IOM Manual

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
Gyratory Crusher
1300 × 1800
Top Service Ultra Duty
Ravenswood Gold Mine 9232510974
September 2021
Copyright © 2021 by FLSmidth Inc., All Rights Reserved.
Documents, drawings, technical manuals, and all other information contained in this manual, provided in conjunction
with the purchase of FLSmidth products and services, are the proprietary property of FLSmidth. No part of this manual
may be disclosed, copied, duplicated, photocopied, reproduced, translated, or reduced to any electronic medium or
machine-readable form without prior written consent from FLSmidth.
The data included in this manual is not to be duplicated, used, or disclosed, in whole or in part, for any purpose other
than in the operation, maintenance, and service of the machine described. Nothing contained herein should be
construed to guarantee, modify, or enhance the operational capabilities as described in the machinery specification.
This manual does not imply liability to the manufacturer for any or all operational capabilities that may be affected by the
misuse or neglect in operating or servicing this machine.
“Original instructions” are provided in the English language. As required, “translation of the original instructions” is
provided in the official community language for the area where the equipment is used
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Table of Contents
Chapter 1: Safety
1.1 Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Hazard Signal Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 Safety Signs and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2.1 Mandatory Action Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2.2 Prohibition Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2.3 Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Safe Working Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 General Safety Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.4 Lockout/Tagout (Energy Isolation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.5 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.6 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.7 Equipment Safety Signs and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8.1 Emergency Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8.2 Safety Trip Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8.3 Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.8.4 Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Equipment-Specific Risks and Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1 Moving Components and Pinch Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1.1 Area Above the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1.2 Power Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1.3 Hydraulic Adjustment Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.2 Slip, Trip, and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.3 Pressurized Hydraulics and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.4 Lifting and Moving Heavy Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.5 Flying or Falling Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.6 Confined Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.7 Respiratory Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.8 High Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.9 Crusher Control System Operating and Safety Interlocks . . . . . . . . . . . . . . 14
1.3.10 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 General Risks and Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.1 Identifying and Controlling Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.2 Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702743 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
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1.4.3 Scaffolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.4 Railings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.5 Elevated Work Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.6 Harness and Line (Fall-Arrest System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.7 Cranes and Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.8 Moving Parts on Stationary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.9 Remote Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.10 Confined Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.11 Welding, Cutting, and Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.12 High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.13 Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.14 Inclement Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.15 Noise and Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.16 Pinch and Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.17 Electrical Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.18 Fuels, Oils, and Lubricating Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.19 Surface Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4.20 Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4.21 Mechanical Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5 Hazardous Chemicals and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5.1 Mineral Powders (Silica) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5.2 Lime and Calcined Raw Meal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5.3 Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5.4 Acids and Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5.5 Cyanide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5.6 Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.6 Emergency Preparedness Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Chapter 2: Introduction
2.1 Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.2 Installation and Start-up Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.3 Shipment and Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.4 Parts and Repair Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.5 Warranty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.5.1 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 Accessory Equipment Manufacturer Information . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.7 FLSmidth Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 3: Storage
3.1 Long-Term Storage Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.1.1 Maintaining Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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3.1.2 Storing OEM Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.2 Outdoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.3 Covered or Indoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Equipment Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5 Preventing Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5.1 Shop Primer Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5.2 Protective Finishes or Seal Coats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5.3 Machined and Non-Coated Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.6 Storing Elastomer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.7 Storing Fiberglass Reinforced Plastic Components . . . . . . . . . . . . . . . . . . . . . . . .33
3.8 Storing Equipment After Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
3.9 Storing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
3.10 Environmental Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Chapter 4: Equipment Overview

4.1 Equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4.1.1 Crusher Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1.2 Spider Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1.3 Concaves and Mantles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1.4 Eccentric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1.5 Mainshaft Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Chapter 5: Installation
5.1 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.1.1 Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1.2 Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2 Interference Fit Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
5.2.1 Heating Components for Installation on a Shaft . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.1.1 Oven Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.1.2 Oil Bath Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.1.3 Induction Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.1.4 Direct Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.2 Cooling Components for Installation in a Bore . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.2.1 Cooling With Dry Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.2.2 Cooling With Liquid Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Receipt of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.4 Foundation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.5 Hydraulic Support and Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.5.1 Hydraulic Support Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.5.2 Hydraulic Cylinder Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.5.3 Hydraulic Cylinder Piston Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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5.6 Bottom Shell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5.6.1 Installing the Bottom Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.6.2 Bottom Shell Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.7 Bottom Shell Liners Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.8 Eccentric Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
5.8.1 Outer Eccentric Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.8.2 Eccentric Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.9 Countershaft Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.10 Dust Bonnet and Gear Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.11 Shells Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
5.11.1 Middle Shell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.11.2 Top Shell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.12 Concave Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
5.12.1 Concave Ring Segment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.12.2 Concave Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.13 Spider and Mainshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.13.1 Spider Pockets, Backing Material Installation . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.13.2 Mainshaft Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.13.3 Spider Lubrication Hose and Spider Bushing Installation . . . . . . . . . . . . . . . 58
5.13.4 Spider Shields Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.13.5 Spider and Spider Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.13.6 Spider Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.14 Lip Seals Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
5.14.1 Determining Seal Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.14.2 Installing the Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
5.15 Top Shell Wear and Seal Plates Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.16 Mantle Position Indicator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.17 Lubrication and Hydraulic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.17.1 Lubrication and Hydraulic System Installation and Connection . . . . . . . . . . 61
5.17.2 Lubrication and Hydraulic System Filling and Flushing . . . . . . . . . . . . . . . . . 62
5.17.3 Spider Bushing Lubrication System Installation . . . . . . . . . . . . . . . . . . . . . . . 63
5.18 Drive Motor, Couplings, and Countershaft Extension Assembly Installation . . .63
5.19 Torque Limiting Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.20 Drive Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.21 Countershaft Low Speed Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.22 Dust Seal Blower Connection (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.23 Rock Breaker Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.24 Post-Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
5.25 Final Mechanical Inspection and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . .65
5.26 Arrangements for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

v
Chapter 6: Operation
6.1 Post-Commissioning Automation Change Disclaimer . . . . . . . . . . . . . . . . . . . . . .68
6.2 Start-Up Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
6.2.1 Pre-Operational Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.2.2 Start-Up From Complete Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.2.3 Start-Up From Standby Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.2.4 Start-Up From Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.2.5 Start-Up From Power Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.3 Shutdown Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
6.3.1 Complete Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.3.2 Standby Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.3.3 Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
6.4 Ore Receiving and Crushing Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.5 Adjusting the Crusher Open-Side Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.6 Clearing the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
6.7 Clearing Tramp Material Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
6.8 Rock Breaker Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Chapter 7: Maintenance
7.1 Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
7.1.1 Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.2 Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
7.2.1 Running Mechanical Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.2.2 Shutdown Mechanical Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.2.3 Major Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.3 Electrical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
7.3.1 Running Electrical Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.3.2 Shutdown Electrical Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.4 Instrument Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
7.5 Manganese Steel Growth and Trimming of Concaves and Mantles . . . . . . . . . . .84
7.6 Stator Insulation Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
7.7 Dust Bonnet Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
7.7.1 Dust Bonnet Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.7.2 Dust Bonnet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.8 Spider Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
7.8.1 Spider Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.8.2 Spider Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.8.3 Spider Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.8.4 Spider Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.9 Mainshaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

vi
7.9.1 Mainshaft Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.9.3 Mainshaft Wearing Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.9.4 Mainshaft Wearing Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.9.5 Mainshaft Sleeve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.9.6 Mainshaft Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.9.7 Mainshaft Split Contact Seal Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.9.8 Mainshaft Split Contact Seal Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.10 Mantle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
7.10.1 Mantle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.10.2 Mantle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.11 Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
7.11.1 Core Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.11.2 Core Contact Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.11.3 Core Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.12 Eccentric Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
7.12.1 Eccentric Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.12.3 Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.12.4 Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.12.5 Gear Set Backlash Measurement and Adjustments . . . . . . . . . . . . . . . . . . . . 95
7.12.6 Inner Eccentric Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.12.7 Inner Eccentric Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.12.8 Outer Eccentric Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.12.9 Outer Eccentric Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.13 Hydraulic Piston Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.13.1 Hydraulic Piston Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
7.13.2 Hydraulic Piston Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.3 Center Wearing Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.4 Center Wearing Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.5 Piston Wearing Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.6 Piston Wearing Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.7 Hydraulic Piston Bushings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.8 Hydraulic Piston Bushings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.14 Hydraulic Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.14.1 Hydraulic Cylinder Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.14.2 Hydraulic Cylinder Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.14.3 Hydraulic Cylinder U-Seal Removal (if applicable) . . . . . . . . . . . . . . . . . . . . 104
7.14.4 Hydraulic Cylinder U-Seal Installation (if applicable) . . . . . . . . . . . . . . . . . . 105
7.14.5 Hydraulic Cylinder V-Ring Packing Removal (if applicable) . . . . . . . . . . . . 105
7.14.6 Hydraulic Cylinder V-Ring Packing Installation (if applicable) . . . . . . . . . . 106

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7.15 Countershaft Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

7.15.1 Countershaft Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.15.2 Countershaft Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.15.3 Outer Race Limit Stop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.15.4 Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.15.5 Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.15.6 Countershaft Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
7.15.7 Countershaft Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7.16 Concaves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.16.1 Concaves Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.16.2 Concaves Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.17 Extension Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.17.1 Extension Shaft Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.17.2 Extension Shaft Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Chapter 8: Troubleshooting
8.1 Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.1.1 General Crusher Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
8.1.2 Mainshaft and Eccentric Assembly Troubleshooting Table . . . . . . . . . . . . . 118
8.1.3 Lubrication System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
8.1.4 Drive System Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.1.5 Concave Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.1.6 Liner Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.1.7 Troubleshooting Process Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Appendix A: Lubrication
A.1 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
A.2 Oil and Grease Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
A.2.1 Crusher Hydraulic and Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . 126
A.2.2 Spider Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
A.2.3 Mainshaft Dust Seal and Countershaft Triple Seal . . . . . . . . . . . . . . . . . . . . 127
A.2.4 Drive Safety Coupling Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
A.3 Oil and Grease Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
A.4 Oil Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
A.4.1 Manufacturing, Transport, and Storage Debris . . . . . . . . . . . . . . . . . . . . . . . 128
A.4.2 Piping Debris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
A.4.3 Dirt Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
A.4.4 Wear Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
A.4.5 Moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
A.5 Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
A.6 Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

viii
A.6.1 Oil Sampling Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

A.6.2 Oil Sampling Location and Sampling Techniques . . . . . . . . . . . . . . . . . . . . 130
A.6.3 Contamination Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
A.7 Cleaning or Replacement of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Appendix B: Pre-Installation Inspection

B.1 Pre-Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Appendix C: Commissioning
C.1 Commissioning Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
C.2 Commissioning Sequence Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
C.3 Pre-Operational Commissioning Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
C.4 Pre-Commissioning Mechanical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
C.5 Pre-Commissioning Electrical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
C.5.1 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
C.6 No-Load Commissioning Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
C.6.1 No-Load Commissioning Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
C.7 50% Feed Load Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
C.7.1 50% Feed Load Commissioning Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
C.8 Full Load Commissioning Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
C.8.1 Full Load Commissioning Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Appendix D: Maintenance Schedule

D.1 Maintenance Schedule Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
D.2 Mechanical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
D.2.1 Daily Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 160
D.2.2 Weekly Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 162
D.2.3 Monthly Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . 162
D.2.4 Annual Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 163
D.2.5 Major Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 164
D.3 Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
D.3.1 Weekly Electrical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 165
D.3.2 Monthly Electrical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 167
D.3.3 Annual Electrical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 170
D.4 Instrument Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
D.4.1 Quarterly Instrument Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . 173
Appendix E: Parts List/Bill of Materials

E.1 1000730929: Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Appendix F: Recommended Spare Parts List

ix
F.1 Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Appendix G: Functional Specification

G.1 1000656041: Functional Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Appendix H: Drawing Package

H.1 1000614305: Crusher General Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
H.2 1000614318: Foundation Load and Clearance Requirements . . . . . . . . . . . . . . .277
H.3 1000633857: Foundation Bolt Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
H.4 1000660387: Mainshaft Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
H.5 1000660800: Spider Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
H.6 1000660799: Top Shell Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
H.7 1000660798: Middle Shell Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
H.8 1000660797: Bottom Shell Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
H.9 1000494407: Spider Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
H.10 1000494882: Top Shell Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
H.11 1000614471: Top Shell Seal Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
H.12 13072581: Middle Shell Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
H.13 13037588: Bottom Shell Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
H.14 1000495367: Bottom Shell Liner Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
H.15 1000497921: Dust Bonnet Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
H.16 1000496410: Eccentric Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
H.17 1000531721: Hydraulic Cylinder Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
H.18 1000500157: Mainshaft Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
H.19 1000519350: Concave Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
H.20 1000520967: Concave Installation Ring Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
H.21 1000521111: Installation Ring Assy, Lower Concave . . . . . . . . . . . . . . . . . . . . . . 296
H.22 1000521942: Installation Ring Assy, Middle Concave . . . . . . . . . . . . . . . . . . . . .297
H.23 1000521945: Installation Ring Assy, Upper Concave . . . . . . . . . . . . . . . . . . . . . 298
H.24 1000716626: Concave Removal Pan Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
H.25 1000652444: Removal Pan Assy, Lower Concave . . . . . . . . . . . . . . . . . . . . . . . 300
H.26 1000670704: Removal Pan Assy, Middle Concave . . . . . . . . . . . . . . . . . . . . . . . . 301
H.27 1000671390: Removal Pan Assy, Upper Concave . . . . . . . . . . . . . . . . . . . . . . . . 302
H.28 1000521941: Bonnet Cover Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
H.29 13036470: Countershaft Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
H.30 1000608222: Lube and Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
H.31 1000636190: Spider Lubrication GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
H.32 1000614472: Countershaft Extension Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
H.33 1000614634: Drive Guard Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
H.34 13072248: Dust Seal Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
H.35 3.507050: Mantle Position Indicator Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

x
H.36 10453395: Hydraulic Jack Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

H.37 1000614463: Mantle Relief Valve and Accumulator Assy . . . . . . . . . . . . . . . . . . 313
H.38 1000614466: Blower Assy Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
H.39 13035139: Gear & Pinion Assy, Field Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 315
H.40 1000730476: Erection and Maintenance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
H.41 7.500234: Acceptable Epoxy Grouts for Installation . . . . . . . . . . . . . . . . . . . . . 320
H.42 1000637275: Instrument List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
H.43 1000636813: Electrical Load List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
H.44 1000627226: Control and Instrumentation Diagram . . . . . . . . . . . . . . . . . . . . . . 331
H.45 1000681661: Interconnection Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
H.46 1000606868: Lubrication Unit Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 341
H.47 1000614108: Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
H.48 1000637276: I/O List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Appendix I: Final Mechanical Inspection

I.1 Final Mechanical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

1
Chapter 1: Safety
1.1 Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Hazard Signal Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 Safety Signs and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2.1 Mandatory Action Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2.2 Prohibition Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2.3 Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Safe Working Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 General Safety Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.4 Lockout/Tagout (Energy Isolation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.5 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.6 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.7 Equipment Safety Signs and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8.1 Emergency Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8.2 Safety Trip Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8.3 Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.8.4 Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Equipment-Specific Risks and Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1 Moving Components and Pinch Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1.1 Area Above the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1.2 Power Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.2 Slip, Trip, and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.3 Pressurized Hydraulics and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.4 Lifting and Moving Heavy Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.5 Flying or Falling Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.6 Confined Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.7 Respiratory Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.8 High Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.9 Crusher Control System Operating and Safety Interlocks . . . . . . . . . . . . . . 14
1.3.10 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 General Risks and Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.1 Identifying and Controlling Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 Chapter 1 Safety
1.4.2 Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.3 Scaffolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.4 Railings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.5 Elevated Work Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.6 Harness and Line (Fall-Arrest System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.7 Cranes and Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.8 Moving Parts on Stationary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.9 Remote Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.10 Confined Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.11 Welding, Cutting, and Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.12 High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.13 Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.14 Inclement Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.15 Noise and Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.16 Pinch and Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.17 Electrical Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.18 Fuels, Oils, and Lubricating Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.19 Surface Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4.20 Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4.21 Mechanical Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5 Hazardous Chemicals and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5.1 Mineral Powders (Silica) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5.2 Lime and Calcined Raw Meal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5.3 Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.5.4 Acids and Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5.5 Cyanide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5.6 Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.6 Emergency Preparedness Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Chapter 1 Safety 3
1.1 Important Safety Information

FLSmidth recommends that equipment be installed, operated, and maintained in accordance with all applicable
governmental safety and health laws, regulations, and generally recognized industrial standards.
The information provided in this chapter is intended to provide a general overview of safety guidelines recommended
by FLSmidth, and is not an exhaustive list of all standard safety procedures. The specific guidelines outlined below may
or may not apply to your particular equipment. FLSmidth is neither responsible nor liable for incorrect or unsafe
practices or policies.
Follow all governing safety standards and local jobsite procedures.
1.1.1 Hazard Signal Indicators

Danger, Warning, and Caution indicators are located throughout the manual at specific points of interest and alert the
reader to the relative degree of a hazard.
These notices are given to prevent personal injury, death, equipment damage, and improper service, and must be
followed to reduce or eliminate these risks. Always heed these notices, and practice common sense when performing
any maintenance or repair procedure.
Hazard Symbol Symbol Description
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury and death.
“Danger” indicates an imminently hazardous situation which, if not avoided,

could result in death.
“Warning” indicates a potentially hazardous situation which, if not avoided,

could result in death, serious injury, or property damage.
“Caution” indicates a potentially hazardous situation which, if not avoided,

MAY result in minor or moderate injury and property damage. It may also
be used to alert against unsafe practices.
“Notice” is used to draw attention to detailed instructions. These notes are

intended to give further important information regarding the equipment or
a step in a procedure.
Table 1-1: Hazard Signal Indicators
1.1.2 Safety Signs and Symbols

Additional safety signs and symbols may appear along with the Danger and Caution indicators, and are used to specify
certain hazards. These warnings describe particular areas where special care and procedures are required in order to
prevent serious injury and possible death.

4 Chapter 1 Safety
1.1.2.1 Mandatory Action Symbols
Mandatory Action Symbols are referred to as Personal Protective Equipment (PPE) and are identified by a blue circle
with a white symbol in the middle signifying the type of protective equipment required. These symbols indicate a
mandatory action required to safeguard personal health and avoid risk of personal injury.
FLSmidth recommends that personnel wear the correct PPE at all times, and that all PPE meet local country standards,
and where appropriate, international standards such as ISO, ANSI and EN. Follow all governing safety standards and
local jobsite procedures.
The following table contains the comprehensive list of mandatory action symbols and their descriptions. The symbols
below may or may not apply to your equipment.
Mandatory Action Description Mandatory Action Description

Symbols Symbols
General Mandatory Action Wear Protective Clothing
Refer to Instruction Manual Use Handrail
Wear Ear Protection Wear a Face Shield
Wear Eye Protection Wear Head Protection
Connect an Earth Terminal to the

Wear High Visibility Clothing
Ground
Disconnect Plug from Outlet Wear a Mask
Wear Opaque Eye Protection Wear a Safety Harness
Disconnect Before Carrying Out

Wear Safety Footwear
Maintenance or Repair
Wear Protective Gloves Use This Walkway
Table 1-2: Mandatory Action Symbols
1.1.2.2 Prohibition Symbols
FLSmidth recommends the use of prohibition symbols that are used to indicate a prohibited action. They are identified
by a red circle with a diagonal line running through and the black symbol in the middle (sometimes accompanied by
words). These symbols signify what you should not do or what is prohibited.

Chapter 1 Safety 5
The following table contains the comprehensive list of prohibition symbols and their descriptions. The symbols below
may or may not apply to your equipment.
Prohibition Description Prohibition Description

Symbols Symbols
General Prohibition No Pushing
No Smoking No Sitting
No Open Flame, Fire, Open

No Stepping on the Surface
Ignition Source, or Smoking
No Thoroughfare Do Not Use Lift in Event of Fire
No Access for People with Active

No Eating or Drinking
Implanted Cardiac Devices
No Metallic Articles or Watches Do Not Use Lift for People
Do Not Touch No Running
No Heavy Load No Climbing
No Reaching In Do Not Enter
Table 1-3: Prohibition Symbols

6 Chapter 1 Safety
1.1.2.3 Warning Symbols
FLSmidth recommends the use of warning symbols that are used to signify potential danger. These symbols are
identified by a triangle with a yellow background and a black symbol in the middle signifying the danger.
The following table contains the comprehensive list of warning symbols and their descriptions. The symbols below may
or may not apply to your equipment.
Warning Description Warning Description

Symbols Symbols
General Warning Automatic Start-up
Explosive Material Crushing
Floor Level Obstacle Flammable Material
Drop Fall Sharp Element
Slippery Surface Corrosive Substance
Electricity Crushing of Hands
Forklift and Other Industrial

Counter Rotating Rollers
Vehicles
Overhead Load Battery Charging
Toxic Material Oxidizing Substance
Hot Surface Explosive Atmosphere
Table 1-4: Warning Symbols
There may be additional types of signage to those shown above depending on the country or site. Ensure that you
familiarize yourself with, and understand the signage that is used at your site.

Chapter 1 Safety 7
1.2 Safe Working Practices

Safe working practices are essential when working in construction areas with heavy equipment. The high noise levels,
dust conditions, and ever-present danger of high-powered machinery demands that safety be observed by all personnel
on the jobsite, and most specifically by those working on or in the immediate area of the equipment.
Do not install, operate, maintain, or repair this equipment until you have read and fully understand the
instructions and warnings in this manual. Failure to follow these safety precautions could result in
personal injury, death, or property damage.
• Proper care is your responsibility.

• All maintenance and repair of this equipment shall be performed in accordance with safety warnings. Failure to do so
may result in personal injury or property damage.
1.2.1 Operator Responsibilities

Machinery is to be operated by those with prior experience operating sophisticated equipment and systems, and who
have been appropriately trained and certified in the proper use of this particular machinery.
FLSmidth recommends that equipment be installed, operated, and maintained in accordance with all applicable
governmental safety and health laws, regulations, and generally recognized industrial standards.
1.2.2 General Safety Recommendations

FLSmidth recommends that assembly, operation, and maintenance personnel observe the following general safety
guidelines.
• Perform both a pre-start inspection as well as a walk-around inspection. This can be done by the installer, operator,
or a designated maintenance technician.
• Do not put equipment into operation unless all regularly scheduled maintenance and any unscheduled, but
necessary, repairs have been performed.
• Adhere to the recommended maintenance schedule for machinery and component parts.
• Use all of the systems designed to keep people safe when in the area of the equipment, including proper safety
signs and any standards appropriate to the specific country where the site is located.
• Do not override any safety system.
• Engage the equipment controls slowly.
• Ease components into motion gradually to prevent shock load damage and unnecessary wear on gear cases and
other moving parts.
• Keep hands and anything you are holding out of any area with moving parts.
• Prevent tripping and falling hazards around the equipment according to your site requirements.
• Ensure all working components come to a complete stop before reversing the controls.
• Do not leave the operator’s station unattended while the equipment is in operation.
• Be familiar with the emergency shutdown procedures and locations where they can activate an emergency stop
system shutdown.
Note: FLSmidth cannot anticipate every possible circumstance that may involve a potential hazard, therefore,
the safety and informational prompts in this manual are not all-inclusive. If a tool, procedure, work method, or
maintenance technique not specifically recommended by FLSmidth is used, ensure its safety prior to use.
Ensure that lubrication, maintenance, or repair procedures don’t damage the machinery or make it unsafe for

8 Chapter 1 Safety
operation. For more information on maintenance and repair procedures for items furnished but not
manufactured by FLSmidth, refer to the original equipment manufacturer instructions.
1.2.3 Unauthorized Modifications

Unauthorized modifications to the equipment may impair its function and capacity to operate safely, and may lead to
shortened equipment life and unsafe operating conditions. Do not take shortcuts on equipment repair. Read all
instructions thoroughly.
1.2.4 Lockout/Tagout (Energy Isolation)

The purpose of Lockout/Tagout (LOTO) and related procedures is to avoid electrocution or accidental start-up of the
machine(s) or parts during maintenance or service. An unwanted start or movement can lead to serious injury or death.
Examples of potential risk include:
1. A machine that was switched off is suddenly restarted from a remote control panel or locally by mistake.
2. A machine unexpectedly energizes due to a failure in the machine control system.
3. Residual energy such as compressed gas or liquid, as well as spring or gravity loads, is suddenly released and
applies considerable force to one or more parts.
Further, FLSmidth recommends that chains, blocking, locking pins or other hardware be used for isolating, securing or
blocking machines or equipment from mechanical energy sources, including springs and gravity loads.
The equipment used for securing the machinery must be strong enough to effectively prevent movement of the
machine, for example, using a weak chain will provide a false sense of security as it may break.
1.2.5 Fire Extinguishers

Fire is a major cause of loss of life and property throughout the world. While fire normally does not pose a grave danger
on open construction sites with steel and concrete as major materials, it may occur at any time and anywhere.
Have fire extinguishers available and know how to use them. Inspect and have them serviced as recommended on their
instruction plates.
1.2.6 Emergency Procedures

The best way to deal with emergencies is to prevent them in the first place.
Each site will have its own procedures, which you will learn at your site induction. If the emergency procedures are not
provided to you, it is your duty to seek out the emergency procedures, telephone numbers, and radio channels that are
used on site.

Chapter 1 Safety 9
Always follow site procedures when dealing with an emergency situation. Use your site emergency call
procedure and be ready to provide relevant information.
1.2.7 Equipment Safety Signs and Labels

Equipment supplied by FLSmidth is fitted with safety signs and labels in accordance with global safety standards. Read
and understand all safety signs and labels on your equipment before installing, operating, lubricating, or maintaining this
equipment. Make sure safety signs and labels are legible.
Replace any safety signs and labels that are damaged or missing. If a safety sign or label is attached to a part that is
replaced, install a new safety sign or label on the replacement part.
1.2.8 Protective Devices

Your equipment may be fitted with devices that are designed to provide protection for personnel who are working on or
around the equipment. To maintain safety it is critical that these devices are kept in place and correctly maintained.
Protective devices may include the following:
• Emergency stop switches

• Safety trip wires
• Interlocks
• Guards
1.2.8.1 Emergency Stop Switches
Moving machines are typically fitted with emergency stop (E-stop) switches located at strategic places on the machine.
These E-stop switches will immediately cut off the power source to the machine, and, once triggered, require manual
(physical) reset before the machine may be started again either locally or from a remote control room.
Locate the nearest E-stop switch as close to moving parts as possible. In some cases, this can be difficult to achieve.
The figure below is a typical E-stop switch fitted to a local control station in the field.
Figure 1-1: Emergency Stop Switch
1.2.8.2 Safety Trip Wire
Trip wire assembly and switches (one cord on each side) allow equipment to be stopped without using the control panel
push buttons.

10 Chapter 1 Safety
Trip wire cords are connected to E-stop switches. Once one of the trip wire cords is pulled, the wiring circuit is broken
and the motor will stop.
Note: If your equipment includes a vacuum pump motor, be advised that this is not stopped by the trip wire
system.
The following figure shows a typical trip wire switch that is often installed along each side of the equipment.
Figure 1-2: Emergency Trip Wire Switch
Never use a trip wire or emergency stop switch as a means of isolating equipment. Trip wire and
emergency stop switches are normally controlled through software systems and as such they do not
provide positive isolation.
1.2.8.3 Interlocks
Machines equipped with interlocks prevent a malfunction from having disastrous consequences. The power source may
be cut off if problems are detected, such as:
• Motor overload (current too large)

• Speed too slow (speed monitors)
• Part of machine out of normal range (proximity switch)
• Excessive vibrations (vibration detector)
• Excessive heating of machine (thermo couple)
If you are operating a chain of transport equipment, a stop on any machine will automatically stop all upstream machines
to avoid overfilling the stopped machine. The downstream machines will, in most cases, be allowed to continue so that
they will empty themselves.
1.2.8.4 Guards
Guards prevent the possibility of personnel becoming entangled in moving parts. Keep guards intact and securely in
place at all times while the machine is operating.
If you need to remove guards to conduct maintenance work or clear a blockage, ensure that the equipment is shut
down, isolated, and rendered safe before doing so.

Chapter 1 Safety 11
Do not operate any part of the equipment if all guards are not securely in place.
There are some moving parts of the equipment for which guards are not practical. Such unguarded areas
have been evaluated as safe to work around with proper training and safe work practices.
1.3 Equipment-Specific Risks and

Hazards
1.3.1 Moving Components and Pinch Points
As with all mechanical equipment that has exposed movable components, workers must be aware of the pinch point
dangers, and adequately protected from them. The following areas must be guarded.
Ensure that all guards are mounted in their proper position prior to crusher operation.
Though proper guarding will protect workers, it is still important that they do not wear loose-fitting clothing, ties, or rings,
and they do not have exposed long hair which can get caught up in the machinery.
Local safety procedures apply in all instances.
1.3.1.1 Area Above the Crusher
The 1300 × 1800 Top Service Ultra Duty (TSU) Gyratory Crusher uses a gyrating motion to provide the forces necessary
to crush rock. The crusher opening is large enough for a person to fall into, and it must be guarded against the
possibility of someone falling into the crushing chamber.
1.3.1.2 Power Transmission
The crusher drive power is normally transmitted from an electric motor which is coupled to a countershaft through a
countershaft extension. The entire area of power transmission must be guarded to protect workers from falling into or
placing a limb into pinch points in the drive arrangement or the high speed rotating elements.
Occasionally, the electric motor is directly coupled to the crusher. If this is the case for the provided crusher, the worker
must be protected from the high-speed rotating elements.
FLSmidth has an available drive guard assembly that will enclose the power transmission for worker and machine
protection.
1.3.1.3 Hydraulic Adjustment Assembly
The hydraulic adjustment assembly operates using a hydraulic piston that raises and lowers with the addition or removal
of hydraulic fluid. An alarm must sound to warn workers whenever the adjustment mechanism is about to be actuated;
workers must be instructed to stand clear of the mechanism.

12 Chapter 1 Safety
1.3.2 Slip, Trip, and Fall Hazards

Working around a rock crusher can present a number of potential slip, trip, and fall hazards, such as rock spillage and oil
leaks. During liner changes and other maintenance activities, it may be necessary to climb down into the internal area of
the crusher for maintenance and clean-up. The interior of the eccentric assembly and gear areas will be wet with
lubricating oil, which presents a serious slipping hazard.
• Clean up all oil spills that may occur in the major crusher components.
• Use particular care when entering the oil-wetted areas of the crusher, and keep the areas clean.
• Ensure that any and all grease collected during lubrication and maintenance procedures is cleaned up and disposed
of properly.
• Ensure that any rock spills that occur around the crusher are cleaned up promptly to eliminate potential slip, trip, and
fall hazards.
• Guard against wet fines on the walkways. Wet feed conditions and excessive dust suppression water spraying can
cause wet fines to accumulate on the walkways; wet fines are very slippery.
1.3.3 Pressurized Hydraulics and Lubrication

The 1300 × 1800 Top Service Ultra Duty (TSU) Gyratory Crusher uses a hydraulic adjustment system with hydraulic oil
pressure of up to 69 bar (1000 psi). The crusher operates with a lower pressure, high volume lubrication system that
incorporates pressure relief valves, a filtration system, motors and pumps, and cooling and heating components.
• Oil under high pressure presents a considerable danger if it is accidentally released by maintenance personnel.
Workers must electrically isolate and lockout the hydraulic power system and dump the hydraulic pressure
whenever maintenance is carried out on the system.
• Hydraulic oil is very flammable. Special care must be taken when doing hot work around the crusher. It is imperative
that the hydraulic power unit be electrically isolated and locked out, and all hydraulic circuits are dumped of
pressure.
• Only workers trained in the maintenance and operation of the gyratory crusher hydraulic system may be permitted to
work on the system.
• Only workers trained in the maintenance of pressure vessels may be allowed to work on the charged accumulators.
• The lubrication system must be shut down, electrically isolated, and locked out whenever maintenance work
involves maintenance of the crusher lubrication or hydraulic components, or working on the lubrication system itself.
This is particularly important when the lubricating oil is to be replaced.
• Workers must be fully trained in the operation and maintenance of the 1300 × 1800 Top Service Ultra Duty (TSU)
Gyratory Crusher lubrication and hydraulic systems.
1.3.4 Lifting and Moving Heavy Components

The gyratory crusher has a number of very heavy components and assemblies that must be removed and installed
during wear liner replacement and other maintenance routines. Crusher workers must be instructed about the following
heavy lifting concerns:
• The weights of major crusher assemblies are listed in Appendix E: “Parts List/Bill of Materials” on page 181. The
weights of the individual parts that make up a crusher assembly are found on the assembly drawings and in
Appendix E: “Parts List/Bill of Materials” on page 181.
• FLSmidth supplies a collection of tools specifically designed for the installation and maintenance of the 1300 × 1800
Top Service Ultra Duty (TSU) Gyratory Crusher. Where applicable, there may be only one tool collection per group of
crushers supplied. This collection of tools has all of the lifting fixtures and specifically sized ring bolts necessary to
install and maintain the gyratory crusher. Workers must be made aware of the importance of keeping the tools in an
environmentally-protective and secure storage area.
• Trained riggers and crane operators, as well as rigging with suitable lifting capacity, must be available when major
crusher maintenance is undertaken.

Chapter 1 Safety 13
• Most of the major components of the gyratory crusher are made up of machined castings. The provided weights are
nominal weights determined by engineering methods. As castings, the actual weights can vary by as much as ±10%.
• Many pieces that make up the various crusher assemblies are at or just over what would be considered a safe
weight for a worker to lift. Workers must refer to Appendix E: “Parts List/Bill of Materials” on page 181 to determine
the actual weight of the piece and to use the proper lifting procedures. Weight lifting restrictions are the
responsibility of the customer’s safety program and governmental agencies, and are thus not addressed in this
manual.
1.3.5 Flying or Falling Objects

Gravity is used to introduce rock into the crusher cavity. Overflow, worn chutes, and other issues that lead to spillage
can cause falling rock to present a safety hazard.
Crushing action can cause rock to be ejected from the crushing chamber, particularly as rock is first being introduced
into the chamber.
• Spillage can accumulate on a lower deck and present slip and trip hazards for workers. Good housekeeping is
absolutely essential for safe crusher operations.
• As crushing systems often involve a gravity flow design with pre- and post-screening applications, it is not
uncommon to have one or more decks above and below the crusher. Workers must be aware of any people working
above or below them. When working in an area above another workspace, coordinate work to eliminate the
potential for dropped tools and parts, cordon off the area under the work being performed, or provide adequate
protection to workers on below decks.
1.3.6 Confined Spaces

The discharge area under the crusher is normally considered a confined space, and it must be treated as such. Address
the following concerns when routine maintenance procedures require the visual inspection of the underside of the
crusher, the crusher lubrication lines, and the discharge cavity.
• Confined space work permits and procedures must be utilized whenever maintenance work is to be carried out
under the crusher or in the discharge cavity.
• Electrically isolate and lock out the feed conveyor to the crusher, the crusher, and the discharge conveyor.
• The discharge area must be designed in such a way as to provide safe and easy access to the area under the
crusher. The discharge area must be designed to eliminate spillage and allow for adequate dust control.
1.3.7 Respiratory Concerns

The crushing of rock produces rock dust. Rock dust is often fine enough to be carried into the lungs during normal
breathing. All rock dust presents some health hazards, and some rock presents especially-serious health hazards. The
customer is responsible to provide a system to control the escape of breathable rock dust or to provide personal
protective equipment to protect the workers.
Working on and around the crusher requires welding, thermal cutting, and the use of chemical reagents, all of which can
present respiratory issues. Address the following concerns.
• When the crusher is installed, areas around the crusher mounting flange, countershaft, feed chute, and the feed
hopper must be sealed, as well as the area between the feed chute and feed hopper, to prevent the escape of
fugitive rock dust. FLSmidth service technicians will be present during the crusher installation to assist the customer
or the customer’s agent in how to best seal up these areas.
• Often the true seriousness of a dust control problem cannot be determined until after the crusher has been in
operation for a short period of time. Therefore, it is often necessary to over-design for dust control system to ensure
proper control at the onset of crushing.
• Working in or near the discharge area of the crusher may agitate breathable dust.

14 Chapter 1 Safety
• The epoxy-based backing compound used with the gyratory crusher has an agent that is caustic enough to burn
through skin contact and breathable fumes. Adequate personal protective equipment and ventilation is necessary
when working with these chemicals.
1.3.8 High Noise Levels

The very nature of crushing rock generates a high decibel level of noise. The actual noise generated is determined by
the type of rock being crushed, the amount of energy being put into the rock, and the type of structure that the crusher
is mounted on. Typically, the decibel readings are in the 85 to 105 dB range. As it is very difficult to abate this noise from
the area around the crusher, it is often necessary to require the use of hearing protection devices for workers.
• The actual noise generated by a gyratory crusher must be determined by measurement during normal crushing
operations. The customer is then responsible to determine what personal hearing protection is required for the
worker, as well as what time exposure limits are required.
1.3.9 Crusher Control System Operating and Safety

Interlocks
The gyratory crusher may come with a programmable logic controller (PLC) system that monitors the vital signs of the
crusher and assists in operating the crusher within the design limitations. Altering or isolating the interlocks of this
system affects the mechanical well being of the crusher, and can also seriously affect the safety of the workers in the
area around the crusher.
• Never make changes to the control system without prior approval of FLSmidth.
• If it becomes necessary to make temporary changes to the control system and FLSmidth cannot be contacted in a
timely manner, ensure that the local mine operational and safety management gives approval, and that any changes
are well documented.
1.3.10 Tools
A wide variety of equipment and tools are used to install and maintain the gyratory crusher. General notes on the safe
use of these tools are provided below.
• Air impact tools are frequently used for assembly and disassembly work. Because of the size of the fasteners, these
tools are frequently large and cumbersome. Workers must be trained in the proper use of these compressed air
tools. Workers are to be trained in the standard safety practices of the use of compressed air and compressed air
tools.
• The air impact tool is frequently used to turn jacking bolts that remove interference-fit parts. When removing
interference-fit parts, remove the part as rapidly as possible, before heat can soak into the mating part. It is advisable
that more than one person be assigned to a tool so that the tool can be utilized without excessive fatigue to an
individual worker.
• Some fasteners used in the gyratory crusher require high torque values to establish the proper pre-load. These high
torque values can require the use of torque multipliers; workers must be trained in the safe utilization of these tools.
• Refer to Chapter 7: “Maintenance” on page 77 for specific cautions on welding components to manganese and high
chrome white iron wear materials.
• Under no circumstances may welding be done on the crusher’s cast components. Though such welding does not
present any particular safety hazard, the high carbon steel alloy of these castings can be seriously compromised by
improper welding techniques. It is imperative that FLSmidth be contacted before any such welding is undertaken.
Due to the fact that many components of the gyratory crusher are assembled with interference fits, maintenance
workers will be required to use an open-flame or cryogenic agents in the installation and removal of various parts.
Address the below safety concerns.

Chapter 1 Safety 15
• Open flames present obvious safety concerns for workers. Because some parts must be heated rapidly and
thoroughly, it is important that two or more workers each use a heating torch at the same time. It is imperative that
workers be trained in the safe use of open-flame heating devices.
• Liquid nitrogen and dry ice are commonly used to chill components for assembly. Working with cryogenics presents
unique safety hazards. Workers must be trained in the safe use of these agents, and be provided with appropriate
personal protective equipment.
Though housekeeping concerns have been mentioned above regarding their relation to slip and trip hazards, it is
important to reiterate the concern.
• Correct the causes of spillage as they occur, and clean up spillage as soon as possible.
• Clean up all oil spills and any other types of spills that can result in a slip hazard.
• Pick up and put away all tools, cable rigging, water hoses, air pressure hoses, and acetylene torch equipment
immediately after they are used.
Working with the gyratory crusher presents many unique safety issues as described above. It is very important that
workers receive proper hazard awareness training relating to these issues.
• All workers must become familiar with the crusher general operation and maintenance.
• Workers must be made aware of the specific safety hazards related to working around the crusher.
• Workers must be trained in the safe use of tools and materials used in crusher maintenance and operation.
As mentioned above, the provided safety information is only to be utilized as a guide to assist the customer in
developing their own safety program for working on and around the 1300 × 1800 Top Service Ultra Duty (TSU) Gyratory
Crusher.
All general site safety instructions apply to a gyratory crusher. Any conflicts within the instructions are to be discussed
with the site manager. Any questions and concerns related to the safe operation and maintenance of the crusher must
be directed to the FLSmidth engineering and sales department.
1.4 General Risks and Hazards

Working at industrial sites unavoidably poses hazards from various activities and conditions. In the following sections,
several well-known industry hazards are outlined and precautions are described accordingly.
1.4.1 Identifying and Controlling Hazards

It is important to identify and control hazards before beginning any work or task. This is called risk management. There
are four basic steps in risk management:
1. Identify the hazards: Before you begin any task on or around the equipment, inspect the area and consider the task
to ensure that you are able to identify hazards or potential hazards.
2. Assess the risks: When you have identified the hazards or potential hazards, assess each one to determine the
overall level of risk. Risk is determined as the potential severity of the hazard and the likelihood of an incident being
caused by it.
3. Eliminate or control the hazards: If the risk is too great, put controls in place to eliminate or control the hazard.
Controls will vary according to the situation so it is up to the established site procedures and the personnel
conducting the task to find methods that are suitable for the conditions.
4. Reassess the risks if conditions change: Whenever the conditions that existed when the initial assessment was
conducted change, carry out the assessment of the hazards and risks again. This is to ensure that the changed
conditions do not increase the likelihood of an incident or increase the severity of an incident.

16 Chapter 1 Safety
1.4.2 Ladders
When the working height is greater than 1.8 m (6 ft) special considerations and equipment is required. Put site
emergency procedures in place when conducting work at heights to ensure any incident will be handled with a proper
emergency response.
1.4.3 Scaffolds
Scaffolds are an important means of ensuring safety when working at heights. Ensure that anyone constructing or
climbing on scaffolds is aware of the basic safety precautions. Correct any scaffold deemed unsafe immediately.
1.4.4 Railings
FLSmidth recommends that all stairways, open-sided floors, and loading docks contain perimeter or fall protection
devices such as a removable guardrail, a guardrail fence, or two chains strong enough to withstand the weight of
someone sitting on it.
1.4.5 Elevated Work Conditions

Train personnel riding in or working from the following devices to the local jobsite requirements and maintain 100% tie-
off procedures.
• Personnel lifts
• Hoisting devices
• Elevated work platforms
1.4.6 Harness and Line (Fall-Arrest System)

FLSmidth recommends that fall arrest system components be properly rated and mutually compatible.
1.4.7 Cranes and Lifting Operations

Operating cranes, whether mobile or fixed, present unique risks for both the operator and the equipment. Train crane
operators by approved site management.

Chapter 1 Safety 17
1.4.8 Moving Parts on Stationary Equipment

The primary risk associated with stationary machinery is that anyone close enough to the machine may get hands, arms,
feet, or loose clothing caught in the moving parts: shafts, rollers, cranks, v-belt drives, and so forth. This type of accident
often occurs when the victim is climbing on or gets too close to a machine that starts suddenly via a remote control, or is
already running. The consequences will be injuries (squeezing or crushing of extremities), but can also result in death.
Take care to ensure the safety of all personnel near moving equipment components. Ensure that all procedures are
followed, and equipment guards are in place and undamaged before starting work. Never place your body near any
moving parts, and always wear the correct PPE.
1.4.9 Remote Starts

Remote starting of machines will normally be accompanied by a start warning: either audible (siren), visual (flashing
lights), or both. The start warning is intended to allow employees enough time to move to a safe distance away from the
machinery.
If maintenance or repair work is to be carried out, machines are furnished with a power source or controls that permit
Lockout/Tagout (LOTO).
1.4.10 Confined Spaces

Confined Space Entry (CSE) is the entry of personnel into any space or structure not normally intended for human
occupancy, in which entry, movement within or exit is restricted, such as underground vaults, tanks, storage bins, pits
and diked areas, vessels, silos, and so forth. These enclosed or partially enclosed spaces:
• Are large enough for an employee to enter fully and perform assigned work.
• Are not designed for continuous occupancy by the employee.
• Have a limited or restricted means of entry or exit.
1.4.11 Welding, Cutting, and Brazing

FLSmidth recommends that all welding and brazing operations have proper ventilation. Fumes such as those produced
when working with zinc, cadmium, and painted surfaces can be toxic.
1.4.12 High Temperatures

Operations involving high air temperatures, radiant heat sources, high humidity, direct physical contact with hot objects,
or strenuous physical activities can have a high potential for causing heat-related illness/injury. Workplaces with these
conditions may include iron and steel foundries, nonferrous foundries, cement plants, rubber products factories,
electrical utilities (particularly boiler rooms), chemical plants, mining sites and smelters. Potential hazards are thermal
burns due to contact with hot equipment or exposure to high temperatures.

