing ring (2) and radial seals for the shaft (3) and fix the plate in place
using bolts (5).

Lay the leather packing in a warm oil bath before inserting it.
Pre-mount the leather packing (4).

To fit the wear insert (1b) screw the eye bolts into the threaded holes (14) of the wear
insert.

Lower the wear insert (1b) into the spider

Unscrew the eye bolts from the threaded holes (14).

To fit the wear spider bushing (1a) screw the eye bolts into the threaded holes (13) of
the spider bushing.

Follow the assembly instructions for calculating the required washer thickness (6) in drawing no. 4609216 in ANNEX 9.1 "Drawings".

Fit washers (6) according to the calculated washer thickness.

Insert spider bushing (1a) into the spider.

Screw bolts (8) with washers (9) into the holes (7) and tighten them.

Unscrew the eye bolts from the threaded holes (13) of the spider bushing (1a).

Install filling level sensor (11) with bracket and route the cables through the cable duct,
so that they are oil-tight.

The two holes (12) must be securely sealed with sealing screws (screw plugs and seals).
These screw plugs must be removed immediately before disassembling the spider bushing (1a). Two oil pumps (provided by the customer) must then be attached to both R 1/
4" threaded connections. Applying an oil film between the surfaces of the spider bushing
and the spider with suitable overpressure will facilitate the subsequent disassembly of the
spider bushing. After having disassembled the rolling contact bush (1a), securely lock the
cleaned R 1/4“ threaded connections in the spider by the cleaned lock screws with the appropriate seals.

5 - 60

Screw plug DIN 910 - G 1/4 A x 8 - A1

2 pieces

Metallic gasket CU DIN 7603 A 14 x 18

2 pieces

2-492-20980 (POS 01)

11/2013 Rev 0

Function of the two holes (12) in the spider:

11/2013 Rev 0

Figure 27

2-492-20980 (POS 01)

5 - 61

5.8.11

Main shaft
See Figure 28 and drawing 4609199 in ANNEX 9.1

Support the main shaft (1) over a trench in a suitable fixture.

Use the eye bolt (7) for transport.

Clean the main shaft (1) and crushing mantle (2).

Light grease the shaft,

grease the inside of the mantle.

INFORMATION

The stop plates (10) are welded to the mantle. Remove after fitting.

Bolt protective nut (8) to the shaft and secure using Loctite 277.

Place the mantle (2) on the cone of the main shaft (1) and measure the protrusion of
the main shaft cone towards the mantle.

Heat up the mantle (2) by approx. 50 °C above ambient temperature and shrink it 5 mm
lower than the protrusion length.

CAUTION
System damage through improper assembly
Damage to the machine/plant or its environment is possible

5 - 62

Before the mantle has cooled during the shrinking process, insert the intermediate ring
(5) and tighten the ring nut (6) slightly.

After the mantle (2) has cooled, remove the ring nut (6) with intermediate ring (5) again.

Back-fill the mantle with synthetic resin sealing compound (9).
See ANNEX 9.4.

Replace the intermediate ring, screw on the ring nut and tighten it up securely. Tackweld the intermediate ring to the ring nut and mantle. To do this, use different filler
materials. Follow the welding instructions in drawing 4609199.

Clean the wear insert (3) and the top shaft of the main shaft.

Screw eye bolts into the wear insert, pre-heat the wear insert by 80 °C above the ambient temperature.

Quickly place the wear insert on the main shaft.

Remove transportation aids.

2-492-20980 (POS 01)

11/2013 Rev 0

• Never shrink the mantle to less than 5 mm lower than the protrusion length.

11/2013 Rev 0

Figure 28

2-492-20980 (POS 01)

5 - 63

5.8.12

Sealing ring of the dust sealing
See Figure 29 and drawing 4470280 in ANNEX 9.1.
Fit a plastic sealing ring (1) in the dust sealing. For this purpose:

Screw the top and bottom sealing rings (2) and (3) together and measure the distance
between them.

Measure the thickness of the plastic sealing ring (1).
The clearance of the plastic sealing ring between the top and bottom sealing ring must
be 1 - 1.5 mm.

To ensure this clearance, determine the required thickness of the shims (4).

Separate the top and bottom sealing rings. Screw the top sealing ring into the main
shaft.

Arrange the plastic sealing ring on the bottom sealing ring, position the shims and
screw the top and bottom sealing rings in place.

11/2013 Rev 0

Figure 29

5 - 64

2-492-20980 (POS 01)

5.8.13

Lower main shaft bearing section
See Figure 30
Further important assembly instructions provided in drawing 4207101 in ANNEX 9.1 must
be followed.

11/2013 Rev 0

Bolt the step bearing upper part (1) to the main shaft:

Insert the upper positioning cylindrical pin (2) in the step bearing upper part.

Screw the step bearing upper part (1) of the axial step bearing to the main shaft.

Secure the screws with binding wire (3).

Figure 30

2-492-20980 (POS 01)

5 - 65

5.9

Assembling the sub-assemblies
See Figure 31 and drawing 4609197, 4470461 Sheets 1 - 5, 4609235 and 4602798 in
ANNEX 9.1.

5.9.1

Bottom shell of the crusher, shells, main shaft, spider

Place the filler plates for the requisite grouted joint on the steel structure/foundation.

Place the bottom shell of the crusher (1) on the steel structure/foundation and align the
pinion assembly tunnel with the motor.

Horizontally align the bottom shell and screw it firmly to the sub-structure (steel
structure/foundation) using anchor bolts/stone bolts (2). See drawing no. 4470461
Sheets 1 - 5.

Cover the crusher feet with BETEC cement mortar, allow to harden and re-tighten the
nuts. (See ANNEX 9.4)

Clean the flange faces and conical seats of the bottom shell and the shells (3, 4).

Place the lower shell (3) on the bottom shell and align it horizontally so that an even
flange joint is obtained.

Insert the bolts (17) from below and tighten as follows:
– Pretensioning force: Fv = 1000 kN,
– gradual pretensioning of the bolts:
1 step: 30% of Fv
2 step: 60% of Fv
3 step: 100% of Fv
– Tighten the bolts (17) evenly in a diagonally opposite sequence until the flanges are
flush.
Screw on lock nuts and tighten up.

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5 - 66

2-492-20980 (POS 01)

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Figure 31

2-492-20980 (POS 01)

5 - 67

Attach the upper shell (4) and align it horizontally so that a uniform flange joint is obtained.

INFORMATION

Longitudinally align the receiving pockets of the upper shell for the spider (5) in
the direction of loading.
Pay attention to the installation position of the grease lubrication line.

Insert the bolts (18) from below and tighten as follows:
– Pretensioning force: Fv = 1000 kN,
– gradual pretensioning of the bolts:
1 step: 30% of Fv
2 step: 60% of Fv
3 step: 100% of Fv
– Tighten the bolts (17) evenly in a diagonally opposite sequence until the flanges are
flush.

Screw on lock nuts and tighten up.

Install the concaves and the liner plates before the assembly of the main shaft and spider.
See Chapter 5.8.8 and Chapter 5.8.9.

Clean and grease the bottom shaft of the main shaft (6), the eccentric bushing (7) and
the components of the axial step bearing (8).

CAUTION
System damage through improper assembly
Damage to the machine/plant or its environment is possible
• When inserting the main shaft, do not damage the oil seal (9), the axial step
bearing (8), the dust sealing (10) or the eccentric bushing (7).

11/2013 Rev 0

• When positioning the spider (5), do not damage the shaft sealing (11) and the
spider bushing (12).
To facilitate fitting, slightly turn the main shaft by means of the eccentric bushing
(7).

5 - 68

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 31

2-492-20980 (POS 01)

5 - 69

Attach a hoist to the eye bolt of main shaft, lift the main shaft and allow it to slide into
the eccentric bushing.

Check the correct position of the oil seal (9), the step bearing lower part of the axial
step bearing (8) and the dust sealing (10) for installing the main shaft.

Pre-assemble the grease lubrication and sensor line on the spider (5).
See Chapter 5.8.

INFORMATION

When positioning and aligning the spider (5), pay attention to the routing of the
grease lubrication line for the spider bearing. Insert eye bolts into the 4 bores of
the spider (5) for transport. After the spider has been set down, remove the eye
bolts and seal the bores with the screw plugs.

Attach the spider (5) and align it horizontally so that a uniform flange joint is obtained.

Do not forget to grease the contact surfaces to the sealing compound beforehand.

Screw on the spider.
Tighten the bolts with superbolt clamping nuts (13) as follows (see also ANNEX 9.12.):
– Tightening torque per pressure bolt (M20): Ma = 500 Nm
– gradual pretensioning of the bolts:
1 step: 30% of Ma
2 step: 60% of Ma
3 step: 100% of Ma
– Tighten the bolts (17) evenly in a diagonally opposite sequence until the flanges are
flush.

Screw on lock nuts and tighten up.

INFORMATION

To release the connection, only loosen the bolts, do not remove them. Loosen
them evenly and gradually.

Backfill the gap (16) between the spider and the upper shell (4) with sealing compound.
See instructions ANNEX 9.4.

Fill the spider bearing with grease as per the table of lubricants.

Mount the spider cap (14).

Mount the arm liners (14). See drawing 4609235 in ANNEX 9.1
11/2013 Rev 0

5 - 70

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 31

2-492-20980 (POS 01)

5 - 71

5.9.2

Arm liners on spider
See Figure 32
For installation of the arm liners, refer to drawing 4609235 in ANNEX 9.1.

INFORMATION

Use suitable lifting tackle.

Place the arm liners (1) onto the two arms (2) of the spider.

Align the arm liners (1) and fix in place using bolts at the side (3).

Bolt the arm liners (1) to the spider using bolts (4).
Tightening torque of the bolts (4): 4227 Nm.

Weld bolts (3).

11/2013 Rev 0

5 - 72

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 32

2-492-20980 (POS 01)

5 - 73

5.9.3

Direct drive
See Figure 33
Take the further important assembly instructions on the drawing 4609407 in ANNEX 9.1
and video in Chapter 7.4.14 "Crusher main drive motor and pinion assembly" into account.

Slide the distance ring (1) and the feather keys (2) and (3) on to the shaft butt ends of
the pinion assembly and motor.

The crusher, pinion assembly and crusher main drive motor must be precisely aligned.
Align the components accordingly and secure them. If possible, backfill up with suitable
sealing compound.

Mount multiple-disc clutches (4), distance tube (5) and safety coupling (6).
See ANNEX 9.2

CAUTION
Plant damage through improper assembly of the clutches
Damage to the machine/plant or its environment is possible
• Mount the multiple-disc steel clutch (4) so that it is unstressed. If necessary,
the motor must be axially displaced during assembly, in order not to exceed the
permissible load.
Comply with the tightening torques!
• In order to protect the safety clutch (6) from damage/destruction, the following
oil filling process must be followed during fitting:
First fill the lubrication chambers with oil. This takes approx. 45 minutes.
The pressure chambers must only be filled with lubrication oil after the lubrication chambers have been filled. See also ANNEX 9.2

Mount the bracket (7) for the speed monitor (8) on the pinion assembly flange.

Screw the 4 cam switches (9) on the flange of the multiple-disc clutch.

Mount, align and connect the speed monitor.

11/2013 Rev 0

5 - 74

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 33

2-492-20980 (POS 01)

5 - 75

5.9.4

Compressor for over-pressure ventilation of dust sealing
See Figure 34
Further important assembly instructions provided in drawing 4350373 in ANNEX 9.1 must
be followed.
Screw on the bracket (1) to accommodate the compressor (2).

Mount the compressor.

Connect the hose/pipe system (3) between the compressor (2) and air pipe (4) in the
bottom shell.

Connect the electric motor and check the direction of rotation.

Install and electrically connect the pressure transducer (5).

11/2013 Rev 0

Figure 34

5 - 76

2-492-20980 (POS 01)

5.9.5

Main shaft hydraulics
See Figure 35 and drawing 4613028, 4207624 and 4613053 in ANNEX 9.1.
Mount the compensation cylinder (1), pressure gauge (2) and compressed air tank (3)
on the bracket (4).

Mount the high-pressure hoses (5) and pipelines (6) as per drawing 4613053.

11/2013 Rev 0

Figure 35

2-492-20980 (POS 01)

5 - 77

5.9.6

Oil circulating lubrication and hydraulic unit
See Figure 36 and drawing 4613051 and 4613052 in ANNEX 9.1.
Clean / blow compressed air through the lubricating oil and hydraulic lines before
mounting.

Set up the oil tank with the oil circulating lubrication unit and the hydraulic unit in an
easily accessible place near the crusher which is as dust-free and protected from the
elements as possible.
If the crusher is installed in enclosed inside areas, provide good ventilation to prevent
heat accumulation.

Install the return pipe systems with a downward gradient of at least 10 %.

Connect the pressure lines of the lubrication pump unit to the lubrication oil supply on
the hydraulic cylinder (internal lubrication) and the oil supply of the crusher (external
lubrication).

Install and connect the hose/pipe systems to the oil cooler.
Install the oil/air cooler in such a way that it is not exposed to direct sunlight.
Make the connections to the hydraulic system of the axle (Chapter 4.4) and the hydraulic cylinder.

Fill with filtered lubricants as per the table of lubricants.

Connect the electric motors of lubrication pumps of the hydraulic unit and the oil cooler
and check the directions of rotation.

11/2013 Rev 0

Figure 36

5 - 78

2-492-20980 (POS 01)

5.9.7

Grease lubrication for spider bearing
See Figure 37 and drawing 4350926 Sheets 1 + 2 and drawing 4350050 in ANNEX 9.1.

Mount a flow meter (1) on the upper shell.

Mount the filling level sensor (2) in the head of the spider and pass the cables through
the cable duct in the spider.

Mount the grease lubrication pump (3) on the filled grease reservoir (4). Mount the
lubricant line of the grease lubrication pump for the spider bearing.

Attach the grease control unit (5) to the support.

Clean all grease and air pipes by air prior to the final connection.

Rinse the lubricating grease lines by hand with grease until clean grease flows. Then
assemble the connection to the grease lubrication unit of the spider bearing.

Pump grease into the cap until the filling level sensor actuates.

11/2013 Rev 0

Figure 37

2-492-20980 (POS 01)

5 - 79

5.10

Prescribed tightening torques for all relevant bolts
See Figure 38 and information on drawings in ANNEX 9.1

INFORMATION

For bolted connections without specified tightening torques see ANNEX 7.5

Position

Bolt

Superbolt

Ma (Nm)

Clamping nut

Stress bolts

ANNEX 9.1

1

M 72 x 6 x 380

-

-

130001

2

M 72 x 6 x 380

-

-

130002

3

M 160 x 6 x 925

M 160 x 6

M 20

5003

4

M 12 x 40

-

-

38

5

M 24 x 80

-

-

310

6

M 56x 460

-

-

4227

7

M 42 x 5 x 280

-

-

1746

8

M 30 x 100

-

-

1200

9

M 30 x 90

-

-

625

10

M 30 x 90

-

-

625

11

M 20 x 200

-

-

180

12

M 30 x 160

-

-

500

13

M 30 x 240

-

-

1400

5 - 80

4609197

4609235

4470280

4609204

11/2013 Rev 0

1.gradual pretensioning of the bolts:
1 step: 30% of MA
2 step: 60% of MA
3 step: 100% of MA
2.gradual pretensioning of the bolts:
1 step: 30% of MA
2 step: 60% of MA
3 step: 100% of MA
3.gradual pretensioning of the bolts:
1 step: 30% of MA
2 step: 60% of MA
3 step: 100% of MA

Drawing

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 38

2-492-20980 (POS 01)

5 - 81

Position

Bolt

Superbolt

Ma (Nm)

Clamping nut

Stress bolts

Drawing
ANNEX 9.1

M 36 x 140

-

-

1100

15

M 16 x 40

-

-

100

16

M 12 x 25

-

-

50

17

M 24 x 100

-

-

230

18

M 24 x 80

-

-

710

19

M 24 x 70

-

-

300

20

M 30 x 130

-

-

1000

21

M 20 x 70

-

-

300

22

M 16 x 65

-

-

295

23

M 30 x 95

-

-

1090

24

M 36 x 90

-

-

630

25

M 30 x 140

-

-

1600

26

M 56 x 280

-

-

4500

27

M 16 x 40

-

-

100

4609216

4207101

4521963 Sheets 1
+2

4609407

4207648
4613028

11/2013 Rev 0

14

5 - 82

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 38

2-492-20980 (POS 01)

5 - 83

11/2013 Rev 0

Blank page

5 - 84

2-492-20980 (POS 01)

6

Commissioning and operation

6.1

General information
For many reasons we highly recommended you call for the assistance of
ThyssenKrupp Resource Technologies staff in the commissioning process. This is not
only for reasons relating to the warranty, but also for the purpose of:

having the machine/plant checked

determining the optimum capacity

training the operating personnel

passing on additional advice on operation, maintenance and upkeep.