18 Chapter 1 Safety
1.4.13 Power Lines

Be aware of power lines in the area and consider all power lines energized unless proper measures have been taken for
de-energizing.
1.4.14 Inclement Weather

The local Health and Safety Executive (HSE) or business management can provide a means to determine the weather
forecast for the project location. FLSmidth recommends that you take precautionary measures during severe conditions.
1.4.15 Noise and Vibrations

Prolonged exposure to loud noise can impair hearing or cause permanent hearing loss. To protect from hearing loss,
FLSmidth recommends the following:
• Always wear PPE to protect against noise.

• Measure the noise levels for areas that may be considered a noise hazard.
• All personnel working in areas that exceed permissible exposure levels are required to wear jobsite-approved ear
protection.
Excessive noise can permanently damage your hearing. If you need to raise your voice to be heard, wear
hearing protection.
Some tools and equipment can expose employees to vibrations that can be harmful if not properly mitigated. Some
vibration when operating this equipment is to be expected. However, excessive vibration is often an indication of a
problem with the machine. Trace the sources of excessive vibration and rectify any problems as soon as possible. Do
not allow yourself to be exposed to vibration for long periods of time.
1.4.16 Pinch and Crush Points

Pinch points or crush points are a major hazard for personnel working around equipment. Loose clothing or hand tools
that are placed anywhere near a pinch point can result in the person being dragged into rotating or moving equipment.
• Always be aware of pinch point hazards.

• Never attempt to remove material from moving equipment.
• Never place your hands, any part of your body, or anything you are holding in a location where rotating or moving
parts could pinch the item and drag you in.
• Never work on any part of equipment that is running.
Crushing and shearing points can occur in the following locations on equipment:
• Between the belt and drive pulley.

• Between the belt and take-up rolls.
• Between the belt and idler rolls.

Chapter 1 Safety 19
This equipment may be provided with casings and covers, specifically at the discharge and feeding points, to reduce
injuries from pinching or crushing. Have maintenance and repair work done only by specifically instructed personnel.
1.4.17 Electrical Energy

Electrical hazards have the potential to cause serious injury to personnel or damage to equipment. FLSmidth
recommends that only trained, competent, and authorized personnel work on electrical components and equipment.
Follow correct isolation procedures when working on electrical equipment. FLSmidth further recommends that the
following precautions be taken:
• Do not override or bypass any electrical safety functions.

• Keep control panel doors closed at all times.
• Do not use oversized fuses, buss bars, or heaters.
• Connect the motor drives and accessories to an electrical ground, such as an underground water piping system, the
frame of a building, or other electrical ground.
Do not undertake electrical work if you are not trained, competent, and authorized to do so.
FLSmidth recommends that electrical systems comply with the relevant electrical provisions, and that all work done on
the electrical system be done by certified electricians. All electrical components must be interconnected and grounded
according to correct and safe electrical procedures.
1.4.18 Fuels, Oils, and Lubricating Fluids

During the operation of this equipment, you may come into contact with fuels, coolant, lubricating oils, and specialized
greases. These products can be hazardous if safety procedures are not followed when handling them. FLSmidth
recommends that you do the following:
• Always read, understand, and follow the directions on the relevant Safety Data Sheet (SDS) before handling any
chemical, fluid, or grease.
• Use the correct PPE for any task you conduct. Some SDS sheets will specify extra PPE.
• Avoid long periods of contact between your skin and any fluids associated with this equipment.
• Avoid breathing mist and vapors from fluids associated with this equipment.
• Do not touch your eyes, mouth, or face with dirty hands.
• Clean up fluid spills immediately using approved jobsite procedures.
• Do not carry oily rags in your pockets.
• Change out of oil-soaked clothing as soon as possible.
• Ensure operators know what they are handling and whether it presents special problems. When the filtered product
has known hazardous characteristics, keep specific antidotes and appropriate first aid supplies in the immediate
area.
• Report any significant contact with fluids or greases to your supervisor.

20 Chapter 1 Safety
1.4.19 Surface Heat

Certain components on equipment can become hot during operation. Be aware of potential hot components in your
working area and treat them with caution.
FLSmidth recommends that if any components seem disproportionately hot, shut down the equipment and investigate
and report immediately. Excessively hot components can indicate a mechanical problem and may result in equipment
damage and unsafe situations for personnel.
During commissioning, operation, maintenance, repair, and shutdown, contact of hot machine components or electrical
equipment may occur. Instruct all personnel accordingly.
Never place your hands on any item of equipment until you are certain it is at a safe temperature.
1.4.20 Lines, Tubes, and Hoses

FLSmidth recommends that operators and maintenance personnel take precautions to isolate and de-pressurize, if
necessary, any pressurized lines or vessels before they are opened. Observe the following safety points:
• Inspect all lines, tubes, and hoses carefully.

• Do not use your bare hands to inspect for leaks.
• Tighten all connections to the recommended torque.
• Do not bend or strike high pressure lines.
• Do not install bent or damaged lines, tubes, or hoses.
• Repair any loose or damaged hydraulic oil lines, tubes, and hoses.
Leaks can cause fires.
Note: Even though the equipment is switched off and electrically isolated, the contents of pipes and vessels
may still be under high pressure.
If high-pressure water or air hoses are used, FLSmidth recommends that all quick-connectors are fitted with a safety clip
similar to one shown in the figure below.
Figure 1-3: Safety Clip

Chapter 1 Safety 21
1.4.21 Mechanical Stability

The machine and its components are designed to minimize hazards due to insufficient mechanical stability; however,
during transport and assembly, maintenance, repair, shutdown, disposal, and storage, machine parts may tip or fall and
endanger the staff.
During commissioning FLSmidth recommends that extensive static and dynamic tests be carried out. Do not overload
the machine during operation, and use it only for its intended purpose.
1.5 Hazardous Chemicals and Materials

Many materials used in the industry contain hazardous ingredients that potentially pose health risks to employees.
FLSmidth recommends that the appropriate Safety Data Sheet (SDS) be obtained for all hazardous materials used on
site, and that the SDS be available for personnel and supervisors working with these chemicals. Careful study of the SDS
and adherence to the required safety precautions can improve on-site safety.
FLSmidth also recommends that chemicals be properly labeled.
1.5.1 Mineral Powders (Silica)

Mineral powders may be natural, such as sand or gravel, but very often they are an intermediate product in the cement
or mining industry (ore concentration). Mineral powders will also be generated as dust from grinding or cutting
operations in stone or concrete, or by handling dry soil.
1.5.2 Lime and Calcined Raw Meal

Lime and calcined raw meal is a fine powder consisting of a mixture of calcined (heat treated) natural minerals, primarily
calcined limestone (CaO) and clay/silicates. Smaller amounts of aluminum, iron and magnesium compounds as well as
reaction products such as calcium-silicates and calcium-aluminates may also be present in the mix, together with trace
amounts of other metal compounds.
1.5.3 Cement
FLSmidth recommends that anyone who uses cement, or mixtures containing it, or is responsible for managing or
supervising its use, is aware that it may be a hazard to health and safety, and to use safe working practices to minimize
risks.

22 Chapter 1 Safety
1.5.4 Acids and Bases

Strong acids include nitric (HNO3), sulphuric (H2SO4), hydrochloric (HCl) and phosphoric (H3PO4) acid. Of especially
dangerous nature is hydrofluoric acid (HF). Strong acids give off heat when diluted with water, which may lead to vapor
explosions.
Some systems use an acid wash containing hydrochloric (muriatic) or other acids. These acids can cause severe burns,
irritation of mucous membranes, and skin irritation even in dilute solutions. Fumes may cause respiratory problems. Eye
protection, skin protection, and respiratory masks are required when working with this material.
1.5.5 Cyanide
In some processes, including gold mining, the use of cyanide (calcium cyanide CaCN; potassium cyanide KCN; sodium
cyanide NaCN) is common. Any work with a direct risk of interacting with cyanide requires additional training.
1.5.6 Solvents
The most abundant toxic materials are solvents; other toxic materials include pigments (lead), paint, binders (epoxies,
polyesters) and additives (organotin).
1.6 Emergency Preparedness Plan

Refer to your site emergency preparedness plan.
Emergency preparedness plans are a critical component of safety.

23
Chapter 2: Introduction
2.1 Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.2 Installation and Start-up Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2.3 Shipment and Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.4 Parts and Repair Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.5 Warranty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
2.5.1 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 Accessory Equipment Manufacturer Information . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.7 FLSmidth Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

24 Chapter 2 Introduction
2.1 Using this Manual

This manual describes the FLSmidth® 1300 × 1800 Top Service Ultra Duty (TSU) Gyratory Crusher and outlines its
installation, maintenance, and operational procedures. It also includes a number of FLSmidth-recommended best
practices.
FLSmidth has designed this equipment to provide dependable, efficient, and economical operation throughout its entire
period of service. In order to achieve the desired level of performance and ensure full warranty coverage, it is required
that users thoroughly read, understand, and follow the contents of this manual before carrying out the installation,
making any adjustments, or operating the equipment. Regular care and maintenance must also be performed as
outlined in this manual.
The accessory items, (items furnished but not manufactured by FLSmidth) shall be stored, installed, operated, and
maintained according to the original equipment manufacturer instructions for complete warranty protection.
Note the following:
• The Manual set includes an Installation, Operation, and Maintenance Manual as well as an OEM (Original Equipment
Manufacturers) Manual containing documentation for items furnished but not manufactured by FLSmidth.
• The procedures described in this manual do not relieve users of their responsibility to exercise caution and common
sense.
• Users are responsible for their own personal safety when operating this equipment.
• Users must comply with all safe working procedures and instructions relevant to their work site at all times.
• Pictures, descriptions, and technical data may not match your equipment in every aspect.
• The information, specifications, and illustrations in this manual are written according to information available at the
time it was produced, therefore, this information may change at any time. These changes could include one or more
of the following: lubrication, storage, installation instructions, maintenance, etc. FLSmidth reserves the right to make
changes without notice and without obligation to replace existing manuals.
• FLSmidth will not furnish editable electronic copies of any data, manuals, and/or drawings at any time and accepts
no liability whatsoever for unauthorized changes and/or alterations to the data provided.
• All information contained in this manual is the property of FLSmidth. None of the content may be copied or made
public without prior written consent from FLSmidth.
• English is the governing language. When manuals are translated into any other language, FLSmidth is not liable for
damages caused by errors in translation. The English translation will govern in case of discrepancies. In the event
there is confusion, notify your FLSmidth representative immediately. Refer to http://www.flsmidth.com/en-US/
Contact for applicable address and telephone numbers for the FLSmidth Office nearest you.
• FLSmidth accepts no liability to update the information contained in this manual. These materials are provided "AS
IS" WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO,
THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR NON-
INFRINGEMENT. YOU ASSUME COMPLETE RESPONSIBILITY AND RISK FOR USE OF THESE MATERIALS. Some
jurisdictions do not allow the exclusion of implied warranties, so the above exclusion may not apply to you.
• BY USING THIS MANUAL YOU AGREE THAT YOU HAVE READ, UNDERSTAND, AND AGREE TO THE TERMS OF
USE.
2.2 Installation and Start-up Services

Experienced FLSmidth engineers and service personnel are available to assist in the installation, safety training, and
start-up of your FLSmidth equipment. These personnel have technical expertise and firsthand knowledge of this
equipment, as well as the backing of the engineering and research facilities of FLSmidth.
Service personnel instruct on proper safety, operating and maintenance procedures, advise on best practices and
troubleshooting assembly, and can supervise the entire installation and start-up.
To request this assistance, make arrangements at the earliest possible date, outlining the services required and the
approximate duration of needed service.

Chapter 2 Introduction 25
Refer to your FLSmidth representative or http://www.flsmidth.com/en-US/Contact to submit your request concerning the
availability and/or charges for these services.
2.3 Shipment and Receiving

Although every precaution is taken by our shipping department to ensure your items arrive as ordered and undamaged,
we strongly recommend that you carefully inspect the shipment upon receipt. If equipment packaging is damaged,
photos of the damage as well as notification to FLSmidth will be required within five days of shipment receipt.
Note: All equipment must be stored in their original shipping containers, especially when such containers are
wooden crates or cardboard cartons as this will maintain necessary storage protection.
• Refer to the installation lifting instructions before handling the equipment.

• Carefully handle boxes when opening for inspection to prevent damage or loss of contents. Repack all parts, or store
them in a safe place with all protective covers reinstalled until assembly.
In case of damage or missing parts, immediately notify the carrier and your FLSmidth representative at http://
www.flsmidth.com/en-US/Contact.
You must notify FLSmidth within the time frame specified in your contract in the event of shortages and/
or discrepancies on the shipment. FLSmidth is not responsible for replacing items if notification occurs
outside the contractual time. If no time-frame has been specified in your contract, you must notify
FLSmidth within 30 days.
2.4 Parts and Repair Orders

Please contact FLSmidth for parts, repair orders, and/or equipment service, referring to http://www.flsmidth.com/en-US/
Contact for the FLSmidth Office nearest you.
To make sure the right replacement parts are received and to avoid undue delay, please provide the following
information with each order:
• Size and Type of Unit: 1300 × 1800 Top Service Ultra Duty (TSU) Gyratory Crusher
• Project Number: 9232510974
• FLS Order Number: 9232510974
• MCN Number: 1000702743 1
• Specific Component Part Numbers and Descriptions: (See individual component part nameplates included on the
drawings for these part numbers.)
• Special Field Modifications: This is important if the original material or design has been changed. Include drawings
and/or other descriptive information.
2.5 Warranty Conditions

Your FLSmidth-provided equipment (the “Equipment”) is designed with dependability in mind. However, this unit can be
damaged through misuse and by failing to follow the storage, installation, and maintenance procedures outlined in this
manual.
FLSmidth will not be responsible for damage to the Equipment, component parts, or other related structures, nor will the
warranty coverage on the Equipment be valid if any of the following apply:

• The Equipment is operated in an incorrect or negligent manner.

• The Equipment is not maintained in accordance with provided instructions.
• Operating conditions fall outside those specified for the Equipment, as originally designed and supplied.
The Equipment must be installed only by trained personnel who have been thoroughly trained in the safety procedures
pertaining to it.
All drawings and erection or installation instructions must be followed. Drawings provided will always govern. In the
event of any discrepancies, notify your FLSmidth representative immediately, referring to http://www.flsmidth.com/en-
US/Contact for contact information.
2.5.1 Limited Warranty

a. FLSmidth warrants the Equipment to be free from defects in material and workmanship. Refer to your contract for
specific warranty terms and conditions.
b. FLSmidth warranties are subject to the Equipment being properly stored, erected, installed, maintained, and oper-
ated in accordance with FLSmidth instructions and good industry practice and exclude ordinary wear and tear,
improper loading of software or firmware, corrosion, erosion, chemical or abrasive action, power failures, power
surges, other fluctuations in power, excessive heat, improper lubrication, extended storage before start-up, unautho-
rized repair, replacement, modification or alteration of the Equipment; or application outside the contractual design
limitations of the Equipment.
c. Buyer shall provide FLSmidth with written notice of a defect in materials or workmanship, including a full description
thereof, within 14 days after the defect is or should have been detected and in any event before expiration of the
warranty period.
d. FLSmidth agrees to repair or, at its option, replace at its expense, FCA shipping point (Incoterms 2010) any Equip-
ment or parts and components thereof, excluding the costs of dismantling and re-installation of the Equipment or
parts and components, that prove during the warranty period to contain defects in materials or workmanship.
e. The remedies stated in this Article are Buyer’s exclusive remedies for breach of this FLSmidth warranty. In no event
shall the exclusive remedies in this Article be considered or alleged to have failed their essential purpose. Buyer
agrees that if there are any discrepancies or inconsistencies between this Limited Warranty and the warranty
terms and conditions accompanying the Contract, the warranty terms and conditions accompanying the Con-
tract shall always govern.
f. EXCEPT FOR THE EXPRESS WARRANTY STATED IN THIS ARTICLE, FLSMIDTH EXPRESSLY DISCLAIMS ALL
OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED, STATUTORY, AT LAW OR IN EQUITY. THERE ARE NO
IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS OF PURPOSE, OR OTHERWISE.
2.6 Accessory Equipment Manufacturer

Information
Whenever the installation, lubrication, maintenance, or operation of an accessory piece of equipment (item which is
furnished by FLSmidth but is fabricated by a third party) is discussed in the FLSmidth instruction manual, this information
is provided only as a courtesy, as provided by the manufacturer at that time, and with no warranty expressed or implied.
This information must be verified by consulting the original equipment manufacturer (OEM) manuals, which are the ruling
documents for any accessory equipment.
As manufacturer instructions or recommendations may change over time, it is the user’s responsibility to periodically
consult the manufacturer to obtain the most up-to-date information, including maintenance instructions and recall
information.

Chapter 2 Introduction 27
In the event of any discrepancies between the information found in the FLSmidth instruction manual and
the information in the OEM manuals, notify your FLSmidth representative immediately, referring to http:/
/www.flsmidth.com/en-US/Contact.
As with any mechanical equipment, there are safety concerns associated with the installation of the primary and
accessory equipment. It is absolutely essential that installers, operators, maintenance personnel, and supervisors be
instructed in safe working practices.
2.7 FLSmidth Offices

After completion of the contract, all service and spare parts will be supported by the closest FLSmidth Regional
Headquarters. To find the FLSmidth office nearest you, refer to http://www.flsmidth.com/en-US/Contact.

THIS PAGE INTENTIONALLY LEFT BLANK

29
Chapter 3: Storage
3.1 Long-Term Storage Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.1.1 Maintaining Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.2 Storing OEM Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 Outdoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.3 Covered or Indoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Equipment Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5 Preventing Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5.1 Shop Primer Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5.2 Protective Finishes or Seal Coats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5.3 Machined and Non-Coated Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.6 Storing Elastomer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.7 Storing Fiberglass Reinforced Plastic Components . . . . . . . . . . . . . . . . . . . . . . . .33
3.8 Storing Equipment After Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
3.9 Storing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
3.10 Environmental Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

30 Chapter 3 Storage
3.1 Long-Term Storage Introduction

The storage procedures in this manual are general guidelines and standard practices that aid in maintaining the
condition of the equipment during long-term and pre-commissioning storage. If storage time is between 3 and 24
months, the following procedures shall be followed. If storage time is to exceed 24 months, contact FLSmidth for further
instructions.
3.1.1 Maintaining Warranty

FLSmidth warranties are subject to the equipment being properly stored as outlined below.
• Items with bearings must be rotated (pulleys, idlers, motors, drives, and so forth) according to the bearing
manufacturer’s requirements.
• For items with lubrication requirements, refer to Appendix A: “Lubrication” on page 125 for more details. In addition,
follow all maintenance requirements from the original equipment manufacturer (OEM) to maintain component life.
Failure to follow these instructions, in addition to the manufacturer’s requirements, will void component warranty.
When storing items for extended periods—six months or longer—detailed records must be kept and regularly updated
for the duration of the storage period. In the event of a warranty claim, these records must be submitted to FLSmidth to
show that all equipment and components have been properly maintained during the storage period. A paid periodic
inspection by an FLSmidth service personnel may be required to maintain the warranty. For the specific terms and
conditions of your equipment warranty please contact your FLSmidth representative.
Failure to comply with these storage instructions will void the FLSmidth warranty.
3.1.2 Storing OEM Components

FLSmidth provides vendor documentation that includes installation, operation and maintenance manuals for all parts
supplied by FLSmidth, but manufactured by a sub-contractor. This can include, but is not limited to, the following:
actuators, bearings, blowers, compressors, gear boxes, heaters, HPU, and other instruments.
For long-term storage requirements of the equipment that is furnished but not built by FLSmidth, refer to the original
equipment manufacturer (OEM) instructions.
3.2 Outdoor Storage

Site selection for outdoor storage of FLSmidth supplied equipment and accessories shall be:
• Level, well-drained, firm surface, clean, and dry

• Isolated or barricaded from possibility of physical damage from transport vehicles
• Accessible for periodic inspection and maintenance
• Away from direct sunlight, moisture, and excessive vibration
• Away from high concentrations of dust or corrosive gas
Sensitive components must be covered with a well drained and ventilated tarp or tent structure.
Painted and protective corrosion-resistant coating must inspected on monthly intervals, repaired, re-applied, or replaced
as necessary.
In the event of substantial corrosion (other than loose surface rusting) consult FLSmidth for recommendations for
corrective action.

Chapter 3 Storage 31
3.3 Covered or Indoor Storage

Covered storage consists of any structure with a roof to protect the equipment and components from the sun and rain.
Indoor storage consists of an enclosed structure that will protect from sun, rain, wind and dust.
Refer to Table 3-1 on page 34 for electrical sensors, wiring, and motor storing methods.
Covered or indoor storage require the following conditions:
• A constant temperature (between 5°C and 40°C [41°F and 104° F]), with no sudden temperature fluctuation
• A relative air humidity of ≤ 50%
• Relatively free of dirt or dust deposits
The following equipment is to be stored indoors:
• Countershaft assembly
• Countershaft extension assembly
• Eccentric assembly
• Electric motors
• Bronze components
• Mainshaft contact seal
• Mainshaft head nut
• Lubrication assembly
• Hydraulic assembly
• Spider lubrication system assembly
• Air and oil coolers
• Control panels and instruments
• Gears
• Couplings
• Dust bonnet
• Gaskets and seals
• Epoxy
• All bolts, nuts, washers, dowel pins, shims, pipe valves, and miscellaneous hardware
3.4 Equipment Support

Support all large fabricated equipment components in a manner that will allow free air flow under and around the
component being stored. Place supports (steel beams or wood timbers—not supplied by FLSmidth) of significant size
and strength at appropriate load-bearing locations. Store and support all components shipped on skids and pallets or in
crates and shipping containers in a manner that will allow free air flow under and around the skid, pallet, crate, or
shipping container.
3.5 Preventing Corrosion

Equipment that is in storage or that is out of service for more than 30 days must be protected against corrosion damage.
Regularly scheduled equipment inspections are critical for proper storage of FLSmidth supplied equipment and
components. These inspections include the following:

• Inspect primer paints, protective finishes, seal coats, and corrosion protection treatments thoroughly on a monthly
schedule.
• Repair, re-apply, or replace protective coatings as necessary.
If there is substantial corrosion (other than loose surface rusting), contact FLSmidth for recommendations for corrective
action.
During inspections, give special attention to machined surfaces because rust on these surfaces may cause irreparable
damage. The following are important examples of the machined surfaces:
• Mainshaft bearing surfaces

• Mainshaft threads
• Shell flanges, tapered fits, and bolt holes
• Spider bore and spider pocket fit surfaces
• Mantle bore
• Core bore and outside diameter
• Soleplates
• Bottom shell bores and flanges
• Bottom plate surfaces
FLSmidth will not be responsible for the condition of protective coatings after the equipment leaves the contracted
fabrication facility. FLSmidth assumes no responsibility for field surface preparation or touch-up of shipping damage to
protective coatings.
Identification tags that are removed for field painting prior to assembly must be reattached to the original components
for correct identification.
3.5.1 Shop Primer Paints

In some cases, equipment is supplied with shop primer paint only. Regularly inspect these finishes for deterioration.
Shop primer paints are intended to serve only as a bonding coat between metal surfaces and protective finishes or seal
coats and to act as a minimal protective finish. In such cases, protective finishes or seal coats shall be applied as soon as
possible. When this is not possible, remove rust or oxidation and re-apply shop primer paints as needed.
All shop primer paints must be applied using the paint manufacturer’s recommended processes and environmental
conditions. Shop primer paints for repair purposes are not supplied by FLSmidth.
3.5.2 Protective Finishes or Seal Coats

In most cases, equipment is supplied with a complete protective finish or seal coat. Regularly inspect these finishes for
deterioration. If rust or oxidation is found, clean the surfaces and re-apply the appropriate protective finishes.
All paint must be applied using the paint manufacturer’s recommended processes and environmental conditions.
Protective finishes or seal coats for repair purposes are not supplied by FLSmidth.
3.5.3 Machined and Non-Coated Surfaces

All machined and other non-coated surfaces (uncoated machined surfaces, shafting, mating surfaces, threaded holes,
piping flange faces, and so forth) must be clean and free of rust and other foreign matter. These surfaces must have a
corrosion protection treatment applied that is adequate for the selected storage conditions. All corrosion protection
treatments must be applied using the manufacturer’s recommended processes and environmental conditions.
Corrosion protection treatments for repair purposes are not supplied by FLSmidth. Some examples of corrosion
protection treatments include the following:

• A.W. Chesterton Company (740 Heavy Duty Rust Guard)

• Esgard Inc. (920 Equipment Kote)
• Tectyl Industrial Products (Tectyl 506EH-WD)
• Houghton International Inc. (Rust Veto 342)
Note: There are many other brands and types of corrosion protection treatments available in the market. If in
doubt about a particular product, contact FLSmidth for recommendations and approval of the product in
question.
3.6 Storing Elastomer Components

Elastomer and elastomer-covered (urethane, polyurethane, natural rubber, neoprene, nitrile, EPDM, M.O.R., and so forth)
products in storage can be adversely affected by temperature, humidity, ozone, sunlight, oils, solvents, corrosive liquids
and fumes, insects, rodents, and radiation. Proper care shall be taken to meet the following requirements.
• Elastomer parts shall be protected from physical damage by objects that can cut or tear.
• If stored below 0°C (32°F), some products may become stiff and will need to be warmed before being placed in
service. Do not store elastomer products near sources of heat, such as radiators and base heaters.
• To protect against the adverse effects of ozone, do not store elastomer products near electrical equipment that may
generate ozone or in geographical areas of known high ozone concentrations. Avoid exposure to direct and
reflected sunlight.
• Whenever feasible, store elastomer products in their original shipping containers, especially when such containers
are wooden crates or cardboard cartons, since this will provide protection against the deteriorating effects of oils,
solvents, and corrosive liquids. This will also afford some protection against ozone and sunlight.
• Since certain rodents and insects thrive on rubber products, provide adequate protection against them.
• Rotate all elastomer products on a first-in, first-out basis. Even if all above conditions are met, a prolonged length of
time in storage will result in the deterioration of elastomeric products.
3.7 Storing Fiberglass Reinforced Plastic

Components
Fiberglass reinforced plastic products (safety guards, receiver tanks, and so forth) in storage can be adversely affected
by temperature, ozone, sunlight, and corrosive liquids and fumes. Proper care shall be taken to meet the following
requirements.
• The ideal storage temperature for fiberglass reinforced plastics is 0°C to 32°C (32°F to 90°F) with a maximum limit of
38°C (100°F). If stored below 0°C (32°F), some products may become brittle and caution must be taken when placing
these components into service. Do not store fiberglass reinforced plastic products near sources of heat, such as
radiators and base heaters.
• Whenever feasible, fiberglass reinforced plastic products shall be stored in their original shipping containers,
especially when such containers are wooden crates or cardboard cartons, since this will provide protection against
the deteriorating effects of corrosive liquids and fumes and will also afford some protection against ozone and
sunlight.
• All fiberglass reinforced plastics products shall be on a first-in, first-out basis. Even if all above conditions are met, a
prolonged length of time in storage will result in the deterioration of fiberglass reinforced plastics products.

3.8 Storing Equipment After Operation

If the equipment will be removed from service for two months or longer after it has been in use, additional steps will be
required for proper storage. Refer to Chapter 7: “Maintenance” on page 77 for detailed instructions on properly storing
the equipment after operation.
3.9 Storing Methods

The table below provides a basic classification of parts supplied by FLSmidth, along with the preferred storage locations
for each part. Not all the parts listed in the table may apply to your particular equipment. Storage method will depend on
the size and quantity of the parts, as well as the preventative measures needed during storage.
Whenever possible, choose the preferred storage method from the table, along with the appropriate preventative
measures. If the preferred storage method is not possible, the optional storage method can be chosen. When neither
the preferred or optional storage methods are possible, contact FLSmidth for additional instructions on alternative
storage methods and preventative measures.
Part Classification Preferred Optional

Storage Method Storage Method
Covered
Covered
Outdoor
Outdoor
Storage
Storage
Storage
Storage
Storage
Storage
Indoor
Indoor
Heavy Fabrications X X
BHSAs X X
Electric Motors X X
Gearboxes X X
Blowers X X
Compressors X X
Pumps X X
HPUs X X
Hydraulic and Pneumatic

X X
Actuators
Instruments X X
Valves X X
Bearings X X
Seals X X
Elastomer and Elastomer

X X
Covered Components
V-Belts X X
Sheaves & Bushings X X
Fiberglass Components X X
Table 3-1: Preferred Storage Methods

3.10 Environmental Precautions

The following table highlights the major environmental precautions that must be addressed in order to maintain proper
condition throughout and after long-term storage. Table 3-2 outlines the specific precautions for equipment that is
stored for up to six months.
Items Environmental Precautions
UV Exposure
Temperature
Cleanliness
Ventilation
Humidity
Metal and Machined Parts
No Yes Yes Yes No
Elastomer parts (Urethane, Polyurethane,

Rubber) Yes No Yes Yes Yes
Fiberglass Parts
Yes No No Yes Yes
Polypropylene/Polyethylene Filter
Components Yes Yes No No Yes
Table 3-2: Environmental Precautions - Storage up to Six Months


37
Chapter 4: Equipment
Overview
4.1 Equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4.1.1 Crusher Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1.2 Spider Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1.3 Concaves and Mantles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1.4 Eccentric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1.5 Mainshaft Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

38 Chapter 4 Equipment Overview
4.1 Equipment Overview

The 1300 × 1800 Top Service Ultra Duty (TSU) Gyratory Crusher has a 450 kW drive motor.
The first number in the size designation is the measurement of the crusher feed opening, which means the crusher has
a 1300 mm (51 in) feed opening. The second number in the size designation is the measurement at the widest diameter
at the bottom of the lower mantle. Therefore, the crusher has a maximum mantle diameter of 1800 mm (71 in).
The crusher feed size must be between approximately 66% to 75% of the radial opening size, which means that the feed
must be approximately 1056 to 1200 mm (42 to 47 in). Feed that is too large increases the possibility of blocking the
crusher openings. Feed that is too small interferes with normal operation.
4.1.1 Crusher Body

The crusher body consists of a cast-steel frame that includes, in its lower part, the driving mechanism. The driving
mechanism is made up of the eccentric (which provides the gyratory movement of the mainshaft and mantle), the gear,
and the countershaft assembly (which includes the pinion and its shaft). The upper portion of the crusher forms a
stationary crushing surface consisting of a cone-shaped chamber made up of the middle and top shell sections. The
chamber is lined with wear-resistant liners called concaves. Inside the gyratory crushing surface is a moving shaft
assembly, called a mainshaft. The mainshaft is lined with a wear resistant liner called a mantle. Relative movement
between these surfaces creates the crushing function.
4.1.2 Spider Assembly

At the top of the crusher is a support for the mainshaft, referred to as the spider assembly. The spider assembly
incorporates a machined journal that positions (restrains laterally) the upper end of the mainshaft.
The spider is a cast-steel structure with the hub in the center and two integrally-cast arms. The ends of the arms are
tapered and machined to fit into pockets in the top shell. Bolts secure the spider to the rim of the top shell, seating the
spider in the tapered pocket.
4.1.3 Concaves and Mantles

The shell and the mainshaft are covered with liners called concaves on the shell, and mantles on the mainshaft.
Typically, when the mantle wears, the mainshaft assembly is removed and replaced with another rebuilt mainshaft
assembly. The mantle on the removed mainshaft can then be replaced, ready for the next change-out. Concave
replacement is carried out in place, with the mainshaft assembly removed. The concave liners are usually replaced as a
complete set. Concave liners may be installed individually or per row, via specialized installation tooling.
The part of the mainshaft assembly in contact with the ore is the mantle. The mantle is retained on the mainshaft by a
heavy head nut. This nut is self-tightening due to the crushing action. The crushing head is supported laterally at the top
in the spider journal.
4.1.4 Eccentric
At the lower end of the crusher, the mainshaft journal passes through the eccentric. This arrangement offsets the lower
end of the shaft with respect to the centerline of the crusher. Therefore, when the eccentric is rotated by the gear train,
the lower end of the mainshaft gyrates (moves back and forth in a small circular path within the crushing chamber),
progressively receding from and approaching the stationary concave liners.
Air is used to pressurize the area above the eccentric. This area is created by an enclosure called the dust seal bonnet.
The core is sealed against the dust seal bonnet by a dust seal ring located at the bottom of the core. This dust seal ring

Chapter 4 Equipment Overview 39
runs against the outer periphery of the dust seal bonnet. By pressurizing the area inside the dust seal bonnet, dust is
prevented from entering the area and contaminating the lubrication system and the eccentric.
A Teflon seal is installed in a groove in the gear cover assembly above the eccentric. The seal rides against the journal
of the mainshaft and contains oil splashed from the eccentric.
4.1.5 Mainshaft Wear Ring

The mainshaft is supported at its lower end by the mainshaft wear ring. The ring is, in turn, supported on a hydraulic
piston and cylinder assembly. Oil is trapped under the piston in the cylinder assembly. By varying the amount of oil, the
mainshaft is raised or lowered to adjust the proximity of the mantle relative to the crushing chamber.
When the crusher is empty, the mainshaft assembly and mantles rotate, driven by the oil shear friction within the
eccentric journal.

40 Chapter 4 Equipment Overview

41
Chapter 5: Installation
5.1 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.1.1 Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1.2 Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2 Interference Fit Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
5.2.1 Heating Components for Installation on a Shaft . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.1.1 Oven Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.1.2 Oil Bath Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.1.3 Induction Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.1.4 Direct Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.2 Cooling Components for Installation in a Bore . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.2.1 Cooling With Dry Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.2.2 Cooling With Liquid Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Receipt of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.4 Foundation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.5 Hydraulic Support and Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.5.1 Hydraulic Support Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.5.2 Hydraulic Cylinder Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.5.3 Hydraulic Cylinder Piston Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.6 Bottom Shell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.6.1 Installing the Bottom Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.6.2 Bottom Shell Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.7 Bottom Shell Liners Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.8 Eccentric Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
5.8.1 Outer Eccentric Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.9 Countershaft Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.10 Dust Bonnet and Gear Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.11 Shells Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
5.11.1 Middle Shell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.11.2 Top Shell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.12 Concave Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
5.12.1 Concave Ring Segment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.12.2 Concave Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.13 Spider and Mainshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

42 Chapter 5 Installation
5.13.1 Spider Pockets, Backing Material Installation . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.13.3 Spider Lubrication Hose and Spider Bushing Installation . . . . . . . . . . . . . . . 58
5.13.4 Spider Shields Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.13.5 Spider and Spider Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.13.6 Spider Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.14 Lip Seals Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
5.14.1 Determining Seal Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.14.2 Installing the Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
5.15 Top Shell Wear and Seal Plates Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.16 Mantle Position Indicator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.17 Lubrication and Hydraulic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.17.1 Lubrication and Hydraulic System Installation and Connection . . . . . . . . . . 61
5.17.2 Lubrication and Hydraulic System Filling and Flushing . . . . . . . . . . . . . . . . . 62
5.17.3 Spider Bushing Lubrication System Installation . . . . . . . . . . . . . . . . . . . . . . . 63
5.18 Drive Motor, Couplings, and Countershaft Extension Assembly Installation . . .63
5.19 Torque Limiting Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.20 Drive Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.21 Countershaft Low Speed Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.22 Dust Seal Blower Connection (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.23 Rock Breaker Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.24 Post-Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
5.25 Final Mechanical Inspection and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . .65
5.26 Arrangements for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Chapter 5 Installation 43
5.1 Installation Overview

This section provides information for the proper assembly and installation of the various components that make up the
1300 × 1800 Top Service Ultra Duty (TSU) Gyratory Crusher. Due to the size and weight of these components, several
pieces will arrive as pre-assembled components; such as the countershaft, eccentric, and hydraulic bottom. FLSmidth
highly recommends reading this manual, including the parts list/bill of material, before assembling the crusher or
performing any maintenance on it.
Specifically, obtain the following information:
1. Weight; refer to Appendix E: “Parts List/Bill of Materials” on page 181
2. Clearances and crusher template; refer to drawing “1000614305: Crusher General Assy” on page 275
3. Unbalanced forces; refer to drawing “1000614318: Foundation Load and Clearance Requirements” on page 277
4. Drawing “1000608222: Lube and Hydraulic Schematic” on page 305
5. Drawing “1000614466: Blower Assy Schematic” on page 314
6. Index for field connections; refer to the original equipment manufacturer (OEM) manual
7. Drawing “1000627226: Control and Instrumentation Diagram” on page 331
5.1.1 Installation Considerations

Normal installation operations include the correction of misfits by straightening, shimming, chipping, cutting, or grinding
for proper fit of elements. Misfits which cannot be corrected by the foregoing means or which require major changes in
equipment configuration are to be reported immediately to FLSmidth for correction of misfits or to approve the most
efficient and economic method of correction to be implemented.
Perform the crusher installation in accordance with the parts list and drawings. The drawings define the physical
arrangements, pertinent dimensions, interconnections, loads, and other characteristics, data, and information needed
for the erection and installation of all supplied components.
While there is a general, overall sequence of installation which will be followed, there are many details for which the
sequence will be determined by conditions existing at the site.
Keep an erection record, compiling all progress made, problems encountered, and measurements obtained during the
different installation phases of the crusher. Complete and transmit the checklists in Appendix B: “Pre-Installation
Inspection” on page 133, Appendix I: “Final Mechanical Inspection” on page 349, and Appendix C: “Commissioning” on
page 139 to the FLSmidth project manager. This information is valuable for comparing conditions during the installation
to the conditions encountered during production; it may help identify the causes of potential future problems for easier
and lasting solutions.
The crusher is shipped in major sub-assemblies; the final assembly must be completed on site. The installation of these
sub-assemblies, and those assembled on site, must be completed in accordance with the appropriate drawings and the
installation data provided in this chapter. Carefully observe match marking of mating components during installation.
Any field modification to components will nullify the warranty unless the modification is authorized by
FLSmidth.

5.1.2 Bolt Torque Values

Unless otherwise indicated on the relevant assembly drawing or drawing “1000730476: Erection and Maintenance
Data” on page 316, tighten all bolts using the recommended tightening torques listed below. Any assembly drawing
torque values supersede the generic values in Table 5-1.
Bolt Sizes (mm) Pitch (mm) Torque (Nm) Torque (ft-lb)
6 1 3.9 2.9
8 1.25 9.4 6.9
10 1.5 19 14
12 1.75 33 24
16 2 86 64
20 2.5 160 120
24 3 270 200
30 3.5 540 400
36 4 950 700
42 4.5 1500 1100
48 5 2300 1700
56 5.5 3700 2700
60 5.5 4600 3400
64 6 5500 4100
72 6 8000 5900
80 6 11000 8300
90 6 16000 12000
100 6 23000 17000
Calculation Basis: 4.6 bolt grade - 34,000 psi
Yield Strength: 240 mpa
Torque to 75% Yield Strength
Dry Steel Coefficient of Friction: 0.179
If using lubrication, reference the lubricant manufacturer’s coefficient of friction chart or information to
determine the required torque value
Table 5-1: Bolt Torque Values
5.2 Interference Fit Components

Installation
The following components have some interference or clearance fits associated with installation.
• Inner eccentric bushing

• Outer eccentric bushing
• Countershaft bearing outer races
• Countershaft bearing inner races
• Eccentric and countershaft housing
• Spider bushing

• Hydraulic support bushings
This section describes recommended methods to expand or contract these components for installation.
5.2.1 Heating Components for Installation on a Shaft
The following heating instructions do not apply to the core.
Numerous methods have been used successfully to expand components for an interference fit on shafts. A few of these
are oven heating, oil bath heating, induction heating, and direct heating.
The preferred methods of heating are oven heating and oil bath heating. These methods provide an even heat
throughout the component, are easy to control, and permit holding the component at an elevated temperature to
ensure complete and consistent expansion.
Use a pin gauge to ensure sufficient expansion of the component. Make the pin gauge with a diameter the size of the
component’s bore, and inspect the bore of the heated component to verify the component has expanded enough to
easily slide onto the shaft.
Manufacturers of anti-friction bearings recommend a maximum temperature of 127°C (260°F) to eliminate

possible dimensional changes of the bearings caused by alterations in the structure of the bearing
material.
5.2.1.1 Oven Heating
Place the component in an oven and heat the oven to 127°C (260°F). Do not allow the component to touch, or be
touched, by the source of heat. Place the component on a support to keep it away from contact with the heat source
and to provide for unrestricted air circulation. Keep the oven at the set temperature for one hour per inch of component
thickness.
Use a pin gauge to test the component expansion before attempting installation.
5.2.1.2 Oil Bath Heating
1. Place the component in a leak-proof container that is approximately 305 mm (12 in) larger in depth and width than
the component being heated. For example, if the part has a side that is 762 mm (30 in) long, the container must be
approximately 1372 mm (54 in) deep and wide.
Note: This ensures that enough oil will fit in the container to heat the part evenly.
2. Elevate the container to allow the placement of a heater beneath the container. Place a screen in the container
several inches off the bottom, and use small support blocks to separate the component from the screen. This keeps
the component from contacting the heat source, and allows the oil to circulate unrestricted.
Use caution when heating components in an oil bath to keep the oil temperature below its ignition
temperature. Do not exceed an oil temperature of 150°C (300°F).
To eliminate the possibility of overheating the oil, the use of an oil and water emulsion is recommended.

3. Use an emulsion of five parts water and one part oil; the emulsion must be perfectly clean. Completely submerse the
component. Slowly heat the emulsion to boiling point, and keep the emulsion at boiling point for one hour.
4. Straight lubricating oil can be used instead of an oil and water emulsion. If using straight oil, slowly heat the oil
to127°C (260°F) and keep the oil temperature at the set heat for one hour.
5. Use a pin gauge to test the component expansion before attempting installation.
5.2.1.3 Induction Heating
Induction heating can be used to expand components for installation on a shaft. This method is rapid and the use of
thermal crayons (such as Tempilsticks) is required to closely monitor the component temperature. Usually, heating the
component being installed to 127°C (260°F) is sufficient for easy installation.
5.2.1.4 Direct Heating
The use of a torch, or torches, to apply heat directly to a component is not encouraged. The direct heating method can
easily overheat a component locally and cause serious and non-repairable damage.
The direct heating method is not to be used to install anti-friction bearings.
If direct heating is used, the use of thermal crayons (such as Tempilsticks) is required to closely monitor the component
temperature. Heat must not be applied directly to critical and sensitive component features such as coupling teeth.
When using an oxy-acetylene torch use an excess acetylene mixture.
Usually, heating the component being installed to 127°C (260°F) is sufficient for easy installation.
5.2.2 Cooling Components for Installation in a Bore

Cooling components with dry ice and frozen nitrogen has been used successfully to contract components for
interference and clearance fits into bores.
Either method may be used; the erection contractor or crusher owner determines preferred method.
Use a calibrated outside micrometer to measure the component diameter to ensure the component has sufficiently
contracted before starting to install the component.
5.2.2.1 Cooling With Dry Ice
Use heavy, well-insulated gloves when handling dry ice. Handling dry ice without adequate protection
could result in severe burns.
Use dry ice only in a well ventilated area. The vapor from dry ice is heavier than air; it can displace
oxygenated air, causing suffocation.