For the initial commissioning routine note the instructions relating to the components included in the ANNEX 9.

6.2

Safety notes for operation

DANGER
Risk of injury from damaged insulation on the connecting cable and missing terminal box covers
Imminent danger of death or severe bodily injuries
• The electrical connections to the drives must be adequately protected.

WARNING
Risk of injury from larger oscillation amplitudes

11/2013 Rev 0

Death or severe bodily injuries are possible
• Do not reach into the spaces between fixed components and oscillating components.
• Repair incorrect oscillation before feeding material.

2-492-20980 (POS 01)

6-1

CAUTION
Risk of injury when operating the drive units without protective clothing
Bodily injury possible
• The machine must never be operated without the guards in position over the
drive units.

Operate the machine / plant only if all protective and safety-oriented devices, such as
removable safety devices and emergency shut-off equipment, sound-proofing elements and exhausters, are in place and fully functional!

Check the machine/ plant at least once every shift for obvious damage and defects!
Report any changes (including changes in the operating performance) to the responsible department immediately! If necessary, stop the machine/ plant immediately and
lock it!

In the event of malfunctions, stop the machine/ plant immediately and lock it!
Have any defects remedied immediately!

Follow the start-up and shutdown procedures and control displays as set out in the
manual!

Before starting up/actuating the machine/ plant, make sure that nobody is at risk!

If abnormal vibrations suddenly occur in the equipment supporting structure the operation of which is corresponding with vibrations and unbalances, these abnormal vibrations must be eliminated prior to feeding the machine with material.

Only work with the prescribed lighting under darkness and with poor visibility.

Switch off the machine/plant immediately if people's lives are at risk, e.g. due to careless working near belt conveyor systems and material transfer points.

Local operation of individual drives is allowed only during inspection, maintenance and
repair work.

Work may only be carried out if the worker is properly qualified and/or has been authorised to do so.
Do not carry out maintenance and repair work without authorization.

11/2013 Rev 0

6-2

2-492-20980 (POS 01)

6.3

Power supply and control system
Power is supplied via mains and feeder circuits.
Gyratory crushers may only be operated in an electrically interlocked condition for safety
reasons and as a protection against overloading.
The start-up and shutdown procedures of the gyratory crusher and the upstream and
downstream units/equipment must be executed in a defined sequence for functional and
safety reasons. To this end, the crusher and these units are electrically interlocked internally and with each other. The control system, all drives as well as the monitoring devices/
local transmitters connected to the control system are included in the interlocking system.
Any faults are signalled to the control station/control cabin.
Depending on the type of failure, only a message is output or the upstream units/the crusher are switched off.
The drives can also be operated separately, i.e. locally, for inspection, maintenance and
repair work as well as for test runs.

CAUTION
System damage through use of the machine/plant contrary to its designated
use
Damage to the machine/plant or its environment is possible
The intended use of the machine/plant is regulated by contract. Any other use contrary to its designated use is prohibited. ThyssenKrupp Resource Technologies
cannot be held liable for damage resulting from such misuse. The risk of such misuse lies entirely with the user.

11/2013 Rev 0

• Electrical interlocking systems may only be switched off by qualified personnel.
All drives must be interlocked during normal operation!

2-492-20980 (POS 01)

6-3

INFORMATION

The safety parts of controllers for the gyratory crushers correspond to the
necessary performance level "d" - category 2.
The scope of supply of ThyssenKrupp Resource Technologies-Business
Unit Processing does not include the "MCC" control unit but only the GYRAMATIC.

11/2013 Rev 0

GYRAMATIC is a compact and reliable control and monitoring system that has been specially designed for the ThyssenKrupp gyratory crusher. It provides all the control functions
as regards operation, calibration and overloads which are necessary for reliable and problem-free operation of the gyratory crusher. The device is designed as a touch screen terminal and enables control and gearing of all motors connected to the gyratory crusher.
Here, the pressure, temperature and oil flow in the lubricant/hydraulic system are displayed.

6-4

2-492-20980 (POS 01)

6.4

Initial commissioning

Check that
– the oil circulating lubrication for the eccentric and axial step bearing,
– the hydraulic system with the balance unit,
– the grease lubrication for the spider bearing and
– the stand oil lubrication unit of the pinion assembly shaft
– the safety coupling

are sufficiently filled with the lubricant and/or hydraulic oil as specified in the relevant table
of lubricants (Chapter 8.4).

Switch on the oil circulating lubrication.

Check that the monitoring, heating and cooling systems of the oil circulating lubrication
have been set correctly and electrically connected/interlocked, so that the crusher cannot be started without lubrication.

Switch on the hydraulic unit. Place the balance unit in a state of readiness for operation.

Set the crushing gap!
Measure the crushing gap by means of a folding rule and set it in accordance with the
required product grain size (see Chapter 2 "Technical data").
Do not exceed the max. permissible piston stroke of the hydraulic cylinder of max.
280 mm.

Pump up the safety clutch between the electric motor and the crusher to 90 MPa (900
bar) as per the instructions. (See ANNEX 9.3).

CAUTION
Plant damage through incorrect oil pressure
Damage to the machine/plant or its environment is possible

11/2013 Rev 0

• Check the oil pressure in the pressure chamber of the safety coupling again after
the run-in period.

Switch on the lubrication pump for the spider bearing.

Switch on the compressor for the dust sealing.

Switch on the crusher main drive motor.

Allow the gyratory crusher to test run for approx. 2 hours without material. Check that
the control equipment, e.g. flow meters, thermostats, level indicators of lubrication
units and the hydraulic unit of the crusher, is functioning correctly. Remedy any faults/
failures immediately or have them remedied.

Increase the feed rate of the material over a period of approx. 8 hours thereby steadily
increasing the load on the gyratory crusher (no maximum size of feed material to start
with).

2-492-20980 (POS 01)

6-5

6.5

Normal operation

6.5.1

Requirements
– Sufficient lubricant and/or hydraulic oil levels (see previous section).
– The associated ball valves upstream/downstream of the pump provided for operation
(one of the two pumps) must be opened.
The ball valves of the second pump (standby pump) must be closed.
– The oil pump must be switched on.
– The oil circulation rate of the external bearing (radial) must be 165 l/min and that of the
internal bearing (axial) 195 l/min.
– The return temperature may not exceed approx. 55 °C.
– The tank heating system and the air/oil cooler must be operative. The lubricating oil
must have a temperature of approx. 35 °C on start-up of the crusher.
Activation of the heating system at 34 °C.
Switch off of the heating system at 38 °C.
– The oil filters must be operative, i.e. excessively clogged filters must be cleaned and/
or replaced.
– The ball valve between the tank and the pump and between the pump and the oil/air
cooler must be open on the pump for the oil cooling circuit.

6.5.2

Checks during operation
Monitor the main shaft / check the crushing gap:

Measure the position of the piston in the hydraulic cylinder and thus the position of the
main shaft by the distance sensor starting from the bottom position

Check display in the control station/control cabin.

Monitor the main shaft / check the overload protection for actuation:
– In case of overload, the operating pressure is exceeded.
– Open two pressure relief valves for a short period of time.
– A negligible amount of oil leaks from the hydraulic cylinder:
– The main shaft is lowered and the crushing gap is increased to empty the crushing
chamber.
The lowering of the main shaft on overload can be seen on the display of the main shaft
adjustment in the control station/control cabin.
Check the temperature of the lubricating oil.

If the temperature of the lubricating oil is too high, an alarm signal is actuated by thermostats. The crusher main drive motor is switched off if the max./ max. oil temperature is exceeded.

Check the flow rate of the lubricating oil.

Monitoring is via flowmeter. If the oil circulating quantity is too low, an acoustic and visual
warning is output and the crusher main drive motor is switched off.

6-6

2-492-20980 (POS 01)

11/2013 Rev 0

Check the electric filter clogging indicator.

The lubricating oil is cleaned by a switchable pressure filter in the supply line. As soon as
one of the filters is clogged, the second (bypass) filter is switched over to and the filter element of the first filter can be replaced.

Check that the heating system switches on and off.

The heating system in the lubricating oil tank is monitored by a temperature controller.

Check that the oil cooling system switches on and off.

The air/oil cooler and the pump of the cooling circuit of the oil circulating lubrication are
controlled via a temperature controller in the return line.
If the oil temperature is above 45 °C, the cooler and the pump motor switch on.
If the oil temperature is below 40 °C, the cooler and the pump motor switch off.

Check the lubricating oil and hydraulic oil levels.

Monitoring is by a magnet level switch. An alarm is output as soon as the level decreases
to the minimum oil level.
The crusher motor is switched off at min.min. after an idling time of 5 minutes.

Check the supply line of the oil circulating lubrication.

Monitoring is via pressure controller. An acoustic and visual warning is output and the
crusher main drive motor is switched off as soon as the pressure is lower than the min.
pressure.

Monitor the feeding of the material to be crushed in the feed opening.

Monitor the pilot lamps/displays and arrange for the necessary maintenance work after
warning messages.

After a failure has been displayed/signalled, acknowledge the failure and arrange for
the cause of failure to be remedied.

Monitor the ammeters (power input) and operating displays.

Monitor the crushing gap/shaft position display.

Switch off the gyratory crusher by pressing the emergency-stop button in the case of
danger.

11/2013 Rev 0

Due to progressive wear of the crushing tools, the product grain size no longer corresponds to the originally set crushing gap after a certain period of operation.

6.6

Reduce the crushing gap by lifting the cylinder according to the condition of wear.

Check the new crushing gap.

Malfunctions, troubleshooting
Failures/faults are displayed in the control station/control cabin.
The crusher is switched off automatically depending on the failure/fault.
The cause of failures/faults which are not displayed must be found and remedied.

2-492-20980 (POS 01)

6-7

Fault list / troubleshooting guide

Fault
Gyratory crusher comes
to a standstill

Cause
Overload, accumulation of material in
the crushing chamber, the safety coupling has actuated.

Lower the main shaft and allow excessive
material to drop out.

Check and change crushing gap, if necessary.

Check material to be crushed for excessive
oversize and undersize.

Check that the material is uniformly fed in
and distributed in the crushing chamber.

Exchange the filter inserts of the supply filters.

Check the function of the flowmeters.

Check the delivery rate of the lubrication oil
pumps.

Check the function of the oil coolers, temperature controllers and cooling circuit
pump.

Check the flow rate and the operating pressure of the oil circulating lubrication.

Metallic foreign bodies in the crushing
chamber, and the overload protection is
not functioning

Correct the setting of the pressure relief
valves in the cylinder bottom/replace the
pressure relief valves.

min./ min oil level in lubricating oil tank

Remedy leaks, top up lubricating oil.

Pressure of dust sealing has fallen
below min

Check the blower, hose lines, pressure
transducers, sealing ring of the dust
sealing.

Grease level in the spider bearing has
fallen below min

Check the grease lubrication pump, grease
lines, flowmeter; grease tank empty.

Grease drum filling level has fallen
below min

Grease tank empty.

Crushing gap too large

Reset the crushing gap by adjusting the
main shaft.

Crushing tools worn

Replace crushing tools.

Overload through foreign bodies

Reset the crushing gap by raising the main
shaft.

Hydraulic oil level too low

Top up hydraulic oil.

Eliminate leakage/retighten bolted connections.

Lubrication oil flow rate too low

Lubricating oil temperature too high

Product grain size too
large

Main shaft has been
lowered

Message - Operating
pressure of oil circulating lubrication too low

6-8

Remedy

Lubrication oil pump defective

Check lubrication oil pump. Replace if damaged/worn.

Supply filter clogged

Clean/replace filter insert.

2-492-20980 (POS 01)

11/2013 Rev 0

6.6.1

Fault

Cause
Leaky oil lines/bolted connections

Eliminate leaks

Retighten screwed and bolted connections.

Hoses and/or bolted connections leaky

Replace hoses and retighten bolted connections.

Oil cooler leaky

Repair oil cooler.

Oil level in oil circulating
lubrication rising and
hydraulic oil level falling

Seal in the piston of hydraulic cylinder
worn

Replace seals in the piston

Message - Increased
return temperature of
lubricating oil

Damage to axial step bearing/eccentric
bushing

Check axial bearing and eccentric bush.

Replace if damaged/worn.

Check return line filter.

Insufficient lubrication

Check the flow rate and the operating pressure of the oil circulating lubrication.

Insufficient cooling of lubricating oil

Check oil cooler, cooling circuit pump and
temperature controller for oil cooler.

Temperature controller for heating rods
defective

Replace temperature controller.

Message - Supply filter
of oil circulating lubrication clogged

Filter inserts clogged

Replace filter inserts

Increased current consumption of the crusher
motor

Gyratory crusher overloaded

Check the feed quantity and feed material
size.

Check the main shaft position.

Speed of pinion assembly shaft too low

Gyratory crusher overloaded

Check the feed quantity and feed material
size.

Check the main shaft position.

Axial clearance between the sealing ring
and sealing housing too large

Replace sealing ring of the dust sealing.

Compressor defective (no over-pressure)/ intake filter of compressor
clogged.

Repair compressor

Clean/replace intake filter of compressor.

– by silver to grey colou- Damage to axial step bearing (step bea- •
red metal deposits
ring lower part)/ bevel gear or pinion of
the pinion assembly shaft

Check bottom spherical disk of axial bearing/ bevel gear or pinion of transmission
shaft.

Message - Oil level in
lubricating oil tank too
low

Return line filter (screen
basket) of oil circulating
lubrication clogged:
– by dust particles

11/2013 Rev 0

Remedy

Lower shaft of the main shaft

– by bronze coloured
metal deposits

Check lower shaft of main shaft.

Replace if damaged/worn.

Check eccentric bushing/

inner eccentric bushing for damage.

Axial step bearing (step bearing upper
part and slide bearing plate)

Check step bearing upper part and slide
bearing plate of the axial step bearing.

2-492-20980 (POS 01)

6-9

Frequent readjustment
of the crushing gap
required

Cause

Remedy

Outer eccentric bushing of the eccentric
bushing in bottom part

Check outer eccentric bushing of the
eccentric bushing.

Axial step bearing ring between the
base plate and the hub of the bottom
shell

Check axial step bearing between the base
plate and the hub.

Replace if damaged/worn.

Crushing tools worn

Replace crushing tools.

Remedy hydraulic leaks/retighten bolted
connections.

Repair/replace hydraulic pump/
Clean the piston slide.

Correct the setting.

Main shaft cannot be lif- Hydraulic pump output too low/defected.
tive/piston slide valve of the way valve
sticking
Incorrect setting of the pressure relief
valve

Leakage oil losses at sealings in hydrau- •
lic cylinder/in valves

Remedy leakage; replace seals.

Material accumulated in the bottom shell
of the crusher, e.g. because the extractor device has failed

Remove the accumulated material.

Balance unit is defective

Repair the balance unit.

Abnormal noises in the
pinion assembly

Roller bearings defective/ gearing worn,
damaged

Localise the noise by means of a stethoscope. Have the damage assessed by a
gear unit specialist. If required, replace the
defective roller bearing/pinion.

Continuous topping up
of oil in the pinion
assembly required

Radial sealing rings worn/ O-ring leaking
at bearing housing

Replace radial sealing rings/ O-ring.

Grease consumption of
spider bearing too high

Hoses defective

Replace hoses.

Bolted connections loose

Retighten screwed and bolted connections.

Spider bush / wear insert worn

Replace top axle mounting and wear insert.

Shaft seal worn

Replace shaft sealing below the spider
bushing.

Spider bush / wear insert worn

Replace top axle mounting and wear insert.

Drive unit or a component of the drive
unit is loose.

Check and retighten fastening bolts.

Alignment inaccurate

Re-align crusher main drive motor.

Roller bearing defective

Replace roller bearing.

Incorrect setting of the pressure relief
valve/valve seat damaged or jammed

Correct setting/ replace valve.

Main shaft cannot be
lowered fully.

Streaks of grease on
the wear insert of the
main shaft

Vibration on the drive
unit

Pressure relief valve
does not maintain the
required pressure.

6 - 10

2-492-20980 (POS 01)

11/2013 Rev 0

Fault

Fault

Cause

Remedy

Pump does not reach
the required delivery
rate.

Internal leakage of pump due to wear

Replace pump.

Jerky movement of the
hydraulic cylinder

Fluctuations in pressure or delivery flow/
air trapped in the hydraulic cylinder

Bleed the hydraulic cylinder.

Foam formation in the
hydraulic oil/lubricating
oil

Water in the hydraulic oil/lubricating oil

Drain the condensation out of the tank/
change hydraulic oil/ lubricating oil.

Use foam inhibitors.

6.6.2

Restart of the crusher
After a standstill of the crusher with a full feed opening, e.g. due to power failure or fault
message from a monitoring device:

Lower the main shaft, several times if necessary, in order to clear it.

Switch on the crusher drive in the bottom axle position during lowering (3 trials/h possible).

If the crusher does not run up:

Clear the crusher by hand.

6.7

Shutting down

6.7.1

Normal operation
The material feed must always be interrupted before the crushing plant is stopped. The
crushing plant can then run "empty."
When the crushing plant is stopped, make sure that sufficient material remains in the feed
hopper to protect the conveyor covering.

CAUTION
Plant damage through false material feeding after emptying the feed conveyor

11/2013 Rev 0

Damage to the machine/plant or its environment is possible
• If the feed hopper is run empty, ensure that small-sized pieces of material are
again initially fed to the feed hopper when material feeding resumes. This serves
to protect the conveyor covering against the impact load of lump material.

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6 - 11

6.7.2

Emergency-stop system

CAUTION
System damage from material overfilling when using emergency-stop
switch
Damage to the machine/plant or its environment is possible
When using an emergency-stop switch, there is a danger of material overfilling at
the transfer points, as all upstream and downstream parts of the plant are switched
off with no specific shutdown sequence.
• The emergency-stop switches must not be used for normal shutdown.
Several emergency-stop switches must be installed on the machine/plant.
The emergency-stop switches are identified by red impact surfaces on yellow background.
The switches engage on actuation.

6.8

The whole electrical system is switched off by the emergency stop.

Ascertain the danger or damage, and provide first aid if necessary.

Have any defects rectified.

In order to restart the plant after having rectified the emergency case, the actuated
switch is to be unlocked by turning the impact surface to the right-hand side.

Acknowledge the fault.

Switch on the main supply again.

Handling of oil hydraulic systems

11/2013 Rev 0

Handling of oil hydraulic systems (see Chapter 5.4 "Handling of oil hydraulic systems").

6 - 12

2-492-20980 (POS 01)

7

Maintenance

7.1

Important information on maintenance

WARNING
Risk of injury through cleaning, inspection, maintenance and repair work
during operation
Death or severe bodily injuries are possible
• Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off and secured against restarting.

Note the information in the Operating Instructions on adjusting, maintenance and
inspection work and observe the intervals set out, including information on the replacement of parts and equipment! The work may only be carried out by qualified personnel.

Inform the operating personnel before starting service and maintenance work! Appoint
a person to supervise the work!

When carrying out any work concerning the operation, conversion or adjustment of the
machine/ plant and its safety-oriented devices or any work related to maintenance,
inspection and repair, always follow the start-up and shutdown procedures described
in the Operating Instructions and the information on maintenance work!

As a general principle, all work on the machine/ plant should only be carried out when
the machine/ plant is at a standstill.

If the machine/ plant has been completely shut down for maintenance and repair work,
it must be secured against inadvertent restart by:
– Locking the main control elements and removing the key and/or

11/2013 Rev 0

– attaching a warning sign to the main switch.

2-492-20980 (POS 01)

7-1

Before restarting the machine/plant after repair work, check that all safety devices have
been attached.

After electrical installation or repair work, test the protection systems (e.g. earth resistance).

To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting gear and secured. Only
use suitable and technically perfect lifting gear and suspension systems with an adequate carrying capacity! Never work or stand under suspended loads!

The fastening of loads and the instruction of crane operators should only be entrusted
to experienced persons! The marshaller must be within eyesight of the operator or
have verbal communication with him.

When carrying out overbelt assembly work, always use specially designed or other suitable and safe climbing aids and working platforms. Never use machine parts as a climbing aid! Wear fall protection when carrying out maintenance work at a higher level.

Keep all handles, steps, handrails, platforms, landings and ladders free of dirt, snow
and ice!

Always tighten up any bolted connections which have been loosened during maintenance and repair work!

Any safety devices removed for setting up, maintenance or repair purposes must be
refitted and checked immediately upon completion of the maintenance and repair work.

Ensure that all consumables and process materials and replaced parts are disposed
off safely and in an environmentally friendly manner!

Only use original fuses with the specified current rating! Shut down the machine/ plant
immediately if faults occur in the electrical power supply!

Work on the electrical system or equipment may only be carried out by a skilled electrician or by specially instructed personnel under the control and supervision of a
skilled electrician and in accordance with the applicable electrical engineering rules.

If prescribed, the power supply to parts of machines and plants on which inspection,
maintenance and repair work is to be carried out must be disconnected. Check that the
isolated parts have been disconnected from the supply, then earth and short-circuit
them and insulate any adjacent live parts!

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2-492-20980 (POS 01)

The electrical equipment of the machine/plant must be inspected at regular intervals.
Any defects such as loose connections or scorched cables must be rectified immediately.

If work on live parts is necessary, it may only be carried out in the presence of a second
person who can disconnect the power supply in an emergency by actuating the emergency stop button or main power switch. Cordon off the working area with a red-andwhite safety chain and a warning sign. Only use insulated tools!

Before starting work on high-voltage assemblies and after disconnecting the power
supply, the supply cable must be earthed and components such as capacitors shortcircuited with an earthing rod!

Only carry out hot work (welding, flame-cutting and grinding) on the plant if this has
been expressly authorised. For example there may be a risk of fire or explosions.

Before carrying out welding, flame-cutting and grinding work, clean dust and other
inflammable substances from the machine/ plant and its surroundings and provide
adequate ventilation (risk of explosion)!

Check all lines, hoses and bolted connections regularly for leaks and obvious damage.
Repair any damage immediately! Splashing oil may cause injury and fires.

Depressurise all system sections and pressure pipes which are to be opened in accordance with the instructions for the assembly group concerned before carrying out any
repair work!

Hydraulic lines must be laid and connected in line with good professional practice!
Ensure that no connections are interchanged! The fittings, lengths and quality of the
hoses must comply with the technical requirements.

Follow the applicable safety regulations when handling oil, grease and other chemical
substances!

Be careful when handling hot consumables and process materials (risk of burning or
scalding)!

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7-3

7.1.1

Information about cleaning

CAUTION
Risk of injury when working without personal safety equipment
Bodily injury possible
• Always wear a face protector when carrying out cleaning work with high-pressure or steam jet cleaners.

Check the degree of soiling of the machine/plant every day. Do not allow material to
accumulate or cake. The mechanical interaction of the plant components may be interfered with and malfunctions and increased wear occur.

Always clean the assembly group in question before commencing maintenance work.

Before cleaning the machine/ plant with water or steam jet (high-pressure cleaners) or
other cleaning agents close/tape up all openings into which water, steam and detergents should not be allowed to penetrate for safety or operational reasons. Electric
motors and switch cabinets are at particular risk.

Do not use corrosive detergents.

Do not direct the spray jet at electrical devices, relay boxes and switch cabinets, intake
and breather filters or greased surfaces.

Always hold the spray jet a sufficiently large distance away from the surface being cleaned and do not direct the spray jet at these surfaces at right angles.

Clean places which are difficult to reach with suitable equipment e.g. special brooms.

The covers and tapes need be removed completely after cleaning.

After cleaning, check all lubricant and hydraulic oil lines for leaks, loose connections,
friction areas and damage! Eliminate any deficiencies immediately!

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2-492-20980 (POS 01)

7.1.2

Information on maintenance and inspection

WARNING
Risk of injury by neglecting proper maintenance intervals
Death or severe bodily injuries are possible
• All pending maintenance work must be completed according to schedule. The
manufacturer does not accept liability for damage resulting from maintenance
work which has not been carried out or has not been carried out according to
schedule.

CAUTION
System damage through improper maintenance
Damage to the machine/plant or its environment is possible.
• Check the machine / plant at least once per shift for obvious damage and
defects! Report any changes (including changes in the operating performance)
to the responsible department immediately!
• In the event of malfunctions, stop the machine / plant immediately and lock it!
Have any defects remedied immediately!

Failures arising from inadequate or improper maintenance may cause high repair costs
and long downtimes. Regular maintenance is therefore indispensable.

11/2013 Rev 0

Functional safety, trouble-free operation and the service life of the machine/ plant depend
on proper cleaning, inspection and maintenance.

Check the machine/ plant at the specified intervals (inspection intervals, maintenance
periods) for proper operation, lubrication condition and wear.

Replace or repair all damaged/ worn parts.

Check the paintwork for corrosion at regular intervals but no later than every 6 months.
Touch up all damaged areas in line with good professional practice.

Have the function of all instrumentation and control devices/ electrical interlocks chekked by qualified personnel at regular intervals.

2-492-20980 (POS 01)

7-5

INFORMATION

Downtimes for repairs can also be used for scheduled maintenance work.

The required frequency of checks for wear, inspection, maintenance and repair cannot be
specified beforehand owing to the variety of service conditions. An appropriate routine inspection schedule must be prepared making allowance for the operating conditions.
The maintenance table (Chapter 7.2) is a guideline for inspection and maintenance work.
For maintenance and repair work strictly follow the general safety notes included in
(Chapter 3).

INFORMATION

For lubricating the machine/ plant see Chapter 8.
For maintenance and repair of the components see ANNEX 9.

11/2013 Rev 0

As recommended during commissioning, you are advised to have initial repairs carried out
by ThyssenKrupp Resource Technologies staff. Your maintenance staff will have the opportunity to take part in an intensive training course.

7-6

2-492-20980 (POS 01)

7.1.3

Notes relating to repairs

WARNING
Risk of injury due to improper fastening
Death or severe bodily injuries are possible
• To avoid the risk of accidents, individual parts and large assemblies being
moved for replacement purposes should be carefully attached to lifting gear and
secured. Only use suitable and technically perfect lifting gear and suspension
systems with an adequate carrying capacity! Never work or stand under suspended loads!
• The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
• When carrying out overbelt assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms. Never use machine
parts as a climbing aid! Wear fall protection when carrying out maintenance work
at a higher level.

Immediately replace worn components with new components.
The strength of worn components is lower and the risk of fracture greater!

Do not re-use seals and safety elements that have been removed.

When re-using assembly groups and parts, always use new bolts, nuts and washers.

Do not leave any tool or other device in the machine/plant.

Observe the welding instructions for the prevention of accidents whenever carrying out
welding work.

During electric welding, secure the earthing cable near the part being welded. Do not
route the welding current return line over movable machine elements (e.g. shafts, bearings). For bridging, fit a cable with a cross-section adequate for the strength of the welding current and for the length over which current must be carried.

Restore the machine/plant to its original state on the completion of the repair work.
Remount protective and safety devices again. Make sure that the machine/plant is working properly by carrying out a test run.

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7-7

7.2

Maintenance intervals
Maintenance intervals are:
– defined periods of time (maintenance periods) or
– a certain number of operating hours (approx. 8000 operating hours/a and the maintenance intervals derived from this).
The following table provides an overview of the maintenance intervals with the abbreviations D (= daily), W (= weekly), and M (= monthly) used in the maintenance tables.

Maintenance interval

Maintenance period

Number of operating hours (Bh)

T

daily/ prior to each start-up

approx. 24

W

weekly

approx. 165

M1

monthly

approx. 720

M3

quarterly

approx. 2200

M6

half-yearly

approx. 4400

M12

annually

approx. 8800

Carry out the relevant inspection/maintenance work as soon as the first of the two possible
maintenance intervals is reached.
The maintenance intervals (maintenance periods and operating hours) for carrying out
maintenance work are suggestions and recommendations of ThyssenKrupp Resource
Technologies.
However the frequency with which maintenance work should be carried out depends on
the particular operating conditions existing on site, such as
– Operating time
– Operating condition and
– Wear.
Therefore the operating conditions must be observed and taken into account. It
may be necessary to change or adapt the maintenance intervals over the course of
time.

11/2013 Rev 0

Observe the instructions for components in the ANNEX 9.

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The maintenance tables include the following:
– The inspection/maintenance work to be carried out in shortened form.
The section numbers in brackets refer to the detailed description of the inspection/
maintenance work;
– The maintenance intervals marked by a dot (starting with T to M12), at which the relevant maintenance work has to be carried out.
Chapter 8 "Lubrication" is to be observed for:
– The quantities of lubricant (grease/lubricating oil);
– The designation of the lubricants whose level has to be checked and which have to be
topped up or changed.

Maintenance interval

11/2013 Rev 0

Inspection/maintenance work

Note

T

Check the setting of the crushing gap (in the
operator's cabin)

Check the crusher for abnormal noises and obvious
damage.

Visually check the oil circulating lubrication and
hydraulic unit for leaks

Check the oil quantity and pressure of the oil
circulating lubrication and hydraulic pressure.

Check the oil temperature of the oil circulating
lubrication.

Check the optical clogging indicators of the filters of
the oil circulating lubrication and hydraulic system,
replace the filters if necessary (Chapter 7.3.7).

Check the function and the degree of soiling of the
oil/air cooler.

Check pre-tension pressure in compressed air tank
of compensation unit.

Check the crusher for soiling and material deposits;
clean if necessary.

-

Check the crusher inlet/outlet for free passage.

-

Check the oil level of the pinion assembly
(Chapter 7.3.8).

-

Check the oil level in the tank of the oil circulating
lubrication (Chapter 7.3.7).

-

Check the oil level in the hydraulic oil tank
(Chapter 7.3.8).

-

Check the screen basket in the lubricating oil tank
for dirt accumulation.

-

with the machine running

2-492-20980 (POS 01)

W

M1

M3

M6

M12

7-9

Maintenance interval
Note

T

W

M1

Manually check/measure the width of the crushing
gap (Chapter 7.3.3).

-

Check the wear parts in the spider and bottom shell
for wear (Chapter 7.3.3).

-

Check the concaves for completeness and damage
(Chapter 7.3.3).

-

Check the mantle and the main shaft sleeve
(Chapter 7.3.3).

-

Check the spider bearing for leaks.

-

Check all fastening bolts for completeness and
secure attachment (Chapter 5.9 and Chapter 7.3.2).

-

Check the filling level in the reservoir of the
lubrication unit of the spider bearing (Chapter 7.3.4).

-

Check the over-pressure system (Chapter 7.3.5).

-

Check the connection cable of the position encoder
for damage.

-

Check the compressed air for free passage
(Chapter 7.3.5).

-

Check the hydraulic pressure of the safety coupling
(90 MPa = 900 bar).

-

Check the breather filter of the pinion assembly;
clean/replace if necessary.

-

Check the breather filter of the oil and hydraulic
tank; clean/replace if necessary.

-

Check the wear of the wear insert in the top axle
mounting and clearance to the main shaft sleeve
(Chapter 7.3.4).

-

Analyse the lubricating oil of the oil circulating
lubrication unit, change the oil if necessary
(Chapter 7.3.7)

Analyse the lubricating oil of the pinion assembly,
change the oil if necessary (Chapter 7.3.9)

Analyse the hydraulic oil, change the oil if necessary
(Chapter 7.3.8)

Check the sealing housing for wear and clearance of
the sealing ring (Chapter 7.3.5).

Change hydraulic oil of safety clutch (ANNEX 9)

7 - 10

M3

M6

M12


Oil change every
2000 Bh, however,
every 6 months at the
latest


after every 15
releases of the safety
clutch or after 12
months

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11/2013 Rev 0

Inspection/maintenance work

Maintenance interval
Inspection/maintenance work

Note

Check the components of the dust sealing for wear.

Change the grease of the spider bearing

T

W

M1

M3

M6

M12

Check the running surfaces of the main shaft, axial
step bearing, eccentric bushing, outer eccentric
bushing in the bottom shell, axial bearing ring for
wear.

when changing the
crushing tools

Check the backlash between the bevel gear and the
bevel pinion.