1. Stand the component vertically on timbers.
2. Measure the diameter of the bushing with a calibrated outside micrometer.
3. Pack the interior (bore) completely with dry ice, and cover the bushing with an insulating blanket or a tarpaulin. The
cooling period may take three or more hours.
4. Measure the outside diameter with the outside micrometer after the three hours.
5. When the outside diameter of the component has been reduced the desired amount, install the component.
Use heavy, well-insulated gloves when handling the component. Handling the component during
installation without adequate protection could result in severe burns.
6. If the component begins to jam or tilt in the bore, withdraw it slightly and realign it. Once the installation begins do
not stop; continue with the installation of the component until it is fully seated.
5.2.2.2 Cooling With Liquid Nitrogen
Liquid nitrogen is a cryogenic liquid. Only trained personnel may handle this liquid.
Use heavy, well-insulated gloves when working with liquid nitrogen. Working with liquid nitrogen without
adequate protection could result in severe burns. Never allow any unprotected part of the body to touch
uninsulated pipes, vessels that contain liquid nitrogen, or parts cooled by the liquid nitrogen. The
extremely cold metal will cause flesh to stick fast, and then tear when one attempts to withdraw from it.
Use liquid nitrogen only in a well ventilated area. The vapor from liquid nitrogen is heavier than air; it can
displace oxygenated air, causing suffocation.
1. Fabricate a tank of mild steel of sufficient height and diameter to accommodate the component.
2. Measure the diameter of the bushing with a calibrated outside micrometer.
3. Place the component into a tank.
4. Fill the tank with liquid nitrogen until the lower 1/4 of the component is submerged.
5. Cover the tank and component with an insulating blanket or tarpaulin.
6. Let the component stand in the liquid nitrogen until it has cooled. This may take more than one hour. Measure the
outside diameter with the micrometer after one hour.
7. When the outside diameter of the component has been reduced the desired amount, install the component.
Use heavy, well-insulated gloves when handling the component. Handling the component during
installation without adequate protection could result in severe burns.
8. If the component begins to jam or tilt in the bore, withdraw it slightly and realign it. Once the installation begins do
not stop; continue with the installation of the component until it is fully seated.

5.3 Receipt of Material

Perform a complete inspection as soon as possible following the delivery of the crusher. Look for any damage that might
have occurred during transit. Also verify that all items that are listed on the Bill of Lading, Freight Bill, or Manifest as
being shipped loose are accounted for. Immediately notify the carrier and FLSmidth of any damage or shortages. Refer
to 2.3 “Shipment and Receiving” on page 25.
5.4 Foundation Preparation

Design the foundation to support the weight of the equipment, and to withstand the operation loads.
The foundation must include personnel access to the underside of the crusher for installation and maintenance.
Leave the top of the foundation rough to provide anchorage for grout.
Refer to drawing “1000614305: Crusher General Assy” on page 275 for the necessary foundation bolt locations. The
bolts must be set in sleeves.
Note: Make allowance for shims, grout, the crusher base, and mounting hardware when setting the bolts.
Note: Make provisions for the supplied supporting items such as the drive unit, lubrication and hydraulic
pumping unit, oil cooler, grease lubrication system, and dust seal blower.
5.5 Hydraulic Support and Cylinder

Installation
5.5.1 Hydraulic Support Ring Installation
Install studs in the bottom shell in the locations shown on drawing “13037588: Bottom Shell Assy” on page 288 and as
indicated on Appendix E: “Parts List/Bill of Materials” on page 181. Quantity and arrangement of the studs and pins may
vary.
It is critical that the correct torque level is achieved for these fasteners as they support all the vertical
loads from the mainshaft.

Figure 5-1: Hydraulic Support Ring (Torque to Specified Value)
5.5.2 Hydraulic Cylinder Housing Installation

The hydraulic cylinder can be installed before the bottom shell. If installing the hydraulic cylinder before the shell, leave
adequate room underneath for clearance of the complete assembly.
1. Thoroughly clean the mounting surface of the hydraulic support ring.
2. Add a light coat of oil on the outside diameter of the housing to facilitate the O-ring installation.
3. Place the large O-ring on the outside diameter of the housing. Carefully move it up to the juncture of the outside
diameter and the flange.
Care must be taken not to nick or rip the O-ring.
4. Place a sufficient bead of RTV silicone on the mounting surface close to the inside diameter of the opening in the
cylinder.
5. Use a guide rod or other means to ensure the cylinder is lowered in place so that the guide pin is located in the hole
on the cylinder housing.
6. Lower the hydraulic cylinder housing using lifting eyes and an overhead crane.
7. Once the cylinder housing is in place, tighten the bolts using a star pattern to the torque listed on drawing
“1000531721: Hydraulic Cylinder Assy” on page 292.
5.5.3 Hydraulic Cylinder Piston Installation

The crusher is designed so the piston can be installed from above using a special installation tool. This can be done
prior to bottom shell installation if desired for easy access.
1. Thoroughly clean the inner surface of the hydraulic cylinder housing.
2. Carefully lubricate the surfaces to aid in installation.

3. Inspect the piston center for obstructions. This is the oil port for the crusher bottom lubrication.
4. Place the cleaned and oiled center wearing ring on the piston wear ring.
5. Thread the supplied special tool into the piston through the lubrication port in the center. This will capture the center
wear for safe handling.
6. Carefully lower the piston into the housing from above until the surface of the piston is about 30 mm (1.25 in) below
the piston bushing flange. Care must be taken to properly align it so it does not cock and seize at installation.
5.6 Bottom Shell Installation
1 Machined upper flange

Figure 5-2: Bottom Shell
5.6.1 Installing the Bottom Shell

The crusher is provided in one, two, or three sections as determined by the crusher size and transportation restrictions.
For split bottom shells, assemble the halves according to drawing “13037588: Bottom Shell Assy” on page 288 and then
follow the instructions shown below.
1. Thoroughly clean the top surface of the foundation and the bottom surface of the bottom shell to remove all dirt,
grease, oil, and paint.
2. Verify the compressive strength of the concrete is sufficient to accommodate
• Prior to grouting: The shim bearing stresses on the concrete from the bottom shell only
• After grouting: The flange bearing stresses from the static crusher weight plus the stone load indicated in
drawing “1000614318: Foundation Load and Clearance Requirements” on page 277.
Note: If the concrete compressive strength is not sufficient for the provided installation instructions, contact
FLSmidth.

3. Place steel shims on the foundation at both sides of each foundation bolt. Typically, 50 × 50 × 50 mm (2 × 2 × 2 in)
are appropriate.
4. Verify that the shim stacks are nearly level. Add shims as required. The shim stacks must be high enough to provide
room for level adjustment and grout.
5. Either install a seal at the top of each anchor bolt hole to stop grout from leaking down the anchor hole, wrap the
anchor bolts in tape to allow them to be stretched later when torqued, or both.
6. Lower the bottom shell onto the shims.
7. Place a precision machinist's level on top of the upper flange of the bottom shell section and level the bottom shell
with wedges and shims to 0.048 mm per meter (0.001 in per foot).
8. Hand-tighten the nuts on the foundation bolts evenly in a cross pattern. Do not torque until after the grout has been
poured and cured.
9. Re-verify the level of the bottom shell.
5.6.2 Bottom Shell Grouting

FLSmidth grout recommendations are found in drawing “7.500234: Acceptable Epoxy Grouts for Installation” on
page 320.
Use a non-shrink epoxy grout suitable for use on heavy operating equipment.
The loads indicated on drawing “1000614318: Foundation Load and Clearance Requirements” on page 277 must be
used to verify the grout strength and selection.
1. Apply the grout according to the grout manufacturer’s directions.
2. Once the grout has sufficiently cured, torque the nuts on the foundation bolts evenly in a cross pattern.
Use caution to ensure there is full contact between the grout and the underside of the bottom shell.
5.7 Bottom Shell Liners Installation

After the grout has become sufficiently strong (as indicated in the grout manufacturer’s instructions), install the following
items:
1. Rib liners
2. Outer bottom shell liners
3. Countershaft liners
4. Rib shields
Liners and the components they mount on are composed of castings. As such, they have cast surfaces
that may differ from the design dimension due to casting tolerance. It is normal for some field fit-up,
trimming, and shimming.

Figure 5-3: Bottom Shell Liners
5.8 Eccentric Installation

5.8.1 Outer Eccentric Bushing Installation
Refer to 7.12.9 “Outer Eccentric Bushing Installation” on page 100.
5.8.2 Eccentric Assembly Installation

1. Clean the chamber for the bevel gear, and the mating surface for the gear cover on the bottom shell.
2. Clean and oil the eccentric support bushing. Lower it into place using the three tapped holes and the provided lifting
eyes. Refer to Figure 5-4.

Figure 5-4: Eccentric Assembly
5.9 Countershaft Assembly Installation

The countershaft assembly is shipped completely assembled. Clean and oil it, and remove any upsets on the machined
surfaces.
Refer to 7.15.2 “Countershaft Assembly Installation” on page 108.
5.10 Dust Bonnet and Gear Guard

Installation
1. Clean the bonnet and remove any upsets.
2. Clean the gear cover and remove any upsets.
3. Trial-fit the gear cover on the bottom shell with the hub liner ring in place. Measure the gap for the pressure ring and
shims to determine the proper shim thickness to provide a 0.6 mm (0.025 in) gap.
4. Place the gear cover upside down and install the shims and pressure ring to the measured thickness. Be careful to
torque all bolts to the proper levels to fully compress the shim stock.
5. Trial-fit the gear cover again, and record the gap between the eccentric and the pressure ring.
6. Place the gear cover right side up and clean the mating surface of the dust bonnet.
7. Place the two seal rings in the angular groove that is formed between the gear cover and the bonnet when they are
assembled.
8. Place the dust bonnet on the gear cover while being careful to align the dowel pin and guide hole.
9. Clean the mounting surface on the bottom shell, taking special care that the oil and air ports are clear.
10. Place the hub liner ring on the bottom shell while taking care not to damage it during lifting. Use a bead of RTV
silicone inside the bolt holes and around the air hole to provide a complete seal.
11. Use care to align the air holes to ensure that air flow to the bonnet is possible.

12. Use care to align the dowel pin and the guide hole, as this will ensure the ports are properly aligned.
13. Place an adequate bead of RTV silicone on the mounting surface of the gear cover. This bead must be on the inside
of the tapped holes to provide an oil seal.
14. Measure the outside diameter of the bonnet, and fabricate a cover to fit over it. Make the cover sufficiently sturdy, as
it will be used as a work platform during later assembly, and to prevent dirt and debris from falling into the eccentric.
5.11 Shells Installation

5.11.1 Middle Shell Installation
For split middle shells, assemble the halves according to drawing “13072581: Middle Shell Assy” on page 287, and then
1. Clean the mating flanges of the bottom shell and middle shell, and remove any upsets on the flange contact
surfaces.
2. Coat the mating surfaces of the bottom shell upper flange and the middle shell lower flange with oil.
3. Determine whether special orientation of the shell is required. Refer to drawing “1000660798: Middle Shell
Handling” on page 282.
4. Lower the shell into position, carefully aligning the holes of the bolts with the bottom shell. The fit between the shells
is a taper fit. Lower the middle shell evenly to prevent cocking the shell in the fit. As the middle shell approaches
contact on the taper fit, level the shell.
5. Install the shell bolts and nuts, and tighten the nuts evenly to prevent cocking the middle shell. Tighten the nuts until
the flanges are in contact for 360 degrees.
6. After the flanges are in contact, torque the nuts to the value given on drawing “13072581: Middle Shell Assy” on
page 287.
5.11.2 Top Shell Installation

For split top shells, assemble the halves according to drawing “1000494882: Top Shell Assy” on page 285, and then
1. Clean the mating flanges of the middle shell and top shell, and remove any upsets on the flange contact surfaces.
2. Coat the mating surfaces of the middle shell upper flange and the top shell flange with oil.
3. Lower the shell into position, carefully aligning the holes of the bolts with the middle shell. The fit between the shells
is a taper fit. Lower the top shell evenly to prevent cocking the shell in the fit. As the top shell approaches contact on
the taper fit, level the shell.
4. Install the shell bolts and nuts, and tighten the nuts evenly to prevent cocking the top shell. Tighten the nuts until the
flanges are in contact for 360 degrees.
5. After the flanges are in contact, torque the nuts to the value given on drawing “1000494882: Top Shell Assy” on
page 285.

5.12 Concave Installation

5.12.1 Concave Ring Segment Installation
1. The concave ring segments support the lower row of the concave assembly during installation. The segments,
consisting of four arcs, are placed into a recess of the shell, and are welded to form a continuous ring.
Note: The ends of each segment are chamfered for welding according to drawing “13072581: Middle Shell
Assy” on page 287.
2. Grind the welds so the welding beads do not protrude above the surface of the ring. The rings are made from mild
steel.
5.12.2 Concave Installation
As a result of crushing, the face of manganese concaves can cold work and expand. Space must be
provided between adjacent concaves in all rows and between adjacent rows of concaves for this
expansion. When positioning the concaves, distribute the vertical space between adjacent concaves as
evenly as practical.
1. Power brush the surfaces of the concaves and the mating portion of the shell bore to remove dirt, grease, oil, and
protective coatings. Remove any upsets on these surfaces.
2. Lubricate the shell with light oil.
3. Determine the horizontal space to be left between each row of concaves.
a. Stack one concave from each row up the side of the shell as shown in Figure 5-5. Notice that the concaves for
the upper row have lugs that must fit into the machined groove in the top shell.
b. Measure the space between the top of the lug and the top of the groove in the top shell.
c. Divide the measurement of the space by 2 for the horizontal space.
Figure 5-5: Tapered Slot of Concave
4. Fit the lower row of concaves to the concave support ring. Do not apply any substance between the lower row and
the support ring.

5. Insert pins between the concaves to space them properly and apply the necessary force to set the concaves. Lightly
tap the pins in place to lock the concave in position. The top of the tapered pins may sit above or below the top of
the concaves due to manufacturing practices and tolerances.
Note: Each concave has half of a tapered slot at the top of each vertical side. When the concaves are
installed in the crusher, the tapered slots in two adjacent concaves form one complete slot.
6. Measure the vertical gaps, and verify they are relatively equal. Reposition the concaves as needed.
7. Forcefully drive the pins between the concaves until they do not move. Use caution when driving the tapered pins
between the adjacent concaves to maintain the equalized spacing of the vertical joints.
8. Apply a bond or sealant between the vertical columns of the bottom row.
a. Seal the gaps and joints to prevent leakage during pouring.
b. Mix the two-part compound thoroughly to the bottom of the container. The mixture can set very fast in the
container. As soon as the two parts are mixed, it must be used.
9. Insert a rope shim of the required thickness between the bottom and middle row.
10. Verify that the crusher shell and concave are at 21°C (70°F). Heat the components as needed to achieve the
minimum required temperature.
11. Pour an epoxy backing material between the row of concaves and the crusher shell. Leave the backing
approximately 25 mm (1 in) from the top of the concave.
Note: The epoxy is intended to function as a material to fill the space between the outside surface of the
concaves and the inside surface of the shell. This distributes the crushing forces evenly from the inside of the
concaves through the backing material and to the shell, and prevents the concaves from flexing.
12. Wait for the epoxy backing to cure.
Note: A partial cure will take approximately four hours before the next row can be installed.
13. Cut off the portion of the tapered pins extending above the top of the concaves.
14. Position the concaves in the following two rows following the above instructions. The vertical joints must not be
aligned.
a. The upper concaves must be installed so that the top of the lug in the upper concave contacts the top of the
groove in the top shell as shown in Figure 5-6: “Sealing the Concave Joints” on page 56.
Figure 5-6: Sealing the Concave Joints

5.13 Spider and Mainshaft Installation

5.13.1 Spider Pockets, Backing Material Installation
1. Clean the spider pockets and the mating ends of the spider arms.
2. Place the required size of shims on the machined ledge at the open side of each pocket to keep the spider elevated
slightly, so that subsequently there will be room to draw the spider down and set it firmly in its taper fit.
• Machines that are 54 × 77 or smaller require 20 mm (0.79 in) shims.

• Machines that are 60 × 89 or larger require 25 mm (0.98 in) shims.
4
3
2
1 Spider pocket 2 Backing 3 Area without backing

4 Shim 5 Feeler gauge measuring location
Figure 5-7: Spider Pockets
3. Block the spider bolt holes in the spider and the top shell spider pocket with wooden plugs or a board. Fill the
bottom of the pocket with clay, plaster of Paris, or another sealing mixture until it is flush with the top of the shims.
4. Center the spider in the top shell. Use a feeler gauge between the machined ledge on the top shell and the lip under
the spider at two or more points on each side to determine when the spider is centered.
5. Lubricate the spider taper faces with light oil. This prevents the backing compound from gluing to the spider and
shell, so it can be later removed.
6. Cover any gap through which backing material could escape.
7. Prepare and pour epoxy backing material in accordance with the instructions provided for the concaves and the
manufacturer of the backing material.
8. Mark an end of the spider and its corresponding pocket of the top shell. This will ensure the proper mating of the
spider ends to the correct top shell spider pocket in the future.
9. After the backing material hardens, remove the spider, shims, plugs, and sealing material.
5.13.2 Mainshaft Assembly Installation

1. Clean and oil the mainshaft assembly eccentric journal.
2. Remove the cover over the bonnet.

3. Lubricate the inner eccentric bushing using the crusher lubrication oil. Refer to A.2 “Oil and Grease Selection” on
page 126.
4. Lift the mainshaft assembly, and carefully lower the mainshaft eccentric journal into the bonnet until it enters the
eccentric. Always lift the mainshaft assembly by the device provided on top of the mainshaft only.
5. Carefully align the contact seal to enter the bonnet, and lower the mainshaft assembly further until the seal ring is
just above the bonnet.
6. Carefully align the dust seal ring so that it will clear the bonnet on the outside.
7. Continue to lower the mainshaft assembly until it has made contact with the center wearing ring.
5.13.3 Spider Lubrication Hose and Spider Bushing

Installation
1. Clean the bushing bore and machined bore for the spider hose clamp. Remove any upsets.
2. Install the spider hose, clamp, and gasket into the spider. Make sure that the bolts are tight.
3. Clean the bushing, and remove any upsets in it.
4. Draw the bushing into the spider bore with the bushing retaining bolts until the bushing flange is firmly seated on the
spider. Watch the hole register while drawing the bushing into place. Use a star tightening pattern on the bolts while
drawing the bushing into place.
5. If the bushing is difficult to draw into place with the bolts, cool it with dry ice or liquid nitrogen. Refer to 5.2
“Interference Fit Components Installation” on page 44.
6. After the bushing is firmly in place, install and tighten all fasteners for the bushing in a star pattern to the torque value
listed on the drawing “1000494407: Spider Assy” on page 284.
5.13.4 Spider Shields Installation

1. Apply foam around the casting holes in the top of the spider.
2. Fit the shields onto the spider.
3. Install the bolts, nuts, and washers into the shields and spider arms, and tighten the nuts securely. To ensure that the
nuts do not loosen, they can be tack-welded onto the bolts.
4. Seal the gaps between the edge of the shields and bolt holes in the spider arms.
5. Prepare and pour epoxy backing material between the shields and spider arms in accordance with instructions
provided for the concaves and the manufacturer of the backing material.
5.13.5 Spider and Spider Seal Installation

1. Grease the machined surfaces at the ends of the spider and the interior of the bushing.
2. Place the spider seal onto the bottom of the spider journal of the mainshaft.
3. Lift the spider and place it over the mainshaft, and into the top shell spider pockets. Level the spider during lifting to
minimize the chance of binding in the spider pockets.
4. Carefully lower the spider into position as the journal of the mainshaft enters the bushing and the ends enter the
pockets. Do not let the spider bind in the pockets. Make sure that the spider grease hose enters in the correct hole
in the top shell.
5. Install the spider bolts and the torque nuts.

a. Place the washers and nuts on the bolts.
b. Thread the nuts onto the bolts by hand until they are firmly in place against the washers, and then back the nut
off two turns.
c. Tighten the torsion bolts on each of the nuts with a torque wrench to the torque listed on drawing “1000494407:
Spider Assy” on page 284. Tighten the bolts in a star pattern, and alternate between the spider ends to prevent
cocking the spider in the spider pockets. Inspect and re-tighten the torsion bolts every hour after crusher
operation begins, continuing to monitor the bolts hourly for a minimum of a week.
Note: It can take up to a week of operation for the spider to settle correctly.
5.13.6 Spider Cap Installation

1. Set the cap into place. It does not have any fasteners.
Note: The hole in the top of the cap is used to place a rod through and lift.
2. If the spider lubrication pump is in operation at this time, operate the pump until grease appears between the spider
bushing and the mainshaft spider journal.
5.14 Lip Seals Installation

Lip seals are used for the spider bushing and the countershaft.
5.14.1 Determining Seal Orientation

The orientation of the lip depends on the type of lubricant used.
Install the seal with the lip spring outside of the lubrication chamber if using grease lubrication. This allows the grease to
purge through the seal to keep dirt from contaminating the lubricant.
1 3
2 4
1 Seal plate 2 Grease side 3 Seal retainer plate 4 Spring

Figure 5-8: Lip Seal Orientation for Grease
Note: Some recovery processes are sensitive to lubricants in the ore stream. It may be necessary to reverse
the spider lip seal so the spring is inside the lubricant chamber to minimize the amount of lubricant purging
through the seal.
Install the seal with the lip spring inside the lubrication chamber if using oil lubrication. This prevents oil from purging
through the seal.

1 3
4
1 Seal plate 2 Oil side 3 Seal retainer plate 4 Spring
Figure 5-9: Oil Lubrication
A multiple taconite seal arrangement is favored on the countershaft housing seals. This seal application uses three lip
seals with the lip springs installed as indicated in Figure 5-10.
The arrangement of the three lip seals forms a chamber on the outboard end of the countershaft. Grease is pumped into
this chamber. The outboard lip seal allows grease to purge from the chamber, and the middle seal prevents grease from
entering the oil side of the countershaft housing. The inboard seal prevents oil from entering the grease chamber.
1
2
4
1 Seal plate 2 Seal retainer plate 3 Oil side 4 Grease side
Figure 5-10: Multiple Taconite Seals
5.14.2 Installing the Seal

1. Clean the seal cavity and the shaft.
2. Lubricate the seal cavity, shaft, lip, and outside diameter of the seal.
3. For non-split seals:
a. Orient the seal lip in the correct direction.
4. For split seals:
a. Separate the seal ends sideways, and position the seal with the lip pointing in the correct direction, around the
shaft.

b. Place the split at the top of the seal cavity to eliminate leakage through the split.
c. Lubricate the spring and place it in the lip spring groove with the ends of the spring 90 degrees away from the
split.
5. Press the seal into the cavity with finger pressure. After the seal is partially in the cavity, tap evenly all around the
seal near its outside diameter until it is seated.
5.15 Top Shell Wear and Seal Plates

Installation
1. Place the top shell wearing and seal plates in position on the top shell, and bolt them into place according to the
drawing “1000614471: Top Shell Seal Assy” on page 286.
5.16 Mantle Position Indicator Installation

1. Install the mantle position indicator (MPI) as it is shown on drawing “3.507050: Mantle Position Indicator Assy” on
page 311. The MPI is mounted to the bottom of the hydraulic cylinder assembly.
5.17 Lubrication and Hydraulic

Installation
5.17.1 Lubrication and Hydraulic System Installation and
Connection
1. Locate the lubrication and hydraulic skid, oil cooler(s), and relief valve accumulator assembly according to drawing
“1000608222: Lube and Hydraulic Schematic” on page 305.
2. Support, level, and anchor the lubrication and hydraulic skid, oil cooler(s), and relief valve or accumulator assembly
as directed in the original equipment manufacturer (OEM) manual.
a. Mount the relief valve or accumulator assembly as close as possible to the crusher, and orient it vertically as
indicated in the equipment manufacturer instructions and drawings. Install the lubrication system cooler(s)
according to the vendor instructions.
b. The lubrication air coolers must be installed one floor above the lubrication skid.
3. Install the interconnection piping and components according to drawing “1000608222: Lube and Hydraulic
Schematic” on page 305. Use of pickled and oiled steel pipe; the piping must be pickled before installing it into the
system to avoid damaging components.
During installation, be particularly careful in keeping pipes, fittings, and hoses free of all forms of dirt,
grease, and foreign matter that could enter the system. Inspect each piece carefully, clean it as
necessary, and blow and flush it clear at the time of connection.

4. Charge the accumulator to 2068 kPa (300 psi) with dry nitrogen. Follow the accumulator manufacturer’s instructions
in the original equipment manufacturer (OEM) manual. If supplied, use the optional charging hose and pressure
gauge. Verify that the accumulator relief valve set point is set according to drawing “1000608222: Lube and
Hydraulic Schematic” on page 305.
5. Verify the oil cooler relief valve set points and all other components are set according to drawing “1000608222:
Lube and Hydraulic Schematic” on page 305, and drawing “1000637275: Instrument List” on page 325.
6. Test the lubrication and hydraulic systems; inspect for leaks.
7. Make appropriate electrical connections to the components of the system.
8. Make provisions for heating all lines that will be exposed to temperatures lower than those specified on drawing
“1000608222: Lube and Hydraulic Schematic” on page 305.
DO NOT activate the sump tank heater or pump until the system has been filled with oil.
5.17.2 Lubrication and Hydraulic System Filling and

Flushing
1. Flush the lubrication system, the hydraulic adjustment system, and the lubrication system cooling circuit for at least
16 hours using a flushing oil with a viscosity of 100 SSU at 38°C (100°F). Continue flushing until no visible
contamination remains in the system.
2. Bypass the crusher and the cooler(s) by connecting the crusher supply line to the crusher return line immediately
adjacent to the crusher, and by connecting the cooler(s) inlet line to the cooler(s) outlet line immediately adjacent to
the cooler(s).
3. Bypass the hydraulic system relief valve and the hydraulic system directional control valve(s) by connecting the inlet
line to the outlet line of these components immediately adjacent to these components.
4. Place screens at the reservoir lubrication oil return and at the reservoir hydraulic system relief valve return.
5. Fill the reservoirs with flushing oil through a 25 micron filter.
6. Raise the flushing oil temperature to approximately 60°C (140°F) using the reservoir heaters.
7. Inspect the screens at the reservoirs frequently, and clean them as required.
8. Continue flushing until the screens indicate acceptable cleanliness levels.
9. After flushing the system, drain all the flushing oil, and verify that all drain plugs are installed and all drains are
closed.
10. Pour in the amount of oil required to fill the reservoirs. Close the covers immediately after filling the reservoir to
prevent contaminants from entering the systems.
Note: The same oil is used in both the lubrication system and the hydraulic adjustment system. This
eliminates possible damage to the crusher anti-friction and plane bearings in the event that the hydraulic oil
leaks past the hydraulic piston packing into the lubrication oil.
Do not activate the heater or pump(s) until the reservoir has been filled with oil. Be sure appropriate
valves are fully open before starting the pump.

5.17.3 Spider Bushing Lubrication System Installation

Lubrication to the spider for the spider bushing is delivered from a barrel pump that can be located near the bottom
shell of the crusher as is convenient. Refer to the manufacturer’s instructions in the original equipment manufacturer
(OEM) manual for installation instructions.
Interconnections and additional instructions for the spider bushing lubrication system are shown on drawing
“1000636190: Spider Lubrication GA” on page 306.
1. Make provisions to heat the lubrication container in use, the pump, and the interconnecting line between the pump
and the spider if they will be subjected to ambient temperatures lower than those specified on drawing
“1000636190: Spider Lubrication GA” on page 306.
2. When the pump is operational, operate the pump and watch for the seal to purge where the mainshaft inserts into
the spider.
Note: Lubricant will be only be pumped to the spider when either the crusher is in operation, or the spider
lubrication equipment is being run independently of the crusher for special functions such as filling the lines.
3. Set the controller to deliver the grease flow rate indicated on drawing “1000636190: Spider Lubrication GA” on
page 306. Refer to the manufacturer’s literature in the OEM manual for programming details.
Note: The controller runs the interval at which lubricant is pumped to the bushing, and then monitors the
system performance. The controller can be set to deliver a constant stream of lubricant when the bushing
area is being filled initially or after the bushing area has been cleaned out.
5.18 Drive Motor, Couplings, and

Countershaft Extension Assembly
Installation
NEVER run the crusher in the reverse direction. The mainshaft and head nut threads have been designed
for rotation in the specified direction only.
1. Prepare to install the drive motor by reviewing drawing “1000614318: Foundation Load and Clearance
Requirements” on page 277 and the motor manufacturer’s installation instructions and drawings in the original
equipment manufacturer (OEM) manual.
2. Install the motor on its foundation according to the manufacturer installation instructions in the OEM manual.
3. Locate and inspect the countershaft extension and safety coupling. Clean the assembly and remove any present
upsets.
4. Align the motor output shaft with the crusher countershaft. Maintain the gaps between the coupling hubs specified
on drawing “1000614472: Countershaft Extension Assy” on page 307 and maintain the coupling manufacturer’s
radial and angular alignment requirements as listed in the OEM manual.
5. Set the motor output shaft at its magnetic center. This is very important for maintaining the coupling hub gaps during
operation.
6. Jog the motor to verify rotation. If it is not rotating in the direction specified on drawing “1000614318: Foundation
Load and Clearance Requirements” on page 277, reconnect it.

5.19 Torque Limiting Coupler Installation

1. Install the coupling using the manufacturer's instructions located in the original equipment manufacturer (OEM)
manual.
2. Adjust the coupling using the manufacturer’s instructions and the torque release set point specified on drawing
“1000614472: Countershaft Extension Assy” on page 307.
5.20 Drive Guard Installation

1. Install the drive guard. Refer to drawing “1000614634: Drive Guard Assy” on page 308.
2. Cut the support legs to the proper length.
5.21 Countershaft Low Speed Switch

Installation
1. Install the low speed switch (also known as a “tak-stik”) using the manufacturer's instructions in the OEM manual.
2. Adjust the low speed switch using the manufacturer's instructions and the Functional Specification.
5.22 Dust Seal Blower Connection (if

applicable)
1. Connect the dust seal blower to the crusher using drawing “1000614466: Blower Assy Schematic” on page 314 if a
dust seal blower was supplied.
5.23 Rock Breaker Installation

Hydraulic rock breakers are a common piece of equipment installed and used at a primary gyratory crusher station. This
equipment manipulates oversized and irregular-shaped pieces of ore into the crusher, and it breaks the large pieces of
feed into pieces small enough that they will enter the crushing chamber.
Since the inception and popularization of hydraulic rock breakers, the number of occasions in which spider shields,
spider caps, top shell wearing plates, and the upper rows of concaves have been dislodged from crushers has
increased. Investigations of a number of these occurrences has revealed the primary causes to be an obstructed
operator’s view and an overly-aggressive use of the rock breaker.
The crusher operator must have an unobstructed view of the pick end of the rock breaker whenever hydraulic power is
applied to the pick.
The view of the entire crusher dump pocket and crushing chamber must be available from the rock breaker controls.
The view of the dump hopper and crushing chamber must not be obstructed by seemingly insignificant items such as
lighting, cameras, and junction boxes. Closed circuit (CC) TV is a common way of providing an unobstructed view.

When CC TV is used, the placement of the monitor is as important as the placement of the camera(s). The TV monitor
must be in a position that is visible to the operator whenever the rock breaker is in use.
5.24 Post-Installation Inspection

1. Before the crusher is started, inspect the entire installation thoroughly, including the following points:
a. All temporary installation aids, debris, tools, and other foreign material have been removed from the interior of
the crusher and the surrounding area.
b. The lubrication system and the hydraulic adjustment system have been prepared for operation; their pumps
rotate in the specified direction.
c. The spider bushing lubrication equipment has been flushed, the spider bushing is lubricated, the controller is
programmed, and the spider cap is installed.
d. All components that require lubrication have been properly lubricated.
e. The drive assembly has been properly aligned.
f. The mantle position indicator has been calibrated in accordance with its manufacturer’s instructions
Note: Any additional information required for installation can be found in Appendix H: “Drawing Package” on
page 273.
5.25 Final Mechanical Inspection and

Commissioning
At the completion of installation, an FLSmidth service representative must complete a final field mechanical inspection
and commissioning of the equipment. Unless accepted and signed off by the service representative at the completion,
the warranty will not be in effect.
Previous inspections will not count toward final acceptance unless a sign-off is obtained, in writing, from the service
representative. Also, depending on any previous inspections, this final inspection may be considered an additional paid
service call.
5.26 Arrangements for Service

Complete the Appendix I: “Final Mechanical Inspection” on page 349 for each mechanism furnished before you contact
your FLSmidth representative to arrange for the final field mechanical inspection.
Make arrangements for the field mechanical inspection at least two weeks in advance with your FLSmidth
representative. Refer to 2.7 “FLSmidth Offices” on page 27 for contact information.


67
Chapter 6: Operation
6.2 Start-Up Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
6.2.1 Pre-Operational Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.2.2 Start-Up From Complete Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.2.3 Start-Up From Standby Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.2.4 Start-Up From Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.2.5 Start-Up From Power Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.3 Shutdown Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
6.3.1 Complete Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.3.2 Standby Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.3.3 Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
6.4 Ore Receiving and Crushing Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.5 Adjusting the Crusher Open-Side Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.6 Clearing the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
6.7 Clearing Tramp Material Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
6.8 Rock Breaker Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

68 Chapter 6 Operation
6.1 Post-Commissioning Automation

Change Disclaimer
Crusher automation touch screen options, language settings, and software navigation are finalized during the on-site
assembly and commissioning of the machine. A revision to this manual may be issued once the final screen options are
confirmed and documented for this machine. To inquire about and obtain the latest revision of the manual available for
this machine, contact the FLSmidth Office nearest you (refer to http://www.flsmidth.com/en-US/Contact) and provide this
project number: 9232510974.
6.2 Start-Up Operations

6.2.1 Pre-Operational Inspection
A pre-operational inspection of all major and auxiliary equipment is required whenever any portion of the primary
crusher is started up from a complete shutdown.
The primary crusher requires the following utilities in order to start up and be operated:
• Electrical power
• Air supply for dust seal
In addition to the start-up procedures specified on the following pages, portions of the primary crusher may be started
after one or more equipment items have been down for maintenance. In this case, perform the appropriate pre-
operational inspection for each equipment item worked on.
When the pre-operational inspection is complete, the primary crusher equipment can be restarted according to the
appropriate start-up procedure, depending on the nature of the maintenance that was performed.
Any personnel working in the area near the primary crusher equipment being started must be warned of the impending
start-up. The primary crusher equipment must not be started until the downstream circuits are prepared to accept feed.
Primary crusher service and utility equipment must be running before starting the process equipment.
The general starting sequence is:
1. Primary crusher lubrication systems
2. Primary crusher hydraulic system
3. Downstream equipment
4. Primary crusher drive motor (the spider lubrication system must be interlocked to start and stop as the crusher drive
motor starts and stops)
6.2.2 Start-Up From Complete Shutdown

1. Inspect the primary crushing area visually before start-up from a complete shutdown. This inspection determines
whether activities, such as maintenance tasks, must be performed before the start-up begins. If the primary crusher
was down for maintenance, or any other activities that required the primary crusher discharge pocket to be
completely emptied, fine ore material must be transported and dumped into the primary crusher.
2. Ensure that all electrical disconnects for the primary crusher and all ancillary equipment are closed (switched on).
3. Remove all lockout devices except for equipment undergoing maintenance.

Chapter 6 Operation 69
4. Visually inspect the primary crusher chamber.
a. Ensure there are no loose or missing liners.
b. Inspect the spider assembly for worn, damaged, or missing wear plates.
5. Prior to starting the primary crusher, ensure that the mantle height is correct and within current operating limits. The
mantle must be at least 50 mm (2 in) above the fully down position. This allows room to move the mantle both up
and down.
Note: An interlock and start permissive is requires that the mantle be at least 50 mm (2 in) above the fully
down position in order for the crusher to start.
6. Initiate the start of the primary crusher discharge conveyor.
7. Initiate the start of the primary crusher.
6.2.3 Start-Up From Standby Shutdown

The start-up actions required for a start-up from a standby shutdown are essentially the same as those required for a
start-up from a complete shutdown. However, during a start-up from a standby shutdown, the auxiliary crushing
equipment (lubrication systems and hydraulic system) is operating. The start-up assumes that the primary crusher was
shut down in a controlled manner.
1. Prior to starting the primary crusher, ensure that the mantle height is correct and within current operating limits. The
mantle height must be at least 50 mm (2 in) above the fully down position. This allows room to move the mantle both
up and down.
2. Initiate the start of the primary crusher discharge conveyor.
3. Determine the time elapsed since the last primary crusher start. Excessive restarts in a short period of time can
damage the crusher motor.
4. If the elapsed time is sufficient, initiate the start of the primary crusher.
6.2.4 Start-Up From Emergency Shutdown

The procedures for starting up from an emergency shutdown differ from those after controlled shutdowns. In an
emergency shutdown, the primary crusher shuts down under load, retaining all the ore that was inside when it shut
down. The primary crusher lubrication systems and hydraulic system continue to run unless all or part of the system was
involved in the emergency.
1. If an equipment fault caused the shutdown, visually inspect the equipment that caused the shutdown and ensure
that the cause has been cleared.
2. If a process-upset condition caused the shutdown, proceed with the start-up when the upset condition is corrected.
3. If necessary, restart the hydraulic and lubrication systems.
4. If ore remains in the crusher, it may be necessary to clear the crusher before starting it. Lower the mantle to reduce
the load on the motor during the subsequent start-up. A failure to do so can result in failure of the crusher motor.
5. Proceed with the crusher start-up following the procedures in 6.2.3 “Start-Up From Standby Shutdown” on page 69.
6.2.5 Start-Up From Power Failure

This procedure is based on the assumption that the primary crushing system was operating normally when the power
failure occurred, and that the crusher discharge conveyor was loaded. If the crusher was not loaded when the power
failure occurred, start the primary crushing system as if it were a standby shutdown (refer to 6.2.3 “Start-Up From

Standby Shutdown” on page 69). After the cause of the power failure has been determined and the condition corrected,
the start-up is essentially the same as that from a complete or standby shutdown.
1. Ensure that the cause of the power failure has been corrected and all power systems have been restored.
2. Ensure that there is no resulting damage to equipment.
3. Ensure that all motor disconnects have been reset. Lowering the mantle reduces the load on the motor during the
subsequent start-up. A failure to do so can result in failure of the crusher motor.
4. If the crusher was loaded at the time the power failure occurred, the crusher must be cleared to restart. Once the
crusher has been cleared, start the primary crushing system as if it was a complete shutdown (refer to 6.2.2 “Start-
Up From Complete Shutdown” on page 68).
6.3 Shutdown Operations

There are two primary objectives of the shutdown procedure: to secure equipment so damage is prevented, and to
make start-up efficient and timely.
• After a complete shutdown, inspect the equipment thoroughly and prepare a list of required maintenance and repair
items.
• After an emergency shutdown, visually inspect the equipment before start-up.
All shutdown functions are controlled from the control console in the crusher control room.
6.3.1 Complete Shutdown

A complete shutdown is generally defined as a shutdown that will last for more than 24 hours or a shutdown of such
duration that the crusher lubrication oil and hydraulic systems are shut down. The crusher lubrication system and
hydraulic system shutdowns are included at the end of this procedure.
1. Notify the mine or haul truck dispatch that the crusher is shutting down, and no more ore may be dumped into the
crusher.
2. Allow the crusher to operate until all material in the dump pocket and crusher has been crushed and passed into the
crusher discharge pocket.
3. If any rocks remain that are either bridging the crusher opening or plugging the crusher chamber, break the rocks
with the rock breaker or remove them with the rock hook.
4. Shut down the primary crusher drive motor.
5. If the shutdown will be for an extended period of time (generally two hours or longer), shut down the auxiliary
equipment.
a. Shut down both the hydraulic system pump(s) and the lubrication system pumps. Unless it is necessary to
remove power from the lubrication system and the hydraulic adjustment system, ensure that the system power
supply remains energized and that the electric reservoir heaters continue to operate. This will ensure a timely
start-up later on.
6.3.2 Standby Shutdown

A standby shutdown occurs when the crusher is expected to remain shut down for a short period of time (generally less
than two hours). The lubrication systems and hydraulic system are not typically shut down.
crusher.

2. Allow the crusher to operate until all material in the dump pocket and crusher has been crushed and passed into the
crusher discharge pocket.
3. If any rocks remain that are either bridging the crusher opening or plugging the crusher chamber, break the rocks
with the rock breaker or remove them with the rock hook.
4. Shut down the primary crusher drive motor. Do not shut down the crusher lubrication systems or hydraulic system
unless instructed to do.
6.3.3 Emergency Shutdown

An emergency shutdown can be caused or initiated by a major equipment malfunction, a personnel safety situation, or
protective interlock conditions that are designed to prevent equipment damage.
Note: For example, an emergency shutdown may be initiated by personnel to prevent damage to the crusher
discharge conveyor.
If the crusher discharge conveyor shuts down due to an emergency condition and it will remain down for a prolonged
period of time, shut down the primary crusher manually. However, do not shut down the crusher before it crushes its
present load.
The following procedure is based on the assumption that when the emergency occurred, the primary crushing system
was operating normally. After the cause of the emergency shutdown has been determined and the condition corrected,
the primary crushing system may be started up according to 6.2.4 “Start-Up From Emergency Shutdown” on page 69.
1. Shut down any necessary equipment to isolate the emergency.
2. Determine whether any personnel have been injured as a result of the emergency, and notify emergency personnel
and emergency services.
3. Set any dump pocket signals to the No Dumping mode.
4. Notify the mine or haul truck dispatch that the crusher has shut down and no more ore may be dumped into the
crusher.
5. Determine the cause of the emergency shutdown, and correct the condition. Ensure that all personnel are
accounted for before restarting any equipment.
Power Failure
When a power failure occurs, the primary crusher may be loaded. In the event of a power failure, all process equipment
stops without further action on the part of the operator. In the event of a power outage, all process equipment trips or
shuts down.
6.4 Ore Receiving and Crushing

Inspections
The operator must monitor the operation of the primary crushing system to ensure that the ore is crushed and
stockpiled in a safe and efficient manner.
Perform the following routine inspection while the unit is in operation. Carry out the inspection several times every shift.
1. Ensure that all personnel working in and around the area are using their personal protective equipment, and that
they are obeying all safety rules and regulations.
2. Throughout the primary crushing area, inspect aisles and walkways around the equipment for debris, maintenance
materials, and other tripping or slipping hazards.