-

Annual inspection

-

11/2013 Rev 0

For maintenance and repair of the components see ANNEX 9.

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7 - 11

7.3

Special maintenance tasks
The following parts of the machine require maintenance at regular intervals:
– Crusher shells and concaves
– Secure attachment of connecting bolts
– Main shaft
– Spider bearing with grease lubrication
– Dust sealing
– Eccentric bushing and axial step bearing
– Check the oil level and change the oil at the oil circulating lubrication unit
– Check the hydraulic oil level and change the hydraulic oil
– Drive and pinion assembly

7.3.1

Crusher shells and concaves
See Illustration 39, drawing 4609197 and 4609235 in ANNEX 9.1
– Check the concaves (1) for damage

Check the positions of the concaves from above through the loading opening for completeness and obvious damage with the crusher empty and at standstill.

INFORMATION

The continuous wear from operation can be detected because the main shaft
height must be increased. For replacing the concaves, see Chapter 7.4.5.

Monitoring interval: weekly

Check the spider cap (2) for damage with the crusher empty and at standstill. The wear
of the wall thickness can only be checked with the cap dismantled (see Chapter 7.4.8).

Check the thickness and condition of the arm liners (3) on the cross bar. Replace worn
arm liners.

Check the thickness and condition of the liner plates (4, 5). Check the attachment of
the liner plates. Replace worn plates.

Check the attachment of the liner plates (6) on the conical part of hub (crusher outlet)
- weld seams - re-weld liner plates if necessary; replace worn plates.

Check the position and condition of the arm liner (7) on the arms (bottom shell of the
hub), realign/replace if necessary.

Inspection interval: weekly

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– Check the spider cap, spider, upper shell, lower shell and bottom shell

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Figure 39

2-492-20980 (POS 01)

7 - 13

7.3.2

Secure attachment of connecting bolts
See Illustration 40

CAUTION
Plant damage through loose fastening bolts
Damage to the machine/plant or its environment is possible.
• Check the following bolts/ screws:
– Anchor bolts/fastening bolts of the bottom shell of crusher
– Fastening bolts (1) between bottom sheet of crusher and the lower shell
– Fastening bolts (2) between the upper and the lower shells
– Fastening bolts (3) between upper shell and cross bar
– Flange screws (4) of the hydraulic cylinder.
• Re-tighten lose bolts to the tightening torque specified in Chapter 5.10 or if not
indicated in accordance with the table in Chapter 7.5.

Check the secure attachment of the ring nut (5) for securing the mantle on the main
shaft.

Re-tighten any loose ring nuts. To do so, weld a knocking cam on the ring nut.

11/2013 Rev 0

Monitoring interval: weekly

7 - 14

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11/2013 Rev 0

Figure 40

2-492-20980 (POS 01)

7 - 15

7.3.3

Main shaft
See Illustration 41
– Check the crushing gap
The height of the main shaft (1) can be vertically adjusted to change the crushing gap locally/centrally.
The crushing gap increases and must be re-adjusted due to increasing wear of the crushing tools (concaves and main shaft).
Check the actual size/width of the crushing gap with the crusher empty and at standstill.
For this purpose:

Open the inspection hole cover (2) in the bottom shell.

Measure the crushing gap (X) at two opposite points and calculate using the following
equation:
OSS= (measuring value1 + measuring value2)/2 + eccentricity
OSS= (measuring value1 + measuring value2)/2 - eccentricity

Re-adjust the crushing gap if necessary.

Inspection interval: depends on material to be crushed. We recommend starting with a
weekly check.
– Check the mantle for damage, check the main shaft sleeve

Check the mantle (3) from above through the feed opening for obvious damage with
the crusher empty and at standstill.
The continuous wear from operation can be detected because the main shaft height
must be increased.
For replacing the concaves, see Chapter 7.4.7 "Main shaft".

Check the secure attachment of the mantle. Re-knock the outer ring nut (4) if necessary.

Check the main shaft sleeve (5) of the main shaft for wear/damage, e.g. wear marks,
longitudinal grooves. Replace the main shaft sleeve if excessively worn/visibly damaged (see Chapter 7.4.7 "Main shaft").

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Monitoring interval: weekly

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Figure 41

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7 - 17

7.3.4

Spider bearing with grease lubrication

INFORMATION

The following checks must be carried out with the main shaft fully lowered (before
switching off the crusher). Always check all components of the spider bearing with
the spider and main shaft dismantled (e.g. replacement of the concaves and mantle).

Checking the wear insert for wear:

Clean the top part of the spider, dismantle the spider cap (1) and remove the lubricating
grease.

Check the clearance (2) between the wear insert (4) and the main shaft sleeve (3).
Press the main shaft on the wear insert by means of a hydraulic device.
Measure the clearance between the wear insert of the top bearing and the wearing
bushing of the crusher axle by means of a feeler gauge. The clearance may be a max.
of 3.5 mm. If this is exceeded, replace the wear insert (see Chapter 7.4.8).

If the clearance exceeds the permissible value to a large extent, the inclination of the main
shaft will change in a way causing abrasion to the inner eccentric bushing due to a wrong
inclination angle.
The main shaft will elevate when exchanging the main shaft sleeve and the wear insert.
This results in an edge pressure in the inner eccentric bushing. The main shaft may seize
during crushing through the action of the operating pressure.
Check the inner eccentric bushing for run-in marks and cracks caused by edge pressure.

CAUTION
Plant damage through worn eccentric insert
Damage to the machine/plant or its environment is possible

Check the condition of the leather packing (5), shaft sealing rings (6) and toroidal
sealing ring (7).

Use a grease pump to fill the space above the spider bearing with grease (see
Chapter 8.5 "Lubricating instructions").

Re-mount the spider cap. Ensure that no dirt to gets into the spider bearing.

Inspection interval: approx. every 3 months

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• When replacing a worn wear insert, also replace the eccentric insert (see
Chapter 7.4.11).

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Figure 42

2-492-20980 (POS 01)

7 - 19

Maintenance of the grease lubrication unit:
The grease level above the spider bearing is monitored by a filling level sensor (8). Grease
is pumped into the chamber until the upper filling level is reached. The grease pump is
then switched off. Please refer to the function specifications for further information.

Check the function of the lubrication pump.

Top up lubricating grease according to Chapter 8.5 "Lubricating instructions" if necessary.

Check for leaks, re-tighten loose bolted connections.

Inspection interval: weekly

CAUTION
Plant damage due to insufficient lubricant
Damage to the machine/plant or its environment is possible.

11/2013 Rev 0

• Check the grease level one month after commissioning. To do so, remove the
cap.

7 - 20

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Figure 42

2-492-20980 (POS 01)

7 - 21

7.3.5

Dust sealing
See Illustration 43 and Illustration 44
Check the dust sealing preferably with fully lifted crusher axle.

INFORMATION

Always check all components of the dust sealing for wear with the spider and the
main shaft dismantled.

With the main shaft installed, this check may be carried out either
– through access A, whereby all dimensions can be checked
– through access B (inspection flap), whereby a visual check from outside can be carried out .

11/2013 Rev 0

Figure 43

7 - 22

2-492-20980 (POS 01)

Check the wear of the sealing housing and the clearance of the sealing ring:

Check the sealing housing (1) for run-in grooves, which can be caused by the polyamide sealing ring (2). If the run-in grooves are deep, the sealing housing must be
replaced.

Check the condition of the polyamide sealing ring (2) and measure the radial clearance
(3) between the polyamide sealing ring (2) and the sealing housing (1). If the radial
clearance is considerably larger than 2 mm, replace the polyamide sealing ring (2).

Ensure that the polyamide sealing ring (2) can slide between the upper (4) and lower
sealing ring (5). The axial clearance may be 1.0 - 1.5 mm. If necessary, change the
clearance by adding other shim packages (6).

11/2013 Rev 0

Monitoring interval: weekly

Figure 44

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7 - 23

Check of the over-pressure system:
See Illustration 45

Carry out a visual check for the secure attachment of bolted joints and damage to
hoses. Re-tighten loose bolted joints, replace damaged hoses.

After the crusher has been switched off, check that the compressor (1) switches off with
a time delay.

As a preventive measure, check the intake air filter (2) of the compressor for clogging.
Clean/replace if necessary.

Remove any dust deposits from the compressor housing.

The operating pressure can be restricted at the pressure controller (5).

Inspection interval: weekly
Check the compressed air for free passage:

Check the connection piping for accumulated oil, e.g. due to splash oil below the dust
sealing. Otherwise the free passage of the compressed air for the dust sealing cannot
be guaranteed.

Unscrew the hose connection (3) to the air pipe and check whether oil flows out.

Blow compressed air through the ducts (4).

Pressure transducer (6) adjustable (70 - 250 mbar).

Inspection interval: monthly

11/2013 Rev 0

For maintenance work on the compressor, see ANNEX "9.5 Compressor (over-pressure
ventilation)".

7 - 24

2-492-20980 (POS 01)

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Figure 45

2-492-20980 (POS 01)

7 - 25

7.3.6

Eccentric bushing and axial step bearing

INFORMATION

Direct checks/inspection of the axial step bearing (1) and the eccentric bushing
(2) are not possible without dismantling the spider, the main shaft and dust sealing
beforehand. Thus, always check and if necessary, replace the axial step bearing
and the eccentric insert in case of dismantled cross bar and main shaft (see
Chapter 7.4.2, Chapter 7.4.3 and Chapter 7.4.4).

Performing maintenance on the oil circulating lubrication system indirect conclusions regarding potential wear or damage of the axial bearing or eccentric bush can be drawn from
signals generated by the control system and visual inspections of plant components:
Control messages:

Increased oil return temperature

Higher current consumption

Visual check of plant components:
Bronze-coloured metal deposits in the screen basket indicate possible damage to the
inner eccentric bushing/the step bearing upper part/the slide bearing plate of the axial
bearing or the outer eccentric bushing.

Silver to grey metal deposits indicate possible damage to the axial bearing, the bevel
gear, the bevel pinion, the eccentric bushing or the main shaft.

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2-492-20980 (POS 01)

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Figure 46

2-492-20980 (POS 01)

7 - 27

7.3.7

Check the oil level and change the oil at the oil circulating lubrication unit
See also Chapter 7.2 "Maintenance intervals"

Carry out a visual check of the oil circulating lubrication system for leaks. Only re-tighten/replace leaky bolted joints in an unpressurised condition.

Check the oil level on the oil inspection glass of the tank with the crusher and lubrication pumps switched off.

Top up with oil if the oil level is too low.

Switch off the crusher and the oil circulating lubrication unit for an oil change. Drain
the oil when it is at operating temperature.

Provide an adequately sized tank (used oil quantity approx. 2,500 l).

Drain and collect the used oil and dispose of it according to the regulations.

Open the maintenance cover of the tank and clean the tank. Only use non-linting cloth
for cleaning (no cotton waste).

Check the tubular steel protective casings of the heating inserts for damage.

Provide the maintenance cover with a new seal if necessary.

Fill with new filtered lubricating oil (filter fineness 25 µm). Oil quantity and quality, see
Chapter 8.5 "Lubricating instructions".

Check the screen basket of the oil circulating lubrication:

Check the screen insert of the screen basket with the cone crusher at standstill and the
oil circulating lubrication switched off; clean, if clogged.

Monitoring interval: weekly
Checks at the oil/air cooler of the oil circulating lubrication

Check that the cooling air can flow freely in and out.

Clean the cooling fins or blow them out by means of compressed air.

Monitoring interval: daily
Depending on the time of year and the oil viscosity, an increase in the oil return temperature, longer switch-on times and shorter pause intervals of the coolers may be an indication of
– mismatched temperature settings, e.g. switch-off function of the heating system
– insufficient protection against strong sunlight

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– insufficient oil flow through the coolers.

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7.3.8

Check the hydraulic oil level and change the hydraulic oil
See also Chapter 7.2 "Maintenance intervals"

Lower the main shaft completely.

Check the hydraulic oil level on the inspection glass of the tank. The hydraulic oil
level must be at the max. mark.

If the oil level is too low, top up with filtered oil (25 µm) until the max. mark is reached.

Carry out a visual check of the complete system for leaks.

In this respect, also unscrew the cover on the cylinder bottom of the hydraulic cylinder
and check the connection of the distance sensor.

WARNING
Risk of injury due to leaky connections / bolted connections
Death or severe bodily injuries are possible
• Tighten / replace only when unpressurised.

CAUTION
Plant damage due to mixing of hydraulic oil with lubricating oil of circulating
lubrication
Damage to the machine/plant or its environment is possible.
• Replace the piston seals of the hydraulic cylinder
If hydraulic oil has to be topped up several times a week without there being any
obvious leaks, this may be an indication of wear on the piston seals of the
hydraulic cylinder.

Remove and repair/ replace hydraulic cylinder (see Chapter 7.4.10).

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Inspection interval: daily

To change the hydraulic oil, lower the main shaft completely and switch off the crusher and the hydraulic unit.

Provide a tank (oil quantity approx. 630 l).

Drain and collect the used oil and dispose of it according to the regulations.

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7 - 29

Open the maintenance cover of the hydraulic oil tank and clean the tank. Only use nonlinting cloth for cleaning (no cotton waste).

Provide the maintenance cover with a new seal if necessary.

Fill with new filtered oil (filter mesh 25 µm). The max. filling level has been reached as
soon as the oil level is at the top edge of the inspection glass.
Oil quantity and quality, see Chapter 8.5 "Lubricating instructions".

Check of the preload pressure of the balance unit

Check the preload pressure on the pressure gauge of the air tank. The pressure
should be between 6 and 8 bar. If the pressure is too low, use the compressed air
system to re-fill with air.

Monitoring interval: daily

7.3.9

Drive and pinion assembly
See Illustration 47

For checks of the multiple-disc clutch and safety coupling, see ANNEX 9.

Oil level check and oil change at the pinion assembly

Read the oil level on the oil inspection glass (1) with the crusher switched off.

If the oil level is too low, unscrew the breather (2) and top up with filtered oil (filter mesh
25 µm) through the filter opening. Use the oil according to Chapter 8.5 "Lubricating
instructions".

Carry out a visual check for leaks.
If oil has to be topped up every week without there being any obvious leaks, the shaft
sealing rings (3) on the pinion side are leaky.

Monitoring interval: daily
See Chapter 7.2 "Maintenance intervals"
Switch off the crusher to change the oil.
Drain the oil when it is at operating temperature.

Place an tank (oil quantity approx. 50 l) under the pinion assembly.

Unscrew the screw plug (4) on the pinion assembly flange.

Collect the used oil and dispose of it according to the regulations.

Screw in the screw plug with a new seal.

Unscrew the breather and fill with filtered oil (filter mesh 25 µm) via the filter opening.
Oil quantity and quality, see Chapter 8.5 "Lubricating instructions". Check the oil level
on the inspection glass.

Clean/replace the breather and screw in.
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Figure 47

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7 - 31

Resistance thermometer (5) for monitoring the bearing temperature

Check the function

Monitoring interval: daily
Accelerometer (optional) (6) for monitoring the condition of the bearing

Check the function

Inspection interval: daily
Fluid switch (7) for monitoring the oil filling

Check the function

Monitoring interval: daily
Speed monitor of the pinion assembly shaft

Check the function

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Monitoring interval: daily

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Figure 47

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7.3.10

Check of the torsional back lash
See Illustration 48 and ANNEX 9.3
The back lash, i.e. the distance between the teeth of the bevel pinion (1) and the bevel
gear (2) must +/- 15% of the suggested value. The backlash refers to the average pitch
circle diameter and the pitch circle radius.
Incorrect backlash, i.e. excessive torsional backlash due to wear, not only causes annoying running noises but also accelerates wear and tooth breakage.
The backlash can only be checked/measured outside the crusher. An auxiliary device
consisting of a
– Magnet support with arm and dial gauge (3),
– Bracket (4) and
– Pipe clip with auxiliary measuring rod (5) is required for this.
Proceeding from an average pitch circle radius (rm) of the bevel pinion, the back lash can
be measured as the path of rotation, the distance to the auxiliary measuring rod measured
by the dial gauge. To reduce measuring inaccuracies, the distance of the dial gauge to the
centre line should be an integer multiple higher than the pitch circle radius as far as possible.
For example, the desired measuring result would be 2x (suggested value +/- 15%) at twice
the distance.
Mount the bracket on the bearing cover of the pinion assembly and set the dial gauge
on the magnet support to the specified distance and align with the centre line of the
pinion assembly shaft.