3. When trucks are dumping, observe the loads being dumped to identify any foreign material or tramp metal that
could jam or damage the crusher.
The primary crusher motor could start without warning from a remote command. DO NOT reach behind
the motor or remove safety guards during the inspection.
4. Visually inspect the crusher.
a. When the crusher is in operation, listen to the motor operation for unusual sounds and vibrations that could
indicate mechanical problems.
b. Inspect the crusher for signs of leaking motor or countershaft seals.
c. Ensure that all safety guards are in place and are securely fastened.
d. Ensure that all safety and warning signs are clearly visible.
e. Inspect the crusher shell for loose or missing bolts. Loose shell bolts will be more apparent when the crusher is
in operation.
5. Visually inspect the spider lubrication system.
a. Inspect the system components for signs of visible damage.
b. Inspect the grease pump and grease line for signs of leaks and other damage.
c. Ensure sufficient grease is remaining in the barrel. Prepare a new barrel if necessary.
Components of the lubrication system could start without warning from a remote command. DO NOT
reach behind the system or remove safety guards during the inspection.
6. Visually inspect the primary crusher lubrication system.
a. Ensure that all safety guards are in place and are securely fastened.
b. Ensure that all safety and warning signs are clearly visible.
c. When the lubrication system is operating, listen for unusual sounds and vibrations that could indicate mechanical
problems.
d. Inspect the oil reservoir, oil coolers, all supply and return piping, and all valves for signs of oil leaks.
e. Inspect the lubrication oil level.
7. Examine the oil coolers.
a. Remove any accumulated debris from the radiators.
b. Listen to the radiator fans for any abnormal noise.
Components of the hydraulic adjustment system could start without warning from a remote command.
DO NOT reach behind the system or remove safety guards during the inspection.
8. Visually inspect the primary crusher hydraulic adjustment system.
a. Ensure that all safety guards are in place and securely fastened.
b. Ensure that all safety and warning signs are clearly visible.
c. When the system is in operation, listen for unusual sounds and vibrations that could indicate mechanical
problems.

d. Inspect the oil reservoir, accumulator, raise and lower valves, and all supply and return piping for signs of oil
leaks.
e. Inspect the hydraulic adjustment system oil level.
9. Visually inspect the crusher discharged product.
a. Evaluate the size of the material, and determine whether a mantle adjustment is necessary.
6.5 Adjusting the Crusher Open-Side

Setting
The operator must set and adjust the primary crusher open-side setting (OSS) to maintain an opening that produces a
crushed ore product of the required size. The closed-side setting is measured; however, the emphasis is placed on
setting the open-side. The near-vertical orientation of the crushing chamber allows some run of mine ore to pass
through the open side of the crusher without being crushed. The open side, therefore, represents the approximate top
size of the crusher product.
Inspect the OSS:
• Once per shift depending on the ore index properties and the wear long-term trending data
• Whenever there is reason to suspect that the setting has changed
• After major crusher maintenance work that may have affected the setting
The OSS is impossible to measure while the crusher is operating. However, it can be calculated after measuring the
closed-side setting and the throw.
1. Determining the closed-side setting.
a. Verify that the crusher is running empty.
Never run the crusher for more than 15 minutes without a load or tires.
b. Equip the operator who is performing the OSS measurement with a safety harness. Attach the harness securely
to a fixed object.
Note: The OSS measurement requires the operator to stand at the edge of the crusher dump pocket above
the running crusher.
c. Tie a rope or wire to soft, malleable metal (such as lead or foil) ball that is only slightly larger than the open-side
setting.
d. Lower the ball slowly through the crusher. As it passes through the crusher, the ball will compress to a thickness
equal to the CSS.
e. Retrieve the ball, and then measure it. The diameter of the ball is the closed-side setting.
2. Determine the throw.
a. Measure the eccentric journal offset distance. This is the throw.
3. Add the closed-side crusher gap to the throw to determine the open-side setting.
CSS + Throw = OSS
4. Approximate how far the mantle must be raised or lowered to attain the desired crusher setting. An upward mantle
movement of 25 mm (1 in) reduces the OSS approximately 6 to 10 mm (0.25 to 0.4 in), depending on the machine
size and the crushing chamber geometry. Always inspect any adjustment by calculating the new OSS.

Note: Lowering the mantle increases the OSS; raising the mantle decreases the OSS.
5. Use the local hydraulic adjustment system controls or the controls in the control room to raise or lower the mantle
until the needed OSS is attained. The crusher mantle height is displayed in mm or in.
6. If the mantle must be raised:
a. Start the hydraulic adjustment system motor.
b. Allow the motor to run for a couple of minutes to ensure the adjustment system is filled with oil.
c. Depress the Raise button.
d. Watch the mantle height on the mantle height indicator, and release the button when the mantle height has
increased the desired amount.
7. If the mantle must be lowered:
a. Press the Lower button.
Note: If the mantle needs to be lowered, the motor does not have to be started.
b. Watch the mantle height on the mantle height indicator, and release the button when the mantle height has
decreased the desired amount.
8. Measure the crusher CSS again, and calculate the new OSS.
9. If the OSS is not within the target range setting, adjust the crusher mantle height again until achieving the target
OSS.
6.6 Clearing the Crusher

During the course of normal crushing operations, there may be occasion (such as a temporary power failure or an
interlock trip condition) when the crusher stops with ore in the dump pocket and crushing chamber. When this occurs,
follow the below steps to restart the crusher.
1. Depress the hydraulic adjustment system mantle Lower button until the mantle has dropped approximately 50 mm
(1.10 in), as shown on the mantle position indicator.
2. Attempt to start the crusher.
3. If the crusher fails to start, lower the mantle to 0, and then raise the mantle to its highest calibrated point. Repeat the
process of lowering and then raising the mantle three times
Note: This generally helps dislodge the material and loosens it enough that it will fall out on its own.
4. Attempt to start the crusher again.
5. If the crusher still fails to start, repeat the process of lowering the mantle to 0, and then raising it to its highest
calibrated point three times.
6. Attempt to start the crusher again.
7. If attempts to start the crusher fail, the crusher may be overloaded or there may be an uncrushable object such as a
shovel tooth or drill bit which is larger than the open-side setting wedged in the crusher. It may be necessary to clear
all material from the crushing chamber to determine why the crusher cannot be started.
a. Lock out the crusher before manually clearing it.
b. Reach down into the crushing chamber with an excavator to manually clear it. A single large rock or a wedged
piece of tramp metal may be enough to prevent the crusher from starting.
c. Attempt to break up any large rocks with the rock breaker. If this is unsuccessful, remove the rock from the
crushing chamber with the service crane.
d. Remove any wedged tramp metal, referring to 6.7 “Clearing Tramp Material Jam” on page 75.

e. Attempt to start the crusher after clearing material from the crushing chamber. Attempts may be made
repeatedly until enough material is cleared from the chamber for the crusher to start.
Note: Ensure that sufficient time is allowed between attempts to avoid overheating and damaging the
crusher motor.
6.7 Clearing Tramp Material Jam

Clearing tramp metal from a gyratory crusher is a major problem that usually requires many hours of downtime to
resolve. Accordingly, every effort must be made to prevent uncrushable objects from entering the crusher. The normal
remedy is to clear such jams with a thermal cutting torch or an oxyacetylene cutting torch.
Each circumstance must be evaluated to determine the best and safest course of action. Using a thermal cutting torch is
considered a safe method to remove tramp iron. Oxyacetylene cutting torches with extra-long gas-mixing chambers
(also called butts) are also used to cut metals. Cutting and burning metals, such as tramp iron, is generally slower with
oxyacetylene torches.
The thermal cutting torch is a self-contained tool consisting of a combination of special metal alloy wires inside a long
steel pipe. Sections are available in standard lengths that are generally approximately 3 m (10 ft) long. Two ore more
lengths may be coupled together to reach into the crusher cavity.
The torch generates heat to temperatures exceeding 2,475°C (4,487°F) when the alloys combine with pressurized
oxygen forced through the pipe. The intense, concentrated heat generated by the torch melts the tramp iron with such
speed that there is usually no structural damage to the surrounding materials.
crusher.
2. Turn the dump light to the No Dumping position.
3. Erect barricades to block access to the dump pocket area.
4. Post signs on the barricades that say, “No Dumping—Workers in Crusher.”
5. Lock out the primary crusher and the rock breaker according to lockout procedure.
6. Clear the crusher of ore.
Always work from the top of the crusher and never enter the crushing cavity. Preferably, work from a
suspended cage.
7. When operating the torch, either stand in a cage that is lowered into a position above and to the side of the tramp
iron, or stand on a temporarily-constructed steel platform erected for clearing the crusher. A torch pipe can be easily
lengthened and bent to reach the tramp iron without placing a person in the crusher.
Do not attempt to dislodge or loosen the tramp material with a sledgehammer, pry bar, or long pipe.
Serious personal injury could result.
Anyone working near the top of the crusher must wear an approved safety harness with a line securely
fastened to a fixed object.
The tramp metal may be under stress. Relieving the stress by heating may cause the tramp metal to be
forcibly ejected. Place the work platform in a protected position.
8. Connect the torch to the appropriate gas supply, and then set the gas pressure to permit a small flow through the
torch.
9. Ignite the torch, while carefully following the manufacturer’s operating instructions.

When working with torch equipment, use heat-resistant protective clothing and gloves, shaded welding
goggles, hardhat, and face shield.
10. Open the gas-regulating valve completely. The torch will now burn vigorously.
Wear a respirator when using a torch around the crusher. The noxious fumes produced during the cutting
process can be harmful if breathed continuously in concentrated form. Avoid inhaling the fumes. Provide
adequate ventilation.
Do not permit anyone to be in a line of sight of the operation. It is possible for material released from the
crusher to fly out with great force and velocity.
11. After locating the tramp iron, lower the torch into the crushing cavity and proceed to “wash” the tramp metal away.
Start at the top of the tramp iron, and wash the molten metal downward. The molten metal must run out freely; do not
allow it to form a puddle on the tramp iron. Slightly rotate the torch to accelerate the washing operation, and to keep
the tramp iron from re-welding to itself.
Do not touch the tramp iron or put any pressure on it with the torch. Always maintain a short gap when
using the torch on metals. Always keep the torch moving in order to prevent it from being fused to the
metal being burned.
12. During the cutting operation, protect the discharge feeder from sparks, molten slag, and metal by maintaining ore in
the crusher surge hopper or otherwise blocking material from reaching the discharge belt feeder. It is possible for
molten slag to drop out of the crusher onto the belt feeder.
13. When using a torch, work quickly because the burning time is short. For a 3 m (10 ft) thermal cutting torch, the burn
time is only three to five minutes. Never start with a torch less than 3 m (10 ft) long because the torch is consumed
during burning. The pipe portion of a torch is similar to a conventional welding electrode in that the entire length of
pipe is self-consuming. Save the torch remains, and remove them from the crusher.
Do not use a torch when the pipe length is shorter than 1.5 m (5 ft). Either thread or push on an additional
3 m (10 ft) of pipe. The torches are designed for quick attachment of additional lengths.
14. When the tramp metal is removed, inspect the crusher and discharge conveyor for damage.
15. Remove the lockouts and barricades, and then restart the crusher.
6.8 Rock Breaker Use

The function of a rock breaker is to apply the amount of force required to break any oversized rock located anywhere in
the dump hopper and the crushing chamber.
This requirement often requires the use of the rock breaker in close proximity to major crusher components.
Use caution to avoid contacting any part of the crusher with any part of the rock breaker, including the rock breaker arm
or rock breaker pick housing, during the use of the rock breaker.
Improper use of the rock breaker can damage crusher components. Avoid contacting of any part of the
crusher with any part of the rock breaker.

77
Chapter 7: Maintenance
7.1 Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
7.1.1 Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.2 Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
7.2.1 Running Mechanical Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.2.2 Shutdown Mechanical Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.2.3 Major Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.3 Electrical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
7.3.1 Running Electrical Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.3.2 Shutdown Electrical Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.4 Instrument Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
7.5 Manganese Steel Growth and Trimming of Concaves and Mantles . . . . . . . . . . .84
7.6 Stator Insulation Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
7.7 Dust Bonnet Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
7.7.1 Dust Bonnet Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.7.2 Dust Bonnet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.8 Spider Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
7.8.1 Spider Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.8.2 Spider Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.8.3 Spider Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.8.4 Spider Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.9 Mainshaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
7.9.1 Mainshaft Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.9.3 Mainshaft Wearing Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.9.4 Mainshaft Wearing Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.9.5 Mainshaft Sleeve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.9.6 Mainshaft Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.9.7 Mainshaft Split Contact Seal Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.9.8 Mainshaft Split Contact Seal Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.10 Mantle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
7.10.1 Mantle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.10.2 Mantle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.11 Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
7.11.1 Core Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

78 Chapter 7 Maintenance
7.11.2 Core Contact Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

7.11.3 Core Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.12 Eccentric Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
7.12.1 Eccentric Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.12.3 Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.12.4 Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.12.5 Gear Set Backlash Measurement and Adjustments . . . . . . . . . . . . . . . . . . . . 95
7.12.6 Inner Eccentric Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.12.7 Inner Eccentric Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.12.8 Outer Eccentric Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.12.9 Outer Eccentric Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.13 Hydraulic Piston Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.13.1 Hydraulic Piston Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
7.13.2 Hydraulic Piston Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.3 Center Wearing Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.4 Center Wearing Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.5 Piston Wearing Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.6 Piston Wearing Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.7 Hydraulic Piston Bushings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.13.8 Hydraulic Piston Bushings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.14 Hydraulic Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.14.1 Hydraulic Cylinder Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.14.2 Hydraulic Cylinder Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.14.3 Hydraulic Cylinder U-Seal Removal (if applicable) . . . . . . . . . . . . . . . . . . . . 104
7.14.4 Hydraulic Cylinder U-Seal Installation (if applicable) . . . . . . . . . . . . . . . . . . 105
7.14.5 Hydraulic Cylinder V-Ring Packing Removal (if applicable) . . . . . . . . . . . . 105
7.14.6 Hydraulic Cylinder V-Ring Packing Installation (if applicable) . . . . . . . . . . 106
7.15 Countershaft Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.15.1 Countershaft Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.15.2 Countershaft Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.15.3 Outer Race Limit Stop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.15.4 Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.15.5 Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.15.6 Countershaft Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
7.15.7 Countershaft Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
7.16 Concaves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.16.1 Concaves Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
7.16.2 Concaves Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
7.17 Extension Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Chapter 7 Maintenance 79
7.17.1 Extension Shaft Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

7.17.2 Extension Shaft Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

7.1 Maintenance Overview

The purpose of this maintenance section is to provide the maintenance technicians and planners with the information
and procedures required to effectively maintain, troubleshoot, and repair the crusher and its auxiliary systems.
Specifications are provided to prepare for component repair and replacement, as well as maintaining the crusher
assembly while in operation and during shutdown periods.
Preventive maintenance checklists are provided to assist maintenance personnel and crusher operators in maintaining
and operating the crusher and its systems. The checklists specify recommended routine mechanical, lubrication,
electrical, and instrument inspection tasks. The checklists can also be used by operators for cursory running inspections
and to report potential and current problems to maintenance personnel.
Predictive maintenance forecasts and failure mode effect analysis provides proactive and active guidelines for
troubleshooting and maintaining the crusher and its systems. The consistent and correct use of these maintenance tools
is intended to contribute to the optimum efficiency and economic life of the crusher assembly.
The component replacement and repair instructions are provided to serve as a baseline set of procedures for the
replacement or repair of major wear components. The intent of these procedures is to make the replacement or repair
effort consistent among work crews, and provide a basis for continued revision and improvement. The ultimate goal is to
improve the efficiency, productivity, and economic life of the crusher and its auxiliary systems.
7.1.1 Component Replacement

This chapter covers the removal and replacement of major components of the TSU Gyratory Crusher. The purpose of
these procedures is to provide management, supervision, and craftsmen with sufficient information to safely and
effectively plan and accomplish crusher component removal and replacement.
These procedures provide a general, overall sequence for component removal and replacement with details of each
step in the sequence. Existing conditions may require that the sequence must be altered slightly to accommodate the
prevailing conditions.
The details of the steps in the sequence will require little modification. Normal component removal and replacement
include the correction of minor misfits by moderate amounts of straightening, shimming, chipping, cutting, grinding, or
polishing for proper fit and location of components.
Misfits that cannot be corrected by the these means, or which require major changes in equipment configuration, must
be reported immediately to FLSmidth USA, Inc. for correction of the misfit, or to approve the most efficient and
economic method of correction to be implemented. When removing or replacing major components, such as shell
sections or the mainshaft assembly, use the site-created Erection Record Book (not supplied by FLSmidth) as a
reference.
The Erection Record Book is a compilation of the original installation progress, problems encountered and their
solutions, and measurements made. This information is valuable for comparing current and original conditions and for
identifying causes and lasting solutions of potential problems. Prior to starting component removal and replacement, the
appropriate equipment must be locked and tagged out and the required work permits obtained in accordance with
established procedures.
7.2 Mechanical Preventive Maintenance

The crusher is started, stopped, and operated from the control console located in the control room. The crusher
lubrication system, hydraulic adjustment system, and spider lubrication system can also be started from the control
console in the control room.
These units also have local control panels normally used for maintenance purposes. Although the operation of the
crusher is accomplished almost entirely from the control console, maintenance personnel can assist the control room

operator with field observations of ore movement to and through the crusher as well as a variety of observations of the
operation of the unit and its auxiliary systems.
The following preventive maintenance instructions provide guidelines on maintaining the crusher and auxiliary
equipment. For a customized schedule that is based on site-specific established maintenance plans, contact FLSmidth.
7.2.1 Running Mechanical Inspections

Running mechanical inspections are only appropriate for daily preventive maintenance. For all other preventive
maintenance inspections, refer to 7.2.2 “Shutdown Mechanical Inspections” on page 81.
1. Perform the daily mechanical preventive maintenance, as shown in Table D-1: “Daily Mechanical Checklist” on
page 160.
This is a running inspection. DO NOT reach behind or remove safety guards. DO NOT work on running
equipment except for specified running inspections and adjustments.
• Ensure that all necessary personal protective equipment is being used.

• Ensure that all test equipment is correctly calibrated and in good operating condition.
• Immediately notify a supervisor of any problems or potential problems concerning safety or problems that might
cause equipment downtime.
• Document unusual conditions observed, measurements made, and any work required.
2. After completing the inspection and any needed tasks, ensure that all safety guards, labels, and signs are in place
and properly secured.
7.2.2 Shutdown Mechanical Inspections

Shutdown mechanical inspections are necessary for all weekly, monthly, annual, and major preventive maintenance. For
daily preventive maintenance inspections, refer to 7.2.1 “Running Mechanical Inspections” on page 81.
1. Shut down and lock out the crusher drive motor, lubrication system, and hydraulic adjustment system according to
site lockout policies.
Ensure that the equipment is properly locked out.
2. Inspect for the presence of main and control power at each locked out piece of equipment. Control power may be in
the form of media pressure, temperature, or low- or high-voltage electrical power.
3. Perform the appropriate mechanical preventive maintenance, as shown in Table D-2: “Weekly Mechanical Checklist”
on page 162, Table D-3: “Monthly Mechanical Checklist” on page 162, Table D-4: “Annual Mechanical Checklist” on
page 163, and Table D-5: “Major Mechanical Checklist” on page 164.


5. Remove the locks and tags from the appropriate equipment, and release the system or unit for service according to
7.2.3 Major Mechanical Preventive Maintenance

Perform the major mechanical preventive maintenance inspection when monthly inspections indicate that a more
detailed inspection and repairs are needed.
Major maintenance may be required at 6-month to 2-year intervals depending on the nature of the ore crushed and
other site-specific operating conditions.
Refer to 7.2.2 “Shutdown Mechanical Inspections” on page 81 and to Table D-5: “Major Mechanical Checklist” on
page 164 for instructions on performing the major mechanical inspection.
7.3 Electrical Preventive Maintenance

The crusher is started, stopped, and operated from the control console located in the control room. The crusher
lubrication system, hydraulic adjustment system, and spider lubrication system can also be started from the control
console in the control room.
These units also have local control panels normally used for maintenance purposes. Although the operation of the
crusher is accomplished almost entirely from the control console, maintenance personnel can assist the control room
operator with field observations of the crusher, auxiliary systems, and drive motor.
7.3.1 Running Electrical Inspections

Running electrical inspections are only appropriate for weekly preventive maintenance. For all other preventive
electrical inspections, refer to 7.3.2 “Shutdown Electrical Inspections” on page 82.
1. Perform the daily mechanical preventive maintenance, as shown in Table D-1: “Daily Mechanical Checklist” on
page 160.
This is a running inspection. DO NOT reach behind or remove safety guards. DO NOT work on running
equipment except for specified running inspections and adjustments.

7.3.2 Shutdown Electrical Inspections

Shutdown electrical inspections are necessary for all monthly and annual preventive maintenance. For weekly
preventive maintenance inspections, refer to 7.3.1 “Running Electrical Inspections” on page 82.

Ensure that the equipment is properly locked out.
2. Inspect for the presence of main and control power at each locked out piece of equipment. Control power may be in
the form of media pressure, temperature, or low- or high-voltage electrical power.
3. Perform the appropriate electrical preventive maintenance, as shown in Table D-7: “Monthly Electrical Checklist” on
page 167, and Table D-8: “Annual Electrical Checklist” on page 170.

7.4 Instrument Preventive Maintenance

Shutdown inspections are necessary for all instrument preventive maintenance.
Ensure that the instruments are properly locked out.
2. Inspect for the presence of control power at the instrumentation. Control power may be in the form of media
pressure, temperature, or low- or high-voltage electrical power.
3. Perform the instrument preventive maintenance, as shown in Table D-9: “Quarterly Instrument Checklist” on
page 173.


7.5 Manganese Steel Growth and

Trimming of Concaves and Mantles
During crushing of medium hard to hard ores, the surface of manganese steel concaves and mantles grow (peen). This
surface growth flows into the gaps between the concaves and mantles. As the growth continues, the concave gaps
peen shut. The surface growth continues, however, and large forces develop in the concaves and mantles.
This force is transferred to the middle and upper shell sections, and in some cases these forces have been great
enough to cause shell failures.
The growth of manganese steel mantles can cause a large force to be applied to the head nut threads, making the
removal of the head nut difficult and occasionally damaging the threads on the mainshaft.
In mining applications, the abrasive wear rate of the mantle usually exceeds the growth rate of the manganese, and
consequently, the joints between the mantle parts never close before the mantle parts are replaced. Occasionally,
however, the peening occurs at the joint between the upper mantle and the burn out ring.
The peening of the manganese during crushing is a condition that affects only the surface of the concaves and mantle.
Usually, the depth of this growth zone is 12 to 16 mm (0.5 to 0.75 in).
To prevent crusher damage, periodically burn (scarf) away any material that flows into the concave and mantle joints.
Use a 400 to 600 Amp welding machine and carbon-arc rods for scarfing.
Use care during the scarfing not avoid damaging the epoxy in the joints between the concaves.
Where possible, scarf at a 45 degree angle to allow for maximum growth before the next scarfing.
Note: The surface of alloy concaves does not work-harden and grow, so there is no need to scarf the joints of
the alloy concaves.
7.6 Stator Insulation Resistance

Measurement
Use care when measuring insulation resistance. Contact with a high voltage electrical current may be
fatal.
Ground windings before and after testing to drain off all charging voltage. The grounding time must be a
minimum of four times the charging time.
1. Measure the stator insulation resistance at ambient temperature using either a motor-driven or a Rectox megger.
2. Ground the windings. Wait approximately 1 minute.
3. Verify the motor operating voltage.
4. Apply the appropriate voltage (generally 500 to 1,000 VDC) between the entire winding, with all leads connected
together, and the windings still grounded.
Note: The test voltage must never exceed the motor operating voltage.
5. Take resistance readings every 15 seconds for two minutes, and then every minute until you end the test. Record all
readings.
6. End the voltage application. Leave the windings grounded for a minimum of four times the charging time.
7. Compare the readings with previous measurements.

8. The minimum allowable insulation resistance at 40°C (104°F) is one megaohm higher than the rated motor terminal to
terminal voltage.
7.7 Dust Bonnet Replacement

7.7.1 Dust Bonnet Assembly Removal
1. Remove the bolts that attach the dust bonnet assembly to the bottom shell, taking care to not remove the clamp
plate bolts.
2. Attach shackles to the lifting holes provided on the inside of the dust bonnet.
3. Slowly lift the assembly out of the crusher. Do not allow the assembly to swing during lift.
4. Place the dust bonnet assembly on blocks and protect it from the elements.
Figure 7-1: Dust Bonnet Assembly
7.7.2 Dust Bonnet Installation

Refer to 5.10 “Dust Bonnet and Gear Guard Installation” on page 53.
7.8 Spider Replacement

7.8.1 Spider Assembly Removal
1. Lock out the primary crusher and the rock breaker according to lockout procedures.
2. Lock out all the ancillary systems of the crusher according to lockout procedures to create a safe environment.
3. Remove the spider cap.

4. Disconnect the lubrication line to the spider bushing at the outside of the top shell and cap or plug the disconnected
ends.
5. Apply denso tape or another protectant over the spider bolt threads. This protects the threads for when they are
later pulled through the top shell holes.
6. Remove the spider bolt nuts.
7. Place two hydraulic jacks of sufficient size (200 ton) on the jacking pads.
8. Support the total spider assembly weight with a crane. Refer to Appendix E: “Parts List/Bill of Materials” on page 181
for the spider weight.
9. Loosen the spider by jacking through the holes provided in the top shell. Be sure to jack the spider evenly.
10. When the spider is free, lift it off the crusher and set it on blocks.
11. Cover the spider bushing to keep it protected.
Figure 7-2: Spider Assembly
7.8.2 Spider Assembly Installation

Refer to 5.13 “Spider and Mainshaft Installation” on page 57.
7.8.3 Spider Bushing Removal

1. Remove the spider seal retaining plate and seal.
2. Remove the spider bushing bolts.
3. Remove the tapered bushing.
4. Remove the spider bushing bolts and place these bolts in the tapped holes in the spider bushing flange. Tighten
these bolts in a star pattern to jack the bushing out of the tapered spider bore.
5. If the mainshaft and the spider have been removed from the crusher, pull the tapered bushing using steps above.
6. The bushing can also be lifted out with an overhead crane or pressed out with a hydraulic jack after the spider has
been removed from the crusher.
7. Clean the bore of the spider before installing a new bushing.

Figure 7-3: Spider Bushing
7.8.4 Spider Bushing Installation

7.9 Mainshaft Replacement

7.9.1 Mainshaft Assembly Removal
1. Lift the mainshaft assembly out of the crusher and stand it vertically in the mainshaft repair pit or maintenance stand
with the use of a crane.
2. Protect machined surfaces. Unless the eccentric will be removed immediately, cover the dust bonnet inside the
crusher to keep out dirt.
7.9.2 Mainshaft Assembly Installation

7.9.3 Mainshaft Wearing Ring Removal

1. Place eyebolts in one or more of the tapped holes provided in the outer diameter of the mainshaft wearing ring.
2. Remove the cotter pin and nut.
3. Pry the ring loose from the recess with a bar. Be aware that a single dowel to keep the ring from rotating is placed
between the ring and mainshaft.
4. Remove the ring when it is free.

5. Clean the recess in the mainshaft. Inspect the tightness of the stud, which is installed with Loctite.
6. If the stud is loose, remove the stud, and clean and reinstall it with Loctite. The stud can be tightened down with
pliers or a pipe wrench; use care not to damage the threads.
7.9.4 Mainshaft Wearing Ring Installation

1. Clean the recess in the mainshaft. Inspect the tightness of the stud, which is installed with Loctite, and the dowel.
a. If the stud is loose, remove it, clean it, and then reinstall it with Loctite. Tighten the stud with pliers or a pipe
wrench; use caution to avoid damaging the threads.
b. Replace the dowel if it is loose or damaged.

2. Inspect the flatness of the mainshaft wear ring with a straight edge.
3. Install eyebolts in the mainshaft wearing ring tapped holes, which are in the outer diameter of the ring.
4. Lift the mainshaft wearing ring into place into the dowel on the mainshaft. Securely nip fit the ring onto the mainshaft
by lightly tapping the ring into place with a rubber mallet. Tap the wear ring edges with the rubber mallet to inspect
for rocking or abnormal noises.
5. Install the nut and cotter pin.
7.9.5 Mainshaft Sleeve Removal

1. Cut the mainshaft sleeve using a circular saw or a thermal lance.
• If using a circular saw, use a saw that is equipped with a cutting disc and depth gauge.
i. Set the saw blade depth to the thickness of the sleeve (as measured when the sleeve was new) so the saw
blade does not contact the shaft journal.
ii. Make a sample cut, ensuring the saw blade depth allows the blade to just clear the shaft journal when sawing
the mainshaft sleeve. Make a blade depth adjustment if needed.
• If using a thermal lance, cut the mainshaft sleeve using caution to avoid damaging the shaft.
2. Pull the sleeve off the mainshaft.
7.9.6 Mainshaft Sleeve Installation

1. Measure the new mainshaft sleeve thickness, and record the measurement for future use when it later becomes
necessary to remove the sleeve.
2. Place the mainshaft in a vertical position.
3. Remove all upsets and gouges on the shaft sleeve area of the mainshaft. Grind all gouges with a pencil grinder to
remove any fissures and to blend the periphery of the gouge into the mainshaft diameter.
4. Clean the shaft sleeve area of the mainshaft.
5. Measure the diameter of the sleeve with a calibrated inside micrometer.
6. Measure the diameter of the mainshaft with a calibrated outside micrometer.
7. Using the two diameter measurements, determine the amount of expansion required for the sleeve to slide onto the
mainshaft.
8. Heat the shaft sleeve uniformly throughout the full diameter and length to 110°C (230°F) above the ambient
temperature. Use temperature indicating sticks to monitor the temperature; do not exceed 260°C (500°F).

Note: Do not apply heat directly to the threads, or they may become distorted or damaged.
9. Monitor the sleeve expansion during heating by measuring the inside diameter with the micrometer. Stop heating
the sleeve once the expansion is adequate for installation.
10. Place the sleeve onto the mainshaft. If the sleeve begins to jam or tilt on the mainshaft, raise it slightly and realign it.
Once the sleeve begins to lower onto the mainshaft, do not stop. Continue with installation until the sleeve is fully
seated.
11. Secure the sleeve to the mainshaft with the retainer plate and two bolts until it returns to ambient temperature.
Note: This ensures the sleeve does not drift from position before it cools enough to form the interference fit.
12. After the sleeve has cooled, secure it to the mainshaft with the remaining bolts, as shown on drawing “1000500157:
Mainshaft Assy” on page 293.
7.9.7 Mainshaft Split Contact Seal Ring Removal

1. Remove dust bonnet bolts from the gear cover and lift the dust bonnet off the assembly.
Note: The contact seal sits free in the cavity between the gear cover and the dust bonnet.
7.9.8 Mainshaft Split Contact Seal Ring Installation

7.10 Mantle Replacement

7.10.1 Mantle Removal
1. Place the mainshaft assembly in a vertical position in its repair pit or stand. Support the weight of the assembly on
the bottom of the shaft, not on the core.
Note: Supporting the weight of the assembly on bottom of the core could loosen the fit on the shaft.
2. Place blocking and wedges between the eccentric journal of the mainshaft and the repair pit walls to support it
vertically.
3. Remove the dowel pins between the head nut and the mantle, and then remove the head nut.
a. Weld ears onto the nut or using the tapped holes provided, then strike the ears with a ram suspended from a
crane.
b. If the nut does not come loose, cut the filler burn-out ring located between the nut and the mantle. This will
relieve the pressure on the head nut threads so the nut can be removed.
4. Loosen the mantle.
a. Striking the mantle on the bottom with the ram used on the head nut.
b. If necessary, heat the lower portion of the lower mantle.
c. If the above steps are not enough to loosen and remove the mantle, cut it in half with a thermal lance and then
pry the pieces apart with hydraulic jacks.
5. Weld lugs to the mantle, and lift it off the core.

7.10.2 Mantle Installation

1. Place the mainshaft and core assembly in a vertical position in its repair pit or stand. Place blocking and wedges
between the eccentric journal of the mainshaft and the repair pit walls or stand members to support the mantle
vertically.
2. Lightly coat the surface of the core with lubricating oil or a release agent where the lower mantle will rest.
3. Place the lower mantle on the core. Center the mantle on the core by equalizing the distance from the core to the
outside surface of the mantle at the upper end of the mantle.
4. Seal the bottom of the mantle to prevent leakage when the epoxy backing material is poured between the core and
mantles. Leave a 5 to 10 mm (0.2 to 0.4 in) gap at the top of the mantle to later seal.
Note: Clay and plaster of Paris may be used for the sealant.
5. Prepare and pour backing material between the bottom mantle and the core in accordance with the information
provided by the backing material manufacturer. The minimum allowable temperature for epoxy pouring is 21°C
(70°F).
6. Lightly coat the core with lubricating oil or a release agent where the middle mantle will rest, and place the middle
mantle on the core.
7. Place 12.7 mm (0.5 in) thick metal blocks on the top of the lower mantle and place the middle mantle on these
blocks, creating a gap between the middle and lower mantles.
8. Center the middle mantle by equalizing the distance from the core to the outside surface at the top and bottom of
the mantle.
9. Seal the gap (such as with expanding foam) at the joint between the middle and lower mantles, filling the gap back to
the core.
10. Prepare and pour backing material between the middle mantle and the core in accordance with the information
provided by the backing material manufacturer.
Allow the epoxy to harden for 18 to 24 hours before proceeding.
11. Lightly coat the core where the upper mantle will rest with lubricating oil or a release agent and place the upper
mantle on the core. Place 12.7 mm (0.5 in) thick metal blocks on the top of the middle mantle, and place the upper
mantle on these blocks, creating a gap between the upper and middle mantles.

Figure 7-4: Mainshaft Assembly
12. Center the upper mantle by equalizing the distance between the core and the outer surface of the bottom of the
upper mantle. Verify that the top surface of the upper mantle is at a 90-degree angle with the mainshaft, and will
mate squarely with the head nut.
13. If the filler burn-out ring was removed from the head nut, weld a new filler burn-out ring to the nut so it can be
reused. Refer to drawing “1000500157: Mainshaft Assy” on page 293 for placement information.
14. Apply the head nut, and insert four equally-spaced 75 mm (3 in) metal blocks to hold it off of the upper mantle top.
This will keep the upper mantle from floating, and keep it centered and square with the mainshaft.
15. Seal the gap at the joint between the middle and upper mantles, filling the gap back to the core.
16. Place troughs near the top of the upper mantle to direct backing material between the upper mantle and the core.
17. Prepare and pour backing material between the upper mantle and the core in accordance with the information
provided by the backing material manufacturer. Do not pour backing material above the top of the core.
18. Tighten the head nut with a slugging (striking) wrench and sledge hammer until no additional movement is obtained.
19. When the backing material has cured, loosen the head nut and remove the metal blocks and other mantle
positioning devices.
20. Tighten the head nut assembly again by striking the ears previously attached to the head nut with a ram suspended
from a crane.
21. Insert four pins into the head nut, recessed 5 to 10 mm (0.2 to 0.4 in), and then plug weld the pins flush.

7.11 Core Replacement

7.11.1 Core Removal
1. Place the mainshaft and core assembly in a vertical position in its repair pit or stand. Support the weight of the
assembly on the bottom of the mainshaft, not on the core.
2. Place blocking and wedges between the eccentric journal of the mainshaft and the repair pit walls or stand
members to support it vertically.
3. Remove the threaded shaft sleeve and the Teflon split seal rings from the mainshaft.
4. Weld lugs to the core and lift it from the mainshaft. Inspect the fit at the inside bottom of the core.
5. If the core is not loose on the mainshaft, apply heat to the core.
a. Raise the core and the mainshaft until the bottom of the mainshaft, or mainshaft wearing ring, is 10 to 12 mm (0.4
to 0.5 in) from the bottom of the pit or stand.
b. Place blocking and wedges between the eccentric journal of the mainshaft and the pit walls or stand to support
it vertically but not prevent the mainshaft from moving vertically.
c. Support the weight of the mainshaft and the core from the bottom of the core.
d. Heat the outside of the core in the area where the core fits onto the mainshaft until the core expands sufficiently
and the mainshaft “drops out” of the core.
7.11.2 Core Contact Inspection

Perform contact testing on the mainshaft and core any time the core is removed, before re-installing it.
1. Verify that the mainshaft and core are at ambient temperature.
2. Position the mainshaft. Place blocking and wedges between the eccentric journal of the mainshaft and the repair pit
walls or stand members to support it vertically.
3. Apply Prussian Blue to the tapered bore of the core lightly and uniformly. The film thickness must not exceed 0.025
mm (0.001 in).
4. Slowly lower the core over the mainshaft. When the core is approximately 25.4 mm (1 in) above its natural resting
place (the point at which gravity will cause the mating tapers to interface), center the top end of the core over the
mainshaft.
5. Utilizing four wooden wedges that are approximately 90 degrees apart, equalize the clearance between the inside
diameter of the core and the outside diameter of the mainshaft.
Note: The core and mainshaft have machined surfaces that mate as a pair. If the mating surfaces were
machined off-center, the core cannot shift to the necessary centered position. Contact FLSmidth if the
alignment is more than 3 mm (0.12 in) off center.
6. Once the core is centered on the mainshaft, drive the wooden wedges in an additional distance of 30 mm (1.25 in).
This maintains the core centrality when it is being lowered to its natural resting position.
7. Slowly lower the core onto the mainshaft until the core reaches its natural resting place and its entire weight is
suspended by the tapered fit.
8. Slowly lift the core off the mainshaft. Ensure the core does not contact the shaft while it is being lifted. Any unwanted
contact between the core and mainshaft may result in a non-uniform bluing transfer to the mainshaft taper.
9. Verify the length and uniformity of the bluing transferred onto the mainshaft taper at all four locations.

10. Take full length tape transfers from the mainshaft taper at all four locations. If desired, take photographs for
additional information or to transmit the results from remote locations.
11. If the measured contact is less than 80%, immediately report the results to FLSmidth for disposition (refer to http://
www.flsmidth.com/en-US/Contact for the FLSmidth Office nearest you).
7.11.3 Core Installation

1. Place the mainshaft in a vertical position in its repair pit or stand. Place blocking and/or wedges between the
eccentric journal of the mainshaft and the stand members to support it vertically.
Use care to ensure that the shaft is not marred during this procedure.
2. Slide the core over the mainshaft and center it. Allow room for the core to drop a limited distance.
3. Place stands beneath the core to permit the core to slide downward when it is set. The stands must have 5.5 to 6.0
mm (0.220 to 0.25 in) shims placed on them.
4. Set the height of the stands so that with the shims in place they touch the core.
5. Remove the shims to create a gap between the core and the stands.
6. Heat the outside area of the core corresponding to the taper fit with four large torches to rapidly heat the core. The
core will begin to drop to the stands as it expands. When the core has retained enough heat to rest on the stands,
stop heating it.
7. Allow the core to cool to 18°C (65°F) or ambient temperature.
8. Measure the gap between the core and the existing stands to confirm that the core has lowered into the correct
position.
9. Prepare and pour backing material to fill the space between the mainshaft and the core in accordance with the
information provided by the backing material manufacturer.
Allow the core to cool prior to installing the mantle.
7.12 Eccentric Replacement

7.12.1 Eccentric Assembly Removal
1. Record the gear set backlash prior to removing the eccentric assembly. Refer to 7.12.5 “Gear Set Backlash
Measurement and Adjustments” on page 95.
2. Install the eccentric assembly lifting shackles.
3. Lift the eccentric assembly slowly. Do not allow the assembly to swing during lift.
4. Place the eccentric assembly on blocks and protect gear and bearing surfaces from the elements.

Figure 7-5: Eccentric Assembly
7.12.2 Eccentric Assembly Installation

Refer to 5.8 “Eccentric Installation” on page 52.
7.12.3 Gear Removal

1. Place wood blocking around the eccentric to within a few millimeters of the gear teeth.
2. Remove the lower counterweight.
3. Incrementally remove the gear bolts to lower the gear onto the blocking.
4. Lift the eccentric out of the gear and set it on separate blocking.
7.12.4 Gear Installation

1. Place the gear on blocking at a height sufficient to align it with the eccentric assembly mounting surface (threaded
rod method).
2. Lower the eccentric assembly into the center of the gear, and align the pilot of the gear carrier with the gear.
3. Install the bolts, and torque them to the required value. Refer to 5.1.2 “Bolt Torque Values” on page 44.
4. Install the outer counterweight, and torque it to the required value. Refer to 5.1.2 “Bolt Torque Values” on page 44.
5. The eccentric assembly must rest on its own blocking, and not on the gear blocking.

The contact surface of the gear must be in 360 degrees contact with the corresponding horizontal
surface of the gear carrier.
7.12.5 Gear Set Backlash Measurement and Adjustments

1. Using an overhead crane or jacks, move the eccentric assembly toward the countershaft assembly until it contacts
the outer eccentric bushing bore. Tightly secure the eccentric against the bushing bore using shims as shown in
Figure 7-6 “Eccentric At 0 Degrees.”
2. Place a dial indicator on the flag attached to the coupling bolt.
3. Measure the distance from the centerline of the pinion shaft to the point where the dial indicator plunger touches the
flag (6). Record this measurement in Column B of Table 7-1, “Gear Set Backlash Data,” on page 97.
4. Measure the backlash using drawing “13035139: Gear & Pinion Assy, Field Installation” on page 315 for the pinion
pitch radius and the recommended backlash.
5. Use a copy of Table 7-1, “Gear Set Backlash Data,” on page 97 to record measurements and calculate the actual
backlash. Send a copy of this completed data sheet to FLSmidth.
6. Rotate the countershaft counterclockwise until the pinion contacts the gear.
7. Set the dial indicator to 0.
8
7
1
5
4
2 3
1 Shim 2 Inside diameter 3 Outside diameter 4 Thin side
5 Thick side 6 Countershaft center 7 Contact point 8 Inside diameter of outer eccentric bushing
line
Figure 7-6: Eccentric At 0 Degrees
8. Rotate the countershaft clockwise until the pinion again contacts the gear. Record the dial indicator reading in
Column C of Table 7-1, “Gear Set Backlash Data,” on page 97.

1
1 Contact point 2 Thick side 3 Countershaft center line 4 Shim
9. Rotate the eccentric 90 degrees again (the pinion is now in contact with the gear 180 degrees from the first
measurement), and repeat the above steps to fill in the necessary data in Table 7-1, “Gear Set Backlash Data,” on
page 97.
1
4
3
2
1 Thick side 2 Contact point 3 Shim 4 Countershaft center line

10. Rotate the eccentric 90° again (the pinion is now in contact with the gear 270° from the first measurement), and
repeat the above steps to fill in the necessary data in Table 7-1, “Gear Set Backlash Data,” on page 97.
4
1
2
1 Thick side 2 Shim 3 Countershaft center line 4 Contact point
11. Rotate the eccentric 90° again (the gear has now made one complete revolution), and repeat the above steps to fill
in the necessary data in Table 7-1, “Gear Set Backlash Data,” on page 97.
12. Calculate the backlash using Table 7-1, “Gear Set Backlash Data,” on page 97.
a. Divide the pinion pitch radius (Column A) by the distance between the countershaft centerline and the dial
indicator (Column B).
b. Multiply the result of the division by the dial indicator reading (Column C).
13. Record the gear set backlash in Column D.

14. Compare the backlash calculated in Column D with the required backlash from the drawing “1000730476: Erection
and Maintenance Data” on page 316.
15. Adjust the backlash as required by rotating the countershaft in the bottom shell bore. Use the values given on
drawing “13035139: Gear & Pinion Assy, Field Installation” on page 315 for the required backlash.
16. When the correct backlash has been set, complete Table 7-1, “Gear Set Backlash Data,” on page 97 by recording
comments, the date, the initials of the personnel who made the measurements, calculations, backlash adjustments,
the angular position of the countershaft assembly, and the number of gaskets at the countershaft.
A B C D
Pinion Pitch Distance of Dial Dial Backlash Angular Comments Date Initials
Radius (mm) Indicator From Indicator Calculation (A Position
Countershaft Reading ÷ B × C) (mm)
Center Line (mm) (mm)
Number of Gaskets at
Thickness of Gaskets Vertical Position of Gear
countershaft
0.79 mm (0.031 in) At Counterweight
180 Degrees From

1.57 mm (0.062 in)
Counterweight
NOTES:
All measurements are in millimeters.
If this is the initial installation of the , record the measurements and calculations in the Erection Record Book (not supplied by
FLSmidth), and send a copy to FLSmidth.
Table 7-1: Gear Set Backlash Data
17. Match and mark the angular position. Make sure to mark the position of the countershaft rotation before removing
the countershaft.
18. Lightly coat the driving flanks of the pinion teeth with a gear marking compound.
19. Install the countershaft assembly into the bottom shell using the thickness and number of gaskets previously
determined. Match the countershaft assembly to the marks made above.
20. Rotate the pinion through 270 degrees.
21. Remove the countershaft assembly from the bottom shell, and observe the contact pattern on the pinion.
22. Select the contact pattern from Figure 7-10 that represents the contact pattern observed, and report it to FLSmidth.