Turn the multiple-disk clutch and thus the bevel pinion to the right until the teeth of the
bevel pinion and the bevel gear contact each other.

Attach the pipe clip and the auxiliary measuring rod to the multiple-disk clutch and align
vertically towards the dial gauge.

Turn the multiple-disk clutch to the left until the teeth contact each other again. Read
off and record the value on the dial gauge. Swing the dial gauge away.

Since approx. 4 rotations of the bevel pinion correspond to one rotation of the bevel
gear, turn the multiple-disc clutch by another 4 full rotations. Repeat the measuring
process after each single rotation. This is to account for the possible influence on the
measured values of the changing clearance between the eccentric bushing and the
outer eccentric bushing.

Average the four measurements and convert to the actual backlash. If the calculated
average value is below/above these values, readjust the backlash.

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Figure 48

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7 - 35

Readjust the backlash. To do so, change the thickness/number of
– the spacer plates (6) between the base plate and the bottom shell and
– the shims (7) of the pinion assembly flange.

Inspection interval: every 12 months
Visual check for damage

Open the inspection opening (8) in the bottom shell with the crusher at standstill.

Carry out a visual check of the bevel pinion (1) and bevel gear (2) for jamming, grooves
and tooth breakage.

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Inspection interval: every 3 months

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Figure 48

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7 - 37

7.4

Repairs

WARNING
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation
Death or severe bodily injuries are possible
• Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off and secured against restarting.

INFORMATION

Chapter 7.1.3 "Notes relating to repairs" observe

Have an annual general plant inspection carried out by responsible qualified personnel
and management staff. If necessary, consult ThyssenKrupp Resource Technologies.
Have any defects and damage remedied immediately!

Co-ordinate the time and location of repair work with the regular maintenance and
inspection work.

Spare parts must comply with the technical requirements specified by the manufacturer. This is always ensured when using original spare parts - see spare parts lists.

Provide a complete set of wear parts - see spare parts lists. Replace when necessary
and re-machine worn parts if possible.

Workshop equipment is required for the repair of assembly groups. Remove and
install assembly groups in the workshop.

The assembly groups and individual components can be assembled and adapted to
the relevant crane capacities at the place of installation.

Suspension points and drawings, see drawings in ANNEX 9.1.

Weights of the components, see Chapter 5.8.1 "Weights:".

Tightening torques for all relevant bolts, see Chapter 7.5.

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The standards and tightening torques for machine bolts are included in Chapter 7.5.1.

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INFORMATION

Always use these tightening torques unless special tightening torques are stated.

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Specific repair work, e.g. disassembly and assembly of structural units, assembly
groups and components are described in separate sections. These descriptions do not exclude the use of other possibilities which may be appropriate from time to time. However,
the safety of the repair personnel and the machine /plant may not be adversely affected.

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7 - 39

7.4.1

Preparation for replacing the crushing jaws
See Illustration 49
To replace the concaves (1), disassemble the arm liners (2), spider (3), main shaft (4) and
liner plates (5). Use tools, e.g. Hytorc torque wrench, Superbolt torque wrench and and
lifting tackles to unscrew the nuts, demounting screws and threaded bolts and to loosen
the cross bar from the top bowl (5) (see ANNEX 9.11).

7.4.2

Empty the crusher, switch it off and secure it against re-connection.

Dismantle the spider cap (6) and remove the grease over the spider bush (7) and dispose of it in an environmentally-friendly manner.

Detach the control cable (8) and grease line (9). (They are located on the upper shell).
Also see drawings in the ANNEX 9.1

Lift off the arm liners (2).

Disassembly of the spider

Screw eye bolts into the transport holes of the spider (3).

Attach the spider to the crane. Undo the connecting bolts and carefully lift the spider
together with the control cable and grease line.

INFORMATION

To detach the spider from the sealing compound (if necessary), insert hydraulic
cylinders (provided by the customer) in the threaded holes in the upper shell.

Lift the spider with the crane and place it down on the floor. Check the sealing elements
and spider bushing, replace if necessary (see Chapter 7.4.8).

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Figure 49

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7 - 41

7.4.3

Disassembly of the main shaft
See Illustration 49

CAUTION
Plant damage due to sticking of the step bearing when lifting the axle
Damage to the machine/plant or its environment is possible
• Make sure the middle spherical disk of the axial bearing does not adhere to the
upper spherical disk (15) when lifting out the crusher axle (4).

Attach crane to the eye bolts (10) of the main shaft (4) and lift the main shaft out of the
inner eccentric bushing (11). Ensure that the oil seal (14) in the sealing housing (13) of
the dust sealing does not catch on the main shaft. Possible safety hazard through falling off!

Protect the step bearing upper part (14) of the axial step bearing from damage and
place the main shaft in a supporting device/shaft stand on the floor.

Cover the sealing housing of the dust sealing, thereby protecting the eccentric bushing
and axial step bearing against the ingress of dust.

Carry out checks with the spider and main shaft dismantled. See Chapter 7.4.4.

Check the liner plates (15) and wearing caps (16) in the bottom shell. Replace them if
necessary.

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Figure 49

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7 - 43

7.4.4

Checks to be made with the spider, main shaft and dust sealing
housing dismantled
See Illustration 50
Certain assembly groups of the crusher must be dismantled, in order to exchange the concaves, mantle and other wearing parts in the crusher.
After dismantling, the following crusher components which are normally inaccessible
should always be checked for wear.

Checks for wear with the spider dismantled:
– Wall thickness of the spider cap ( 1)
– Spider bushing and wear insert of the top axle mounting (2).
For the exchange, see Chapter 7.4.8.
– Seals (toroidal sealing ring, shaft sealing rings, leather packing) of the spider
bushing.
For the exchange, see Chapter 7.4.8.

Checks for wear with the spider and main shaft dismantled:
– Main shaft sleeve (3) and lower shaft of the main shaft.
For the exchange, see Chapter 7.4.7.
– Step bearing upper part (4) of the axial step bearing.
For the exchange of the axial step bearing, see Chapter 7.4.10.
– Check polyamide sealing ring (5) between top and bottom sealing ring of dust
sealing for wear and clearance. For replacing the polyamide sealing ring, see
Chapter 7.4.7.

– Other checks:
– Free passage of air duct to the sealing housing.
If necessary, detach the air connection from the bottom shell of the crusher and
blow compressed air through the air duct.
– Check the bottom sealing ring (6) for secure attachment.
– Check the sealing housing for damage through the polyamide sealing ring (5). For
the exchange of the sealing housing, see Chapter 7.4.9.

Checks for wear with the spider, main shaft and dust sealing housing dismantled:
– Inner eccentric bushing (7) of the eccentric bushing. For the exchange, see
Chapter 7.4.11.
– Clearance between the outer eccentric bushing and the eccentric bushing. To
check, turn the eccentric bushing, so that it contacts one side of the outer eccentric
bushing.
For the exchange of the outer eccentric bushing, see Chapter 7.4.13.
– Check the step bearing lower part (8) and slide bearing plate (9) of the axial step
bearing for damage.
For the exchange of the axial step bearing, see Chapter 7.4.10.

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– Other checks:

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Figure 50

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7 - 45

7.4.5

Exchanging the concaves
See Illustration 51
Dismantling the concaves

Weld lifting eye to the concaves (1 to 4) and attach the concave to be dismantled to the
crane.

Remove the concaves in rings from top to bottom. For this purpose:
– Separate/flame cut one crushing jaw of the relevant crushing jaw ring.
– Loosen and lift out the concaves by means of a hydraulic hammer or pneumatic
hammer.

WARNING
Risk of injury due to dust loading
Death or severe bodily injuries are possible
• Ensure proper ventilation.
• Wear a respirator as protection against dust of the grouting compound.

Remove old grouting compound from spider and bowl and clean the latter.

Mounting the concaves

For mounting the concaves, see Chapter 5.8.8 and drawings in ANNEX 9.1.

INFORMATION

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Since casting parts have higher manufacturing tolerances, it might be necessary
to adjust the relevant crushing jaws before their installation.

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Figure 51

2-492-20980 (POS 01)

7 - 47

7.4.6

Wear parts
See Illustration 51
To replace the liner plates:

Weld lifting eyes to the liner plates (5, 6, 8).

Separate (grind off, flame-cut, gouge) the weld seams which join the liner plates to the
crusher shells, and dismantle the liner plates in rings from top to bottom.

Clean/re-grind the bearing surfaces.

Position, press on, tack-weld and weld new liner plates (horizontal weld seams at top,
bottom and plug weld).
Pay attention to the notes in the drawings in ANNEX 9.1 when welding!

INFORMATION

Since casting parts have higher manufacturing tolerances, it might be necessary
to adjust the relevant liner plates before their installation.

Check, exchange and re-position the arm liners (7) on the arms in the bottom shell.

Check, exchange and re-position the arm liners on the cross bar (9).

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For mounting the liner plates and the arm liners, see Chapter 5.8.3, Chapter 5.8.9 and
Chapter 5.9.2.

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Figure 51

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7 - 49

7.4.7

Main shaft
Exchange of the main shaft sleeve

Screw eye bolts into the threaded holes of the main shaft sleeve (1), attach to lifting
gear and pull sling ropes tight.

To remove the main shaft sleeve (1) from the main shaft, proceed as follows if possible:

Heat the main shaft sleeve to approx. 100 °C above the ambient temperature.

Quickly withdraw the main shaft sleeve from the main shaft and set it down immediately. If the main shaft sleeve cools down too rapidly during the pulling process and reshrinks on the main shaft, reheat it.

Allow the main shaft to cool down.

If the main shaft sleeve (1) cannot be pulled off this way:

Cut main shaft sleeve (1) lengthways and then insert for disassembly.

CAUTION
Plant damage due to damage to the axle when cutting
Damage to the machine/plant or its environment is possible.
• Do not cut through wearing bushing (1) completely.

Clean the seat of the main shaft sleeve and the shaft of the main shaft.

Attach a new main shaft sleeve to a hoist and heat it up to approx. 100 °C above ambient temperature.

Quickly place the main shaft sleeve on the shaft. If necessary, continue to heat the
main shaft sleeve during installation.

After the installation, clean and grease the main shaft sleeve.

7 - 50

In order to avoid damage to the dust sealing when replacing the mantles (2) and (3),
remove the bottom sealing ring (3), the polyamide sealing ring (4) and the top sealing
ring (5) from the main shaft.

In order to avoid damage, remove the step bearing upper part (6).

Place the main shaft in the supporting device.

Detach the protective cap (7) and outer ring nut (8). If this is not possible, the intermediate ring (9) must be separated by a horizontal flame cut to relieve the pretension in
the thread.

Lift the crushing mantle (2) off. To do so, weld on 4 lifting eyes (10) offset by 90°
(mantle made of austenitic manganese steel).

Pre-heat the bottom third of the mantle (2) to approx. 50 °C above ambient temperature
and loosen it by hitting it around the entire circumference; then lift it off.

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Exchanging the mantles

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Figure 52

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7 - 51

Mounting the mantle

Clean the contact surface of the mantle.

For mounting the new mantle, see Chapter 5.8.11.

Screw top spherical disk (6) of the axial bearing back onto the crusher axle.

We recommend checking the complete axial step bearing. Also check the dust sealing before mounting the main shaft.
Re-mount the dust sealing. Check the bolts on the sealing housing for secure attachment/re-tighten if necessary.

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7 - 52

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Figure 52

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7 - 53

7.4.8

Spider bearing with grease lubrication
If excessive grease leaks from the wearing bushing of the crusher axle and the clearance
between the wearing bushing of the crusher axle and the rolling contact bush of the top
axle mounting is considerably below the max. value of 3.5 mm, replace only the sealing
elements of the rolling contact bush.
If the clearance exceeds 3.5 mm, the spider bushing must be exchanged. In both cases,
remove the spider cap and withdraw the spider bushing from its seat in the spider (see
Chapter 7.3.4) - check the spider bushing for wear.

Empty the crusher, switch it off and secure it against re-connection.

Set up a working platform in the crusher inlet.

Clean the spider cap (1) and spider (2). Remove the spider cap.

Remove the sensor bracket (3).

Remove the grease filling over the spider bushing (4) and dispose of it in an environmentally-friendly manner.

Unscrew the bolts (5) of the spider bushing. Screw in four forcing screws into the
threaded bores (6) and press off the rolling contact bush from the seat of the spider.
For this purpose use the forcing hydraulics (12) and/or (14).

INFORMATION

For removal of the spider bushing (4) and installation of the sealing ring (9) see
Chapter 5.8.10 "Spider bearing" and ANNEX 9.1 "Drawings".

Insert eye bolts into the threaded holes (6).

Use an appropriate hoist to lift out and set down the spider bushing (4) with spacer (13).

Replace sealings
Screw eye bolts into the threaded bores (8) of the sealing ring (9) and withdraw sealing
ring.

Remove leather packing (10).

Replace the leather packing (10) and shaft sealing rings (11). Soak the new leather
package in oil beforehand.

Clean and grease the seat of the spider.

Coat the outside edge of this area (2) of the spider with sealing gel Loctite 574.

Re-install the sealing ring (9).

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Figure 53

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7 - 55

Replace the spacer (13).

To do this, the spider bushing (4) must be dismantled.

Loosen the locking ring (15).

Screw eye bolts into the threaded holes (7) in the spacer (13).

Lift the spacer (13) slightly.

INFORMATION

Use a wood block.

Heat the spider bushing (4) quickly.

If it is not possible to remove the spacer this way, rip the spacer (13).

For installation of the new wear insert (13) see Chapter 5.8.10 "Spider bearing".

Installation

Insert spider bushing (4).

INFORMATION

The spider bushing must slide into the seat of the spider without force. Do not
press in or cool the bushing under any circumstances. Rework the spider bushing
if necessary.

Mount the sensor bracket (3).

Top up the grease and mount the spider cap (1).

Restore the operational condition.

Exchange of the grease lubrication pump

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If the delivery rate of the grease pump is too low and no other causes are detected, the
grease lubrication pump is defective and must be replaced (see ANNEX 9).

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Figure 53

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7 - 57

7.4.9

Dust sealing
See Illustration 54
Dismantle the spider and the main shaft (see Chapter 7.4.2 and Chapter 7.4.3) and
replace the worn components of the dust sealing.

Unscrew the bottom sealing ring (1) from the top sealing ring (2) on the dismantled
main shaft and remove the plastic sealing ring (3).

Apply a small amount of grease to the new plastic sealing ring. Re-insert the spacer
disks (4). The plastic sealing ring must slide radially (clearance 1.0 to 1.5 mm) and may
not jam.

To replace the sealing housing (5), remove the oil seal (6), undo the bolts and remove
the sealing housing.

INFORMATION

Check the clearance (max. 3 mm) between the outer eccentric bushing in the bottom shell of the crusher and the eccentric bushing with the sealing housing dismantled. If the clearance is excessive, remove the outer eccentric bushing and
replace it.

Clean the bearing face of the sealing housing on the bottom shell of the crusher. Insert
a new toroidal sealing ring (7) and O-ring (8).

Place a new sealing housing in the seat of the bottom shell of the crusher and bolt it in
place. Ensure that the holes of the air and oil duct are on top of each another.

Insert the oil seal (6) and reinstall the main shaft and spider.

Restore the operational condition.

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Figure 54

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7 - 59

7.4.10

Axial step bearing of the main shaft
See Illustration 55
To check the wear directly and to exchange the axial step bearing, either
– dismantle the hydraulic cylinder (1) (see Removing the hydraulic cylinder and
exchanging the eccentric bushing, Chapter 7.4.12) and remove the axial step bearing
(2) and (3) in a downward direction or
– dismantle the spider and the main shaft (see Chapter 7.4.2 and Chapter 7.4.3) and
remove the axial step bearing in an upward direction.
The second possibility is described here, i.e. the spider and main shaft are dismantled.

To dismantle the axial step bearing, remove the oil seal (4) and dismantle the sealing
housing (5) of the dust sealing. We also recommend removing the inner eccentric
bushing (6) (see Chapter 7.4.11).

Screw eye bolts into the threaded holes of the slide bearing plate (3) and attach the
slide bearing plate to a hoist.

Lift out the slide bearing plate and the step bearing lower part resting on it (2) through
the eccentric bushing. Tilt the slide bearing plate if it cannot be lifted off the piston of
the hydraulic cylinder.