1 2
3 4 5
6 7 8
9 10 11
12 13 14
15 16
1 Central toe contact 2 Desired contact under full load 3 Toe contact 4 Heel contact
5 Cross contact 6 Low contact 7 High contact 8 Lame contact
9 Wide contact 10 Narrow contact 11 Bride (profile) contact 12 Long (full length) contact
13 Short contact 14 Bridged (lengthwise) contact 15 Bias in 16 Bias out
Figure 7-10: Gear Set Contact Patterns
7.12.6 Inner Eccentric Bushing Removal

1. Remove the bolts, oil deflector, counterweight (if provided), and seal (if provided).
2. Cut a 51 mm (2 in) slot from the bushing using either a circular saw with a depth gauge set at the bushing thickness
(as measured when the bushing was new), or a 127 mm (5 in) grinder with a 1 mm (0.04 in) razor cutting disc.
A grinder with a razor cutting disc does not have a depth gauge. If using the grinder to remove the inner
eccentric bushing, closely monitor the cut for sparks, as sparks indicate the grinder is cutting into the
eccentric.
3. Remove the piece cut from the bushing.
4. Continue cutting and removing bushing pieces until it collapses. Pull out the bushing, using care to avoid damaging
the pinion or the gear.

7.12.7 Inner Eccentric Bushing Installation

1. Measure the new bushing thickness, and record the measurement for future use when it later becomes necessary to
remove the bushing.
2. Place the eccentric with the eccentric bore vertical.
3. Carefully clean the eccentric bore.

Note: The bore must be clean before inserting a new bushing.
4. Measure the bore inside diameter with a calibrated micrometer. Record the measurement, and report it to the
maintenance leader.
A tracking system must be set up to verify that the measurements are normal. Report any abnormal taper
or ovality deviations to FLSmidth.
5. Coat the bore of the eccentric with oil. Do not use grease, as grease will contaminate the lubrication oil filter(s).
6. Examine the arrangement of drilled and tapped holes in the inner eccentric bushing flange and the eccentric. One
hole is spaced unevenly to orient the bushing in the eccentric. Identify and mark this hole in each piece before
proceeding.
7. Insert a threaded guide rod in two holes of the eccentric to ensure alignment of the bushing during installation. The
guide rods must be of sufficient length to permit the rods to guide the bushing its entire length during installation.
8. Carefully clean the inner eccentric bushing, and remove any upsets on the surfaces. To facilitate the installation of
the bushing, cool the bushing with either dry ice or liquid nitrogen to 80°C (176°F) below ambient temperature.
Note: Refer to 5.2 “Interference Fit Components Installation” on page 44 for further instructions and
precautions.
9. Rig the bushing with a crane, and lower the bushing onto the guide rods, taking care of the bushing alignment with
respect to the drilled and tapped holes.
10. Slowly insert the bushing into the cylinder. If the bushing begins to jam or tilt in the cylinder, raise it slightly and
realign it. Once the bushing begins to lower into the cylinder, do not stop. Continue with installation until the
bushing is fully seated.
7.12.8 Outer Eccentric Bushing Removal

1. Remove the bolts.
2. Cut a 51 mm (2 in) slot from the bushing using either a circular saw with a depth gauge set at the bushing thickness
(as measured when the bushing was new), or a 127 mm (5 in) grinder with a 1 mm (0.04 in) razor cutting disc.
A grinder with a razor cutting disc does not have a depth gauge. If using the grinder to remove the inner
eccentric bushing, closely monitor the cut for sparks, as sparks indicate the grinder is cutting into the
eccentric.
3. Remove the piece cut from the bushing.
4. Pull out the bushing, using care to avoid damaging the pinion or the gear.

7.12.9 Outer Eccentric Bushing Installation

1. Measure the new bushing thickness, and record the measurement for future use when it later becomes necessary to
remove the bushing.
2. Carefully clean the top, bore, and lower portion of the bottom shell hub, including the countershaft chamber.
3. Coat these areas with oil, not grease, as grease will contaminate the lubrication filter.
4. Inspect the bore holes in the hub for the outer eccentric bushing lubrication feed, the dust bonnet air feed, and
optional eccentric wearing surface oil feed, making sure that they are clear of foreign material.
5. Examine the arrangement of the drilled and tapped holes in the outer eccentric bushing flange and the crusher shell.
The pattern is not equally spaced. Make sure the holes are properly aligned.
6. Install the resistance temperature detector (RTD) in the top flange of hub.
The top flange RTD must be installed before the outer eccentric bushing.
7. Insert a threaded guide rod in two holes of the bottom shell hub to ensure bushing alignment during installation. The
guide rods must be of sufficient length to permit the rod to guide the bushing its entire length during installation.
Refer to Figure 7-11.
1 Outer eccentric bushing

Figure 7-11: Outer Eccentric Bushing
8. Carefully clean the outer eccentric bushing, and remove any upsets on the surfaces.
9. Cool the bushing with dry ice to 80°C (176°F) below the receiving component temperature. Pack the interior (bore)
completely with dry ice, and cover the bushing with an insulating blanket or a tarpaulin.
10. When the bushing is sufficiently cooled, use a crane to lower the bushing onto the guide rods. Use caution to ensure
bushing alignment with respect to the drilled and tapped holes.
11. Slowly insert the bushing into the bottom shell. If the bushing begins to jam or tilt in the bottom shell, raise it slightly
and realign it. Immediately continue the insertion.

Once the bushing begins to lower into the bottom shell, DO NOT STOP. Continue with the installation of
the bushing until it is fully seated.
12. Immediately bolt the bushing in place and torque the bolts to the values on the drawing “1000496410: Eccentric
Assy” on page 291.
7.13 Hydraulic Piston Replacement

7.13.1 Hydraulic Piston Assembly Removal
1. Verify that all hydraulic lines have been drained. Suction could inhibit the piston assembly removal.
2. Thread the piston removal tool into through the center wearing ring, into the top of the piston until it is fully engaged.
3. Slowly lift the piston out of the crusher with the piston removal tool.
4. Do not allow the assembly to swing during the lift.
5. Place the piston assembly on blocking, and protect the entire assembly from the elements.
Figure 7-12: Hydraulic Piston Assembly

7.13.2 Hydraulic Piston Assembly Installation

Refer to 5.5.3 “Hydraulic Cylinder Piston Installation” on page 49.
7.13.3 Center Wearing Ring Removal

The center wearing ring may be removed from the crusher with the piston assembly as one unit. The following
directions also allow it to be removed separately.
1. Install eye bolts in the threaded center wearing ring holes.
2. Lift out the ring using the eye bolts. The center wearing ring will lift easily; it rests on the piston wearing ring in a
spigot fit.
7.13.4 Center Wearing Ring Installation

1. Install eye bolts in the threaded center wearing ring holes.
2. Lower the ring onto the piston wearing ring. There are no applicable fasteners.
7.13.5 Piston Wearing Ring Removal

The piston wearing ring may be removed from the crusher with the piston assembly as one unit. The following directions
also allow it to be removed separately.
1. Remove the retaining bolts.
2. Lift the piston wearing ring out of the crusher.
7.13.6 Piston Wearing Ring Installation

1. Clean and oil the piston wearing ring before re-installing it.
2. Place the wearing ring into the piston, and center it.
7.13.7 Hydraulic Piston Bushings Removal

1. Remove the bolts holding the seal retainer to the piston.
2. Chip grooves along the outside diameter of the bushing until it springs open or use a lifting bar along the bushing’s
bore. Pull out the bushing.
3. With the bottom bushing removed, invert the piston.
4. Remove the piston wear ring bolts and the wear ring.
5. Chip grooves along the outside diameter of the bushing until it springs open or use a lifting bar against the bottom of
the bushing. Remove the bushing.

7.13.8 Hydraulic Piston Bushings Installation

1. Place the hydraulic piston with the cylinder vertical.
2. Carefully clean the piston cylinder.
3. Coat the bore of the hydraulic piston with oil. Do not use grease, as grease will contaminate the lubrication oil
filter(s).
4. Carefully clean the piston bushing, and remove any upsets on the surfaces.
Note: Refer to 5.2 “Interference Fit Components Installation” on page 44 for further instructions and
precautions.
5. Heat the bushing to 70°C (158°F) above ambient temperature.
6. Rig the bushing with a crane, and lower the bushing onto the guide rods, taking care of the bushing alignment with
respect to the drilled and tapped holes.
7. Slowly insert the bushing into the hydraulic cylinder. If the bushing begins to jam or tilt in the cylinder, raise it slightly
and realign it. Once the bushing begins to lower into the hydraulic cylinder, do not stop. Continue with installation
until the bushing is fully seated.
7.14 Hydraulic Cylinder Replacement

7.14.1 Hydraulic Cylinder Assembly Removal
1. Open the lines at appropriate places to drain the lubricating and hydraulic oils from the bottom of the crusher.
2. Remove the protection around the lubrication and hydraulic lines.
3. Remove all piping and wiring connected to the underside of the crusher.
4. Cap or plug all disconnected hydraulic and lubrication lines.
5. Remove socket head cap screw.
6. Lift and remove the assembly.

Figure 7-13: Hydraulic Cylinder Assembly
7.14.2 Hydraulic Cylinder Assembly Installation

Refer to 5.5 “Hydraulic Support and Cylinder Installation” on page 48.
7.14.3 Hydraulic Cylinder U-Seal Removal (if applicable)

The hydraulic assembly has either a V-ring packing set or a U-seal to seal the fluid beneath the piston. Follow the below
steps to remove the U-seal if applicable.
1. Remove the wiper ring retainer and the wiper ring from the top of the hydraulic cylinder.
2. Invert the piston assembly.
3. Remove the seal retainer. The U-seal will likely stay on the retainer.
4. Remove the U-seal from the retainer by prying it from the retainer. The U-seal is a single, one-piece ring as shown in
Figure 7-14.

2
4
3
1 U-seal 2 Piston 3 Seal retainer 4 Piston bushing
Figure 7-14: U-Seal
7.14.4 Hydraulic Cylinder U-Seal Installation (if

applicable)
1. Remove the hydraulic bottom from the crusher.
2. Place the hydraulic bottom in an inverted position so the large diameter flange is facing down.
3. Thoroughly coat the U-seal with an ISO 220 or ISO 320 lubricating oil.
4. Install the U-seal. The lips of the U-seal may contact both the seal cavity wall and the inside of the piston bushing,
requiring the use of a wood block shaped to fit into the U and a mallet. If necessary, tap the U-seal into the cavity by
working 360 degrees around the U-seal with the shaped wood block and mallet.
Do not use sharp tools such as screwdrivers to install the U-seal. These tools may cut the seal, causing it
to leak.
5. Install the seal retainer plate.
7.14.5 Hydraulic Cylinder V-Ring Packing Removal (if

applicable)
The hydraulic assembly has either a V-ring packing set or a U-seal to seal the fluid beneath the piston. Follow the below
steps to remove the V-ring packing set if applicable.
1. Remove the wiper ring retainer and the wiper ring from the top of the hydraulic cylinder.
2. Invert the piston assembly.

3. Remove the seal retainer.
4. Remove the V-ring packing by prying it from the retainer or from between the piston and piston bushing. Use care in
prying out the seal to avoid scraping or scoring the seals and mating or surrounding surfaces.
The packing set consists of a female adapter, a set of v rings, a male adapter, a spring ring, and a piston seal retaining
plate as shown in Figure 7-15.
5
4
1
3
2
1 Piston 2 Seal retainer 3 Piston bushing 4 Spring ring
5 Male adapter 6 V-rings 7 Female adapter
Figure 7-15: V-Ring Package Set
7.14.6 Hydraulic Cylinder V-Ring Packing Installation (if

applicable)
1. Remove the hydraulic bottom from the crusher.
2. Thoroughly coat all rings and adapters with an ISO 220 or ISO 320 lubricating oil.
3. Install the female adapter ring.
Do not use sharp tools such as screwdrivers to install the V-ring packing. These tools may cut the seal
components, causing the seal to leak.
4. Install the first V-ring packing. The lips of the V-ring may contact both the seal cavity wall and the inside of the piston
bushing, requiring the use of a wood block shaped to fit into the V and a mallet. If necessary, tap the V-ring into the
cavity by working 360 degrees around the V-ring with the shaped wood block and mallet.
The V-rings are furnished cut to size; do not trim them. The slight overlap at the joint is necessary for
satisfactory sealing. If the V-rings do not overlap at the joint, the packing may not seal.
5. Install the remaining V-rings with the joints on successive V-rings 180 degrees from the preceding V-ring joint.

If the joints are not staggered, the packing may not seal.
6. Install the male adapter ring.
7. Install the spring ring.
8. Install the piston seal retainer plate. Before applying any bolting load on the retainer plate, measure the distance
between the piston and the bottom of the piston seal retainer plate with a feeler gauge.
As the space between the piston and the bottom of the piston seal retainer plate is removed during
bolting, the lips of the V-ring packing are forced into contact with the wall of the cavity in the piston and
the wall of the piston bushing. If the lips of the V-rings do not contact the cavity and bushing walls
sufficiently, the packing may not seal. If the lips of the V-rings contact the cavity and bushing walls with
excessive force, free movement of the piston may be prevented.
9. Verify that the space between the piston and the bottom of the piston seal retainer plate is approximately 2.5 mm
(0.10 in).
If the space between the piston and the bottom of the piston seal retainer plate is less than 2 mm (0.080
in), add a gasket of the required thickness between the piston seal retaining plate and the spring ring.
If the space between the piston and the bottom of the piston seal retainer plate is more than 3 mm (0.120
in), remove the required amount of material from the spring ring.
10. Tighten the seal retainer plate bolts.
7.15 Countershaft Assembly Maintenance

7.15.1 Countershaft Assembly Removal
1. Record the gear set backlash prior to removing the countershaft assembly. Refer to 7.12.5 “Gear Set Backlash
Measurement and Adjustments” on page 95.
2. Record the number and thickness of the gaskets between the countershaft housing and the bottom shell.
3. Remove the countershaft extension and safety coupling.
4. Remove the resistance temperature detector (RTD) wiring and lubrication lines. Cover and protect these lines after
removal.
5. Match mark the countershaft position on the housing and the bottom shell.
6. Remove the bolts retaining the countershaft assembly to the bottom shell.
7. Rotate the assembly 90 degrees so the arrow is facing to the right when viewed from the motor. This is the
maximum backlash condition.

Figure 7-16: Countershaft Assembly Removal
For the installation and removal of the countershaft assembly, rotate it 90 degrees clockwise from
standard operating position. This will turn the arrow from pointing up (in the standard operating position)
to pointing right.
8. Turn in the jacking bolts to start moving the countershaft assembly out of the bottom shell. Lift the assembly slightly
with a lifting device and slide the assembly out. Use care in lifting the countershaft assembly during removal to
prevent damage to either the pinion or the gear.
7.15.2 Countershaft Assembly Installation

1. Place the assembly gaskets and the gear set adjustment gaskets onto the countershaft assembly housing. Refer to
drawing “13036470: Countershaft Assy” on page 304 and Appendix E: “Parts List/Bill of Materials” on page 181 for
the number and description of the gaskets required.
2. Insert the curved tooth gear by rotating the countershaft assembly housing clockwise 90 degrees from operating
condition. Once the housing is rotated properly, the arrow will point up, and the pinion will be lower than the gear.
Note: The countershaft housing is designed with an offset between the bore and the outside diameter of the
housing.
3. Insert the countershaft assembly. Once the countershaft assembly is fully inserted, carefully rotate it
counterclockwise 90 degrees until it is in operating position. Refer to drawing “13036470: Countershaft Assy” on
page 304 for the necessary position of the countershaft directional arrow.
Note: A turning lug is provided to aid the rotation of the assembly. Refer to drawing “13036470: Countershaft
Assy” on page 304 and Appendix E: “Parts List/Bill of Materials” on page 181.
4. Bolt the assembly to the bottom shell, and torque the bolts to the values specified on drawing “13036470:
Countershaft Assy” on page 304.

2
1 2
1 4
3 3
6
1 Temporary indicating surface 2 Dial indicator mounted on countershaft 3 Magnetic base

4 Plunger 5 Countershaft 6 Distance of dial indicator from
countershaft centerline
Figure 7-17: Countershaft
5. Measure the gear set backlash. Refer to 7.12.5 “Gear Set Backlash Measurement and Adjustments” on page 95.
7.15.3 Outer Race Limit Stop Installation

For most crushers, the an outer race limit stop is not necessary. For some demanding crusher applications, the pinion is
pulled inward during crushing activities, over-compressing the spring. Only perform the following maintenance task if
required during troubleshooting. Refer to Table 8-1: “General Crusher Troubleshooting Table” on page 116.
1. Design a limit stop to install on the bearing retainer plate. The limit stop must:
• The limit stop must offer absolute minimum clearance on the bearing, allowing a minimum bearing end play of
0.13 mm (0.005 in) when the spring cavity is at its minimum tolerance. Refer to Table 7-2: “Bearing and Spring
Retainer Limit Stop Length” on page 110.
• The limit stop must restrict the outer race movement, thereby limiting the bearing backward movement.

2 4
3
1 Spring cavity minimum tolerance 2 Retainer plate 3 Bearing end play 4 Outer race
5 Wavespring 6 Limit stop 7 Limit stop maximum length
Figure 7-18: Limit Stop Design
2. Install the limit stop on the bearing retainer plate.
Crusher Value Type Design Dimensions
Spring Cavity Length Retainer Limit Stop Length
Maximum 25.80 mm (1.016 in) 24.61 mm (0.969 in)

1600 × 2000 NT
Minimum 24.74 mm (0.974 in) 24.51 mm (0.965 in)

54 × 77 NT

60 × 89 NT

60 × 113 NT

60 × 113 UD

1100 × 1800 TS

1400 × 2100 TSU
Table 7-2: Bearing and Spring Retainer Limit Stop Length

Crusher Value Type Design Dimensions
Spring Cavity Length Retainer Limit Stop Length

1600 × 2400 TSU

1600 × 2900 TS

1600 × 3000 TSU
Table 7-2: Bearing and Spring Retainer Limit Stop Length
7.15.4 Pinion Removal

1. Place the countershaft assembly in a horizontal position and remove the retaining ring from the pinion end of the
countershaft.
2. Pull the pinion from the countershaft with a hydraulic-assisted gear puller.
3. Due to the geometry of the pinion and the countershaft housing, the jaws of the puller may not fit between the pinion
and the countershaft housing. In this case, remove the countershaft and mounted pinion from the countershaft
housing (refer to 7.15.6 “Countershaft Bearings Removal ” on page 112). Then pull the pinion from the countershaft
with the gear puller.
Figure 7-19: Countershaft Assembly
7.15.5 Pinion Installation

1. Heat the pinion to 176°C (350°F) using the heating methods described in 5.2 “Interference Fit Components
Installation” on page 44.
2. Allow the pinion to sit at 176°C (350°F) for one hour. Use a pin gauge to confirm the inside diameter of the pinion has
increased by at least 0.25 mm (0.010 in).
3. Place a cloth lifting strap around the pinion in a choker hitch, and lift and level the pinion.
4. Place the key in position on the countershaft.

The back surface of the pinion must be in 360-degree contact with the corresponding surface of the
spacer or pinion bearing.
5. Slowly install the pinion on the countershaft. If the pinion begins to jam on the countershaft, remove the pinion
slightly and realign it. Once the pinion begins to go on the countershaft, do not stop. Continue with installation until
the pinion is fully in contact with the inboard countershaft bearing inner race.
6. Install the key retainer ring in the groove of the countershaft.
7.15.6 Countershaft Bearings Removal

1. Remove the coupling hub on the outboard end of the assembly by applying heat with rosebud torch tips until it is in
the range of 149° to 260°C (300° to 500°F).
2. Once the coupling hub reaches the desired temperature, pull it off with a puller.
3. Loosen the clamping Allen head screws on the nut, and unscrew the nut.
4. Remove the pinion. Refer to 7.15.4 “Pinion Removal ” on page 111.

5. Remove the spring retainer, trough, and the spring from the pinion end of the countershaft.
6. Remove the locknut and shaft bushing from the drive end.
7. Remove the inner seal retainer, spacer, and any attached seals and retainers not previously removed from the drive
end of the countershaft.
8. Pull the outer races from both ends of the assembly.
9. If the rollers will not slide through the housing, cut the roller cage free and remove the rollers from one end of the
countershaft.
10. Slide the shaft out of the housing.
11. Pull the inner races from the shaft.
12. Clean the shaft, and inspect it for defects.
7.15.7 Countershaft Bearings Installation

1. Heat the bearing’s inner race with its cage and rollers to 127°C (260°F) using the heating methods described in 5.2
“Interference Fit Components Installation” on page 44.
2. Allow the inner race to remain at 127°C (260°F) for an hour. Use a pin gauge to confirm that the inside diameter of the
bearing has increased by at least 0.12 mm (0.005 in).
3. Place a clean cloth lifting strap around the bearing in a choker hitch, and then lift and level the bearing.
Cleanliness when working with bearing components is vital. All heating and handling devices and tools
must be free of burrs, metal splinters, and debris.
4. Slowly place the inboard bearing’s inner race and rollers on the countershaft. If the bearing begins to jam on the
countershaft, remove the bearing slightly and realign it. Once the bearing begins to go on the countershaft, do not
stop. Continue with installation until the bearing is fully in contact with the shoulder on the countershaft.
5. Repeat the procedure with the outboard bearing’s inner race and rollers.
6. Install the inner bearing’s outer race, wave spring, pinion spacer, and bearing plate. Install the pinion as shown in
7.15.5 “Pinion Installation” on page 111.

7. Lay the shaft and assembly horizontally; insert the shaft into housing. Install the remaining components, and torque
the fasteners as indicated on drawing “13036470: Countershaft Assy” on page 304.
8. Install the coupling hub to complete the assembly of the countershaft.
7.16 Concaves Replacement

7.16.1 Concaves Removal
1. Place a cover over the bonnet to prevent dirt from falling into the interior of the crusher.
2. Attach a lifting device to the concave.
• If the concave removal pans are supplied, insert the pans into the crusher and knock the concave into the pan.
• If the concave removal pans are not supplied, starting with the top row of concaves, weld lifting eyes to each
concave.
3. Use a thermal lance or arc air to split one concave with a 50 mm (2 in) wide, full-depth, and full-height cut (or cut
locking pins).
4. Use wedges to remove the free concave.
5. Remove the other concaves in the row by driving wedges between the shell and the remaining concaves.
6. Remove the successive rows of concaves using the same method.
7.16.2 Concaves Installation

1. Clean the backing material from the concaves that are to be reused.
2. Clean the backing material and any other foreign material from the insides of the shell sections.
3. Refer to 5.12 “Concave Installation” on page 55.
7.17 Extension Shaft Maintenance

7.17.1 Extension Shaft Coupling Removal
1. Place the countershaft assembly in a horizontal position and remove the retaining ring from the extension shaft
coupling end of the countershaft.
2. Pull the extension shaft coupling from the countershaft with a hydraulic-assisted gear puller.
3. Due to the geometry of the extension shaft coupling and the countershaft housing, the jaws of the puller may not fit
between the coupling and the countershaft housing. In this case, remove the countershaft and mounted extension
shaft coupling from the countershaft housing (refer to 7.15.6 “Countershaft Bearings Removal ” on page 112). Then
pull the extension shaft coupling from the countershaft with the gear puller.

7.17.2 Extension Shaft Coupling Installation

1. Heat the extension shaft coupling to 176°C (350°F) using the heating methods described in 5.2 “Interference Fit
Components Installation” on page 44.
2. Allow the extension shaft coupling to sit at 176°C (350°F) for one hour. Use a pin gauge to confirm the inside
diameter of the coupling has increased by at least 0.25 mm (0.010 in).
3. Place a cloth lifting strap around the extension shaft coupling in a choker hitch, and lift and level the extension shaft
coupling.
4. Place the key in position on the countershaft.
The back surface of the pinion must be in 360-degree contact with the corresponding surface of the
spacer or pinion bearing.
5. Slowly install the extension shaft coupling on the countershaft. If the coupling begins to jam on the countershaft,
remove the extension shaft coupling slightly and realign it. Once the coupling begins to go on the countershaft, do
not stop. Continue with installation until the extension shaft coupling is fully in contact with the inboard countershaft
bearing inner race.
6. Install the key retainer ring in the groove of the countershaft.

115
Chapter 8: Troubleshooting
8.1 Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.1.1 General Crusher Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
8.1.2 Mainshaft and Eccentric Assembly Troubleshooting Table . . . . . . . . . . . . . 118
8.1.3 Lubrication System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
8.1.4 Drive System Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.1.5 Concave Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.1.6 Liner Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.1.7 Troubleshooting Process Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

116 Chapter 8 Troubleshooting
8.1 Troubleshooting Overview

The purpose of the troubleshooting information is to provide guidelines and assistance to personnel maintaining and
operating the gyratory crusher and its associated equipment and systems. The troubleshooting chapter is a guide that is
used to identify potential causes of functional and physical failure conditions of the crusher and its systems.
The troubleshooting information and direction contained in this manual is a summary of crusher design, maintenance,
operating, and management skill, knowledge, and operating experience. It provides a logical path to take when
something is about to go wrong, or is going wrong, with the operation or physical condition of the crusher.
If problems arise that are not covered in the following troubleshooting tables, or if site maintenance
operations lack the skill or resources required to correct problems as directed in the troubleshooting
tables, contact FLSmidth for field assistance.
8.1.1 General Crusher Troubleshooting Table

Problem Possible Cause Corrective Action
1. Lower the mainshaft assembly to clean

out the chamber.
2. Reset the crusher main drive motor,

a. Packing has occurred in the crushing and restart the crusher.
chamber 3. Verify the OSS is not smaller than is
recommended.
4. Ensure that the discharge area of the

crusher chamber is not choked.
1. Lower the mainshaft assembly to clean

out the chamber.
2. Reset the crusher main drive motor,

and restart the crusher.
3. If the mainshaft assembly cannot be

1. The crusher stops b. Tramp iron is present in the crushing lowered because the obstruction is
chamber wedged too tightly, clear the crusher
chamber manually.
NOTE: Do not attempt to raise the

mainshaft assembly if it cannot be
lowered to prevent damaging the
bushings.
c. Low or no lubrication oil flow (increased

1. Inspect the lubrication oil heaters and
oil viscosity causes the lubrication pump to
thermostats for correct functioning.
overload)
1. Inspect all piping for excessive leaks or

d. Broken pipe
breaks.
1. Disassemble the pump, and determine

e. The lubrication pump shaft has seized the reason for pump jamming (possibility
of material jamming pump).
Table 8-1: General Crusher Troubleshooting Table

Chapter 8 Troubleshooting 117
1. Inspect the lubrication tank screen

basket for excessive numbers of bronze
a. There is an excessive load near the
or lead flakes. An excessive load may
bottom of the crusher
cause pressures to develop between
gear teeth and wearing ring surfaces.
b. The gear mesh is incorrect. 1. Adjust the gear set backlash.
1. Install a limit stop on the bearing

2. The crusher makes unusual noises c. The pinion is being pulled inward, over- retainer plate to restrict the outer race
compressing the wavespring. movement, which limits the bearing
backward movement.
1. Inspect the extension shaft for damage

d. The extension shaft has dry or damaged and replace it as necessary.
couplings.
2. Lubricate the extension shaft couplings.
e. The countershaft bearings are damaged. 1. Replace the countershaft bearings.
1. Install a limit stop on the bearing

a. The pinion is being pulled inward, over- retainer plate to restrict the outer race
3. The wavespring fails prematurely.
compressing the wavespring. movement, which limits the bearing
backward movement.
1. Inspect the mantle for tightness by

a. The mantle is excessively worn shutting off the feed so the crushing
chamber may be observed.
1. As the last part of the feed is being

b. Mantle elongation (caused by localized
crushed, study the joint between the head
hardening) is causing it to weave on the
nut and the mantle. If the mantle is loose,
core
movement will occur at the joint.
4. The mantle breaks
1. Clear the tramp metal.
c. Tramp metal is jammed in the crushing 2. Evaluate means of decreasing tramp
chamber. metal, such as increased screens or
magnets.
1. Install the mantle according to the

d. The mantle was incorrectly installed.
provided instructions.
a. The hydraulic adjustment system oil is 1. Inspect the hydraulic adjustment system
leaking piping for leaks.
1. Replace the valve seals.

b. The relief valve is leaking
2. Replace the valve.
5. The crusher fails to maintain a setting 1. Replace the valve seals.

c. The solenoid or check valves are leaking
2. Replace the valve.
1. Determine the cause of seal failure if it is

d. The hydraulic piston seals are worn or premature, and correct the issue.
defective
2. Install new seals.

1. Replace the broken bolts.

a. The bolts were torqued incorrectly
2. Inspect torque of all bolts.
2. Inspect torque of all bolts.

b. There is movement between the shell 3. If the taper joint is destroyed, weld and
6. The shell bolts are broken sections machine it to build it up.
NOTE: The crusher may be operated

temporarily by shimming the taper joint.
c. Manganese concave growth is present 2. Inspect torque of all bolts.
3. Scarf the joints.
8.1.2 Mainshaft and Eccentric Assembly

Troubleshooting Table
1. Carefully follow the torque

a. The bolts are over-tightened
recommendations for bolts.
1. Remove the spider, chip out the liner,

b. Spider pocket liners in poor condition
1. The spider removal is difficult reset the spider, and re-line the pockets.
c. Spider ends in poor condition 1. Remove any burrs or upsets.
1. Coat the spider pocket with lubricant

d. Lubrication is needed
such as EP-2 grease.
1. Replace the cap.

a. The fit between the spider cap and 2. Inspect the diameter of the fit of the cap
spider is worn on the spider. Rebuild it if it is excessively
2. The spider cap is loose and has a
worn.
tendency to fall off
b. The cap has been elongated by the
continual pounding of material being 1. Replace the cap.
dumped on it
3. The spider assembly is loose in the a. The spider bolts are loose 1. Tighten the spider bolt nuts.
spider pocket b. The spider pocket liner is worn 2. Re-line the spider pockets.
4. The spider shields are worn a. Rock has worn the shields 1. Replace the spider shields.
Table 8-2: Mainshaft and Eccentric Assembly Troubleshooting Table

1. Repair the spider lubrication system.
a. The bushing is not receiving lubrication 2. Inspect the grease supply hose and
lines for leaks, and the pump and
controller for operation.
1. Inspect the mainshaft journal condition.

If possible, polish the surface of the
b. The mainshaft is in poor condition, journal, or weld and machine it to
scoring the bushing recondition it.
5. The spider bushing fails
2. If the journal is fitted with a sleeve,
replace the sleeve.
1. Install a new seal with its lip down.

c. Material is passing the lubrication seal,
scoring the bushing 2. Decrease the level of rock fed to the
crusher.
d. A lack of lubrication causes the bushing 1. Inspect lubrication system for operation
to burn or crack and grease delivery quantity.
1. Dress out the grooves if possible.
2. If a journal is in very poor condition, the

mainshaft may have to be repaired.
6. The mainshaft assembly spider or
a. A foreign object is between the journal Consult FLSmidth for more information.
eccentric journal is in poor condition
and bushing
(grooved) 3. Trace and eliminate the reason for the
foreign object(s) entering the area
between the shaft journal and the
bushing.
1. Polish out the discoloration.

7. The mainshaft assembly spider or 2. Inspect and correct malfunction in the
a. The journal is overheating
eccentric journal is discolored lubrication system, cooling system, or
crushing chamber packing.
1. Replace the broken dust seal ring, using

care during installation.
a. The ring was damaged during installation NOTE: It is possible that the seal was
8. The mainshaft assembly dust seal ring is
allowed to rest on top of the bonnet,
broken
bearing the total weight of the mainshaft.
b. Product ingress occurred due to

1. Slow the product feed.
overfilling the vault.
1. Re-tighten the head nut.
2. Reinstall the pins.

a. The crusher is running counterclockwise
3. Inspect the drive rotation, and ensure it
is as indicated.
b. The mainshaft assembly was incorrectly 1. Re-assemble the mainshaft, following

assembled. the provided installation instructions.
9. The mainshaft assembly head nut 1. Tighten

the head nut with a
comes loose
slugging wrench and sledge
c. The head nut was incorrectly tightened.
hammer until no additional
movement is obtained
1. Install the mantle according to the
d. The mantle comes loose.
provided instructions.
e. Product has damaged the burn filler ring 1. Replace the burn filler ring, carrying out
and relieved the pressure. the correct welding procedure.
10. The mainshaft assembly Teflon- 1. Inspect the mainshaft labyrinth for free
a. The rings are broken
graphite contact oil seal is leaking movement.

1. Replace the gear.

a. The gear has reached the end of its 2. Contact FLSmidth to determine if it is
useful life possible to reverse the direction of the
drive.
11. The eccentric assembly bevel gear is 1. Replace the gear.

worn
2. Inspect the condition of the lubrication
oil to determine if it is dirty.
b. The gear has failed prematurely
3. Inspect the filter operation to determine
if the lubrication oil is bypassed. Change
filter elements as needed.
1. If possible, dress the sharp edges of the

bevel gear chipped teeth.
12. The eccentric assembly bevel gear is a. A foreign object has entered the pinion
2. Replace the bevel gear.
chipped and bevel gear mesh
3. Inspect the pinion condition and
replace it if required.
1. Inspect the lubrication oil system.

a. There is no lubrication
2. Replace the bushings.
1. Inspect for bin level indicator operation

below the crusher.
b. There is rock back-up or packing in the
crushing chamber 2. Regulate the feed to the crusher.
1. Clear the crusher of tramp.

c. The crusher has experienced tramp
events. 3. Evaluate increased screening or
magnets to reduce the probability of
tramp events in the future.
13. The eccentric assembly inner and outer 1. Replace the bushings.
bushings are burnt and cracked d. The crusher OSS is too small.
2. Increase the OSS.
2. Ensure the seal blow motor is

operational.
e. An ingress of contaminants has occurred
between the bushings. 3. Ensure there is positive air pressure at
the dust bonnet.
4. Ensure the inner and outer contact

seals are installed correctly.
2. Replace the oil.

f. Oil contamination has occurred.
3. Refer to the lubrication contamination
troubleshooting steps.
1. Replace the eccentric wearing ring.

a. The wearing ring has reached the end of NOTE: This part affects the height of the
14. The eccentric wearing ring is worn
its useful life eccentric gear, which in turn affects the
gearset backlash.
15. The mainshaft assembly is fluctuating a. There is air in the hydraulic adjustment
1. Bleed the air from the hydraulic system.
(as indicated by the mantle position system
indicator); the head returns to erratic 1. Increase or decrease the accumulator
settings when the crusher is empty b. The accumulator pre-charge is incorrect.
pre-charge as needed

a. Oil temperature is too cold. 1. Contact FLSmidth for directions.

16. The mainshaft rotates faster than 13
b. Damaged mainshaft journal. 1. Contact FLSmidth for directions.
rpm when the crusher is empty
c. Damaged inner eccentric bushing. 1. Contact FLSmidth for directions.
8.1.3 Lubrication System Troubleshooting

1. Inspect the radiators and remove any

debris.
a. The radiator fan motor (if supplied) is not
running 2. Inspect the operation of the fan motors.
3. Inspect the cooling circuit operation.
b. The chiller (if supplied) not functioning 1. Inspect the chiller operation, and
correctly correct any malfunctions.
c. The cooling circulating pump or motor is 1. Inspect the pump and motor operation,
not functioning correctly and correct malfunctions.
d. The automatic motorized valve is not

1. Replace the automatic motorized valve.
1. The lubrication oil is too hot entering the functioning
crusher
1. Remove the cooler and send it to
e. The cooler is plugged.
FLSmidth for cleaning and testing.
1. Deadhead the lubrication system, and

set the relief valve accordingly. Refer to
f. The cooler relief valve is not set correctly.
the OEM manual for the manufacturer
information.
1. Re-set the setpoint according to

drawing “1000656041: Functional
g. The distributed control system (DCS)
Specification” on page 244 or the
setpoints have changed.
commissioning document that is supplied
by the commissioning field agent.
1. Determine the OSS, and correct it as

a. The crusher OSS is too tight
required.
1. Inspect the lubrication tank screen

basket for excessive numbers of bronze
b. Bushing problems are beginning or lead flakes.
2. If the flakes are excessive, disassemble

the crusher and inspect the bushings.
2. The lubrication oil is too hot leaving the
crusher. 1. Inspect the crushing chamber discharge
for blockage.
c. Rock is packed in the crushing chamber 2. Verify that the OSS is not smaller than
is recommended.
3. Determine the feed regulation.
1. Refer to the above troubleshooting

d. The oil entering the crusher is too hot.
step.
Table 8-3: Lubrication System Troubleshooting Table

1. Inspect the crushing chamber discharge

frequently to determine if material is
a. Discharge material is rubbing against the rubbing against the dust seal.
3. There is excessive dirt in the lubrication dust seal, allowing dirt to enter 2. Determine whether the air
oil.
pressurization system is functioning
properly.
b. The dust blower motor is inoperative. 1. Repair or replace the motor.
a. The seal worn; end of life 1. Replace the seal.
4. The countershaft assembly is leaking b. The seal sleeve is worn; end of life 1. Replace the seal and sleeve.
lubrication oil at the seal
c. The countershaft housing drain is 1. Clean the drain hole in the countershaft
plugged housing.
Table 8-3: Lubrication System Troubleshooting Table
8.1.4 Drive System Troubleshooting Table

1. Refill the coupling with the specified

lubricant.
31. The drive system gear-type coupling is a. There is no lubrication
2. Pump grease into the coupling until
noisy
grease begins to slip past seal.
b. The coupling is worn; end of life 1. Replace the coupling(s).
Table 8-4: Drive System Troubleshooting Table
8.1.5 Concave Troubleshooting Table

a. The crusher is jammed by an 1. Keep uncrushable objects out of the

uncrushable object crushing chamber.
1. The concaves are cracking
1. Verify the concave thickness, and
b. The concaves are too thin
replace them as needed.
1. Follow the concave installation

2. The concaves are falling out a. The concaves were installed poorly
instructions
a. The rock being crushed is wearing out 1. Contact FLSmidth about the possibility
3. The concaves are wearing rapidly
the concaves of using alloy concaves.
a. The ring was damaged when removing

4. A concave segment ring is broken 1. Replace or repair the segment ring.
the concaves
Table 8-5: Concave Troubleshooting Table

8.1.6 Liner Troubleshooting Table

1. Repair the liners if possible by welding

a. The abrasion of the crushed rock has on manganese blocks.
1. The bottom shell liners are worn
worn the liners
2. Replace the liners as required.
1. Tighten the bolts or nuts.
2. If necessary, tack weld the nuts onto

2. The bottom shell liner bolts or nuts are the bolts. Tack weld the nuts that are
a. The liners were poorly installed
loose inside the bottom shell as they are not
readily visible during the crusher
operation.
Table 8-6: Liner Troubleshooting Table
8.1.7 Troubleshooting Process Variables

Process Variable Target Range Control Method Impact on Process
Ore larger than the target may bridge the

crusher, resulting in reduced throughput,
All ROM less than
Primary run-of-mine Control drilling and blasting to provide excessive downtime, and potential safety
80% of the crusher
(ROM) feed the desired feed size hazards to personnel and equipment; ore
feed opening
that is finer than optimum can choke the
crusher and reduce throughput
Mine blasting procedures must be

Improper size distribution, too low a truck
Less than rated done correctly for proper feed size
Crusher throughput dumping rate, and an improper crusher
capacity distribution; ensure that the crusher
OSS reduce the crusher’s throughput
open-side setting is correct
Adjust the crusher open-side setting as Too small of a crusher product size may
80% less than
the crusher mantle and concaves wear; result in a low crusher throughput, and
Crushed product size crusher open side
replace the mantle and concaves when high crusher power consumption, and
setting
they are worn concave wear
Ensure that trucks dump at a rate that

Between the high- is fast enough to prevent the low level Too low of a level is an indication of low
Discharge pocket level and low-level alarm from being activated; slow the production rates; too high of a level can
alarms dumping rate when the high level is damage the crusher
reached
Table 8-7: Troubleshooting Process Variables


125
Appendix A: Lubrication
A.1 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
A.2 Oil and Grease Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
A.2.1 Crusher Hydraulic and Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . 126
A.2.2 Spider Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
A.2.3 Mainshaft Dust Seal and Countershaft Triple Seal . . . . . . . . . . . . . . . . . . . . 127
A.2.4 Drive Safety Coupling Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
A.3 Oil and Grease Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
A.4 Oil Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
A.4.1 Manufacturing, Transport, and Storage Debris . . . . . . . . . . . . . . . . . . . . . . . 128
A.4.2 Piping Debris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
A.4.3 Dirt Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
A.4.4 Wear Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
A.4.5 Moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
A.5 Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
A.6 Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
A.6.1 Oil Sampling Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
A.6.2 Oil Sampling Location and Sampling Techniques . . . . . . . . . . . . . . . . . . . . 130
A.6.3 Contamination Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
A.7 Cleaning or Replacement of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

126 Appendix A Lubrication
A.1 Lubrication Schedule

Lubricated Part Lubricant Lubrication Addition Lubrication Full Change
Frequency Frequency
ISO VG 320
Hydraulic System Monthly Yearly and after contamination
(1500 SUU @ 38°C [100°F])
ISO VG 320
Lubrication System Monthly Yearly and after contamination
(1500 SUU @ 38°C [100°F])
Mainshaft Dust Seal NLGI #1 Monthly N/A
Countershaft Triple Seal NLGI #1 Monthly N/A
NLGI #1 in summer Replace barrel when it runs

Spider Lubrication System N/A
NLGI #0 in winter empty
Drive Safety Coupling Bearing Yearly and after each

Refer to OEM manual Every 15 releases
Lubrication release
Drive Safety Coupling Bearing

Refer to OEM manual N/A After each release
Pressurization
Extension Shaft Coupling

Bearing Lubrication
Table A-1: Lubrication Schedule
A.2 Oil and Grease Selection

Multiple lubricant suppliers manufacture oil and grease products suitable for use.
A.2.1 Crusher Hydraulic and Lubrication Systems

For the crusher hydraulic and lubrication systems, use an EP gear reducer oil with a viscosity of 320 Centistokes at 38°C
(100°F) or 1500 SSU at 38°C (100°F).
The following lubricating oils have been used successfully in gyratory crushers:
• Shell Omala
• Mobile Gear
This list of oils is not intended to include all oils which can be used successfully. Rather, it is intended to provide a
reference for use in selecting an oil.
A.2.2 Spider Lubrication System

For the spider lubrication system, use a NLGI #1 grease during summer months, and a NLGI #0 grease during winter
months. Either of the following two types of grease may be used:
• Lithium–sodium grease
• Sodium calcium grease

Appendix A Lubrication 127
A.2.3 Mainshaft Dust Seal and Countershaft Triple Seal

For the mainshaft dust seal and countershaft triple seal, use a NLGI #1 grease. Either of the following two types of grease
may be used:
• Lithium–sodium grease
• Sodium calcium grease
A.2.4 Drive Safety Coupling Bearings

For the drive safety coupling bearings, use Mobil SHC 522 for lubrication and pressurization. Refer to the original
equipment manufacturer (OEM) manual for additional lubrication information.
A.3 Oil and Grease Quantity

Lubricated Part Initial Fill and Full Change Lubricant Addition Quantity Quantity Used in One Year of
Quantity Operation
Hydraulic System 681 L (180 gal) As needed to fill tank 1363 L (360 gal)
Lubrication System 4921 L (1300 gal) As needed to fill tank 9842 L (2600 gal)
Mainshaft Dust Seal Less than 3.8 L (1 gal) Less than 3.8 L (1 gal) 18.9 L (5 gal)
Until grease is purged from

Counterhshaft Triple Seal Less than 3.8 L (1 gal) 7.6 L (2 gal)
seal
Spider Lubrication System 208 L (55 gal) barrel N/A 1 barrel per 528 hours run

349 mL (11.8 oz) As needed to fill tank 710 mL (24 oz)
Lubrication

3 mL (0.1 oz) N/A 30 mL (1 oz)
Pressurization
Table A-2: Oil and Grease Quantity
A.4 Oil Contamination

The contaminants in a crusher circulating oil system can come from several sources, and can be a one-time short term
contamination, or a continual long-term contamination. To differentiate between these events, the one-time
contaminants are designated as debris, and the continual contaminates are designated as wear particles and dirt
particles.
The source of the debris, wear particles, and dirt particles are:
1. The crusher
• Debris generated during manufacturing, transport, and storage

• Wear particles
2. The piping system
• Debris generated during installation
3. The environment
• Dirt particles naturally present in the ore being crushed

Additionally, moisture may be present in the lubricating oil.
A.4.1 Manufacturing, Transport, and Storage Debris

The debris generated during manufacturing usually is steel or bronze chips, cuttings, and grit; casting sand; and casting,
welding, or steel slag. This type of debris is generally found and removed during manufacturing. The debris from
transport and storage occurs as moisture, rust, and dirt. This debris is generally found and removed during erection.
A.4.2 Piping Debris

The debris from the piping system is usually steel chips, pipe sealing tape, pipe sealing compound, pipe cleaning
materials, and gasket materials. This debris is generally found and removed during the flushing of the piping system.
A.4.3 Dirt Particles

Dirt particles from the ore being crushed can enters the crusher oil system through a worn dust seal, faulty dust seal
gasket, damaged or dislodged dust bonnet, or an oil system sump tank open portal or faulty seal.
Small amounts of dirt will be present in the oil continually. However, if a large amount of dirt intrudes into the system,
find and eliminate the cause.
The primary dirt particle in the oil is silica (Si). Trace amounts of (Ni), silver (Ag), aluminum (Al), and sodium (Na) can also
appear as secondary particles. Monitoring these particles is generally not productive. Therefore, it is not recommended.
A.4.4 Wear Particles

Lubricating oil passes through the crusher and over wear surfaces, which are worn during normal operations. Because
of this interaction, wear particles are added to the lubricating oil. The primary wear particles in the oil are iron (Fe),
copper (Cu), and lead (Pb). The secondary wear particles are tin (Sn), chromium (Cr), and nickel (Ni).
Small amounts of the primary and secondary wear particles will be present in the oil on a continual basis. An increase in
the number of primary wear particles in the oil is an indication of an abnormal condition requiring attention. However,
monitoring the secondary wear particles is generally not productive; therefore, it is not recommended.
The contaminant levels listed in Table A-3, “Normal Contaminant and Alert Levels,” on page 129 are the result of actual
operating experience at a number of mines throughout the world. Variations were evident in the normal levels
experienced and the alert levels used. The table represents a regime intended to provide the maximum possible
protection for the crusher and the mining operation by using an aggressive preventive maintenance program. Make
adjustments to the listed alert levels to suit actual operating conditions experienced and the maintenance philosophy
used.