Unscrew the step bearing upper part (8) from the main shaft. See Chapter 7.4.7.

Place the components of the axial bearings on top of each another and measure them,
i.e. determine the wear. The overall height of the new axial step bearing is approx. 200
mm.
The depth of the lubrication grooves in the step bearing upper part and the slide bearing plate is 8 mm in each case. If the overall height is less than approx. 185 mm (depth
of lubrication grooves only approx. 1 mm ) or if there is other damage, replace all the
components of the axial step bearing.

Check all the components of the axial step bearing, in particular:
– Sliding surface and lubrication grooves of the step bearing upper part
– Sliding surface of the step bearing lower part and
– Sliding surface and lubrication grooves of the slide bearing plate for damage.
Replace the components if they are damaged.
The axial step bearing is installed in the reverse order. Ensure that the new slide bearing plate rests on the rotary locking (9) of the piston.

Mount the main shaft and spider.

Restore the operational condition.

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Figure 55

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7 - 61

7.4.11

Exchanging the inner eccentric bushing
See Illustration 56
To exchange the inner eccentric bushing (1), either
– demount the cross bar, the crusher axle and the sealing housing of the dust sealing or
– the hydraulic cylinder and the eccentric bushing (see Chapter 7.4.12)
should be dismantled.
The first possibility is described here, i.e. the spider, main shaft and sealing housing of
dust sealing are dismantled.

Check the inner eccentric bushing (and the main shaft) for grooves, cracks, run-in
marks caused by an excessive edge pressure and increased bearing temperatures.
Check the dimensional accuracy.

CAUTION
Plant damage due to damage to the eccentric insert
Damage to the machine/plant or its environment is possible.
• Check the spider bushing of the upper spider bearing and replace them in case
of wear (see Chapter 7.4.8).
• When mounting a new inner eccentric bushing, also replace the spider bushing.

Unscrew the device for compensating unbalance (2) from the eccentric bushing (3) and
screw eye bolts into the inner eccentric bushing (1).

Remove the inner eccentric bushing including the feather key (4) from the eccentric
bushing by means of a hoist.

Insert a new inner eccentric bushing and feather key in the groove of the eccentric
bushing and re-mount the device for compensating unbalance.

Mount the sealing housing of the dust sealing.

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Figure 56

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7 - 63

7.4.12

Replacement of eccentric bushing
To remove the eccentric bushing (1), dismantle the hydraulic cylinder (2) and the base plate (3) beforehand.
For preparation of the superstructures:

Empty the crusher, change over to local operation, lift the main shaft. Switch off the
crusher.

Open the inspection hole cover (4) on the bottom shell and place supporting trestles
(5) on the three arms of the bottom shell.

Lower the crusher axle so that the crushing mantle rests safely on the three supporting
trestles.

Lower the piston (5) of the hydraulic cylinder to the full extent.

Switch off the hydraulic unit and depressurise the hydraulic system.

Drive the maintenance car (with scissor-type elevating platform) under the hydralic
cylinder.

The hydraulic cylinder (2) and the ground (3) can be improved.

WARNING
Danger of crushing due to maintenance car moving
Death or severe bodily injuries are possible
• Make sure no unauthorised persons are near the maintenance car.
• Leave the area of danger!

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• Read the separate documentation "Maintenance car with scissor-type elevating
table in the ANNEXE of the plant documentation.

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Figure 57

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7 - 65

Removing the hydraulic cylinder:

Drain and collect residual oil from the lines, cylinder and the surface of the piston.

Remove the pipes of the hydraulic system (7) and (8) and the oil circulation lubrication
(9) and protect them from the ingress of dust.

Disconnect the connection cable (10) of the distance sensor (11).

Mark the position of the hydraulic cylinder with respect to the bottom shell.

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7.4.12.1

Figure 57

7 - 66

2-492-20980 (POS 01)

Position and use the maintenance car to dismantle the hydraulic cylinder (2) and the
ground (3) and the eccentric insert (1). See the documentation of the maintenance car.

Use the sub-structure (S) to dismantle the hydraulic cylinder (2).

Figure 58

INFORMATION

11/2013 Rev 0

Do not support the hydraulic cylinder (2) on the remaining pipes (7).

Move the scissor-type elevating platform with sub-structure under the hydraulic cylinder, see Illustration 59 (Video)

Unscrew the fastening bolts (12) of the secured hydraulic cylinder.

Lower the hydraulic cylinder (2) with the help of the scissor-type elevating platform and
move the maintenance car back to its initial position.

2-492-20980 (POS 01)

7 - 67

INFORMATION

Check the axial step bearing after the hydraulic cylinder has been removed and
replace it if necessary (see Exchanging the axial step bearing, Chapter 7.4.10).

11/2013 Rev 0

Figure 59 (Click the image to open video)

7 - 68

2-492-20980 (POS 01)

7.4.12.2

Dismantling of the ground and the eccentric insert

Prepare the maintenance car with the scissor-type elevanting platform.

WARNING
Risk of squeezing due to moving maintenance car or scissor-type elevating
platforms
Death or severe bodily injuries are possible
• Make sure no unauthorised persons are near the maintenance car.
• Leave the area of danger!
• Pay attention to the separate documentation in ANNEX 9.15 "Maintenance car
with scissor-type elevating platform".

WARNING
Risk of injury due to uncontrolled movements of the eccentric insert on the
base plate
Bodily injury possible
• Lower the base plate and eccentric bushing, so that the eccentric bushing is still
guided in the bottom shell.
• Secure the eccentric bushing against lateral sliding from the base plate.

11/2013 Rev 0

• Persons may not stand on the upper scissor-type elevating playforn during the
lowering process

2-492-20980 (POS 01)

7 - 69

Position the carrying device on the scissor-type elevating platform.

Drive the maintenance car with scissor-type elevating platform under the base plate.

Prepare the carrying device (6) with suitable fixing equipment (4) for lifting with the
crane. Also see Chapter 5.2 "Hoisting devices and slinging equipment"

Retract the scissor-type elevating platform slowly till end stop (A).

Lift the carrying device with the crane and insert the upper part of the carrying device
into the eccentric insert (1) (B). Here, adjust the carrying device (6) such that the fastening bolts of the base plate (2) are not covered.

Lift the carrying device further till it is located on the base plate (2) (C).

Secure the base plate (2) against sliding laterally by screwing it (5) on to the dismantling device (6).

11/2013 Rev 0

Figure 60

7 - 70

2-492-20980 (POS 01)

Figure 61 (Click the image to open video)

Unscrew the fastening bolts (3) of the secured base plate (2).

Remove and keep the spacer plates in sets for reuse (7–10) - important for setting the
backlash between the bevel pinion and the bevel gear.

Position the base plate (2) and the eccentric insert (1) on the scissor-type elevating
platform (D).

Lower the scissor-type elevating platform and move the maintenance car to the starting
position.

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2-492-20980 (POS 01)

7 - 71

Screw eyelet bolts into the eccentric bushing.

Lift the eccentric bushing from the base plate and the axial bearing ring (4) using a
crane and set it down.

Check the following for wear and damage:
– Eccentric bushing (1) (including inner eccentric bushing) and bevel gear (5)
– Bevel pinion (6) of the pinion assembly (Chapter 7.4.14.1 "Replace the bevel gear
- transmission")
– Axial bearing ring (4)
– Outer eccentric bushing (11) in the bottom shell of the crusher (Chapter 7.4.13
"Exchanging the outer eccentric bushing").

Replace the eccentric bushing body if it is damaged.

Heat the damaged/worn bevel gear (max. 150 °C) and lift it off the eccentric bushing
(which can be re-used) by means of a hoist.

Replace the feather key (12) and install a new warm bevel gear.

CAUTION
Plant damage due to uneven wear
Damage to the machine/plant or its environment is possible.
• When replacing the bevel gear, also replace the bevel pinion of the pinion
assembly (see Chapter 7.4.14.1).

Replace a damaged/worn axial bearing ring (4).

Replace a damaged/worn axial bearing ring (11) (see Chapter 7.4.13).

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7 - 72

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 62

2-492-20980 (POS 01)

7 - 73

See Illustration 63
Mounting the eccentric bushing:
Replace all the sealing rings and clean and oil the sliding surfaces before mounting the
eccentric bushing (3). Replace the sealing cord (4) of the base plate.

Place the maintenance car with scissor-type elevating platform under the crusher to
install the ground (5), axial step bearing ring (6) and eccentric insert (3). Secure the
components against sliding.

Move the eccentric insert (3) into the bushing (2) of the lower shell using the carrying
device (see Chapter 7.4.12.2 "Dismantling of the ground and the eccentric insert").

Place and align the spacer plate (7–10) on the base plate.

Lift the base plate and the eccentric bushing up further. Slightly turn the drive coupling/
pinion assembly shaft, so that the teeth of the bevel gear can engage the pinion.

Press the base plate into the seat of bottom shell; do not damage the sealing cord (4).
Screw on the base plate (5) by means of bolts (11).

Check the backlash, re-adjust if necessary (see Chapter 7.3.9).

Replace the O-rings and sealings on the flange of the hydraulic cylinder before mounting the hydraulic cylinder.

When mounting the hydraulic cylinder, ensure that the bores (residual oil drain) in the
base plate and the cylinder flange are on top of each other.

Re-connect the lubricating oil lines, hydraulic lines and distance sensor.

Bleed the hydraulic cylinder.

Close the revision opening for visual inspection of the provided backlash.

Lift the main shaft, remove the supporting trestles (12), close the inspection hole cover.

Restore the operational condition.

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7 - 74

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 63

2-492-20980 (POS 01)

7 - 75

7.4.13

Exchanging the outer eccentric bushing
See Illustration 63
The busher is replaced when the eccentric insert is dismantled (see Chapter 7.4.12)

WARNING
Danger of crushing due to maintenance car moving
Death or severe bodily injuries are possible
• Make sure no unauthorised persons are near the maintenance car.
• Leave the area of danger!

Place the maintenance car with scissor-type elevating platform under the crusher (also
see the documentation of the maintenance car).

Secure the flange ring (2) of the outer eccentric bushing (1).

Unscrew the bolts and detach the flange ring of the outer eccentric bushing by means
of jack screws.

Lower the outer eccentric bushing and the flange ring, remove them from the working
area and replace them.

For mounting, oil the new outer eccentric bushing and re-mount in the reverse order.

11/2013 Rev 0

7 - 76

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 63

2-492-20980 (POS 01)

7 - 77

7.4.14

Crusher main drive motor and pinion assembly
See the following video to dismantle the crusher motor:

Figure 64 (Click the image to open video)

7.4.14.1

Replace the bevel gear - transmission
See Illustration 65 and also Chapter 5.9.3

7 - 78

Remove the protective hood over the crusher main drive motor.

Remove the bracket of the speed monitor (5).

Remove the hose connection (6) of the fluid switch (7) and drain and collect the oil from
the pinion assembly and dispose of it.

Attach the distance tube (8) to ropes, mark the flanged connections.

Remove the screws of the distance tube.

Push back the multiple-disc clutch (3) towards the motor (2) until the centerings of
distance tube are exposed.

Set down the distance tube and remove/set down the multiple-disc clutch (3) with
safety coupling (9) from the clutch hub (on the pinion assembly shaft) (4).

2-492-20980 (POS 01)

11/2013 Rev 0

If the bevel pinion (1) has to be replaced:

11/2013 Rev 0

Figure 65

2-492-20980 (POS 01)

7 - 79

Unscrew the pinion assembly. Remove the shims (10) and keep them in a safe place
- they are important for setting the back lash between the bevel pinion and the bevel
gear.

Remove the pinion assembly partially from the pinion assembly tunnel using a cable
winch - keep it horizontal.

Support the transmission at the rear.

Again fix the rope pull and place the transmission with the pinion showing upwards into
a stable supporting unit.

Unscrew the end disk (11), screw in eye bolts and attach the pinion to a hoist.

Heat the pinion and remove it by means of a hoist.

INFORMATION

The roller bearings of the pinion assembly can be exchanged in this dismantled
state (see the following section).

Screw in the eye bolts before mounting the new bevel pinion. Preheat the new bevel
pinion to a max. 150 °C in the oil bath and install it.

11/2013 Rev 0

7 - 80

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 65

2-492-20980 (POS 01)

7 - 81

CAUTION
Plant damage due to uneven wear
Damage to the machine/plant or its environment is possible.
• When replacing the bevel gear of the transmission, also replace the bevel pinion
(see Chapter 7.4.12.2 "Dismantling of the ground and the eccentric insert").

Screw on the end disk.

Replace the toroidal sealing ring (12).

Insert the pinion assembly in the pinion assembly tunnel by means of cable winches.
Slightly turn the pinion assembly shaft (4) so that the pinion can engage in the bevel
gear.

Insert shims (10) and screw on the pinion assembly.

Check the backlash and the contact pattern.
See Chapter 7.3.9 and ANNEX 9.3.

Re-mount the distance tube (8), multiple-disc clutch (3) and safety coupling (9).
See Chapter 5.9.3 and ANNEX 9.3.

Re-mount the bracket of the speed monitor (5).

Mount the hose connection (6).

Fill with Chapter 8.5 "Lubricating instructions" filtered oil (25 µm) according to the and
check the oil level on the oil level indicator (13).

Restore the operational condition.

11/2013 Rev 0

7 - 82

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 65

2-492-20980 (POS 01)

7 - 83

7.4.14.2

Exchange of the roller bearings - transmission
See Illustration 66
Removal

Unscrew the bolts (1) and remove the bearing cover (2).

Place transmission shaft (3) vertically with the pinion side downward in a stable supporting device. Attach the pinion assembly shaft (4) to a hoist (A).

Detach the locking plate (5) and unscrew the shaft nut (6).

Remove the ring (7) and V-ring (8).

Unscrew the bolts (9) and remove the bearing cover (10) with helical compression
springs (11), spacer plates (24) and shaft sealing ring (12).

Remove the spacer sleeves (13) and (14).

Remove the spacer sleeve (15).

Remove the pinion assembly shaft (4) together with the bearings (16), inner race of the
bearing (17) and spacer sleeve (18) from the pinion assembly housing; place it horizontally on a support.

Remove the bearing (16) from the pinion assembly shaft.

Remove the outer race of the bearing (17) from the housing (3).

Installation
Check all the spacer sleeves for grooving, replace if necessary.

Replace the toroidal sealing rings (19, 20, 21).

Install new bearings (16) on the shaft.

Insert a new bearing (17) in the bearing housing (3).

Lower the pinion assembly shaft (4) into the housing together with the bearings (16).

Re-insert the spacer sleeves (14) and (13) in the housing.

Exchange the O-ring (22) and push the spacer sleeve (15) on the shaft.

Insert (9) bearing cover (10) with helical compression springs (11) and shaft sealing
ring (12).

Adjust bearing clearance using the spacer plates (24).

Tighten up the bolts (9).

Install the V-ring (8) and ring (7) on the shaft.

Attach the locking plate (5) and tighten and secure the shaft nut (6).

Push the spacer sleeve (18) on to the shaft.

Insert the shaft sealing ring (23) and tighten the bearing cover (2) by means of bolts (1).

11/2013 Rev 0

7 - 84

2-492-20980 (POS 01)

11/2013 Rev 0

Figure 66

2-492-20980 (POS 01)

7 - 85

7.5

Screw connections
Always protect all screwed and bolted connections against corrosion.

7.5.1

Machine structures

For machine structures:

Standard

Quality

Hexagon bolt (thread up to head)

DIN EN ISO 4017

8.8 / 10.9 / 12.9

Hexagon socket head cap bolt

DIN EN ISO 4762

8.8 / 10.9 / 12.9

DIN 7984

8.8 / 10.9 / 12.9

DIN EN ISO 4032

8 / 10 / 12

Washer

DIN 6916

C 45 hardened

Hexagon fitted bolts

DIN 609

8.8 / 10.9 / 12.9

Hexagon socket head cap bolt with short head
Hexagon nut

Use only the following bolts and nut qualities together:
Bolt quality:

8.8

10.9

12.9

Nut quality:

8

10

12

11/2013 Rev 0

7 - 86

2-492-20980 (POS 01)

Tightening torques for machine structures
Calculated with µk = 0.14 (new bolts, without post-treatment) in accordance with VDI 2230

Tightening torque Ma (Nm)
Class

Bolt diameter
8,8

10,9

12,9

M6

11

15

18

M8

26

36

43

M10

51

71

86

M12

88

123

148

M16

211

300

358

M20

412

579

697

M24

711

1000

1196

M30

1422

2010

2403

M36

2481

3491

4197

M42

3991

5609

6727

M48

6021

8473

10150

M56

9650

13582

16279

M64

14416

20300

24320

INFORMATION

11/2013 Rev 0

Only use the tightening torques listed in the table when no special tightening torques are indicated in the relevant section.