A.4.5 Moisture
Moisture usually enters the oil system through the dust seal, dust seal bonnet, or the oil system sump tank access
opening during a clean-up of the crusher or crusher area. Find and eliminate the route for water intrusion into the oil
system.
Element Class Where Element is Used or Present High Normal (ppm) Alert (ppm)
Iron (Fe) Mainshaft, eccentric, gear set, countershaft

bearings, dust bonnet, bottom plate, center 100 150
wearing ring, piston
Copper (Cu) Inner eccentric bushing, outer eccentric 35 50
Lead (Pb) bushing, eccentric wearing ring, piston 15 50

Wear
bushing, mainshaft wearing ring, piston
Tin (Sn) (1) wearing ring Not specified Not specified
Chromium (Cr) (1) Gear set, countershaft bearings Not specified Not specified
Nickel (Ni) (1) Gear set, countershaft bearings Not specified Not specified
Silica (Si) 50 75
Nickel (Ni) (1)
Silver (Ag) (1) Dirt Ore

Not specified Not specified
Aluminum (Al) (1)
Sodium (Na) (1)
Moisture in oil 0.2% 0.4%
(1) Amount present in components and ore is too small to be used as a contamination indicator.
Table A-3: Normal Contaminant and Alert Levels
A.5 Oil Viscosity

In addition to the oil contamination level, a change in the oil viscosity is also a reason to change the crusher oil.
Experience has indicated the oil must be replaced if the oil viscosity changes by +/- 5%.
A.6 Oil Sampling

Use an oil sampling and contaminant monitoring program to provide the information needed to maximize the crusher
availability.
A.6.1 Oil Sampling Frequency

Take an oil sample immediately after the commissioning is complete to confirm the removal of any manufacturing and
piping debris.

Table A-4 gives the recommended oil sampling frequency for various operating scenarios.
Sample Number Event Time (Operating Hours) (1)
1st Initial Operation (2) 16 hours after commissioning
2nd 80 hours after previous sample
3rd 160 hours after previous sample
4th 320 hours after previous sample
Continuing Operation Every 640 hours
1st Major Overhaul 16 hours after start-up
2nd 80 hours after previous sample
3rd 320 hours after previous sample
Within hours (To determine possible

Crusher Stall
damage)
(1) As the crusher is used and operating and maintenance experience is gained, an increase in the
period between oil samples may be possible. Conversely, decrease the period between oil sampling
if a reason to suspect crusher damage becomes apparent.
(2) The 2nd through 5th samples establish a wear particle count and a dirt particle count baseline for
future reference.
Table A-4: Oil Sampling Frequency
A.6.2 Oil Sampling Location and Sampling Techniques

Take the oil sample from the stream of oil returning from the crusher to ensure a representative sample. Use ASTM- or
ISO-accepted oil sampling techniques.
A.6.3 Contamination Trends

Table A-5 lists the significance of contamination trends.
Element Comments
Iron A rapid increase in the quantity of iron present in the lubricating oil is usually
an indication of accelerated wear or extreme damage to the eccentric.
A slow, steady increase in the iron present in the lubricating oil is an indication
of normal wear.
Copper or Lead A rapid increase in the quantity of copper or lead present in the lubricating oil
is usually an indication of accelerated wear or extreme damage to the inner
and outer eccentric bushing.
A slow, steady increase in the copper or lead present in the lubricating oil is
an indication of normal wear.
Silica A rapid increase in the quantity of silica present in the lubricating oil is usually
an indication of accelerated wear or extreme damage to the mainshaft dust
seal or the dust bonnet, or a failure of the dust seal air blower.
A slow, steady increase in the silica present in the lubricating oil is an

indication of normal wear.
Table A-5: Significant Contamination Trends

Element Comments
Moisture Moisture may be present in the lubricating oil in minute amounts as a result of
condensation or may be introduced into the lubrication system during filling.
Large amounts of moisture present in the lubricating oil are usually the result
of a flawed oil filling or clean-up procedure.
Table A-5: Significant Contamination Trends
A.7 Cleaning or Replacement of Oil

When the oil sample exceeds the recommended particle or moisture level, clean or replace the oil.
Replace the oil when the viscosity changes by an amount greater than the recommended amount.


133
Appendix B: Pre-
Installation Inspection
B.1 Pre-Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

134 Appendix B Pre-Installation Inspection
B.1 Pre-Installation Inspection

Serial Number:
Sign off by initialing and dating each inspection made. Complete this form before the components are installed into the
crusher. Retain the original of the completed form in the erection site master IOM manual, and transmit a copy of the
completed form to the FLSmidth project manager for inclusion in the contract documents.
Item Value (If Date Initials

Applicable)
Countershaft Assembly
Countershaft end play
Inboard bearing RTD contact N/A
Outboard bearing RTD contact N/A
Pinion position relative to bearing inner race
Condition of pinion teeth N/A
Condition of countershaft housing inboard support surface N/A
Condition of countershaft housing outboard support surface N/A
Condition of gasket contact surface N/A
Location of seal splits relative to housing vertical centerline N/A
Location of bearing seal grease fitting relative to housing vertical

N/A
centerline
Presence of grease in seal chamber N/A
Eccentric Assembly
Presence of retaining bars on lower counter weight bolts N/A
Presence of tack welds on upper counter weight bolts N/A
Gear position relative to gear locating ledge of eccentric—measure any

N/A
gap in the horizontal plane at four equally spaced locations
Condition of gear teeth N/A
Condition of outside diameter contact surface N/A
Condition of inner eccentric bushing contact surface N/A
Condition of eccentric wearing ring contact surface N/A
Presence of lock wire on inner eccentric bushing bolts N/A
Dust Bonnet
Air passages (for plugging) N/A
Condition of inside diameter seal contact surface N/A
Condition of outside diameter seal contact surface

N/A
Spider Assembly
Condition of spider pocket contact surfaces N/A
Condition of spider bushing contact surface N/A
Condition of spider cap locating and support surfaces N/A
condition of surfaces used for the radial location of spider N/A
Top Shell (if no epoxy in spider pockets)
Table B-1: Pre-Installation Inspection

Appendix B Pre-Installation Inspection 135

Applicable)
Condition of spider pockets and epoxy anchors N/A
Condition of surfaces used for the radial location of spider N/A
Condition of surfaces used for the axial location of spider N/A
Top Shell (if epoxy poured in spider pockets)
Condition of spider pocket epoxy N/A
Condition of the tapered fit contact surfaces N/A
Condition of the bolting flange contact surface N/A
Condition of the inside surface of the shell N/A
Condition of the upper concave lug groove N/A
Location of the upper concave lug groove—measure vertically from the

N/A
spider axial locating rim
Middle Shell
Condition of the lower tapered fit contact surfaces N/A
Condition of the upper tapered fit contact surfaces N/A
Condition of the lower bolting flange contact surface N/A
Condition of the upper bolting flange contact surface N/A
Condition of the inside surface of the shell N/A
Bottom Shell
Condition of the bottom shell support (grout) surface N/A
Condition of the tapered fit contact surfaces N/A
Condition of the bolting flange contact surface N/A
Condition of the outer eccentric bushing contact surfaces N/A
Condition of the oil return passage N/A
Location of the top of the oil return passage from the top of the bottom
N/A
shell eccentric bushing hub
Condition of the tapped holes for the outer eccentric bushing bolts N/A
Condition of the countershaft housing contact surfaces N/A
Condition of the countershaft housing gasket contact surface N/A
Condition of the tapped holes for the countershaft housing bolts N/A
Condition of the bottom plate locating diameter N/A
Condition of the bottom plate contact surface N/A
Condition of the tapped holes for the bottom plate and hydraulic bottom
N/A
studs
Air line holes (for plugging) N/A
Condition of the outer eccentric bushing oil supply line N/A
Eccentric Wearing Ring
Condition of eccentric contact surface N/A
Condition of bottom plate contact surface N/A
Center Wearing Ring
Center wearing ring contact surfaces N/A
Bottom Piston Wearing Ring


Applicable)
Condition of piston contact surface N/A
Condition of center wearing ring contact surface N/A
Bottom Plate
Condition of eccentric wearing ring contact surface
Condition of bottom shell contact surface
Condition of hydraulic bottom contact surface
Condition of bottom shell location diameter
Hydraulic Bottom Assembly
Condition of bottom piston wearing ring contact surface N/A
Condition of piston interior chamber N/A
Condition of chamber beneath piston N/A
Vertical movement of piston N/A
Condition of bottom plate contact surface N/A
Tightness of hydraulic bottom studs N/A
Mainshaft (if core and mantles installed separately)
Condition of core contact surface N/A
Condition of mainshaft contact seal mounting surfaces N/A
Condition of core epoxy contact surface N/A
Condition of head nut threads N/A
Core (if received loose from mainshaft)
Condition of mainshaft contact surface N/A
Condition of mainshaft epoxy contact surface N/A
Condition of lower mantle contact surface N/A
Condition of mantle epoxy contact surface N/A
Lower Mantle (if received loose from mainshaft)
Condition of the core contact surface N/A
Condition of the core epoxy contact surface N/A
Condition of contact surface for middle or upper mantle N/A
Largest diameter of mantle
Smallest diameter of mantle
Middle Mantle (if received loose from mainshaft)
Condition of contact surface for lower and upper mantles N/A
Upper Mantle (if received loose from mainshaft)

Appendix B Pre-Installation Inspection 137

Applicable)
Condition of the core epoxy contact surface N/A
Condition of contact surface for lower or middle mantles N/A
Condition of head nut contact surface N/A
Condition of head nut pin contact surface N/A
Head Nut
Condition of interior and exterior threads of inner head nut N/A
Condition of interior threads of outer head nut N/A
Condition of upper mantle pin contact surface N/A
Condition of upper mantle contact surface N/A
Mainshaft Assembly (if received assembled)
Presence of grease for dust seal ring N/A
Condition of dust seal ring to dust seal bonnet contact surface N/A
Movement of dust seal ring N/A
Movement of contact seal N/A
Mantle gap
Horizontal offsets (ledges) at mantle joints
Gap between bottom of head nut and top of upper mantle—measure at

four equally spaced locations
Gap between the top of the mainshaft and the bottom of the flange on
the mainshaft sleeve—measure at four equally spaced locations
Number of welds and length of welds between the mainshaft and the
mainshaft sleeve
Presence of head nut pin N/A
Absence of head nut angle iron N/A
_________________________________ _________________
(Installer or Erector) (Date)
_________________________________ _________________
(FLSmidth Service Representative) (Date)


139
Appendix C: Commissioning
C.1 Commissioning Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
C.2 Commissioning Sequence Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
C.3 Pre-Operational Commissioning Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
C.4 Pre-Commissioning Mechanical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
C.5 Pre-Commissioning Electrical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
C.5.1 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
C.6 No-Load Commissioning Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
C.6.1 No-Load Commissioning Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
C.7 50% Feed Load Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
C.7.1 50% Feed Load Commissioning Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
C.8 Full Load Commissioning Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
C.8.1 Full Load Commissioning Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

140 Appendix C Commissioning
C.1 Commissioning Overview

The purpose of commissioning is to ensure that all the crusher systems and associated equipment have been
constructed according to design. Commissioning includes preoperational testing and initial run-in and operation of the
crusher without feed. Commissioning begins in accordance with the overall project schedule, and commences during
the construction phase.
There are several phases in placing a new crusher into operation. There is an initial running-in period when the crusher
is operated under no-load conditions for an eight-hour period. This is followed by a one-hour operating period with a
partial feed load. Upon satisfactory completion of this operation, the crusher is prepared for normal, full-load service by
operating at 50 percent feed load for six to eight hours. After satisfactory operation at this feed rate, the load is
gradually increased to 100 percent of design feed load over a period of 40 hours.
C.2 Commissioning Sequence Flow

Chart
Activity Responsible Party Forms and Reports
Engineering, procurement, and

Schedules with completion
Final stages of construction construction management (EPCM)
Milestones for equipment
contractor
Prepare preoperational and functional

Manufacturer Written guidelines for each equipment type
test guidelines
Content of each package:
Equipment list
Instrument list
Identify test packages Marked up C&IDs
Manufacturer
Prepare procedures and database Test description
Test data sheets
Test certificate
Procedure
Manufacturer
Prepare preliminary test schedule Owner Bar chart of each package
EPCM contractor
Prepare detailed test schedule EPCM contractor Printout of equipment with milestone dates
EPCM contractor
Vendor end of service form
Final installation and vendor approvals Manufacturer
Daily summaries
Vendors
EPCM contractor
Test certificates
Conduct preoperational test Manufacturer
Data sheets
Owner witness
EPCM contractor
Punchlist Printout of deficiencies and responsibilities
Manufacturer
All equipment in package is successfully EPCM contractor

tested Manufacturer
EPCM contractor Test certificates

Conduct package functional test
Manufacturer Data sheets
EPCM contractor
Punchlist Printout of deficiencies and responsibilities
Manufacturer
Table C-1: Commissioning Sequence Flow Chart

Appendix C Commissioning 141
Activity Responsible Party Forms and Reports
EPCM contractor
Monitor operation of crusher package in a
Owner
no-load run
Manufacturer
EPCM contractor
Resolve performance issues Manufacturer
Vendors
EPCM contractor Turnover package:

Package successfullytTested as a system Manufacturer
Turnover letter
Vendors
Exceptions list
Test data sheets
EPCM contractor
Crusher package turnover to owner and Test certificates
Manufacturer
signoff: hang green tags Vendor data
Vendors
Other required information
EPCM contractor
Monitor operation of crusher package as
Owner
feed is introduced
Manufacturer
EPCM contractor
Resolve performance issues Manufacturer
Vendors
Table C-1: Commissioning Sequence Flow Chart
C.3 Pre-Operational Commissioning

Testing
1. Clean and flush the equipment.
2. Inspect the area and equipment for any potential for personal injury or equipment damage as a result of moving the
crusher mainshaft and mantle.
a. This includes the exterior of the crusher shell, the drive system, and the interior of the crusher. They must be
inspected prior to starting the crusher for repositioning the mainshaft, inspection, or testing.
b. Also inspect the motor control center (MCC), hydraulic adjustment skid, lubrication skid, and spider lubrication
system to ensure they are operable and present no hazards to personnel or equipment in the area.
3. Test the controls and instrumentation.
4. Perform preliminary system run-in performance tests and inspections.
5. Install the temporary facilities required to perform the tests and run-in.
6. Schedule and coordinate participating vendors and their associated activities.

C.4 Pre-Commissioning Mechanical

Inspection
Complete the pre-commissioning mechanical inspection checklist during the crusher assembly. The original of the
completed form is to be maintained in the IOM manual, and a copy of the completed form is to be transmitted to the
FLSmidth project manager for inclusion in the contract documents.
Item Value Date Initials

(If Applicable)
Crusher, Mechanical and Lubrication
Ensure the crusher drive system is locked out and tagged in

N/A
accordance with the established procedure.
Inspect the interior of the crusher for missing or loose liners, bolts,
and nuts. Pay particular attention to the following parts:
a) Spider arms and cap
b) Concaves N/A
c) Mantle
d) Bottom shell interior and exterior
e) Countershaft assembly
Remove all temporary installation aids, debris, and construction

N/A
materials from inside the crusher.
Inspect the exterior of the crusher shell for missing or loose flange
N/A
bolts and nuts. Tighten or install bolts and nuts as required.
Verify that there is grease at the spider bushing. If there is none, flush
the spider lubrication system, reconnect it, and prepare it for N/A
operation.
Verify that all components that require lubricants have been

N/A
lubricated.
Verify that the countershaft extension assembly has been securely

N/A
attached to the crusher and it’s motor, and is in correct alignment.
Ensure that the mantle position indicator is in place, wired, and has
N/A
been calibrated according to the manufacturer’s instructions.
Ensure that the mantle position indicator is in place, wired, and has
N/A
been calibrated according to the manufacturer’s instructions.
Inspect all piping and wiring under the crusher to make sure that all
N/A
are protected from damage.
Bleed the air from the hydraulic adjustment system, and inspect the
N/A
hydraulic lines for leakage.
Raise the crusher mainshaft 50 mm (2 in) using the hydraulic

N/A
adjustment system.
When the lubricating oil is at operating temperature, start the oil pump
and allow the oil to circulate through the crusher until a full flow can N/A
be seen returning to the sump tank.
Monitor the volume of oil flow to the eccentric and countershaft

N/A
bearings.
Bearing, Mechanical and Lubrication
Inspect the physical and functional condition of the crusher lubrication

N/A
system and its mechanical components.
Table C-2: Mechanical Pre-Commissioning Checklist


(If Applicable)
Hydraulic, Mechanical and Lubrication
Inspect the physical and functional condition of the hydraulic

N/A
adjustment system and its mechanical components.
Mantle Position Indicating System, Mechanical and Lubrication

Verify the physical and functional condition of the mantle position
N/A
indicating system and its mechanical components.
General Crusher Components
Spider bushing lubrication N/A
Frequency lubrication pump is actuated min
Number of “counts” or times the pump is actuated
Dust bonnet air supply air pressure psi
Lubrication oil tank level
Hydraulic tank oil level
#1 lubrication pump relief valve setting psi
#2 lubrication pump relief valve setting psi
Hydraulic oil flow to hydraulic bottom gpm
#1 hydraulic pump relief valve setting psi
#2 hydraulic pump relief valve setting psi
#1 cooling pump relief valve setting psi
#2 cooling pump relief valve setting psi
Lubrication oil flow to hydraulic bottom gpm
Lubrication oil flow to bottom shell gpm
Lubrication oil flow to countershaft housing gpm
Lubrication oil flow to pinion N/A
Inspect the countershaft housing for leaks N/A
Inspect the hydraulic bottom to bottom shell for leaks N/A
Inspect the lubrication system piping for leaks N/A
Inspect the hydraulic system piping for leaks N/A
Inspect the cooling system piping for leaks N/A
Inspect the countershaft seal for leaks N/A
Contents of lubrication tank screen basket N/A
Lubrication tank oil temperature N/A
Hydraulic tank oil temperature N/A
Controlled torque coupling pressure N/A
Presence of grease in countershaft housing seal chamber N/A
Head nut tightness N/A
Free vertical movement of mainshaft N/A
Table C-2: Mechanical Pre-Commissioning Checklist

C.5 Pre-Commissioning Electrical

Inspection
Complete the pre-commissioning electrical inspection checklist during the crusher assembly. The original of the

(If Applicable)
Crusher, Electrical
Verify that all instruments, sensors, alarms, timers, and interlocks are
N/A
at their specified settings.
Verify the operation of the alarms on the lubrication oil inlet and outlet
N/A
lines.
Bearing, Electrical
N/A
Verify the operation of the alarms on the lubrication oil inlet and outlet
N/A
lines.
Hydraulic, Electrical
N/A
Verify the operation of the alarms on the hydraulic adjustment system. N/A
Mantle Position Indicating System, Electrical

Verify the calibration of the signal transmitter, and adjust it if required. N/A
With no hydraulic fluid beneath the piston, turn the transducer “0”
N/A
potentiometer until it indicates 0 mm (0 in) on the output (bar graph).
Measure the distance between the top of the head nut and the bottom
of the spider. Raise the mainshaft the lesser distance of either 300
mm (12 in) or the measured distance. Turn the transducer “E” N/A
potentiometer until the distance the mainshaft was raised is read on
the output (bar graph).
Set the low set point of the indicating alarm at 50 mm (2 in). N/A
Subtract 25 mm (1 in) from the distance previously measured between

the top of the head nut and the bottom of the spider. Set the high set
N/A
point at the lesser distance of either the value obtained or 280 mm (11
in).
N/A
at the specified settings.
Lubrication Skid, Lubrication System Pump Motors
With the pump motors isolated from their power and control circuits,
verify that the power connections are set up to the correct motor
N/A
terminals and inspect for tightness. Disconnect and clean loose
terminals, and reconnect securely.
Inspect the junction box cover seals for signs of leakage and damage.
N/A
Replace as required. Vacuum-clean the junction box interiors.
Inspect local control panels (if purchased) for damaged or missing

N/A
buttons, switches, and indicators. Repair or replace as required.
Table C-3: Electrical Pre-Commissioning Checklist


(If Applicable)
Inspect power cable and conduit for physical damage. Repair or

N/A
replace as required.
At the MCC, megger the stator and record the measurements. N/A
Remove the fan cover, inspect the fan for cracks, and clean the
blades. Inspect the outboard bearing housing for leaks and signs of N/A
excessive heat. Replace the cover.
Clean motor housing surfaces to assist cooling. Remove locks at MCC

according to established procedure when all the preceding
N/A
inspections and tests have been completed, and release the unit for
running inspections.
When all other inspections have been completed, start and run the
system, one motor and pump set at a time. Verify the rotation of each N/A
and record direction looking from motor to fan.
When the lubricating system is operating normally, take voltage and

current readings for all three phases at the MCC. Compare values and N/A
inspect for an unbalanced condition (more than 5%).
Lubrication Skid, Cooling System Pump Motors
With the pump motors isolated from their power and control circuits,
N/A
N/A

N/A
Inspect power cable and conduit for physical damage.Repair or

N/A

N/A
When the cooling system is operating normally, take voltage and

Lubrication Skid, Cooling System Fan Motors
With the fan motors isolated from their power and control circuits,
N/A
N/A

N/A


(If Applicable)

N/A
excessive heat.

N/A

Lubrication Skid, Cooling System Drain Valve
Inspect the valve for signs of physical damage and excessive heat.
N/A
Replace the unit as required.
N/A
Inspect power and control cable and conduit for physical damage.
N/A
Repair or replace as required.
Inspect the power and control wiring for connection to the correct
terminals and inspect for tightness. Disconnect and clean loose N/A
Apply appropriate input voltage and ensure that valve opens and
N/A
closes. Reconcile switch and signal with position of valve.
Cooling System Drain Valve at the Coolers
Inspect the valve for signs of physical damage and excessive heat.
N/A
Replace the unit as required.
N/A
Inspect power and control cable and conduit for physical damage.
N/A
Inspect the power and control wiring for connection to the correct
terminals and inspect for tightness. Disconnect and clean loose N/A
Apply appropriate input voltage and ensure that valve opens and
N/A
closes. Reconcile switch and signal with position of valve.
Lubrication Skid, Heaters
With the heaters isolated from their power and control circuits, verify
that the power connections are set up to the correct motor terminals
N/A
and inspect for tightness. Disconnect and clean loose terminals, and
reconnect securely.
N/A

N/A
Inspect each heater for continuity. Replace the junction box covers. N/A


(If Applicable)
Remove locks at MCC according to established procedure when all

the preceding inspections and tests have been completed, and N/A
release the unit for running inspections.
Hydraulic Skid, Pump Motors
With the fan motors isolated from their power and control circuits,
inspect the power connections to the correct motor terminals and
N/A
inspect for tightness. Disconnect and clean loose terminals, and
reconnect securely.
N/A

N/A

N/A

N/A

Hydraulic Skid, Heaters
With the heaters isolated from their power and control circuits, verify
that the power connections are set up to the correct motor terminals
N/A
and inspect for tightness. Disconnect and clean loose terminals, and
reconnect securely.
N/A

N/A
Inspect each heater for continuity. Replace the junction box covers. N/A
Remove locks at MCC according to established procedure when all

the preceding inspections and tests and been completed, and release N/A
the unit for running inspections.
Hydraulic Skid, Direction Control Solenoid Valve(s)
Inspect valve(s) for Raise function N/A
Inspect valve(s) for Lower function N/A

C.5.1 Instrumentation
Complete the pre-commissioning instrumentation inspection checklist during the crusher assembly. The original of the

(If Applicable)
Lubrication Skid, Temperature Gauges
Inspect the gauges for physical damage. Repair or replace as

N/A
required.
Verify the date on the calibration sticker if applicable. N/A
Lubrication Skid, Temperature Switch(es)—Thermostats
Inspect the switch for physical damage. Repair or replace as required. N/A
N/A
Inspect for correct connection to terminals. Inspect wiring terminals

for signs of excessive heat. Disconnect loose terminals, clean contact N/A
surfaces until bright, and reconnect the terminals.
Inspect wire and conduit for physical damage, abrasion and exposed
N/A
conductors. Repair or replace as required.
Place bulb (sensor) of switch in a liquid and heat and/or cool the liquid
to the required switch actuation temperature(s) and set the switch to N/A
actuate at these temperature(s).
Record the actuation temperatures. N/A
Lubrication Skid, Temperature Sensor(s) (If Purchased)
Inspect the sensor for physical damage. Repair or replace as required. N/A
N/A

N/A
Place all related control loops in the manual mode and with an
independent calibrator inspect the span (4 – 20 mA) and zero
N/A
settings. Compare with conditions at the sensing element. Set zero as
required.
Verify the date on the calibration sticker. N/A
Lubrication Skid, Level Gauge
Inspect the gauge for signs of leakage and physical damage. Repair
N/A
or replace as required.
Clean the glass and enclosure. N/A
Inspect the level gauge and reconcile with visual observation of the
N/A
reservoir level.
Lubrication Skid, Low Level Switch
Inspect the switch for signs of leakage and physical damage. Repair
N/A
Table C-4: Instrumentation Pre-Commissioning Checklist


(If Applicable)
N/A

N/A
Physically move float until switch actuates. Adjust switch actuation as

N/A
required.
Lubrication Skid, Pressure Gauges
Inspect the gauge for signs of leakage and damage. Repair or replace
N/A
as required.
Verify the date on the calibration sticker. Recalibrate if required. N/A
Lubrication Skid, Filter Differential Switch
N/A
N/A

N/A
With an independent calibrator, inspect the switch actuation point.

N/A
Adjust if required. Record switch set point.
Lubrication Skid, Cooling System Flow Switch
N/A
N/A

N/A
Operate the cooling system pump with the oil at the operating
temperature and verify the switch actuation point. Adjust switch N/A
actuation as required. Record switch set point.
Hydraulic Skid, Temperature Gauges
Inspect the gauge for physical damage. Repair or replace as required. N/A
Verify the date on the calibration sticker if applicable. N/A
Hydraulic Skid, Temperature Switch(s)—Thermostats
Inspect the switch for physical damage. Repair or replace as required. N/A
N/A


(If Applicable)

N/A
Place bulb (sensor) of switch in a liquid and heat and/or cool the liquid
to the required switch actuation temperature(s) and set the switch to N/A
actuate at these temperature(s).
Record the actuation temperatures. N/A
Hydraulic Skid, Temperature Sensor(s) (If Purchased)
Inspect for physical damage. Repair or replace as required. N/A
N/A

N/A
independent calibrator inspect the span (4 – 20 mA) and zero N/A
settings.
Compare with conditions at the sensing element. Set zero as required. N/A
Hydraulic Skid, Level Gauge
Inspect the gauge for signs of leakage and physical damage. Repair
N/A
Inspect the level gauge and reconcile with visual observation of the
N/A
reservoir level.
Hydraulic Skid, Low Level Switch
N/A
N/A

N/A
Physically move float until switch actuates. Adjust switch actuation as

N/A
required.
Hydraulic Skid, Pressure Gauges
Inspect the gauge for signs of leakage and damage. Repair or replace
N/A
as required.
Verify the date on the calibration sticker. Recalibrate if required. N/A
Cooling System, Ambient Temperature Sensor


(If Applicable)
N/A

N/A
independent calibrator inspect the span (4 – 20 mA) and zero N/A
settings.
Compare with conditions at the sensing element. Set zero as required. N/A
Lubrication System, Flow Switches
N/A
N/A

N/A
Operate the cooling system pump with the oil at the operating
temperature and verify the switch actuation point. Adjust switch N/A
actuation as required. Record switch set point.
Mainshaft Position Indicating System
N/A

N/A
Verify both HIGH and LOW alarm actuation points. Adjust as required. N/A
Inboard and Outboard Countershaft Bearing Temperature Sensors
N/A

N/A
Inspect the operation of the sensor. Compare the readings with

N/A
conditions at the sensing element. Correct if required.
Countershaft Speed Sensor


(If Applicable)
N/A

N/A
Inspect the operation of the sensor. Correct if required. N/A
Crusher Drive Motor High Power Draw Alarm/Shutdown Circuit
Confirm circuit is operational. N/A
Confirm starting torque limit is set at 180% of full load torque and
N/A
breakdown torque limit is set at 250%.
C.6 No-Load Commissioning Inspection

The crusher must be operated under no-load conditions for eight hours before it is fed a partial load. The purpose of the
running-in test is to allow the crusher to bed-in and run-in the bearings and gears so operation can be closely monitored.
1. Perform the no-load commissioning pre-inspection.
a. Raise the crusher mainshaft 50 mm (2 in) with the hydraulic adjustment system.
b. Verify that the lubricating oil is at operating temperature, an oil pump has been started, and oil is circulating
through the crusher. A full flow of oil is visible returning to the sump tank reservoir on the lubrication skid.
c. Verify that the correct volume of oil is flowing to the eccentric, pinion, and countershaft.
d. Verify that the spider lubrication system is operational.
e. Verify that the countershaft extension is secure and its coupling covers are in place.
f. Verify that the motor lockout locks have been removed at the motor control center (MCC).
g. Ensure that all safety interlocks have been tested and are functional.
2. Insert two grader size tires into the crushing chamber with steel cables. Place them 180 degrees apart. This will
prevent the mainshaft from rotating too rapidly during the breaking-in period.
Note: The normal motion of the mainshaft is gyratory, which means the bottom end of the shaft moves in a
circle while the top is stationary. In some cases, due to the viscosity of the oil between the shaft and the
eccentric, there is a tendency for the idle running mainshaft to rotate or spin in addition to gyrating. Spinning
is detrimental during the running-in period. The grader tires provide enough friction to keep the shaft from
spinning. They will move from their original positions as the crusher runs.
Never operate the crusher for more than 15 minutes without a load or tires.
3. Start the crusher from the local control panel or from the distributed control system (DCS).
4. While the crusher is in operation, perform the no-load commissioning inspection.
a. Look for oil leakage from the oil inlet and return pipe lines.

b. Monitor the countershaft bearing temperature. If the temperature is within normal range, no discomfort will be
felt when a bare hand is placed on the countershaft housing. Confirm suspected excessive temperatures
through the countershaft bearing temperature detectors and with a portable thermal detector.
c. Ensure that the oil cooling system is operating properly. Verify that the temperature and pressure gauges
operating on the pumping unit are steady and operating correctly.
d. Ensure that the spider bushing lubrication system is functioning properly.
e. Test the hydraulic support and adjustment systems.
f. Record the data listed on C.6.1 “No-Load Commissioning Data” on page 154. Take and record the readings at 15-
minute intervals until the oil temperature remains constant for one hour, and then continue the readings at 1-hour
intervals throughout the 8-hour test period.
g. Observe the drive motor winding and bearing temperatures with the motor monitoring instruments (if
purchased).
5. At the end of the 8-hour running-in period, stop the drive motor and record the time it takes for the crusher to stop
(run down). Stop the lubrication systems and the hydraulic adjustment system.
6. Remove the return screen from the lubrication oil skid reservoir. Inspect its contents and record any observations,
and clean the screen with solvent. Install the screen and secure it. It is normal to find a small amount of foreign
material in the screen basket due to the bedding-in process and dislodged particles not removed by flushing.
7. Remove the tires from the crushing chamber.
8. Ensure that the shell bolts, spider bolts, and foundation bolts are tight.
9. Ensure that the crusher drive motor foundation bolts are tight.
10. Prepare the crusher for initial start-up with feed.

C.6.1 No-Load Commissioning Data

Time
Motor
Power
Crusher
Setting
Mainshaft
Position
Oil Temp to
Crusher
Oil Temp
From
Crusher
Oil Temp to
Cooler
Oil Temp
From
Cooler
Lube Tank
Temp
Hydraulic
Tank Temp
Hydraulic
System
Press.
Ambient Air
Temp
Cooler
Pump On or
Off
No. of Fans
Inboard
RTD Temp
Outboard
RTD Temp
Crushing
Rate
Table C-5: No-Load Commissioning Data

C.7 50% Feed Load Commissioning

Procedure
Run the crusher for 1 hour with a 50% feed load. It is important to ensure that the feed material is dry and does not
contain fines or lumps larger than two-thirds of the feed opening. Once the crusher has run for an hour, stop the feed,
allow the crusher is to run empty, and then also stop and inspect the crusher.
1. Verify that the crusher mainshaft has been raised 50 mm (2 in) with the hydraulic adjustment system.
2. Verify that the lubricating oil is at operating temperature, an oil pump has been started, and oil is circulating through
the crusher. A full flow of oil is visible returning to the sump tank reservoir on the lubrication skid.
3. Verify that the correct volume of oil is flowing to the eccentric and countershaft.
4. Verify that the spider lubrication system is operational.
5. Verify that the countershaft extension is secure and its coupling covers are in place.
6. Verify that the motor lockout locks have been removed at the motor control center (MCC).
7. Ensure that all safety interlocks have been tested and are functional.
8. Start the crusher from the local control panel or from the distributed control system (DCS), and establish a 50% feed
rate.
9. With the crusher in operation, perform the 50% feed load commissioning inspection.

f. Record the data listed on C.7 “50% Feed Load Commissioning Procedure” on page 155. Take and record the
readings at 15-minute intervals until the oil temperature remains constant for one hour, and then continue the
readings at 1-hour intervals throughout the 8-hour test period.
purchased).
10. At the end of the 8-hour 50% load period, stop the feed and allow the crusher to empty. Once the crusher is empty,
stop the drive motor and record the time it takes for the crusher to stop (run down).
11. Verify that the lubrication systems and the hydraulic adjustment systems remain in operation.
12. Ensure that the shell bolts, spider bolts, and foundation bolts are tight. Tighten any loose bolts and nuts as required.
13. Ensure that the crusher drive motor foundation bolts are tight. Tighten any loose bolts and nuts as required.

C.7.1 50% Feed Load Commissioning Data

Time
Motor
Power
Crusher
Setting
Mainshaft
Position
Oil Temp to
Crusher
Oil Temp
From
Crusher
Oil Temp to
Cooler
Oil Temp
From
Cooler
Lube Tank
Temp
Hydraulic
Tank Temp
Hydraulic
System
Press.
Ambient Air
Temp
Cooler
Pump On or
Off
No. of Fans
Inboard
RTD Temp
Outboard
RTD Temp
Crushing
Rate
Table C-6: 50% Feed Load Commissioning Data

C.8 Full Load Commissioning Inspection

1. Start the crusher again at a feed rate of 50% of capacity. Run the crusher for an additional eight hours at a 50% feed
rate.
2. If the crusher is within operating and design specifications, run it for 40 hours while gradually increasing feed rate to
the full design capacity.
3. Set the adjustment system relief valve while the crusher is operating under a normal full crushing load. Adjust the
relief valve until the normal load causes it to open and allows the mainshaft to descend, then set it higher so that it
will hold under the normal load peaks. Several adjustments may be necessary to attain a satisfactory setting.
Note: The required setting of the relief valve may vary as ore is extracted from different locations in the mine
or pit due to the hardness of the ore. The purpose of the relief valve is to protect the crusher from
uncrushable objects. If an object gets caught in the crusher, the valve opens and the mainshaft descends to
discharge the uncrushable object.
Record the relief valve setting at the initial set-up, and then every time the setting is changed.
4. During the following 40 hours, perform the feed load commissioning inspection.
f. Record the data listed on C.8.1 “Full Load Commissioning Data” on page 158. Take and record the readings at 1-
hour intervals throughout the 40-hour test period.
purchased).

C.8.1 Full Load Commissioning Data

Time
Motor
Power
Crusher
Setting
Mainshaft
Position
Oil Temp to
Crusher
Oil Temp
From
Crusher
Oil Temp to
Cooler
Oil Temp
From
Cooler
Lube Tank
Temp
Hydraulic
Tank Temp
Hydraulic
System
Press.
Ambient Air
Temp
Cooler
Pump On or
Off
No. of Fans
Inboard
RTD Temp
Outboard
RTD Temp
Crushing
Rate
Table C-7: Full Load Commissioning Data

159
Appendix D: Maintenance
Schedule
D.1 Maintenance Schedule Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
D.2 Mechanical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
D.2.1 Daily Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 160
D.2.2 Weekly Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 162
D.2.3 Monthly Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . 162
D.2.4 Annual Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 163
D.2.5 Major Mechanical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 164
D.3 Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
D.3.1 Weekly Electrical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 165
D.3.2 Monthly Electrical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 167
D.3.3 Annual Electrical Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 170
D.4 Instrument Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
D.4.1 Quarterly Instrument Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . 173

160 Appendix D Maintenance Schedule
D.1 Maintenance Schedule Overview

Schedule daily, weekly, monthly, and yearly inspections. Keep a written log of what was done and found at each
inspection. Make repairs in advance to avoid major breakdowns.
The following mechanical, electrical, and instrument maintenance schedules provide guidelines on maintaining the
crusher and auxiliary equipment. For a customized schedule that is based on site-specific established maintenance
plans, contact FLSmidth.
D.2 Mechanical Maintenance

D.2.1 Daily Mechanical Preventive Maintenance
Refer to 7.2.1 “Running Mechanical Inspections” on page 81 for further information about the daily mechanical
preventive maintenance tasks.
Maintenance Operation Reference Repairs Required,

Date, Initials
Crusher Assembly
Closely observe the operation of the crusher for unusual conditions such as
sounds, odors, excessive temperature, and vibration.
Observe the area between the spider and mantle for excessive grease.
When grease delivery is correct, arrange for a thorough inspection of the
bushing or excessive wear or damage.
Inspect the shell and spider bolts for missing items and signs of looseness.
Arrange for adjustments and replacements as required.
Inspect the countershaft assembly mounting flange and countershaft seal

for signs of lubricant leakage. Arrange for required repairs and adjustment.
Observe the operation of the countershaft extension for unusual noises

and vibration. Arrange for required repairs.
Inspect the lubrication oil supply flow meters to ensure the flow is steady
and is moving at the correct flow rate. Inspect the hoses, pipelines, and
fittings for damage and leaks. Arrange for required repairs.
Inspect the return hoses, pipeline, and fittings for damage and leaks.
Inspect the return oil temperature through the DCS. Arrange for more
thorough inspections and repairs as required.
Lubrication Oil System Skid
Inspect the operating oil pump for unusual conditions such as sounds,
odors, excessive temperature, and vibration. Arrange for more thorough
inspection and repairs as required.
Inspect the level of the oil in the reservoir with the sight gauge. During
normal operation the level must be at the mark on the sight gauge.
Inspect that the pressure relief valves are not chattering and are not
excessively hot. Inspect the pressure in the lines downstream of the valves
for steady operation.
Inspect all hoses, pipe lines, gaskets, seals, and fittings for leaks. Arrange
for required repairs.
Table D-1: Daily Mechanical Checklist

Appendix D Maintenance Schedule 161

Date, Initials
Inspect the oil filter differential pressure gauge. Switch to the stand-by filter
if the pressure exceeds the maximum operating pressure. Arrange to have
the dirty filter cleaned.
Coolers
Inspect the coolers for damage and leaks. Arrange for required repairs.
Inspect the fans and their shrouds for contact, damage, cracks, or erosion.
Arrange for required repairs.
Inspect the temperature of the oil entering and leaving the coolers. Record
unusual conditions.
Hydraulic Adjustment System Skid
Inspect the level of the oil in the reservoir with the sight gauge. During
normal operation, the level must be at the mark on the sight gauge.
Inspect that the pressure relief valves are not chattering and are not
excessively hot. Inspect the pressure in the lines downstream of the valves
for steady operation.
Inspect the oil filter differential pressure gauge. Switch to the stand-by filter
if the pressure exceeds the maximum operating pressure. Arrange to have
the dirty filter cleaned.
Spider Bushing Lubrication System
If an air-operated system is provided, ensure the inlet air pressure to the

pump is at or near plant air pressure on the pressure gauge near the
regulator.
If an air-operated system is provided, inspect the air regulator for damage

or leaks. Arrange for required repairs.
If an air-operated system is provided, inspect the condition of the filter

through the filter bowl. If the filter is not visible through the bowl, arrange
for cleaning of the filter when the crusher is not operating. Drain the filter
with its valve if it is not equipped with an automatic drain valve.
If an air-operated system is provided, inspect the oil-dispensing rate of the

air line lubricator; it must be two drops per minute. Adjust as required with
the adjustment valve on the lubricator. If the oil drops are not visible,
arrange for cleaning of the filter when the crusher is not operating.
Inspect the pump for unusual conditions such as sounds, odors, excessive
temperature, and vibration. Arrange for more thorough inspection and
repairs as required.
Inspect the level of the grease in the drum either visually or with the weight
reading scale (if provided). Arrange for a replacement drum as required.
Table D-1: Daily Mechanical Checklist

D.2.2 Weekly Mechanical Preventive Maintenance

Refer to 7.2.2 “Shutdown Mechanical Inspections” on page 81 for further information about the daily mechanical

Date, Initials
Complete the daily preventive maintenance checklist. Correct all abnormal Table D-1: “Daily Mechanical
conditions observed and measured. Checklist” on page 160
Crusher Assembly
Inspect the mantle for excessive wear and cracks. Repair or replace as
required.
Inspect the space between the head nut and the bottom of the spider to
determine the amount of wear and remaining shaft adjustment. Record
observations.
Inspect the concaves for excessive wear and cracks. Repair or replace as
required.
7.5 “Manganese Steel

Growth and Trimming of
Inspect the concave joints for peening, and scarf as needed.
Concaves and Mantles” on
page 84
Inspect the dust seal for excessive wear. Replace as required, or record
observations when wear is minimal or normal.
Lubricate the dust seal with grease using the grease fittings in the dust seal
retainer.
Inspect the dust seal retainer for tightness to prevent bolt breakage.
Tighten or replace as required.
Lubricate the countershaft seal with grease using the grease fittings in the
countershaft seal retainer.
Table D-2: Weekly Mechanical Checklist
D.2.3 Monthly Mechanical Preventive Maintenance


Date, Initials
Table D-1: “Daily Mechanical

Checklist” on page 160 and
Complete the daily and weekly preventive maintenance checklists. Correct
Table D-2: “Weekly
all abnormal conditions observed and measured.
Mechanical Checklist” on
page 162
Crusher Assembly
Inspect the bottom shell liners for cracks, missing pieces, unusual wear
patterns, and excessive wear. Replace liners as required.
Inspect the clearance between the spider bushing and the mainshaft.
Replace the spider bushing if clearance is excessive, or record
measurements if the clearance is within normal limits.
Table D-3: Monthly Mechanical Checklist


Date, Initials
Take an oil sample from the reservoir in an approved container. Write the
source and the date of the sample on the label of the container, and submit
it for analysis.
Inspect the pumps and piping for signs of leakage. Repair as required.
Clean the pump housings. Ensure all guards are securely in place.
Inspect all equipment mounting bolts for tightness and missing units.
Replace and tighten as required.
Coolers
Inspect the radiators for damage and leaks. Clean the exterior cooling
surfaces as required.
Take an oil sample from the reservoir in an approved container. Write the
source and the date of the sample on the label of the container, and submit
it for analysis.
Inspect the pumps and piping for signs of leakage. Repair as required.
Clean the pump housings. Ensure all guards are securely in place.
Hydraulic Adjustment System Accumulator
Lower the mainshaft to the full down position (hydraulic pressure will be
zero) and measure the nitrogen pressure in the accumulator bladder.
Recharge the accumulator as required.
Table D-3: Monthly Mechanical Checklist
D.2.4 Annual Mechanical Preventive Maintenance


Date, Initials
Table D-1: “Daily Mechanical

Checklist” on page 160 ,
Complete the daily, weekly, and monthly preventive maintenance
Mechanical Checklist” on
checklists. Correct all abnormal conditions observed and measured.
page 162, and Table D-3:
“Monthly Mechanical
Checklist” on page 162
Inspect filter elements and housings for dirt and sludge. Inspect filter
housings and fittings for signs of leakage and damage. Replace damaged
components as required.
Remove and inspect the reservoir screens. Record observation of the

material in the screens. Clean the screens. Inspect for damage and holes in
the screen material and its seals. Replace the screens as required.
Drain and clean the reservoir. Remove all traces of sludge and sediment
from both compartments of the reservoir and its dividers.
Table D-4: Annual Mechanical Checklist


Date, Initials
Closely inspect all gaskets and seals. Replace aged or leaking components
as required.
Fill with the correct grade and type of new oil to the mark on the sight
gauge. Close and secure the openings. Clean the exterior of the reservoir.
Coolers
Clean the exterior of the coolers with strong detergent and water.
Inspect the top tube sheet for corrosion, sediment, and sludge. If sludge is
observed, drain and clean the cooler.
Clean the fan.
Inspect filter elements and housings for dirt and sludge. Inspect filter
housings and fittings for signs of leakage and damage. Replace damaged
components as required.
Remove and inspect the reservoir screens. Record observation of the

material in the screens. Clean the screens. Inspect for damage and holes in
the screen material and its seals. Replace the screens as required.
Drain and clean the reservoir. Remove all traces of sludge and sediment
from both compartments of the reservoir and its dividers.
Closely inspect all gaskets and seals. Replace aged or leaking components
as required.
Fill with the correct grade and type of new oil to the mark on the sight
gauge. Close and secure the openings. Clean the exterior of the reservoir.
Table D-4: Annual Mechanical Checklist
D.2.5 Major Mechanical Preventive Maintenance

Refer to 7.2.3 “Major Mechanical Preventive Maintenance” on page 82 and to 7.2.2 “Shutdown Mechanical Inspections”
on page 81 for further information about the daily mechanical preventive maintenance tasks.

Date, Initials
Disassemble the crusher to the degree necessary to inspect and measure

components for these major PM tasks.
Inspect the outer eccentric bushing for excessive wear and scoring.
Replace the bushing as required.
Inspect the eccentric wear ring for excessive wear and scoring. Replace the
wear ring as required.
Inspect the inner eccentric bushing for excessive wear and scoring.
Replace the bushing as required.
Inspect the outer and inner surfaces of the eccentric for excessive wear
and scoring. Replace the eccentric as required.
Inspect the mainshaft bearing journals for scoring. Repair or replace the
shaft as required.
Inspect the condition of the bevel gear and its pinion gear. Also Inspect the
condition of the pinion bearings. Replace excessively worn components as
required.
Inspect the piston and its bushings for excessive wear and scoring. Replace
excessively worn and damaged components as required.
Table D-5: Major Mechanical Checklist


Date, Initials
Clean and dry the seal and inspect it for excessive wear and damage.
Replace the seal as required.
Table D-5: Major Mechanical Checklist
D.3 Electrical Maintenance

D.3.1 Weekly Electrical Preventive Maintenance
Refer to 7.3.1 “Running Electrical Inspections” on page 82 for further information about the daily mechanical preventive
maintenance tasks.

Date, Initials
Main Drive Motor
Inspect the bearing area temperature with a portable thermal detector;

temperatures must be in the range of 75°C to 90°C (167°F to 194°F),
depending on ambient temperature. Confirm unusually high temperatures
through the distributed control system (DCS). Excessive temperature of the
bearings may be due to damaged or worn bearings, loose mounting bolts,
excessively worn coupling elements, or misalignment.
Inspect the temperature of motor housing with a portable thermal detector;

temperature must not exceed 65.5°C (150°F). Excessive temperature of the
housing may be due to overload, mechanical defect, or phase imbalance.
Feel the motor for excessive vibration. If vibration feels excessive, confirm
with a portable vibration detector.
Vibration velocity must not exceed 2 mm (80 mils)/sec at 1X frequency.

Excessive vibration may be due to damaged or worn bearings, loose
mounting bolts, a mechanical defect, misalignment, or phase imbalance.
Listen to the motor for excessive and unusual noise. Excessive noise may
indicate mechanical or electrical defects or loose mounting bolts.
Inspect the temperature of the junction box cover. Excessive temperature

may be caused by loose power terminal connections.
Visually inspect the motor bearing areas for signs of excessive heat, such
as leaking lubricant and discolored paint. Inspect bearing area temperature
with a portable thermal detector; temperatures must not exceed 82°C
(180°F).
Excessive temperature of the bearings may be due to damaged or worn

bearings, loose mounting bolts, excessively worn coupling elements, or
misalignment.
Lubrication Oil Pump Motors
Inspect temperature of motor housing with a portable thermal detector;

with a portable vibration detector. Vibration velocity must not exceed 2 mm
(80 mils)/sec at 1X frequency. Excessive vibration may be due to damaged
or worn bearings, loose mounting fasteners, mechanical defect,
misalignment, or phase imbalance.
Table D-6: Weekly Electrical Checklist


Date, Initials
indicate mechanical or electrical defects or loose mounting fasteners.

Cooler Fan Motor(s)
(180°F).

misalignment.

Inspect the temperature of the junction box cover. It must be warm to the
touch, cooler than the housing. Excessive temperature may be caused by
loose power terminal connections.
Lubrication System Sump Tank Heaters
Inspect the temperature of the junction box cover. It must be warm to the
touch. Excessive temperature may be caused by loose power terminal
connections.
Hydraulic Adjustment System Pump Motors
(180°F).

misalignment.

indicate mechanical or electrical defects or loose mounting fasteners.

Hydraulic Adjustment System Sump Tank Heaters

Table D-6: Weekly Electrical Checklist

D.3.2 Monthly Electrical Preventive Maintenance

Refer to 7.3.2 “Shutdown Electrical Inspections” on page 82 for further information about the daily mechanical

Date, Initials
Complete the weekly preventive maintenance checklist. Correct all Table D-6: “Weekly
abnormal conditions observed and measured. Electrical Checklist” on
page 165
Main Drive Motor
Ensure the motor has been isolated from its main and control power
sources at the MCC, and try to start it from its local control panel. Open the
main lead junction box and inspect the main power terminals and the
heater terminals for signs of excessive heat. Disconnect and clean loose
Replace as required. Vacuum-clean the junction box interior, and replace
the cover.
Inspect local control panel for damaged or missing buttons, switches, and
indicators. Repair or replace as required.
Inspect power cable and conduit for signs of excessive heat and physical
damage. Repair or replace as required.
With the lubrication oil system operating normally, measure and record the
total current draw of operating pump motor and the current in each phase
at the MCC. Compare the phase currents. Each must be at least 93% of the
greatest current reading. Low phase current measurements indicate a
motor phase unbalance and may require motor replacement.
Shut down the lubrication system, lock out and tag at the MCC, and try to
start from the local control panel.
With the pump motor isolated from its power and control circuits, inspect
the power terminals for signs of excessive heat. Disconnect and clean
loose terminals until their contact surfaces are bright, and reconnect
securely.
Replace as required.
Vacuum-clean the junction box interiors, and replace the covers.
Inspect the local control panel for damaged or missing buttons, switches,
and indicators. Repair or replace as required.
Clean motor housing surfaces to assist cooling.
Cooler Pump Motors
motor phase unbalance and may require motor replacement.
Table D-7: Monthly Electrical Checklist


Date, Initials
With the pump motor isolated from its power and control circuits, Inspect
securely.
Correct all abnormal temperature, vibration, and noise conditions observed

and measured during weekly PM inspections.
Cooler Fan Motors
motor phase imbalance and may require motor replacement.
securely.
Lubrication System Reservoir Heaters
Inspect the continuity and resistance of each heater. Record results and
compare with previous measurements. Replace the elements as required.
With the heaters isolated from their power and control circuits, Inspect the
power terminals for signs of excessive heat. Disconnect and clean loose
terminals until their contact surfaces are bright, and reconnect securely.
Replace as required. Vacuum-clean the junction box interiors, and replace
the covers.
Inspect power cables and conduit for signs of excessive heat and physical
Remove the locks and tags at the MCC according to established procedure
when all maintenance and repair work has been completed, and release
the system for service.


Date, Initials
Hydraulic Adjustment Pump Motors
at the MCC. Compare the phase currents. Each must be at least 93 percent
of the greatest current reading. Low phase current measurements indicate
a motor phase unbalance and may require motor replacement.
securely.
Vacuum-clean the Vacuum-clean the junction box interiors, and replace the
covers.
Correct all abnormal temperature, vibration, and noise conditions observed

and measured during weekly PM inspections.
Hydraulic System Reservoir Heaters
Inspect the continuity and resistance of each heater. Record results and
compare with previous measurements. Replace the elements as required.
With the heaters isolated from their power and control circuits, Inspect the
power terminals for signs of excessive heat. Disconnect and clean loose
terminals until their contact surfaces are bright and reconnect securely.
Replace as required. Vacuum-clean the junction box interiors, and replace
the covers.
Inspect power cables and conduit for signs of excessive heat and physical
Mainshaft Position Indication System
Inspect the sensing unit for signs of oil leaks. If oil is observed, trace the
cause and correct. The position indicator sensing unit is located at the
bottom of the crusher.
Inspect the power and signal conduit for impact damage. Replace as
required.
Inspect the converter box cover seals for signs of leakage and damage.
Replace as required. Vacuum-clean the converter box interior, and replace
the covers.
Inspect the indicator box cover seals for signs of leakage and damage.
Replace as required. Vacuum-clean the indicator box interior, and replace
the covers.

D.3.3 Annual Electrical Preventive Maintenance

Refer to 7.3.2 “Shutdown Electrical Inspections” on page 82 for further information about the daily mechanical

Date, Initials

Electrical Checklist” on
Complete the weekly and monthly preventive maintenance checklists.
page 165 and Table D-7:
Correct all abnormal conditions observed and measured.
“Monthly Electrical
Checklist” on page 167
Main Drive Motor
Inspect all interior components for signs of excessive heat discoloration.

Closely inspect all insulation for signs of blistering, discoloration, and
charring. Inspect all electrical connections for frayed and damaged
insulation, cracked varnish, and coil movement.
7.6 “Stator Insulation

Measure the stator insulation resistance at 1,000 VDC. Resistance Measurement”
on page 84
Measure the air gap between the rotor and stator at eight equally spaced
locations around the rotor. Record the measurements and compare with
previous measurements.
Inspect all nuts and bolts to ensure they are tight. This is particularly
important for fasteners on the rotor and the fasteners that could fall onto
the rotor if loosened during operation.
Inspect the main lead terminals for signs of excessive heat and corona.
Remove all loose connections, clean their contact surfaces until bright, and
reconnect securely.
Inspect the interior again for loose dirt and dust. Vacuum-clean again if
required.
Install the end covers and the main lead junction box cover/door. Clean the
exterior surfaces.
Local Control Panel
Inspect the face panel for damaged and missing components. Replace
items as required.
Open the panel/door to gain access to the interior of the control box.
Inspect all wiring for exposed conductors. Inspect terminal strips for signs
of excessive heat. Inspect PCBs for damaged components. Repair or
Vacuum-clean the interior of the control panel box. Clean the exterior
surfaces.
Replace and secure the junction box cover. When all maintenance and
repair work has been completed, remove the lock and tag at the MCC
according to established procedure, and release the unit for service.

Remove the junction box cover, disconnect the power leads, and measure
Resistance Measurement”
the stator insulation resistance at 500 VDC.
on page 84
Inspect power terminals for signs of excessive heat and arcing. Replace as
required. Clean power terminal contact surfaces until bright.
Table D-8: Annual Electrical Checklist


Date, Initials
Megger the power cables from the MCC. Repair or replace cables with low
resistance insulation. Reconnect power terminals in the junction box and at
the MCC.
Support the shaft, remove the outboard end bell, and blow out the motor
interior with compressed air at 207 kPa (30 psi). Reinstall the end bell, and
clean the outside surface of the housing.
Remove the fan cover, inspect the fan for cracks, and clean the blades.
Inspect the outboard bearing housing for leaks and signs of excessive heat.
Replace the cover.
Inspect bearing radial and axial clearances at the coupling hub with a dial
indicator. Record results, and compare with previous measurements.
Measurements in excess of 0.076 mm (0.003 in) may indicate a
requirement for bearing replacement.
Cooler Pump Motors

on page 84
Inspect the power cables from the MCC. Repair or replace cables with low
the MCC.
Replace the cover.
Cooler Fan Motors

on page 84
the MCC.
Replace the cover.
Measurements in excess of 0.076 mm (0.003 in) may indicate a need for
bearing replacement.


Date, Initials
Lubrication System Reservoir Heaters
When the oil has been drained from the reservoir, Inspect the surfaces of
the heaters for hot spot discoloration, physical damage, and erosion.
Inspect the condition of mounting gaskets and isolators. Replace elements
as required.
Inspect the physical condition of the thermal switches and their control
wiring. Repair or replace as required.
Ensure that preventive maintenance has been completed on the control

cabinet. Remove the locks and tags at the MCC according to established
procedure when all maintenance and repair work has been completed, and
release the unit for service.
Hydraulic Adjustment Pump Motors

on page 84
the MCC.
Replace the cover.
Hydraulic Adjustment System Reservoir Heaters
When the oil has been drained from the reservoir, Inspect the surfaces of
the heaters for hot spot discoloration, physical damage, and erosion.
Inspect the condition of mounting gaskets and isolators. Replace elements
as required.
Inspect the physical condition of the thermal switches and their control
wiring. Repair or replace as required.
Ensure that preventive maintenance has been completed on the control

cabinet. Remove the locks and tags at the MCC according to established
procedure when all maintenance and repair work has been completed, and
release the unit for service.

D.4 Instrument Maintenance

D.4.1 Quarterly Instrument Preventive Maintenance
Refer to 7.4 “Instrument Preventive Maintenance” on page 83 for further information about the daily mechanical

Date, Initials
Crusher Assembly Components
Countershaft Bearing Temperature Sensor (Inboard Bearing)
Remove the junction box cover and inspect the seal for signs of dust and
moisture entry. Repair or replace as required.
Inspect the wiring terminals for signs of excessive heat. Disconnect loose
terminals, clean contact surfaces until bright, and reconnect the terminals.
Inspect conduit and wire for signs of excessive heat and physical damage.
Countershaft Bearing Temperature Sensor (Outboard Bearing)
Main Drive Motor Stator Temperature Sensor
Main Drive Motor Rotor Temperature Sensor
Motor Protection Relay(s)
Inspect the instrument for physical damage.
Clean and Inspect the condition of the display.
Table D-9: Quarterly Instrument Checklist


Date, Initials
Inspect wiring terminals for signs of excessive heat and tightness. Remove
loose terminals, clean until bright, and reconnect.
Inspect card rack for damage or burned components.
Lubrication System Flow Switch/Transmitter—Countershaft
Inspect the instrument for physical damage and signs of leakage. Replace
as required.
Clean the display glass and the exterior of the enclosure.
Remove the junction box cover and Inspect the seal for signs of dust and
moisture entry. Repair or replace the seal as required.
Inspect wiring terminals for signs of excessive heat. Disconnect loose

With the oil at the operating temperature, observe the flow meter. Adjust
the switch setting as required; using the globe valve after the switch reduce
the flow while observing the flow rate indicator and the flow when the
switch actuates.
With the oil at the operating temperature and with an independent DC

power supply, inspect the span (4 to 20 mA) and zero settings. Compare
with no-flow condition. Set zero as required.
Flow Switch/Transmitter—Hydraulic Bottom (Inner Bushing)
as required.

switch actuates.

Flow Switch/ Transmitter—Bottom Shell (Outer Eccentric Bushing)
as required.


Date, Initials

switch actuates.

Pressure Indicating Transmitter
as required.

With calibration tester, Inspect span (4 to 20 mA) and zero settings.

Compare with pressure at the sensor. Set Zero as required.
Pressure Indicator (Gauge)
Inspect the gauge for signs of leakage and damage. Repair or replace as
required.
Clean the glass and enclosure.
Inspect last calibration date. Calibrate if required.
Hydraulic System Pressure Relief Valve
Inspect the valve body for physical damage and signs of leakage. Replace
as required.
Lubrication Skid
Temperature Indicator(s) (Gauge)
required.
Temperature Sensor(s)/ Transmitter(s)
as required.


Date, Initials
With a temperature calibrator inspect span (4-20 ma) and zero settings.
Compare with temperature at the sensing element. Set zero as required.
Level Gauge
Inspect the instrument for signs of leakage and heat damage. Repair or
Inspect and reconcile with visual observation of reservoir level.
Level Indicating Transmitter
Inspect the instrument for physical damage and signs of leakage. Repair or
With an independent DC power supply, inspect span (4-20 mA) and zero
settings. Compare with sensing element. Set zero as required.
Pressure Relief Valve(s)
Inspect set points as listed on the drawings and bill of material.
Inspect valve body and bonnet for damage and leaks. Repair or replace as
required.
Ensure valve mounting is secure.
Pressure Indicator(s) (Gauge)
required.


Date, Initials
Pressure Differential Indicating Transmitter
Inspect the instrument housing for signs of physical damage and excessive
heat. Replace unit as required.
With a pressure calibrator, inspect span (4-20 mA) and zero settings.
Compare with ambient pressure differential at the sensing locations. Set
zero as required.
Lubrication Oil Coolers Ambient Air Temperature Sensor(s)/

Transmitter(s)
Inspect the housing for physical damage and signs of leakage. Replace as
required.
Lubrication Oil Coolers Temperature Indicator(s) (Gauge)
required.
Motorized Ball Valve
Inspect the housing for signs of physical damage and excessive heat.
Repair or replace the unit as required.
Apply appropriate input voltage and ensure that switch opens and closes.
Reconcile position of valve.


Date, Initials
Hydraulic Skid
Hydraulic Adjustment Skid Level Gauge
Inspect the instrument for signs of leakage and heat damage. Repair or
Inspect and reconcile with visual observation of reservoir level.
Level Indicating Transmitter
Inspect the instrument for physical damage and signs of leakage. Repair or
With a calibrator Inspect span (4-20 mA) and zero settings. Compare with
sensing element. Set zero as required.
Pressure Indicator(s) (Gauge)
required.
Temperature Indicator(s) (Gauge)
required.
Temperature Sensor/Transmitter
as required.
With a temperature calibrator, Inspect span (4-20 mA) and zero settings.
Compare with temperature at the sensing element. Set zero as required.


Date, Initials
Spider Bushing Lubrication System
Spider Bushing Lubrication System Pressure Indicator(s) (Gauge)
required.
Pressure Indicating Transmitter
as required.

With calibration tester, inspect span (4 to 20 mA) and zero settings.

Compare with pressure at the sensor. Set Zero as required.
End of Cycle Switch
Inspect the housing for physical damage and signs of leakage. Replace as
required.
Manually actuate switch and Inspect for switch actuation.
Controller
Inspect the instrument for physical damage. Replace as required.
Inspect the power and signal cables and plugs for damage and bare
Clean the display.


Date, Initials
Inspect the instrument for physical damage. Replace as required.
Inspect the signal cables and plugs for damage and bare conductors.
Inspect the cabinet cover seal for signs of dust and moisture entry. Repair

181
Appendix E: Parts List/Bill

of Materials
E.1 1000730929: Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

182 Appendix E Parts List/Bill of Materials
E.1 1000730929: Parts List
Original
Equipment Parts list
Gyratory Crusher, TSU, 1300x1800
Queensland, Australia
1300 X 1800 TSU Gyratory
Project Number:9232510974
Document Type:List
Created by:rami Doc:1000730929

Approved by:TRTH Rev:1
FLSmidth,03-Sep-2021
Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited
purposes of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this
document is not permitted without the prior written permission of FLSmidth A/S.

Appendix E Parts List/Bill of Materials 183
1000730929: Parts List (Sheet 2)

Gyratory Crusher, TSU, 1300 x 1800
Part no. 1000606584 Rev .02
Page 2 of 57
Parts list report explanation
This parts list consists of pages in the following sequence:
A) General information section:

Cover - identifies the specific parts number from which the parts list has been drawn. Explanation - provides
explanation of parts list structure.
B) Table of contents - provides an overall view of all assemblies in parts list report
C) Parts lists
Column 1: Find no - Identifies the parts on the corresponding assembly drawing.
Column 2: Description - Contains a defining description of component or equipment.
Column 3: Part no. - provides the part number associated to the component described.
Column 4: Drawing no. - Provides drawing number (if any) for part.
Column 5: Quantity - the quantity of a component needed for the equipment/assembly.
Column 6: U/M - Indicates unit of measure for quantity value. Empty field means each.
Column 7: Mat. - States a code for the material to be used for the Find Number. The code refers to
material data sheet in the FLSmidth material list. Alternatively a specific material specification
may be included on the drawing. If the two codes or specifications are different, this parts list
specification shall be used.
Column 8: Total weight kg. - indicates total weight for the quantity of components listed.
The weight is rounded up to a whole number.
All units of measure are in millimeters unless specified otherwise.
Common parts list report structure:
Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.


Part no. 1000606584 Rev .02
Page 3 of 57
Table of Contents
Description Part. Part No. Drawing no. Qty. Total Weight Level Page
rev. kg. No.
Gyratory Crusher, TSU, 1300 x 1800 .02 1000606584 220404 Top 5

asm.
Assembly, Gyratory crusher, TS 1300 x 1800 1 1000511419 1.0 166659 1 6

Assembly, Spider, Gyratory Crusher, TS, 1300 x 3 1000494407 1000494407 1.0 16157 2 7
1800 1000135380
1000024420
70011456_0_1-
PDB1
Assembly, Top Shell, Gyratory Crusher, TS, 2 1000494882 1000494882 1.0 29581 2 9
1300 x 1800 ED90.500.002-
PDB1
1000024420
Assembly, Middle Shell, Gyratory Crusher, TS, 1 1000495143 520530 1.0 27718 2 10
1300 x 1800 13072581-PDB1
Bottom Shell Assembly, Gyratory Crusher, TS, 3 4377424-PDB1 13037588-PDB1 1.0 20430 2 11
1300 x 1800 520530
Assembly, Bottom Shell Liner, Gyratory 2 1000495367 1000495367 1.0 1609 2 13
Crusher, TS, 1300 x 1800 1000024420
Assembly, Dust Bonnet, Gyratory Crusher, TS, 4 1000497921 1000497921 1.0 2110 2 15
1300 x 1800 1000024420
1000524740
Assembly (Dual Throw), Eccentric, Gyratory 3 1000496410 1000496410 1.0 5257 2 17
Crusher, TS, 1300 x 1800 1000135380
1000024420
Assembly, Hydraulic Cylinder, Gyratory 1 1000531721 1000531721 1.0 4845 2 18
Crusher, TS, 1300 x 1800 ED90.500.002-
PDB1
1000024420
Assembly, Mainshaft, Gyratory Crusher, TS, 2 1000500157 1000500157 1.0 34213 2 20
1300 x 1800 1000135380
1000024420
1000198038
Dust Seal Ring Assembly 0 6168369-PDB1 13072248-PDB1 1.0 61 3 22
Assembly, Concave, Gyratory Crusher, TS, 1300 2 1000519350 1000519350 1.0 21192 2 23
x 1800 1000024420
Counter shaft assembly, Type TS, Diameter 1800 8 4422511-PDB1 70019642-PDB1 1.0 1489 2 24
mm, Opening size 1100 mm ED90.500.002-
PDB1
520530
13036470-PDB1
Lube & Hydraulic System, Gyratory Crusher, 3 1000657353 1000024420 1.0 3200 1 27
TSU, 1300x1800 1000625613
1000608222
Lubrication Components 3 1000657354 1000024420 1.0 841 1 28
1000608222
Hydraulic Components 2 1000658906 1000024420 1.0 313 1 30
1000608222
Spider Lubrication System 2 1000636190 1000636190 1.0 36 1 31
1000024420
Lincoln Electrical Operated Barrel Pump 5 3568534-PDB1 1.0 29 2 32
Assembly
XL Series Manifold Feeder 10 3466951-PDB1 520530 1.0 0.0 2 33
Mantle Position Indicator 3 7137260-PDB1 4.500767-PDB1 1.0 24 1 34
3.507050-PDB1
70010350-PDB1


Part no. 1000606584 Rev .02
Page 4 of 57
Description Part. Part No. Drawing no. Qty. Total Weight Level Page
rev. kg. No.
Tools, Gyratory Crusher, TSU, 1300x1800 1 1000718742 70010350-PDB1 1.0 499 1 35

Hydraulic Jack Assembly 200 Ton 1 1000722366 10453395-PDB1 1.0 291 2 36
Hydraulic Jack Assembly 1 1000722367 10453395-PDB1 1.0 291 3 37
Service Box P115 1 4082757-PDB1 ED90.500.002- 1.0 7.7 2 38
PDB1
Assembly, Countershaft Extension, Gyratory 2 1000614472 1000614472 1.0 564 1 39
Crusher, TSU, 1300 x 1800 1000024420
Assembly, Drive guard, Gyratory Crusher, 2 1000614634 1000614634 1.0 201 1 40
TSU, 1300 x 1800 1000024420
Blower Assembly Schematic - 1400 Series 1 1000614466 1000614466 1.0 38 1 42
1000024420
Assembly, Oversize Mainshaft, Gyratory 1 1000714197 1000714197 1.0 34874 1 43
Crusher, TS, 1300 x 1800 1000135380
1000024420
1000198038
Dust Seal Ring Assembly 0 6168369-PDB1 13072248-PDB1 1.0 61 2 45
Assembly, Concave Installation & Removal 1 1000716863 1000024420 1.0 10728 1 46
Tools, Gyratory crusher, TS, 1300x1800
Assembly, Concave Installation Ring 1 1000520967 1000520967 1.0 5292 2 47
1000024420
Assembly, Lower Concave Installation Ring 1 1000521111 1000521111 1.0 1792 3 48
1000024420
Assembly, Middle Concave Installation ring 2 1000521942 1000521942 1.0 1518 3 49
1000024420
Assembly, Upper Concave Installation Ring 1 1000521945 1000521945 1.0 1983 3 50
1000024420
Assembly, Concave Removal Pan 1 1000716626 1000716626 1.0 5359 2 51
1000024420
Assembly, Lower Concave Removal Pan 1 1000652444 1000652444 1.0 1407 3 52
1000024420
Assembly, Middle Concave Removal Pan 1 1000670704 1000670704 1.0 1540 3 53
1000024420
Assembly, Upper Concave Removal Pan 1 1000671390 1000671390 1.0 2412 3 54
1000024420
Assembly, Bonnet cover 1 1000521941 1000521941 1.0 77 2 55
1000024420
Assembly, Foundation bolt, Gyratory 2 1000633857 1000633857 1.0 458 1 56
Crusher, TSU, 1300x1800 1000024420
Assembly, Top Shell Seal 1 1000614471 1000614471 1.0 1970 1 57
1000024420


Part no. 1000606584 Rev .02
Page 5 of 57
Part no.: 1000606584

Gyratory Crusher, TSU, 1300 x 1800 Rev. no.: .02
Unit Weight: 220404 kg
Total
Find
Description Part No. Drawing no. Qty. UOM Mat. Weight
No.
kg.
00.01 Assembly, Gyratory crusher, TS 1300 1000511419 1.0 EA 166659

x 1800
02.01 Lube & Hydraulic System, Gyratory 1000657353 1000024420 1.0 EA 3200
Crusher, TSU, 1300x1800 1000625613
1000608222
02.02 Lubrication Components 1000657354 1000024420 1.0 EA 841
1000608222
02.03 Hydraulic Components 1000658906 1000024420 1.0 EA 313
1000608222
03.01 Spider Lubrication System 1000636190 1000636190 1.0 EA 36
1000024420
04.01 Mantle Position Indicator 7137260-PDB1 4.500767-PDB1 1.0 EA 24
3.507050-PDB1
70010350-PDB1
05.01 Tools, Gyratory Crusher, TSU, 1000718742 70010350-PDB1 1.0 EA 499
1300x1800
07.01 Assembly, Countershaft Extension, 1000614472 1000614472 1.0 EA 564
Gyratory Crusher, TSU, 1300 x 1800 1000024420
07.02 Assembly, Drive guard, Gyratory 1000614634 1000614634 1.0 EA 201
Crusher, TSU, 1300 x 1800 1000024420
08.01 Blower Assembly Schematic - 1400 1000614466 1000614466 1.0 EA 38
Series 1000024420
10.01 Assembly, Oversize Mainshaft, 1000714197 1000714197 1.0 EA 34874
Gyratory Crusher, TS, 1300 x 1800 1000135380
1000024420
1000198038
11.01 Assembly, Concave Installation & 1000716863 1000024420 1.0 EA 10728
Removal Tools, Gyratory crusher, TS,
1300x1800
18.01 Assembly, Foundation bolt, Gyratory 1000633857 1000633857 1.0 EA 458
Crusher, TSU, 1300x1800 1000024420
20.01 Assembly, Top Shell Seal 1000614471 1000614471 1.0 EA 1970
1000024420


Part no. 1000606584 Rev .02
Page 6 of 57
Part no.: 1000511419

Rev. no.: 1
Assembly, Gyratory crusher, TS 1300 x 1800 Unit Weight: 166659 kg
Parent assembly part no.: 1000606584
Total
Find
No.
kg.
01.01 Spider Cap 1000494236 13071308-PDB1 1.0 EA Cast Mangane 2057

520530 se
7.500173-PDB1
01.02 Assembly, Spider, Gyratory Crusher, 1000494407 1000494407 1.0 EA 16157
TS, 1300 x 1800 1000135380
1000024420
70011456_0_1-
PDB1
01.03 Assembly, Top Shell, Gyratory 1000494882 1000494882 1.0 EA 29581
Crusher, TS, 1300 x 1800 ED90.500.002-
PDB1
1000024420
01.04 Assembly, Middle Shell, Gyratory 1000495143 520530 1.0 EA 27718
Crusher, TS, 1300 x 1800 13072581-PDB1
01.05 Bottom Shell Assembly, Gyratory 4377424-PDB1 13037588-PDB1 1.0 EA 20430
Crusher, TS, 1300 x 1800 520530
01.06 Assembly, Bottom Shell Liner, 1000495367 1000495367 1.0 EA 1609
01.07 Assembly, Dust Bonnet, Gyratory 1000497921 1000497921 1.0 EA 2110
Crusher, TS, 1300 x 1800 1000024420
1000524740
01.08 Assembly (Dual Throw), Eccentric, 1000496410 1000496410 1.0 EA 5257
1000024420
01.09 Assembly, Hydraulic Cylinder, 1000531721 1000531721 1.0 EA 4845
Gyratory Crusher, TS, 1300 x 1800 ED90.500.002-
PDB1
1000024420
01.10 Assembly, Mainshaft, Gyratory 1000500157 1000500157 1.0 EA 34213
Crusher, TS, 1300 x 1800 1000135380
1000024420
1000198038
01.11 Assembly, Concave, Gyratory 1000519350 1000519350 1.0 EA 21192
Crusher, TS, 1300 x 1800 1000024420
01.12 Counter shaft assembly, Type TS, 4422511-PDB1 70019642-PDB1 1.0 EA 1489
Diameter 1800 mm, Opening size ED90.500.002-
1100 mm PDB1
520530
13036470-PDB1


Part no. 1000606584 Rev .02
Page 7 of 57
Assembly, Spider, Gyratory Crusher, TS, 1300 x Part no.: 1000494407

Rev. no.: 3
1800 Unit Weight: 16157 kg
Drawing No: 1000494407, 1000135380, 1000024420, 70011456_0_1-PDB1 Parent assembly part no.: 1000511419
Total
Find
No.
kg.
01.02. Spider 1000494391 13032020-PDB1 1.0 EA Cast steel 11957

01.03 520530
ED90.500.002-
PDB1
3.504151-PDB1
1.504889-PDB1
70007193-PDB1
01.02. Spider Bushing 1000494395 70008368-PDB1 1.0 EA Bronze 513
01.05 13071312-PDB1
520530
01.02. Screw, hexagon head, ISO 4017, 1000007099 6.0 EA Plain Carbon S 2.5
01.07 M24x80, 8.8 teel
01.02. Washer, spring lock, form A, DIN 1000000524 6.0 EA Plain Carbon S 0.1
01.09 128, 24 teel
01.02. Mounting plate, Grease hose, 1_2 1000140617 1000024420 1.0 EA ASTM A36 1.0
01.11 NPT 1000135522
1000024422
01.02. Spider hose clamp gasket 2829131-PDB1 720-82-1-0211- 1.0 EA Non-Asbestos 0.0
01.13 PDB1 Gasketing
720-85-1-6801-
PDB1
01.15 M12x30, 8.8, electroplated teel
01.02. Washer, spring lock, form A, DIN 1000000485 12.0 EA Plain Carbon S 0.1
01.17 128, 14 teel
01.02. Hose Assembly, Length 102 in, Hose 3943731-PDB1 1.0 EA 1.0
01.19 size 1/2 in
01.02. Spider Seal, Thickness 20.5 mm, 4595902-PDB1 1.0 EA 0.0
02.01 Shaft diameter 570 mm, Bore
diameter 620 mm
01.02. Spider Seal Retainer 1000494573 1000134632 1.0 EA 1100 15
02.03 1000024422
1000024420
01.02. Spider Shield 1000494583 13071469-PDB1 2.0 EA Cast manganese 3032
02.07 520530
7.500173-PDB1
01.02. Bolt, Taper head 1000165033 1000164959 4.0 EA ASTM A36 64
02.11
01.02. Washer, Taper bolt 1000135521 1000024420 4.0 EA ASTM A36 4.0
02.13 1000135521
1000024422
01.02. Nut, hexagon, ISO 4032, M48, 8, 1000006031 8.0 EA Plain Carbon S 7.3
02.15 electroplated teel
01.02. Heavy Duty Crusher Liner Epoxy 3454826-PDB1 1000421140 5.0 EA 113
02.17
01.02. Bolt, spider 1000150568 1000134634 4.0 EA AISI 1020 356
02.19


Part no. 1000606584 Rev .02
Page 8 of 57
Total
Find
No.
kg.
01.02. Nut, Spider bolt, M110 1000139181 1000135525 4.0 EA AISI 1020 68
02.21 1000024420
01.02. Washer, Spider bolt, M110 1000140614 1000135524 4.0 EA AR 235 9.0
02.23 1000024420
01.02. Screw, hexagon head, ISO 4017, 1000187974 24.0 EA Plain Carbon S 14
03.01 M20x200, 10.9 teel


Part no. 1000606584 Rev .02
Page 9 of 57
Assembly, Top Shell, Gyratory Crusher, TS, 1300 x Part no.: 1000494882
Rev. no.: 2
Drawing No: 1000494882, ED90.500.002-PDB1, 1000024420 Parent assembly part no.: 1000511419
Total
Find
No.
kg.
01.03. Top Shell 1000495052 13071530-PDB1 1.0 EA cast Steel 26601

01.03 13071529-PDB1
ED90.500.002-
PDB1
520530
70007193-PDB1
1000524745
01.05
01.03. Top Shell Wear Plate 1000494774 520530 2.0 EA 500 BHN /Luk 664
01.07 13071433-PDB1 ens 500 F
01.03. Top Shell Wear Plate 1000494779 13071436-PDB1 2.0 EA 500 BHN / Luk 680
01.09 520530 ens 500 F
01.03. Top Shell Wear Plate 1000494800 520530 2.0 EA 500 BHN / Luk 664
01.11 13071472-PDB1 ens 500 F
01.03. Web Liner 4455354-PDB1 13033760-PDB1 2.0 EA 500 BHN / LU 110
01.13 KENS 500F
01.03. Web Liner 4455355-PDB1 13033761-PDB1 2.0 EA 500 BHN / LU 110
01.15 KENS 500 F
01.03. Liner Mounting Disc 2829811-PDB1 70008359-PDB1 16.0 EA ASTM A128 32
01.17 ED90.500.002-
PDB1
7.500173-PDB1
3.504267-PDB1
01.03. Bolt, 0213, L 180 mm, d M24 1188653-PDB1 4.0 EA 8.8 2.8
01.19
01.03. Hexagon head bolt, 0235, M24 x 200 906632-PDB1 12.0 EA 8.8 9.7
01.21 Lg
01.03. Hexagon nut, 0122, d M24 4095850-PDB1 16.0 EA 8 1.9
02.01
01.03. Washer, 0701, Screw diameter M24 614-PDB1 16.0 EA Steel 0.5
02.03
01.03. Shell Bolt, L 340 mm, d M72 4465469-PDB1 24.0 EA DIN 931, 8.8 485
02.05
01.03. NUT, Pitch 6 mm, d M72 mm 272214-PDB1 7.000304-PDB1 48.0 EA (ISO 8), 2110 130
02.07


Part no. 1000606584 Rev .02
Page 10 of 57
Assembly, Middle Shell, Gyratory Crusher, TS, 1300 Part no.: 1000495143
Rev. no.: 1
x 1800 Unit Weight: 27718 kg
Drawing No: 520530, 13072581-PDB1 Parent assembly part no.: 1000511419
Total
Find
No.
kg.
01.04. Middle Shell 1000495138 70007193-PDB1 1.0 EA Cast Steel 26447

01.03 1.504888-PDB1
ED90.500.002-
PDB1
520530
13031989-PDB1
01.04. Concave Ring Segment 1000495141 13071495-PDB1 2.0 EA 1100 206
01.05 520530
01.04. Concave Ring Segment 1000495142 13071496-PDB1 2.0 EA 1100 172
01.07 520530
01.09
01.10
01.04. NUT, Pitch 6 mm, d M72 mm 272214-PDB1 7.000304-PDB1 46.0 EA (ISO 8), 2110 124
01.11
01.04. Middle Shell Liner 1000495140 520530 12.0 EA AR 235 228
01.13 13071478-PDB1
01.04. Adjustment Disc 1000495139 520530 24.0 EA 1100 24
01.15 13019189-PDB1
01.04. Hexagon socket countersunk head cap 4816575-PDB1 24.0 EA 8.8 31
01.17 screw, Length 220 mm, Size 20
01.04. Nut, 0113, d M20 434-PDB1 48.0 EA 8 3.4
01.19
01.21
01.04. Steel Washer, Thickness 9.5 mm, 4650082-PDB1 4.0 EA 1.2
01.23 Inner diameter 75.1 mm, Outer
diameter 105.0 mm


Part no. 1000606584 Rev .02
Page 11 of 57
Bottom Shell Assembly, Gyratory Crusher, TS, 1300 Part no.: 4377424-PDB1
Rev. no.: 3
Drawing No: 13037588-PDB1, 520530 Parent assembly part no.: 1000511419
Total
Find
No.
kg.
01.05. Bottom Shell 4381616-PDB1 13033753-PDB1 1.0 EA ASTM A27 Gr 19352

01.03 1000583727 ade 70-40
70007193-PDB1
1000524741
ED90.500.002-
PDB1
70008359-PDB1
13037281-PDB1
13033752-PDB1
13033754-PDB1
1.504889-PDB1
01.05. Outer Eccentric Bushing 4453347-PDB1 13034533-PDB1 1.0 EA Bronze 885
01.05 2.707906-PDB1
70008368-PDB1
13034534-PDB1
01.05. Pipe Cap, Thread diameter 1 NPT 3680153-PDB1 1.0 EA Forged STEEL 0.0
01.07
01.09 size 1 in
01.05. Hose Assembly, Length 54 in, 4664408-PDB1 1.0 EA 3.0
01.11 Diameter 1½ in
01.05. Hose Assembly, Length 54 in, 4714155-PDB1 1.0 EA 3.0
01.13 Diameter 1½ in
01.05. NEOPRENE SHEET, Length 330 4113951-PDB1 3.0 EA NEOPRENE 3.0
01.15 mm, Thickness 6 mm, Width 102 mm
01.05. Access Port Cover 3660459-PDB1 13037824-PDB1 3.0 EA ASTM-A36 39
01.17
01.05. CIRCULAR GASKET 2829861-PDB1 7.500085-PDB1 3.0 EA Non-Asbestos 3.0
01.19
01.05. Screw, 0223, L 35 mm, d M12 3588-PDB1 12.0 EA 8.8 0.5
01.21
01.05. Spring washer, 0722, d M12 917796-PDB1 12.0 EA Spring steel 0.3
01.23
01.05. ACCESS PORT COVER 3660462-PDB1 3.505269-PDB1 1.0 EA ASTM A36 6.0
02.01
01.05. CIRCULAR GASKET 2829861-PDB1 7.500085-PDB1 1.0 EA Non-Asbestos 1.0
02.03
02.05
02.07
01.05. Threaded Bar, Rod diameter 36 mm, 4467566-PDB1 24.0 EA AISI 4340 Allo 96
02.09 Length 500 mm y steel, anneale
d min 115000 p
si tnsl str
01.05. Adapter 2611548-PDB1 1.0 EA 1.0
02.11
01.05. Adhesive, Container volume 50 ml 484625-PDB1 2.0 EA 0.2
02.13


Part no. 1000606584 Rev .02
Page 12 of 57
Total
Find
No.
kg.
01.05. RESISTANCE TEMPERATURE 3678399-PDB1 1.0 EA 0.0

02.15 DETECTOR
01.05. DETECTOR HOLDER 3233276-PDB1 3.0 EA 0.0
02.17
02.19 DETECTOR, Note 1 100 Ohm,
Platinum, 3 Wire, 0.00385 Ohm/
Ohm/C
02.21 DETECTOR
01.05. Nut, 0113, d M36 1203-PDB1 48.0 EA 8 20
02.23
03.01
01.05. RTD INSERT 3702326-PDB1 39002407-PDB1 1.0 EA ASTM A36 0.2
03.03
01.05. Adapter 4714158-PDB1 1.0 EA 1.0
03.05
01.05. Plug, pipe, square head, solid, NPT, 1000151643 1.0 EA Plain Carbon S 0.7
03.07 ASME B16.14, 2 in teel
01.05. Temperature transmitter 4394072-PDB1 3.0 EA 6.0
03.09
01.05. BRACKET ASSEMBLY 2829850-PDB1 4.500643-PDB1 1.0 EA ASTM A36 4.0
03.23 ED90.500.002-
PDB1
02 MACHINE I.D. PLATE 4413852-PDB1 20088405-PDB1 1.0 EA Aluminum 0.3


Part no. 1000606584 Rev .02
Page 13 of 57
Assembly, Bottom Shell Liner, Gyratory Crusher, Part no.: 1000495367

Rev. no.: 2
TS, 1300 x 1800 Unit Weight: 1609 kg
Drawing No: 1000495367, 1000024420 Parent assembly part no.: 1000511419
Total
Find
No.
kg.
01.06. Cap Liner 1 1000527383 1000527383 2.0 EA ASTM A128A 166

01.03 1000024423 Aust. Mn (18
1000024420 %)
1000134858
01.06. Cap Liner 2 1000531318 1000531318 2.0 EA ASTM A128A 132
01.05 1000024423 Aust. Mn (18
1000024420 %)
1000134858
01.06. Rib Liner 1 4512396-PDB1 13036115-PDB1 2.0 EA AR 500F 126
01.07
01.09
01.11
01.13
01.06. Countershaft Cap Liner 1 1000527789 1000527789 1.0 EA ASTM A128A 145
01.17 1000024423 Aust. Mn (18
1000024420 %)
1000134858
01.06. Countershaft Cap Liner 2 1000531319 1000531319 1.0 EA ASTM A128A 147
01.19 1000024423 Aust. Mn (18
1000024420 %)
1000134858
01.06. Countershaft Side Liner 1 4512664-PDB1 13036122-PDB1 1.0 EA AR 500F 32
01.21
01.23
02.01
02.03
01.06. Outer Shell Liner 1 4512678-PDB1 13036126-PDB1 1.0 EA AR 235F 66
02.05
02.07
02.09
02.11
01.06. Outer Wall Liner 1 4513048-PDB1 13036130-PDB1 1.0 EA AR 235F 71
02.13
01.06. Outer Wall Liner 2 4513053-PDB1 13036131-PDB1 1.0 EA AR 235F 66
02.15
01.06. ADJUSTMENT DISC 3637003-PDB1 ED90.500.002- 24.0 EA ASTM A36 24
02.17 PDB1
2.506591-PDB1
01.06. Liner Mounting Disc 2829811-PDB1 70008359-PDB1 8.0 EA ASTM A128 16
02.19


Part no. 1000606584 Rev .02
Page 14 of 57
Total
Find
No.
kg.
ED90.500.002-
PDB1
7.500173-PDB1
3.504267-PDB1
01.06. Countersunk Bolt, Length 200 mm, 6322042-PDB1 24.0 EA 10.9 16
02.21 Thread M20x2.5
01.06. Nut, 0113, d M20 434-PDB1 48.0 EA 8 3.4
02.23
01.06. Bolt, 0213, L 200 mm, d M24 3261701-PDB1 8.0 EA 8.8 0.4
03.01
01.06. Nut, 0113, d M24 610-PDB1 16.0 EA 8 1.9
03.03
01.06. Oversize Flat Washer, Thickness 8 3253860-PDB1 8.0 EA STEEL 5.4
03.05 mm, Inner diameter 26 mm, Outer
diameter 120 mm
03.07


Part no. 1000606584 Rev .02
Page 15 of 57
Assembly, Dust Bonnet, Gyratory Crusher, TS, 1300 Part no.: 1000497921
Rev. no.: 4
Drawing No: 1000497921, 1000024420, 1000524740 Parent assembly part no.: 1000511419
Total
Find
No.
kg.
01.07. Dust Bonnet 1000510906 1000024420 1.0 EA ASTM A27 GR 444

01.03 1000510906 ADE 70-40
1000024423
1000134855
01.07. Gear Cover 1000510890 1000510890 1.0 EA ASTM A27 GR 814
01.05 1000024423 ADE 70-40
1000134855
1000024420
01.07
01.07. Screw, cap, hexagon socket head, ISO 1000012495 12.0 EA Plain Carbon S 6.6
01.09 4762, M24x110, 8.8 teel
01.07. Pressure Ring 4453457-PDB1 70008368-PDB1 1.0 EA ASTM B584 U 62
01.11 13034181-PDB1 NS No. C93700
01.13
01.07. Liner, hub 1000498166 1000024420 1.0 EA ASTM A36 St 165
01.15 1000024422 eel
1000498166
01.17 1000024422 eel
1000498167
01.19 1000024422 eel
1000498168
01.07. Plate, Fish 1000499478 1000024420 1.0 EA ASTM A36 St 17
01.21 1000024422 eel
1000499478
01.07. Plate, Fish 1000499479 1000024420 2.0 EA ASTM A36 St 38
01.23 1000024422 eel
1000499479
02.01
02.03
01.07. Gasket, Dust Bonnet 1000524746 1000024420 1.0 EA GARLOCK 30 0.4
02.05 1000524746 00
1000024422
01.07. Oil Seal Ring 4455357-PDB1 13034182-PDB1 1.0 EA Teflon 13
02.07
01.07. Liner - Cone Plate 1000510840 1000024422 4.0 EA AR 500 212
02.09 1000510840
1000024420
01.07. Washer, spring lock, form B, DIN 1000194523 12.0 EA Plain Carbon S 0.1
02.11 127, 16, electroplated teel
01.07. RTV Silicone Gasket 3640007-PDB1 1.0 EA 0.5
02.13
01.07. Washer, spring lock, form B, DIN 1000194525 12.0 EA Plain Carbon S 0.2
02.15 127, 20, electroplated teel


Part no. 1000606584 Rev .02
Page 16 of 57
Total
Find
No.
kg.