2-492-20980 (POS 01)

7 - 87

7.5.2

High-tensile bolted joints
In the case of high-tensile (friction-type bolted connections), the force is transmitted by
friction between the contact faces and depends on the pretensioning force of the bolts.
The contact faces must be bright. They must be cleaned by sandblasting, flame cleaning
or chemical detergents (DIN 18800, DIN V 18800-7 - Annex D.1.6).

Use bolts, nuts and washers from one manufacturer only. A uniform protection against
corrosion is compelling.

Only use properly oiled bolts in perfect condition.

Use a torque wrench to produce the required bolt pretensioning force.

Components are marked as follows

Material data

Manufacturer
data

Marked HSFG

Hexagon bolt HSFG
as per DIN 6914

10,9

yes

HSFG

Hexagon nut HSFG
as per DIN 6915

10

yes

HSFG

-

yes

HSFG

Washer
as per DIN 6916

Use only the following bolts and nut qualities together:
Bolt quality

10.9

12.9

Nut quality

10

12

For steel structures:

Quality

Hexagon bolt

DIN 6914

10.9 / 12.9

Hexagon nut

DIN 6915

10 / 12

Washer

DIN 6916

C 45 hardened

Use the required pretensioning forces indicated in the table below or in the drawing.

11/2013 Rev 0

Standard

7 - 88

2-492-20980 (POS 01)

Pretensioning forces and tightening torques applicable to torque methods for sets corresponding to
tensile strength class 10.9 according to table 5, DIN V 18800-7.
Torque method
Basic pretensioning
force Fv in kN

Dimensions

Required tightening torque to achieve the basic pretensioning force
MA in Nm
Hot-galvanised and lubricated (1)

As manufactured and
slightly oiled

M 12

50

100

120

M 16

100

250

350

M 20

160

450

600

M 22

190

650

900

M 24

220

800

1100

M 27

290

1250

1650

M 30

350

1650

2200

M 36

510

2800

3800

1)

Nuts lubricated with molybdenum disulphide or equivalent lubricants

Check the friction grip connection immediately following installation and at least once a year:
Pre-stressed bolt connections (DIN V 18800-7 1.2.2.2)
(1216) When using the torque method, at least 5 % of the sets of the connection must be
checked (at least 2 bolted connections for connections with less than 20 bolts). A test torque which is a maximum of 10% higher than the applied tightening torque is transmitted
to the set on the side on which it was tightened. Proceed as described in Table 7 depending on the angle of rotation that is achieved till the torque wrench is activated. If necessary, retain the element not to be turned in order to prevent it from turning.
Checking the pre-stressing force according to the torque method
(DIN V 18800-7 Table 7)
Angle of additional
rotation

Measure
none, pretensioning is adequate

30° to 60°

pretensioning is adequate, check two adjacent bolts of the same connection

> 60°

replace the bolt, check two adjacent bolts of the same connection

11/2013 Rev 0

< 30°

2-492-20980 (POS 01)

7 - 89

11/2013 Rev 0

Blank page

7 - 90

2-492-20980 (POS 01)

8

Lubrication

8.1

Introduction and technical instructions

WARNING
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation
Death or severe bodily injuries are possible
• Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off.
Maintaining the operating reliability and an adequate service life calls for orderly lubrication with lubricants which are most suitable for the individual application. It is not possible
to determine the complete characteristics of the lubricants by means of the reference values stated in the table of lubricants. The supplier of the lubricant is solely responsible for
the correct selection of the lubricant with due consideration given to the local conditions
and conditions of application of such industrial systems as well as the state-of-the art-in
the field of lubrication engineering.
The lubricants are provided by the owner on-site.
We will not accept any claim for defects or damage which can be attributed to incorrectly
selected lubricants.
In summary, we recommend the exclusive use of high-quality lubricants which have been
selected by reputable companies in accordance with our guiding values.

INFORMATION

All of the mineral oil companies stated in the table of lubricants offer a lubrication
service, and their technicians are available to our customers to answer any questions about appropriate lubrication.

11/2013 Rev 0

CAUTION
System damage through improper lubrication
Damage to the machine/plant or its environment is possible
• Lubrication and any work in connection with lubrication must be carried out at
operating temperature with the machine/ plant at a standstill.

2-492-20980 (POS 01)

8-1

In particular, the following points must be noted:
– For recommended lubricants, see table of lubricants (Chapter 8.4special lubricants,
Chapter 8.4.2).
– Carry out lubrication at the lubrication intervals specified in the lubricating instructions
(Chapter 8.5) using the stated lubricants and quantities.
– It goes without saying that this recommendation does not exclude lubricants of another
make with the same properties.

Storage of lubricants

Carefully close the container immediately after removing lubricant. Store the containers in enclosed dry indoor areas. You thereby avoid contamination of the lubricants.
Ensure that lubricants are stored, used and disposed of in an environmentally friendly
manner and comply with the relevant national environmental regulations when handling lubricants.

Observe the relevant national occupational safety, health and fire protection regulations when storing and handling lubricants.

Mark drums, canisters, oil cans and grease guns with different colours according to
their content. Mixing of lubricants is not allowed.

11/2013 Rev 0

8.2

8-2

2-492-20980 (POS 01)

8.3

General information on lubrication

8.3.1

Oil groups
The oil types listed in Chapter 8.4 "Table of lubricants (Index 8)" are broken down into the
following oil groups:

Mineral oils

=

CLP

Polyglycols

=

CLP PG (synthetic oils)

Poly-a-olefins

=

CLP HC (synthetic oils)

Hydraulic oils

=

HLP

Hydraulic oils

=

HVLP (improved viscosity-temperature relationship)

INFORMATION

Gear unit
To select oils, refer to the viscosity indicated on the ID plate of the gear unit.
Comply with the oil quality required by the manufacturer. If necessary, have the
quality confirmed by your supplier. Every lubricant manufacturer or supplier is
responsible for the quality of its products.
The required quantity depends on the oil level measured on the inspection glass,
the dipstick or the oil overflow opening.
Change the oil in accordance with the intervals stipulated by the gear unit manufacturer. In addition, check the oil level regularly and top-up, if necessary.
When the oil type is changed, as little old oil as possible may remain in the gear
unit. As a rule, small residues do not cause any problems. Gear oils of different
types and from different manufacturers may not be mixed together. If necessary,
have the compatibility of the new oil with the residues of the old oil confirmed by
the manufacturer.

11/2013 Rev 0

When changing from polyglycols to other gear oils or vice versa, always thoroughly purge the gear unit with the new oil. Residues of the old oil must be completely removed from the gear unit.

Carry out regular relubrication at appropriate intervals. Poor lubrication may cause
damage to the machine components.

When purging, use a low-viscosity oil type of the same basis and from the same manufacturer; never mix mineral oil with synthetic oil.

Rinse out and dry the bearing and bearing housing if a grease with different soap properties is to be used.

Completely fill the bearings with grease. Only partially fill the free space in the housing
with grease (around 30-50 %). Then mount the bearings.

Completely fill the labyrinth gaps with grease.

Relubricate the bearings and labyrinths.

2-492-20980 (POS 01)

8-3

After lubricating:

Do not wipe grease off lubricating nipples/lubricating heads!

CAUTION
System damage from contamination in the grease
Damage to the machine/plant or its environment is possible
• Work in a clean manner! Even minor contamination in the grease will affect the
service life of the bearing points.

8.3.2

Open toothed gears

DANGER
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation
Imminent danger of death or severe bodily injuries. Open toothed rim drives and
toothed racks may draw in and crush parts of the body
• Never lubricate the machine while it is in operation.

11/2013 Rev 0

Thoroughly clean open toothed rim drive units and toothed racks before lubrication. Apply
lubricant in a thin and even layer.

8-4

2-492-20980 (POS 01)

8.3.3

Lubricant lines

11/2013 Rev 0

Ensure that the lubricant lines are thoroughly cleaned before commissioning and that they
are filled with the prescribed lubricant.

2-492-20980 (POS 01)

8-5

Table of lubricants (Index 8)

8.4.1

Standard lubricants

8.4.1.1

Lubricating oils

Index
number

Used for

Class

Aral

BP

ESSO

Fuchs
Europa

Mobil

Shell

Texaco

Klüber

A1

Hydraulic couplings and
hydraulic systems

ISO VG 32
HLP

Vitam
GF 32

Energol
HLP-HM
32

Nuto
H 32

Renolin
B 10

DTE 24

Tellus 32

Rando
HD 32

LAMORA
HLP 32

ISO VG
46 HLP

Vitam
GF 46

Energol
HLP-HM
46

Nuto
H 46

Renolin
B 15

DTE 25

Tellus 46

Rando Oil
HD 46

LAMORA
HLP 46

A3

ISO VG
68 HLP

Vitam
GF 68

Energol
HLP-HM
68

Nuto
H 68

Renolion
B 20

DTE 26

Tellus 68

Rando Oil
HD C-68

LAMORA
HLP 68

B1

ISO VG
32 HVLP

Vitam
HF 32

Bartran
HV 32

Univis
N 32

Renolin
MR 32 MC

DTE 13 M

Tellus
T 32

Rando Oil
HD AZ 32

ISO VG
46 HVLP

Vitam
HF 46

Bartran
HV 46

Univis
N 46

Renolin
MR 46 MC

DTE 15 M

Tellus
T 46

B3

ISO VG
68 HVLP

Bartran
HV 68

Univis
N 68

Renolin
MR 68 MC

DTE 16 M

Tellus
T 68

Rando Oil
HD CZ 68

C1

ISO VG
150 CLP

Degol
BG 150

Energol
GR-XP
150

Spartan
EP 150

Renolin
CLP 150/
Plus

Mobilgear
600 x P150

Omala
150

Meropa
150

Klüberoil
GEM
1-150 N

C2

ISO VG
220 CLP

Degol
BG 220

Energol
GR-XP
220

Spartan
EP 220

Renolin
CLP 220/
Plus

Mobilgear
600 x P220

Omala
220

Meropa
220

Klüberoil
GEM
1-220 N

ISO VG
320 CLP

Degol
BG 320

Energol
GR-XP
320

Spartan
EP 320

Renolin
CLP 320/
Plus

Mobilgear
600 x P320

Omala
320

Meropa
320

Klüberoil
GEM
1-320 N

C4

ISO VG
460 CLP

Degol
BG 460

Energol
GR-XP
460

Spartan
EP 460

Renolin
CLP 460/
Plus

Mobilgear
600 x P460

Omala
460

Meropa
460

Klüberoil
GEM
1-460 N

C5

ISO VG
680 CLP

Degol
BG 680

Energol
GR-XP
680

Spartan
EP 680

Renolin
CLP 680/
Plus

Mobilgear
600 x P680

Omala
680

Meropa
680

Klüberoil
GEM
1-680 N

D1

ISO VG
150 CLP
HC

Degol
PAS 150

Renolin
Unisyn
CLP 150

Mobilgear
SHC XMP
150

Omala
HD 150

Pinnacle
EP 150

Klübersynth
GEM
4-150 N

D2

ISO VG
220 CLP
HC

Degol
PAS 220

Enersyn
EP-XF 220
(is no
longer produced)

Renolin
Unisyn
CLP 220

Mobilgear
SHC XMP
220

Omala
HD 220

Pinnacle
EP 220

Klübersynth
GEM
4-220 N

D3

ISO VG
320 CLP
HC

Degol
PAS 320

Enersyn
EP-XF 320

Renolin
Unisyn
CLP 320

Mobilgear
SHC XMP
320

Omala
HD 320

Pinnacle
EP 320

Klübersynth
GEM
4-320 N

D4

ISO VG
460 CLP
HC

Degol
PAS 460

Renolin
Unisyn
CLP 460

Mobilgear
SHC XMP
460

Omala
HD 460

Pinnacle
EP 460

Klübersynth
GEM
4-460 N

D5

ISO VG
680 CLP
HC

Renolin
Unisyn
CLP 680

Mobilgear
SHC XMP
680

Omala
HD 680

Klübersynth
GEM
4-680 N

A2
Hydraulic systems

B2

C3

Hydraulic systems

Gear units and
gear motors

Synthetic gear oil

8-6

2-492-20980 (POS 01)

11/2013 Rev 0

8.4

Index
number

Class

Aral

BP

ESSO

Fuchs
Europa

Mobil

Shell

Texaco

Klüber

E1

ISO VG
150 CLP
PG

Degol
GS 150

Renolin
PG 150

Tivela
S 150

Synlube
CLP 150

Klübersynth
GH 6-150

E2

ISO VG
220 CLP
PG

Degol
GS 220

Enersyn
SG-XP
220

Glycolube 220

Renolin
PG 220

Glycoyle
HE 220

Tivela
S 220

Synlube
CLP 220

Klübersynth
GH 6-220

ISO VG
320 CLP
PG

Degol
GS 320

Enersyn
SG-XP
320

Renolin
PG 320

Glycoyle
HE 320

Tivela
S 320

Synlube
CLP 320

Klübersynth
GH 6-320

E4

ISO VG
460 CLP
PG

Degol
GS 460

Enersyn
SG-XP
460

Glycolube 460

Renolin
PG 460

Glycoyle
HE 460

Tivela
S 460

Synlube
CLP 460

Klübersynth
GH 6-460

E5

ISO VG
680 CLP
PG

Degol
GS 680

Enersyn
SG-XP
680

Renolin
PG 680

Glycoyle
HE 680

Tivela
S 680

Klübersynth
GH 6-680

ISO VG
46 CL

Degol
CL 46

Energol
CS 46

Teresso
46

DTE Oil
Medium

Tellus Oil
C 46

Rando
Oil 46

ISO VG
100 CL

Degol
CL 100

Energol
CS 100

Renolin
DTA 100

Morlina
100

Rando
Oil EE

ISO VG
150 CL

Degol
CL 150

Energol
CS 150

Renolin
DTA 150

Morlina
150

Rando
Oil F

G3

ISO VG
220 CL

Degol
CL 220

Energol
CS 220

Renolin
DTA 220

Morlina
220

Ursa Oil
P 45

G4

ISO VG
320 CL

Degol
CL 320

Energol
CS 320

Renolin
DTA 320

Morlina
320

Viscoma
Oil 144

E3

Used for

Synthetic gear oil
Cannot be mixed
with mineral oil.

F1

Non-return
devices

G1
G2

Neck bearings
and
Slide bearings

H1

Rollers

Motor oil
SAE 30

Kowal
Motor Oil

- VanellusT
-Energol
HDS

ESSOLUBE
-XD-3
-HDX

TITAN
Universal
HD SAE 30

Delvac
Super

Rimula
X 30

Ursa
Super LA
Ursatex

Klüberoil
GEM
1-100 N

J1

Gear unit
chain links

API GL 4
SAE 90
EP

Gear Oil
Hyp 90

Gear Oil
EP SAE
90

Gear oil
GX-D 90

TITAN
Gear MP
SAE 90

Mobilube
HD 90-A

Spirax
G 80 W
90

Multigear
SAE
85 W-90

Klübersynth
GEM
4-220 N

Index
number

Minimum requirement to DIN

Pour point

=

Oil to DIN 51524-2 based on mineral oil

- 24 °C to - 27 °C

B

=

Oil to DIN 51524-3 based on mineral oil

- 42 °C

C

=

Oil to DIN 51517-3 based on mineral oil

- 9 °C to - 24 °C

D

=

Oil to DIN 51517-3 based on poly-a-olefins

- 30 °C to - 48 °C

E

=

Oil to DIN 51517-3 based on polyglycols

- 27 °C to - 45 °C

F+G

=

Oil to DIN 51517-2 based on mineral oil

11/2013 Rev 0

A

2-492-20980 (POS 01)

8-7

8.4.1.2

Lubricating greases
Marking to DIN 51502 / 51825
Base oil: Mineral oil
Saponification type: Lithium-12-hydroxystearate
Application temperature range: - 20 °C to 120 °C

Index
number

Used for

Class

Aral

BP

ESSO

Fuchs
Europa

Mobil

Shell

Texaco

Klüber

K1

Grease lubrication
unit for spider bearing

NLGI
000

Aralub
GFP 000

Energrease
HT 000 EP

Low-viscosity
grease
000

Mobilux
EP 023

Simnia
Grease 000

CENTOPLEX
GLP 500

K2

Tooth couplings of
main shaft bearings

NLGI
00

Aralub
FDP 00

Energrease
HT-EP 00

Low-viscosity
gear
grease

Renolit
SO-D8024

Mobilplex
44

Alvania
GL 00

Marfak
00

MICROLUBE
GB 00

K3

Tooth couplings
and grease lubrication systems

NLGI 0
KPO K-20

Energrease
LS 0

Beacon
EP 0

Alvania
grease
EP ROEP1

Multifak
EP 0

MICROLUBE
GB 0

K4

Grease lubrication
systems

NLGI 1
KP1K-20

Energrease
LS-EP 1

Beacon
EP 1

Renolit
FEP 2

Mobilux
EP 1

Alvania
Grease EP
1

MICROLUBE
GL 261

K5

Lubrication systems and roller
bearings (heavyduty)

NLGI 2
KP2K-20

Aralub
H-LP 2

Energrease
LS-EP 2

Beacon
EP 2

Renolit
FEP 2

Mobilux
EP 2

Alvania
Grease EP
(LF) 2

Multifak
EP 2

CENTOPLEX
2 EP

K6

Roller bearings
(normal-duty type)

NLGI 3
K3K-20

Aralub
HL 3

Energrease
LS 3

Beacon 3

Renolit
FWA 220

Mobilux 3

Alvania
Grease RL
3

Glissando
FT 3

CENTOPLEX 3

8.4.1.3

Heavy-duty lubricating greases
Marking to DIN 51502
Base oil: Poly-alpha-olefin (PAO), fully synthetic
Saponification type: Gel thickener
Application temperature range: - 50 °C to 200 °C
Application range: high-speed bearings (e.g. pinion assembly bearings, …)

Used for

Class

Aral

BP

ESSO

Fuchs

Mobil

Shell

Texaco

Klüber

L1

Roller bearings
(high temperature
load)

NLGI 2

Mobiltemp
SHC 100

11/2013 Rev 0

Index
number

8-8

2-492-20980 (POS 01)

Marking to DIN 51502
Base oil: fully synthetic
Saponification type: Lithium complex
Application temperature range: - 40 °C to 160 °C
Application range: Crusher rotor bearings, RollSizer, …
Index
number

Used for

Class

Aral

BP

ESSO

Fuchs

Mobil

Shell

Texaco

L2

Roller bearings
(high temperature
load)

NLGI 2

Mobilith
SHC 220

Albida
PPS 2

Marking to DIN 51502
Base oil: Poly-alpha-olefin (PAO), fully synthetic
Saponification type: Gel thickener
Application temperature range: - 50 °C to 180 °C
Application range: slow-speed bearings (e.g. feed conveyor, chain scraper, …)
Index
number

Used for

Class

Aral

BP

ESSO

Fuchs

Mobil

Shell

Texaco

L3

Roller bearings
(high temperature
load)

NLGI 1,5

Mobiltemp
SHC 32

8.4.2

Special lubricants

8.4.2.1

Lubricating oils for tube mills
Application range: Lubrication of toothed rim

Index
number

Lubrication of toothed rim
(nozzle greasing)

M1

Klüber

Fuchs
Lubritech

transparent

Priming lubrication by hand

GRAFLOSCON
A - G1 ULTRA

Klüberplex
AG 11-462

Ceplattyn 300

M2

Inlet process

GRAFLOSCON
B - SG-00 ULTRA

Klüberfluid
B-F 2 ULTRA

Inlet Ceplattyn - RN

M3

Operating lubrication
(Adhesive lubricant with good EP characteristics.)
FZG special test A/2, 76/50 > 12th Degree of
load,
Wear < 0.2 mg/kWh

GRAFLOSCON
C - SG-0 Ultra

Klüberfluid
C-F 8 ULTRA

Ceplattyn KG 10 HMF

M4

Operating lubrication from + 5 °C up to 100 °C

GRAFLOSCON
C - SG-1000 Ultra

Klüberfluid
C-F 4 ULTRA

Ceplattyn KG 10 HMF - 1000

M5

Operating lubricant from + 15 °C up to +
120 °C

GRAFLOSCON
C - SG-2000 Ultra

Klüberfluid
C-F 3 ULTRA

Ceplattyn KG 10 HMF - 2500

11/2013 Rev 0

black

2-492-20980 (POS 01)

8-9

8.4.2.2

Lubricating oils for gyratory crushers
Oils

Index
number

Used for

CASTROL

Class

CASTROL

ISO VG
32 HLP

Tribol 943 AW 32

Tribol BioTop 1448 / 32

ISO VG
46 HLP

Tribol 943 AW 46

Tribol BioTop 1448 / 46

N3

ISO VG
68 HLP

Tribol 943 AW 68

Tribol BioTop 1448 / 68

N4

ISO VG
100 CLP

Tribol 1100/100

ISO VG
150 CLP

Tribol 1100/150

Tribol BioTop 1418 / 150

ISO VG
220 CLP

Tribol 1100/220

Tribol BioTop 1418 / 220

N1
N2

N5

Hydraulic unit
Axle adjustment and overload protection.
Pinion assembly of the V-belt drive

Oil unit
Oil circulating lubrication

N6

BIO TOP

Greases
Index
number

Used for

P1

CASTROL

NLGI 000

Tribol 3020/1000-000
GP 000K-40

NLGI 00

Tribol 3020/1000-00
GP 00K-40

NLGI 2
KP2K-20

Tribol 3020/1000-2

Molub-Alloy
Bio Top 9488-1

Grease lubrication system
for spider bearing
P2
Roller bearings

BIO TOP

11/2013 Rev 0

P3

CASTROL

Class

8 - 10

2-492-20980 (POS 01)

8.4.2.3

Hydrodynamic couplings
Application range: Power transmission oils
Pour point down to -42 °C

Index
number

Used for

Class

Aral

BP

ESSO

Fuchs
Europa

Mobil

Shell

Texaco

Q1

Hydraulic couplings
(Voith)

ISO VG 32
HLP

Degol BG
32

Energol
HLP-HM 32

Torque
Fluid N 45

Renolin
MR 10

Mobilfluid
125

Tegula
32

Rando
HD 32

Application range: Power transmission oils
Base oil: fully synthetic
Pour point: - 42 °C to - 63 °C

8.4.2.4

Index
number

Used for

Class

Castrol

Klüber

Mobil

Q2

Hydraulic couplings
(Voith)

ISO VG 32

Hyspin
AWH-M 32

Summit
HySyn
FG 32

SHC 524

CASTROL Hyspin AWH-M 32

=

Pour point - 42 °C

Klüber Summit HySyn FG 32

=

Pour point - 45 °C

Mobil SHC 524

=

Pour point - 63 °C

Hydraulic oils for low temperature applications
Application temperature range: min. - 40 °C up to max. + 70 °C
Pour point: down to -60 °C

8.4.2.5

Index
number

Used for

Class

Shell

R1

Hydraulic systems

ISO VG 32

Tellus
Arctic 32

Fire-resistant hydraulic oils

11/2013 Rev 0

Flash point: 300 °C
Fire point: 360 °C
Pour point: down to - 20 °C
Index
number

Used for

Class

Fuchs Europa

Quintolubric

S1

Hydraulic systems

ISO VG 46

PLANTOFLUX AT-S
VG 46

Quintolubric
888-46

S2

Hydraulic systems

ISO VG 68

PLANTOFLUX AT-S
VG 68

Quintolubric
888-68

2-492-20980 (POS 01)

8 - 11

8.5

Lubricating instructions

CAUTION
System damage due to incorrect indications of oil quantities and/or oil classes
Damage to the machine/plant or its environment is possible
• The specifications on the type plates of gears, motors etc. referring to the oil
quantity and oil class to be filled take priority over the specifications in these
lubricating instructions.
• Observe the lubricating instructions for components given in ANNEX 9.

Num
ber

Lubricant
acc. to
Chapter 8.4
index number

1

Oil circulating
lubrication system
Eccentric bearing:
Eccentric bearing
and eccentric
bushing, eccentric
insert and main
shaft, bevel gear
and drive pinion,
axial bearing main
shaft

1

C2,
recommendation D2

2

Transmission

1

C1

3

8 - 12

Hydraulic system
Axle adjustment
and overload protection

1

B2

Lubricating intervals in operating hours
Oil change

Relubrication

We recommend
that oil checks
are carried out
every 3 months.
Without these
regular oil analyses, change the
oil every 2000 h,
but no later than
every 6 months.

Always check
the oil level in
the tank
before startup

We recommend
that oil checks
are carried out
every 3 months.
Without these
regular oil analyses, change the
oil every 2000 h,
but no later than
every 6 months.

Always check
the oil level in
the tank
before startup

2-492-20980 (POS 01)

Lubricant quantity
Oil change

Relubrication

approx.
1500 litres
and approx.
300 litres in
the system

Inspection
glass and
min./ max.
signal to control station

approx.
50 litres

Inspection
glass

approx.
250 litres and
approx.
40 litres in the
system

Inspection
glass and
min./ max.
signal to control station
11/2013 Rev 0

Lubricating point

Lubricating point

5

HYGUARD
Safety coupling
type BWL 125
Spec.

Lubricant
acc. to
Chapter 8.4
index number

Lubricating intervals in operating hours
Oil change

1

K1,
Recommendation P1

Replenish
grease level

1

A1,
Recommendation N1

After every
15 releases or
after 12 months
at the latest:
Change oil

Relubrication

Lubricant quantity
Oil change

approx.
200 kg in the
grease tank of
Setting at
the grease
level indicator
pump and
approx. 50 60 litres in
the system

Relubrication

Visual inspection of tank
filling and
min./ max.
signal to control station

0.067 litres

11/2013 Rev 0

4

Grease lubrication
unit for spider
bearing
Spider bushing of
the spider and
wear insert of the
main shaft

Num
ber

2-492-20980 (POS 01)

8 - 13

11/2013 Rev 0

Blank page

8 - 14

2-492-20980 (POS 01)

11/2013 Rev 0

9

ANNEX

9.1

Drawings

9.2

Couplings

9.3

Clearance of teeth and bearings

9.4

Processing synthetic sealing compound
Processing of Betec sealing compound

9.5

Compressor (over-pressure ventilation)

9.6

Monitoring devices

9.7

Central lubrication

9.8

Oil circulating lubrication and hydraulic unit

9.9

Shaft hydraulics (balance unit, hydraulic cylinder)

9.10

Tools

9.11

SUPERBOLT® Mechanical clamping elements

9.12

Gyramatic Version 2.4 - user manual / fault list

9.13

Fluid starter

2-492-20980 (POS 01)

9-1

11/2013 Rev 0

9-2

2-492-20980 (POS 01)

9.1

Drawings

Name

Drawing No.
4602798

Installation plan

4470461 Sheets 1 - 5

Crusher shells, complete

4609197

Concaves, complete

4609240

Wear parts, complete

4609235

Base, complete

4350085

Shaft, complete

4609199

Dust sealing, complete

4470280

Eccentric bushing, complete

4609204

Main shaft hydraulics, complete

4613028

Hydraulic cylinder

4207648

Spider bearing

4609216

Axial step bearing, complete

4207101

Pinion assembly complete

4521963 Sheets 1 + 2

Drive, complete

4609407

Balancing device

4207649

Balancing cylinder

4207624

On-site piping

4613053

Lubrication for spider bearing, complete

4350050

Grease lubrication pump complete

4350926 Sheets 1 + 2

Blower, complete

4350373

Clearance of teeth and bearings

4207338

Cooler piping

4613051

Cylinder piping

4613052

Hydraulic unit

4358834

Hydraulic diagram

4473148

11/2013 Rev 0

Gyratory crusher coupling

2-492-20980 (POS 01)

9-3

11/2013 Rev 0

Blank page

9-4

2-492-20980 (POS 01)

9.2

Couplings
– Multi-plate clutch

11/2013 Rev 0

– Safety clutch

2-492-20980 (POS 01)

9-5

11/2013 Rev 0

Blank page

9-6

2-492-20980 (POS 01)

9.3

Clearance of teeth and bearings
– Drawing "Clearance of teeth and bearings" (4350802)

11/2013 Rev 0

– Installation instructions for bevel gears

2-492-20980 (POS 01)

9-7

11/2013 Rev 0

Blank page

9-8

2-492-20980 (POS 01)

9.4

Processing synthetic sealing compound

11/2013 Rev 0

Processing of Betec sealing compound

2-492-20980 (POS 01)

9-9

11/2013 Rev 0

Blank page

9 - 10

2-492-20980 (POS 01)

Compressor (over-pressure ventilation)

11/2013 Rev 0

9.5

2-492-20980 (POS 01)

9 - 11

11/2013 Rev 0

Blank page

9 - 12

2-492-20980 (POS 01)

Monitoring devices

11/2013 Rev 0

9.6

2-492-20980 (POS 01)

9 - 13

11/2013 Rev 0

Blank page

9 - 14

2-492-20980 (POS 01)

Distance sensor of main shaft setting unit

11/2013 Rev 0

9.6.1

2-492-20980 (POS 01)

9 - 15

11/2013 Rev 0

Blank page

9 - 16

2-492-20980 (POS 01)

Grease filling level sensor of the top axle mounting

11/2013 Rev 0

9.6.2

2-492-20980 (POS 01)

9 - 17

11/2013 Rev 0

Blank page

9 - 18

2-492-20980 (POS 01)

Fluid switch for monitoring the oil filling of the pinion assembly

11/2013 Rev 0

9.6.3

2-492-20980 (POS 01)

9 - 19

11/2013 Rev 0

Blank page

9 - 20

2-492-20980 (POS 01)

Resistance thermometer, pinion assembly

11/2013 Rev 0

9.6.4

2-492-20980 (POS 01)

9 - 21

11/2013 Rev 0

Blank page

9 - 22

2-492-20980 (POS 01)

Monitoring of the torque

11/2013 Rev 0

9.6.5

2-492-20980 (POS 01)

9 - 23

11/2013 Rev 0

Blank page

9 - 24

2-492-20980 (POS 01)

Central lubrication

11/2013 Rev 0

9.7

2-492-20980 (POS 01)

9 - 25

11/2013 Rev 0

Blank page

9 - 26

2-492-20980 (POS 01)

Oil circulating lubrication and hydraulic unit

11/2013 Rev 0

9.8

2-492-20980 (POS 01)

9 - 27

11/2013 Rev 0

Blank page

9 - 28

2-492-20980 (POS 01)

Shaft hydraulics (balance unit, hydraulic cylinder)

11/2013 Rev 0

9.9

2-492-20980 (POS 01)

9 - 29

11/2013 Rev 0

Blank page

9 - 30

2-492-20980 (POS 01)

Balancing device

11/2013 Rev 0

9.9.1

2-492-20980 (POS 01)

9 - 31

11/2013 Rev 0

Blank page

9 - 32

2-492-20980 (POS 01)

Hydraulic cylinder

11/2013 Rev 0

9.9.2

2-492-20980 (POS 01)

9 - 33

11/2013 Rev 0

Blank page

9 - 34

2-492-20980 (POS 01)

Tools

11/2013 Rev 0

9.10

2-492-20980 (POS 01)

9 - 35

11/2013 Rev 0

Blank page

9 - 36

2-492-20980 (POS 01)

SUPERBOLT® Mechanical clamping elements

11/2013 Rev 0

9.11

2-492-20980 (POS 01)

9 - 37

11/2013 Rev 0

Blank page

9 - 38

2-492-20980 (POS 01)

Gyramatic Version 2.4 - user manual / fault list

11/2013 Rev 0

9.12

2-492-20980 (POS 01)

9 - 39

11/2013 Rev 0

Blank page

9 - 40

2-492-20980 (POS 01)

Fluid starter

11/2013 Rev 0

9.13

2-492-20980 (POS 01)

9 - 41

11/2013 Rev 0

Blank page

9 - 42

2-492-20980 (POS 01)

Maintenance car with scissor-type elevating platform

11/2013 Rev 0

9.14

2-492-20980 (POS 01)

9 - 43

11/2013 Rev 0

Blank page

9 - 44

2-492-20980 (POS 01)