02.17
02.19 4762, M16x40, 8.8 teel
01.07. Shim Pack 4465429-PDB1 13034180-PDB1 1.0 EA 1100 28
02.21
02.23 M20x70, 8.8 teel


Part no. 1000606584 Rev .02
Page 17 of 57
Assembly (Dual Throw), Eccentric, Gyratory Part no.: 1000496410

Rev. no.: 3
Crusher, TS, 1300 x 1800 Unit Weight: 5257 kg
Total
Find
No.
kg.
01.08. Eccentric (Dual Throw) 1000496391 520530 1.0 EA Cast Steel 2206
01.03 70007195-PDB1
13071719-PDB1
01.08. Spiral bevel gear data 4455599-PDB1 70008179-PDB1 1.0 EA Alloy Stee 690
01.05 13035138-PDB1
70008180-PDB1
70008178-PDB1
13035135-PDB1
13035136-PDB1
70008181-PDB1
3.503744-PDB1
13035139-PDB1
13035134-PDB1
2.502649-PDB1
1.510791-PDB1
01.08. Gear Carrier 6032125-PDB1 13077982-PDB1 1.0 EA Cast Steel 668
01.07 ED90.500.002-
PDB1
70008359-PDB1
70007195-PDB1
01.08. Inner Eccentric Bushing (Dual) 1000496397 520530 1.0 EA Bronze 632
01.09 70008368-PDB1
13078162-PDB1
01.08. Outer Counterweight, HT 1000514554 1000024420 1.0 EA ASTM A36 520
01.11 1000024422
1000514554
01.08. Counterweight, Inner 1000513917 1000024420 1.0 EA 1100 107
01.13 1000024422
1000513917
01.08. Hexagon head screw, 0241, L 60 mm, 3104278-PDB1 7.0 EA 8.8 1.5
01.15 d M20
01.08. Hoist Ring 4496874-PDB1 2.0 EA 7.3
01.17
01.08. Hoist Ring 3603174-PDB1 1.0 EA 3.7
01.18
01.08. Wire rope, 6100, Nominal rope 671729-PDB1 1.0 EA SS 304 0.1
01.19 diameter 1.6 mm, Length L 2000 mm
01.08. SCREW, 0303, L 80 mm, d M20 9393-PDB1 24.0 EA 8.8 5.9
01.21
01.23
01.08. Hexagon head bolt, 0235, L 110 mm, 3935970-PDB1 5.0 EA 8.8 1.7
02.01 d M20
02.07
01.08. Hexagon head bolt, 0235, L 80 mm, d 778442-PDB1 20.0 EA 8.8 5.1
02.11 M20
01.08. Outer Counterweight, LT 1000513992 1000024420 1.0 EA ASTM A36 407
02.13 1000024422
1000513992


Part no. 1000606584 Rev .02
Page 18 of 57
Assembly, Hydraulic Cylinder, Gyratory Crusher, Part no.: 1000531721

Rev. no.: 1
Drawing No: 1000531721, ED90.500.002-PDB1, 1000024420 Parent assembly part no.: 1000511419
Total
Find
No.
kg.
01.09. Hydraulic Cylinder 4422303-PDB1 13034279-PDB1 1.0 EA ASTM A27 Gr 1528

01.03 ED90.500.002- ade 70-40
PDB1
70008359-PDB1
70007195-PDB1
01.09. Bottom Plate 4422255-PDB1 13034644-PDB1 1.0 EA 1100 357
01.05
01.09. Threaded Stud, Diameter M36, 4526436-PDB1 24.0 EA AISI 4340 Allo 53
01.07 Length 275 mm y steel, anneale
d min 115000 p
si tnsl str
01.09. Nut, 0113, d M36 1203-PDB1 48.0 EA 8 20
01.11
01.09. Piston 4422305-PDB1 70008359-PDB1 1.0 EA ASTM A27 Gr 1118
01.13 ED90.500.002- ade 70-40
PDB1
13034278-PDB1
70007195-PDB1
01.09. Mounting Ring 4422307-PDB1 13034513-PDB1 1.0 EA ASTM A27 Gr 1312
01.15 ED90.500.002- ade 70-40
PDB1
70008359-PDB1
70007195-PDB1
01.09. Lower Bushing 4422292-PDB1 ED90.500.002- 1.0 EA Bronze 43
01.17 PDB1
13034562-PDB1
70008368-PDB1
01.09. Upper Bushing 4422294-PDB1 70008368-PDB1 1.0 EA Bronze 143
01.19 13034564-PDB1
01.09. Seal Retainer 4422278-PDB1 13034641-PDB1 1.0 EA 1100 18
01.21
01.23
01.09. Piston Seal, Thickness 34.00 mm, 4668651-PDB1 1.0 EA G-ECOPUR 1.8
02.01 Outside diameter 590.25 mm, Inside
diameter 550 mm
01.09. Piston Wearing Ring 4422297-PDB1 70008368-PDB1 1.0 EA Bronze 85
02.03 13034563-PDB1
02.05
01.09. MPI Mounting Plate 4422281-PDB1 13034642-PDB1 1.0 EA 1100 16
02.07
01.09. Bolt, 0213, L 100 mm, d M24 609-PDB1 8.0 EA 8.8 3.7
02.09
01.09. MAGNET MOUNTING PLATE 3634858-PDB1 3.504769-PDB1 1.0 EA ASTM A36 1.0
02.11
02.13
01.09. Wiper Seal 4422284-PDB1 13034639-PDB1 1.0 EA Rubber 1.0
02.15


Part no. 1000606584 Rev .02
Page 19 of 57
Total
Find
No.
kg.
01.09. Wiper Retainer 4422286-PDB1 13034640-PDB1 1.0 EA 1100 5.0

02.17
01.09. Screw, 0223, L 40 mm, d M10 1152-PDB1 12.0 EA Steel 0.4
02.19
02.21
01.09. Positioning Pin, Length 85 mm, 4467567-PDB1 2.0 EA AISI 1040 1.0
02.23 Diameter 20 mm
01.09. Wear ring, Center 1000531495 1000531495 1.0 EA AISI 4340 127
03.01 1000024422
1000024420
70011849-PDB1
01.09. O-RING, Thickness 0.09375 in, Inner 3639902-PDB1 1.0 EA RUBBER 0.1
03.03 diameter 6 in
01.09. O-RING 4465490-PDB1 1.0 EA RUBBER 0.2
03.05
01.09. Plug, square head, Thread diameter 7658-PDB1 1.0 EA Steel 0.0
03.07 1/4 NPT
03.09
03.11
01.09. O-Ring, Nitrile, 70 Durometer, Thick 1000556740 1.0 EA Rubber 0.1
03.13 0.275 inch
01.09. RTV Silicone Gasket 3640007-PDB1 1.0 EA 0.5
03.15
01.09. ADHESIVE/SEALANT, STUD- 190386-PDB1 1.0 EA 0.2
03.17 LOCK, Container volume 50 cm³
03.19 4762, M24x45, 8.8 teel
01.09. Plug, hexagon,1/4 NPFT male, 1000589640 1.0 EA Plain Carbon S 0.0
03.21 galvanized teel
01.09. Screw, set, hexagon socket, cone 1000560314 3.0 EA Plain Carbon S 0.2
03.23 point, ISO 4027, M20x35, 45 H teel


Part no. 1000606584 Rev .02
Page 20 of 57
Assembly, Mainshaft, Gyratory Crusher, TS, 1300 x Part no.: 1000500157

Rev. no.: 2
Drawing No: 1000500157, 1000135380, 1000024420, 1000198038 Parent assembly part no.: 1000511419
Total
Find
No.
kg.
01.10. Mainshaft, Integral 1000500074 1000135074 1.0 EA ASTM A668 24749

01.03 70007184-PDB1
1000024420
1000500074
01.10. Pin, dowel, Tolerance Tolerance e8, 4465803-PDB1 1.0 EA AISI 1018 1.0
01.07 Length 40 mm, Diameter 25 mm
01.10. Mantle, upper 1000406779 1000024420 1.0 EA Cast Mang 2456
01.13 1000406778
1000134858
1000024423
1000406811
1000406812
01.15
01.10. Mantle, lower 1000406787 1000024420 1.0 EA SM 310 5755
01.17 1000406786
1000134858
1000406810
1000406794
1000024423
01.19
01.10. Headnut 4819902-PDB1 13042508-PDB1 1.0 EA AISI 1045 187
01.21
01.10. Sleeve Cap Plate 1000503618 520530 1.0 EA 1100 35
01.23 13071825-PDB1
01.10. Filler ring 1000138304 1000138304 1.0 EA AISI 1045 41
02.01 1000024420
1000024422
1000135074
01.10. Bolt, 0213, d M30, L 100 mm 1334322-PDB1 16.0 EA CL 8.8 15
02.03
01.10. Pin, dowel, Length 65 mm, Diameter 4511393-PDB1 4.0 EA AISI 1018 4.0
02.05 25 mm
01.10. Dust Seal Ring Assembly 6168369-PDB1 13072248-PDB1 1.0 EA 61
02.07
01.10. Dust Seal Retainer 1000503620 520530 1.0 EA ASTM A36 131
02.09 70007195-PDB1
13071847-PDB1
02.11
01.10. Bar, Length 40 mm, Thickness 6 mm, 3645790-PDB1 12.0 EA AISI M1020 2.2
02.13 Width 20 mm
01.10. Lubricating Fitting 3223598-PDB1 2.0 EA 0.0
02.15
01.10. Shaft wear ring 1000503621 70008368-PDB1 1.0 EA Bronze 129
02.17 13071941-PDB1
520530
01.10. Threaded Bar 4511396-PDB1 13036445-PDB1 1.0 EA AISI 1018 1.0
02.19


Part no. 1000606584 Rev .02
Page 21 of 57
Total
Find
No.
kg.
01.10. Hexagon castle nut, 0142, d M24 477429-PDB1 1.0 EA 6 0.1

02.21
01.10. Cotter pin, Length 63 mm, Diameter 3645787-PDB1 1.0 EA Steel 1.2
02.23 3mm
01.10. Mainshaft Sleeve 1000503622 1000024420 1.0 EA AISI 1045 460
03.01 1000024422
1000503622
03.03


Part no. 1000606584 Rev .02
Page 22 of 57
Part no.: 6168369-PDB1

Dust Seal Ring Assembly Rev. no.: 0
Unit Weight: 61 kg
Drawing No: 13072248-PDB1

Total
Find
No.
kg.
01.01. Dust Seal Upper 6168373-PDB1 13071873-PDB1 1.0 EA 1100 41

01.03
01.01. Dust Seal Lower 6168374-PDB1 13071893-PDB1 1.0 EA Nylatron 11
01.05
01.01. SCREW, CAP, HEX SOCKET 3713839-PDB1 24.0 EA 10.9, STEEL 0.2
01.07 BUTTON HEAD, Note DIN 7380,
Diameter M12, Length 35 mm, Pitch
1.75
01.01. Lock washer, Thread diameter M12 4369669-PDB1 24.0 EA Spring steel HR 0.1
01.09 C 44-51
01.01. Packing Seal 3248727-PDB1 2.0 EA 9.1
01.11
01.13


Part no. 1000606584 Rev .02
Page 23 of 57
Assembly, Concave, Gyratory Crusher, TS, 1300 x Part no.: 1000519350

Rev. no.: 2
Total
Find
No.
kg.
01.11. Concave, upper 1000454122 1000024420 16.0 EA SM 330 6176

01.03 1000134858
1000454121
01.11. Concave, middle 1000449519 1000024420 16.0 EA SM 330 5920
01.05 1000134858
1000139387
01.11. Concave, lower 1000452738 1000139392 16.0 EA SM 330 6688
01.07 1000024420
1000134858
01.11. CONCAVE LOCKING PIN 2806131-PDB1 ED90.500.002- 48.0 EA ASTM-A36 72
01.09 PDB1
3.501397-PDB1
01.11
01.13
01.15


Part no. 1000606584 Rev .02
Page 24 of 57
Counter shaft assembly, Type TS, Diameter 1800 Part no.: 4422511-PDB1
Rev. no.: 8
mm, Opening size 1100 mm Unit Weight: 1489 kg
Drawing No: 70019642-PDB1, ED90.500.002-PDB1, 520530, 13036470-PDB1 Parent assembly part no.: 1000511419
Total
Find
No.
kg.
01.12. Countershaft Housing 4422574-PDB1 13034337-PDB1 1.0 EA ASTM A48 Cla 793
01.03 70008359-PDB1 ss 40 Cast iron
ED90.500.002-
PDB1
13034338-PDB1
7.500173-PDB1
01.12. Countershaft 4470550-PDB1 13036471-PDB1 1.0 EA Steel 396
01.05 70007184-PDB1
01.12. Key, Length 155 mm, Height 22 mm, 4546273-PDB1 1.0 EA AISI 1018CFS 1.1
01.07 Width 40 mm
01.12. Key, Length 190 mm, Height 25 mm, 4546282-PDB1 1.0 EA AISI 1018CFS 1.7
01.09 Width 45 mm
01.12. Spiral bevel pinion data 4455607-PDB1 13035139-PDB1 1.0 EA AISI 4320 110
01.11 13035138-PDB1
13035134-PDB1
2.502212-PDB1
70008181-PDB1
13035136-PDB1
70008178-PDB1
70008180-PDB1
1.511178-PDB1
13035137-PDB1
3.503744-PDB1
70008179-PDB1
01.12. Spiral Retainer Ring, Note Heavy 4546284-PDB1 1.0 EA Steel 1.0
01.13 Duty Shaft
01.12. Bearing, Inside diameter 8.125 in, 4468495-PDB1 2.0 EA Steel 38
01.15 Outside diameter 13.25 in
01.12. Gasket 4470560-PDB1 13036473-PDB1 3.0 EA Non-asbestos 1.5
01.17 720-85-1-6801-
PDB1
01.19 d M30
01.12. Spring washer, Thread diameter M30 2037373-PDB1 6.0 EA Spring steel HR 0.1
01.21 C 44-51
01.12. Inner Seal Retainer 4470569-PDB1 13036474-PDB1 1.0 EA ASTM-A36 45
01.23
02.01
01.12. Spring washer, Thread diameter M30 2037373-PDB1 6.0 EA Spring steel HR 0.1
02.03 C 44-51
01.12. Outer Seal Retainer 4470571-PDB1 13036475-PDB1 1.0 EA ASTM-A36 18
02.07
01.12. Hexagon head bolt, 0235, L 90 mm, d 3196159-PDB1 6.0 EA 8.8 1.7
02.09 M20
02.11
01.12. Lubricating Grease Fitting, Thread 62059-PDB1 1.0 EA Steel 0.1
02.13 diameter 1/8 in NPT


Part no. 1000606584 Rev .02
Page 25 of 57
Total
Find
No.
kg.
01.12. Liquid gasket, Container size 13 oz 3182289-PDB1 1.0 EA 0.4

02.15
01.12. Seal Retainer Plate 4470576-PDB1 13036480-PDB1 1.0 EA ASTM-A36 2.0
02.17
02.19
02.21
01.12. Countershaft Bearing Shim 4470577-PDB1 13036472-PDB1 1.0 EA ASTM-A36 4.0
02.23
01.12. Pinion Spacer 4470579-PDB1 13036479-PDB1 1.0 EA ASTM-A36 6.0
03.01
01.12. Spring Retainer Plate 4470580-PDB1 13036482-PDB1 1.0 EA ASTM-A36 15
03.03
03.05 d M20
03.07
01.12. Clipper Seal - Split 4560544-PDB1 3.0 EA Nitrile 3.0
03.09
03.11 DETECTOR
01.12. DETECTOR HOLDER 3233276-PDB1 2.0 EA 0.0
03.13
01.12. Jiffy clip, Diameter 5/8 in x 1-3/16 in 3632051-PDB1 1.0 EA Steel 0.0
03.15
03.17
01.12. ELBOW, 45°, Angle 45 °, Thread 3281904-PDB1 1.0 EA Brass 0.2
03.19 diameter 1/2 NPT
01.12. NIPPLE, Length 3 in, Thread 3281921-PDB1 1.0 EA Brass 0.1
03.21 diameter 1 1/2 in NPT
01.12. COUPLING, d1 1/2 in NPT 3282047-PDB1 1.0 EA Brass 0.1
03.23
01.12. Sealing Connection 3282054-PDB1 1.0 EA 1.0
04.01
01.12. Temperature transmitter 4394072-PDB1 2.0 EA 4.0
04.03
01.12. Resistance temperature detector 3637375-PDB1 1.0 EA 0.2
04.05
01.12. COUPLING, d1 1/2 in NPT 3282076-PDB1 1.0 EA Brass 0.0
04.07
01.12. NIPPLE, Length 2 in, Thread 3282176-PDB1 1.0 EA Brass 0.1
04.09 diameter 1 1/2 in NPT
01.12. PIPE, Classification SCHEDULE 40, 4560545-PDB1 1.0 EA Steel 0.2
04.11 Diameter 3/4 in, Length 34 mm
01.12. Lubrication Tube, Classification 4560546-PDB1 13036483-PDB1 1.0 EA ASTM-A36 1.0
04.13 Schedule 40, Diameter 3/4 in, Length
510 mm
01.12. ELBOW, 90°, Thread diameter 3/4 in 3282183-PDB1 1.0 EA STEEL 0.1
04.15 NPT Sch40
01.12. Spirawave, Crest-to-Crest 4562815-PDB1 60091615-PDB1 1.0 EA Carbon steel, sp 0.0
04.17 ring temper
01.12. DIRECTIONAL ARROW 2829927-PDB1 3.504804-PDB1 1.0 EA AISI 304 0.0
04.19
04.21


Part no. 1000606584 Rev .02
Page 26 of 57
Total
Find
No.
kg.
01.12. ADHESIVE/SEALANT, STUD- 190386-PDB1 1.0 EA 0.2

04.23 LOCK, Container volume 50 cm³
01.12. TURNING TOOL 3632072-PDB1 3.505134-PDB1 1.0 EA ASTM A36 6.0
05.01
01.12. Screw, L 90 mm, Pitch 3.5, d M30 20283-PDB1 7.000299-PDB1 1.0 EA 8.8 0.7
05.03
01.12. Gear Lubrication Tube 4560678-PDB1 13036476-PDB1 1.0 EA ASTM-A36 2.0
05.05
05.07
05.09 C 44-51
01.12. Oil Trough 4470669-PDB1 13036478-PDB1 1.0 EA ASTM-A36 5.0
05.11 ED90.500.002-
PDB1
520530-PDB1
05.13
05.15
01.12. Shaft Sleeve 4470671-PDB1 13036481-PDB1 1.0 EA Alloy Steel 17
05.17
01.12. Locking Plate 4470674-PDB1 13036484-PDB1 1.0 EA ASTM A36 1.0
05.19
01.12. O-RING, Outer diameter 200 mm, 627671-PDB1 1.0 EA Buna-N, IDG 0.0
05.21 Thickness 5 mm, Inner diameter 190 Mat. NB 111-
mm 70


Part no. 1000606584 Rev .02
Page 27 of 57
Lube & Hydraulic System, Gyratory Crusher, TSU, Part no.: 1000657353
Rev. no.: 3
1300x1800 Unit Weight: 3200 kg
Total
Find
No.
kg.
02.01. Lube and Hydraulic system BOM 1000658051 1000606865 1.0 EA 0.0
01.05
02.01. Lube and Hydraulic system GA 1000658055 1000606866 1.0 EA 3200
01.06
02.01. Lube and Hydraulic system 1000658057 1000606867 1.0 EA 0.0
01.07 Schematic
02.01. Lube and Hydraulic system Electrical 1000659491 1000606868 1.0 EA 0.0
01.08 schematic


Part no. 1000606584 Rev .02
Page 28 of 57
Part no.: 1000657354

Lubrication Components Rev. no.: 3
Unit Weight: 841 kg
Drawing No: 1000024420, 1000608222

Total
Find
No.
kg.
02.02. Oil Cooler unit, ANSI Flanges 1000625615 1000625615 1.0 EA 600
01.01
02.02. Pressure relief valve, Connection size 3017923-PDB1 1.0 EA 9.1
01.04 2 in NPT
02.02. Pressure Gauge, Note 4.5 in Dia Dial, 4463037-PDB1 2.0 EA 0.4
01.07 1/2 in bottom adapter, Range Dual
Scale 0-300 psi / 0-2,000 kPa
02.02. Needle Valve, Note 1/4 in npt 3494136-PDB1 2.0 EA 0.2
01.10
02.02. Temperature gauge, Range 0-250F 4548911-PDB1 2.0 EA 0.0
01.13 (-17-121C)
02.02. Thermowell 4463069-PDB1 2.0 EA 304SS 0.2
01.14
02.02. Ball Valve, 3 in Flgd, Class 150 3033887-PDB1 2.0 EA Steel 32
01.16 Class, Size 3 in
02.02. 2 in Flow Transmitter 3480108-PDB1 60097903-PDB1 2.0 EA 46
01.19
02.02. 1 in Flow Transmitter 3480135-PDB1 60097902-PDB1 3.0 EA 39
01.22
02.02. Globe valve 2 in , Connection type 3034102-PDB1 2.0 EA Bronze 12
02.01 NPTF, Size 2 in
02.02. Globe valve 1 in , Connection type 3715990-PDB1 3.0 EA Bronze 6.6
02.03 NPFT, Size 1 in
02.07 size 2 in
02.02. Adapter 4586932-PDB1 1.0 EA 1.0
02.10
02.02. Flange threaded, Class 150 Class, 4368143-PDB1 2.0 EA ASTM A105 F 3.6
02.13 Pipe diameter 2 in orged steel
02.16 size 3/4 in
02.02. Split Flange Kit, SAE flange code 4750652-PDB1 1.0 EA 9.1
02.19 Code 61, Pipe size 2 in
02.02. FLANGE THREADED, Class 150 lb, 3715991-PDB1 3.0 EA ASTM A105 F 3.0
02.22 Pipe diameter 1 in orged steel
02.02. Hose, Flexible Metal, Length 60 in , 3223527-PDB1 1.0 EA Corrugated, 31 37
03.01 Diameter 6 in ID 6LSS w/single l
ayer of 321 SS
wire braid
02.02. Bolt, Length 60 mm, Pitch 2.5, d 20 3495478-PDB1 8.0 EA 8.8 0.1
03.04
02.02. Gasket, Thickness 0.0625 in, Outside 3495654-PDB1 2.0 EA Neoprene 2.0
03.07 diameter 8.75 in, Inside diameter
6.625
02.02. RTD & Thermowell w/ Temperature 3116982-PDB1 1.0 EA 2.5
03.19 Transmitter
02.02. ELBOW 45°, Diameter 6 in 3496784-PDB1 1.0 EA ASTM B16.1 27
04.04


Part no. 1000606584 Rev .02
Page 29 of 57
Total
Find
No.
kg.
02.02. Bolt, Length 90 mm, Pitch 2.5, d 20 3496791-PDB1 8.0 EA 8.8 0.8
04.07
02.02. Nut 180470-PDB1 8.0 EA 8 0.1
04.10


Part no. 1000606584 Rev .02
Page 30 of 57
Part no.: 1000658906

Hydraulic Components Rev. no.: 2
Unit Weight: 313 kg
Drawing No: 1000024420, 1000608222

Total
Find
No.
kg.
02.03. Mantle Relief Valve and Accumulator 1000614463 1000614463 1.0 EA 234
01.01 20001047-PDB1
1000024420
02.03. Flange, Socket Weld, SAE flange 3469209-PDB1 1.0 EA 0.6
01.07 code Code 61, Pipe size 3/4 in
02.03. Socket head cap screw, Dimension 4281461-PDB1 4.0 EA 0.4
01.08 M10x40
02.03. O-ring 3483306-PDB1 1.0 EA NBR 70SH 0.0
01.09
02.03. Flange, Socket Weld, SAE flange 3483414-PDB1 3.0 EA 34
01.10 code Code 61, Pipe size 3 in
02.03. Socket head cap screw, Dimension 3489991-PDB1 20.0 EA 2.0
01.11 M16x75
02.03. O-ring 415267-PDB1 5.0 EA NBR 70SH 0.0
01.12
02.03. Rotary hose, Length 42 in, Hose size 4399042-PDB1 1.0 EA 33
01.13 3 in
02.03. 3 in 90° Elbow SAE Flanged 4752414-PDB1 30066381-PDB1 1.0 EA 1100 8.0
01.22
02.03. Pressure transmitter, Range 0-4000 4318368-PDB1 1.0 EA 1.1
02.07 psi, Output 4 - 20 ma


Part no. 1000606584 Rev .02
Page 31 of 57
Part no.: 1000636190

Spider Lubrication System Rev. no.: 2
Unit Weight: 36 kg
Drawing No: 1000636190, 1000024420

Total
Find
No.
kg.
03.01. Lincoln Electrical Operated Barrel 3568534-PDB1 1.0 EA 29

01.03 Pump Assembly
03.01. XL Series Manifold Feeder 3466951-PDB1 520530 1.0 EA 0.0
01.09
03.01. Terminal Box 4182562-PDB1 1.0 EA 5.0
01.17
03.01. Hose Assembly, Note 3/8 in 5000psi 4294628-PDB1 1.0 EA 1.0
01.23 x 48 in lg
03.01. Hex Bushing, Pressure rating 3000 3287516-PDB1 1.0 EA Steel 0.1
02.03 psi, Pipe thread type 1/2 in NPTM x
1/4 in NPTF
03.01. TEE, Pressure rating 3000 psi, Thread 3287575-PDB1 1.0 EA Steel 0.2
02.05 diameter 1/2 NPT
03.01. Pressure Gauge, Note 2.5 in Dia Dial, 3903745-PDB1 1.0 EA 0.2
02.07 1/4 in bottom adapter, Range Dual
Scale 0-5,000 psi / 0-35,000 kPa
03.01. 2 Valve Manifold, Connection size 3979721-PDB1 1.0 EA 316SS 0.9
02.09 Process 1/2 in NPTM, Gauge 1/2
in NPTF, 1/4 in Plugged vent port,
Pressure rating 6000 psi


Part no. 1000606584 Rev .02
Page 32 of 57

Rev. no.: 5
Lincoln Electrical Operated Barrel Pump Assembly Unit Weight: 29 kg
Total
Find
No.
kg.
03.01. Electric Pump 3503450-PDB1 1.0 EA 29

01.04
03.01. Drum Cover 3503451-PDB1 1.0 EA 0.0
01.05
03.01. Follower Plate 3503452-PDB1 1.0 EA 0.0
01.06
03.01. Safety Unloader, Pressure setting 3503453-PDB1 1.0 EA 0.0
01.07 3000 psi


Part no. 1000606584 Rev .02
Page 33 of 57

XL Series Manifold Feeder Rev. no.: 10
Unit Weight: 0.0 kg
Drawing No: 520530

Total
Find
No.
kg.
03.01. Base Plate 4292235-PDB1 1.0 EA 0.0

01.10
03.01. Distribusion Block - 15S, Note 0.3 4292236-PDB1 2.0 EA 0.0
01.11 cubic inch Total Displacement
03.01. Distribution Block - 10S, Note 0.2 4292237-PDB1 2.0 EA 0.0
01.12 cubic inch Total Displacement
03.01. Crossing Plate 4292238-PDB1 3.0 EA 0.0
01.13
03.01. 1/4 in Pipe Plugs 4292241-PDB1 7.0 EA 0.0
01.14
03.01. Cycle Proximity Switch 4292239-PDB1 1.0 EA 0.0
01.15


Part no. 1000606584 Rev .02
Page 34 of 57

Mantle Position Indicator Rev. no.: 3
Unit Weight: 24 kg
Drawing No: 4.500767-PDB1, 3.507050-PDB1, 70010350-PDB1

Total
Find
No.
kg.
04.01. Linear Transducer, Rod BTL7 6792192-PDB1 1.0 EA 1.0

01.03
04.01. Cable 3350038-PDB1 1.0 EA 1.0
01.05
04.01. Rod Style Magnet 3350039-PDB1 1.0 EA 1.0
01.07
04.01. Spacer 3350040-PDB1 1.0 EA 1.0
01.09
04.01. Bargraph Indicating Alarm 7137449-PDB1 1.0 EA 20
01.11
04.01. Hexagon Socket Head Cap Screw, l 4391279-PDB1 2.0 EA 316 Stainless S 0.0
01.13 25 mm, d M4 teel
01.15
01.17
01.19


Part no. 1000606584 Rev .02
Page 35 of 57
Part no.: 1000718742

Tools, Gyratory Crusher, TSU, 1300x1800 Rev. no.: 1
Unit Weight: 499 kg

Total
Find
No.
kg.
05.01. Impact spanner 4709790-PDB1 1.0 EA 1.5

01.01
05.01. Striking face box-end wrench, 41464-PDB1 1.0 EA 12
01.03 Opening size 105 mm
05.01. Shackle 4709697-PDB1 1.0 EA Forged Alloy S 24
01.05 teel
05.01. Shackle 3722278-PDB1 3.0 EA AISI 1035/AIS 36
01.07 I 4240
05.01. Eye bolt, 0601, Thread diameter M36 913408-PDB1 2.0 EA C 15 5.3
01.09
01.11
01.13
01.15
01.17
05.01. HYDRAULIC REMOVAL TOOL 3796374-PDB1 2.509137-PDB1 1.0 EA ASTM A36 / 1 86
01.19 045 Hot rolled
05.01. Shell Splitting Wedges 2829864-PDB1 4.500495-PDB1 4.0 EA AISI 4140 24
01.21
05.01. Accumulator charging kit 1000194018 1.0 EA 1.0
02.03
05.01. Hydraulic Jack Assembly 200 Ton 1000722366 10453395-PDB1 1.0 EA 291
02.07
05.01. Service Box P115 4082757-PDB1 ED90.500.002- 1.0 EA 7.7
02.17 PDB1
05.01. Pressure relief valve 3073399-PDB1 1.0 EA 0.5
02.19


Part no. 1000606584 Rev .02
Page 36 of 57
Part no.: 1000722366

Hydraulic Jack Assembly 200 Ton Rev. no.: 1
Unit Weight: 291 kg

Total
Find
No.
kg.
01.01 Hydraulic Jack Assembly 1000722367 10453395-PDB1 1.0 EA 291


Part no. 1000606584 Rev .02
Page 37 of 57
Part no.: 1000722367

Hydraulic Jack Assembly Rev. no.: 1
Unit Weight: 291 kg

Total
Find
No.
kg.
01.01. Pump, electric, two stage, 700 bar 1000721106 1.0 EA 74

01.03
01.01. Gauge adapter 4583243-PDB1 1.0 EA 0.3
01.07
01.01. Pressure gauge 4583245-PDB1 1.0 EA 0.3
01.09
01.01. High Pressure Hose Assembly, 8741257-PDB1 2.0 EA 1.0
01.11 Length 6 ft, Inside diameter 0.25 in
01.01. Flow control valve 8748277-PDB1 1.0 EA 2.0
01.13
01.01. Thermoplastic Hose, Length 50 ft, 8741266-PDB1 4.0 EA 28
01.15 Inside diameter 0.25 in
01.01. Half Coupler 4583251-PDB1 4.0 EA 1.0
01.17
01.01. Hydraulic Jack, Stroke Stroke 6 , 1000520504 2.0 EA 184
01.19 Capacity 200 t
01.01. Tee 8741338-PDB1 1.0 EA 0.3
01.21
01.01. High-Flow Half Coupler Female 8741293-PDB1 2.0 EA 0.5
01.23


Part no. 1000606584 Rev .02
Page 38 of 57

Service Box P115 Rev. no.: 1
Unit Weight: 7.7 kg
Drawing No: ED90.500.002-PDB1

Total
Find
No.
kg.
01 Pump, hand 3097510-PDB1 1.0 EA 3.0

02 Washer 2934244-PDB1 2.0 EA 0.0
03 Screw 3097520-PDB1 2.0 EA 0.8
04 Torque wrench 3097519-PDB1 1.0 EA 2.0
05 Screw 3097523-PDB1 1.0 EA 0.4
06 Tool 3097524-PDB1 1.0 EA 0.4
07 Tool 3097525-PDB1 1.0 EA 0.4
08 Tool 3097527-PDB1 1.0 EA 0.4
09 Oil can 3097529-PDB1 1.0 EA 0.1
10 Socket 3097530-PDB1 1.0 EA 0.1
11 Seal set kit 3097537-PDB1 1.0 EA 0.1


Part no. 1000606584 Rev .02
Page 39 of 57
Assembly, Countershaft Extension, Gyratory Part no.: 1000614472

Rev. no.: 2
Crusher, TSU, 1300 x 1800 Unit Weight: 564 kg
Total
Find
No.
kg.
07.01. Countershaft extension shaft 1000632769 1.0 EA 123

01.03
07.01. Ring Hub - Motor side 1000616188 1.0 EA 80
01.07
07.01. Ring Hub - Countershaft side 4893532-PDB1 1.0 EA Steel 38
01.08
07.01. Flex Hub 4523046-PDB1 2.0 EA Steel 116
01.09
07.01. Drive ring 4523052-PDB1 2.0 EA Steel 40
01.11
07.01. Drive Ring bolt kit (T8) 1000633650 2.0 EA 4.0
01.13
07.01. Yellow insert, limited end float 4523067-PDB1 2.0 EA Polyurethane 6.0
01.15
07.01. Adpator, spacer body 4523069-PDB1 1.0 EA Steel 40
01.17
07.01. Hex Head Cap Screw, Note: HCS 1000633651 20.0 EA 5.0
01.19 3/4-10 X 3.500 + LW
07.01. Hex Nut, Note 0.750-10-D-C 4523276-PDB1 20.0 EA Steel 1.2
01.21
07.01. Safety coupling 4406657-PDB1 69001558-PDB1 1.0 EA Steel 109
02.01
07.01. Shear tube, L28 622054-PDB1 20.0 EA 0.4
02.03
07.01. Oil 3070900-PDB1 1.0 EA 0.9
02.05


Part no. 1000606584 Rev .02
Page 40 of 57
Assembly, Drive guard, Gyratory Crusher, TSU, Part no.: 1000614634

Rev. no.: 2
1300 x 1800 Unit Weight: 201 kg
Total
Find
No.
kg.
07.02. Drive Guard cover - Crusher End 1000615259 1000615259 1.0 EA Plain Carbon S 16
01.03 1000024422 teel
1000024420
07.02. Drive Guard Cover - Middle 1000637767 1000637767 1.0 EA 1100 14
01.05 1000024422
1000024420
07.02. Drive guard cover - Motor end 1000615258 1000615258 1.0 EA Plain Carbon S 16
01.07 1000024422 teel
1000024420
07.02. Drive Guard Bottom Frame 1000615261 1000024422 1.0 EA 1100 87
01.09 1000615261
1000024420
07.02. Drive Guard Mounting Base 2829853-PDB1 3.503004-PDB1 16.0 EA Steel 16
01.11
07.02. Square tube 1000644784 1000644784 8.0 EA 1100 16
01.13 1000024422
1000024420
01.15
07.02. Nut, 0113, d M10 524-PDB1 56.0 EA 8 0.6
01.17
01.19
07.02. Washer, Thread diameter M10 12476-PDB1 18.0 EA Mild steel 2.2
01.21
07.02. Screw, 0223, L 40 mm, d M10 1152-PDB1 16.0 EA Steel 0.5
01.23
07.02. BRACING ANGLE 4044941-PDB1 39000337-PDB1 8.0 EA ASTM A36 22
02.01
07.02. SCREW - FULL THREAD, 0223, L 3778-PDB1 8.0 EA 8.8 0.4
02.03 75 mm, d M10
07.02. Inspection door 1000482709 1000482709 2.0 EA ASTM A36 St 2.0
02.05 1000024420 eel
07.02. Inspection door 1000481117 1000481117 2.0 EA ASTM A36 St 2.0
02.07 1000024420 eel
07.02. Hinge 1000482733 4.0 EA ASTM A36 St 0.4
02.09 eel
07.02. Stud, bolt, type B, DIN 976-1, 1000277763 2.0 EA Plain Carbon S 0.0
02.11 M8x16, 8.8 teel
07.02. Nut, wing, DIN 315, M8, galvanized 1000277196 2.0 EA Plain Carbon S 0.0
02.13 teel
02.15 M4x8, 8.8 teel
07.02. Nut, hexagon, ISO 4032, M4, 6 1000007834 8.0 EA Plain Carbon S 0.0
02.17 teel
07.02. Guard, Wire mesh 1000510146 1000510146 2.0 EA ASTM A36 St 2.0
02.21 1000024420 eel


Part no. 1000606584 Rev .02
Page 41 of 57
Total
Find
No.
kg.
07.02. Screw, countersunk head, hexagon 1000011749 8.0 EA Plain Carbon S 0.0
02.23 socket, ISO 10642, M6x16, 8.8 teel
07.03. Motion sensing probe 60855-PDB1 1.0 EA 1.0
01.01
07.03. Sensor mounting bracket 6216065-PDB1 13083415-PDB1 1.0 EA 1100 0.8
01.05
07.03. Sensing Bracket 4850609-PDB1 13043315-PDB1 2.0 EA 1100 0.3
01.07
07.03. Motion Failure Alarm 3353488-PDB1 1.0 EA 1.0
01.11
01.13 d M6
01.17


Part no. 1000606584 Rev .02
Page 42 of 57
Part no.: 1000614466

Blower Assembly Schematic - 1400 Series Rev. no.: 1
Unit Weight: 38 kg
Drawing No: 1000614466, 1000024420

Total
Find
No.
kg.
08.01. Dust Seal Blower 4360350-PDB1 1.0 EA 33

01.03
08.01. Inlet Filter, Particle size, 5 mm 3767173-PDB1 1.0 EA 2.0
01.05
08.01. Adjustable relief valve, Connection 4051076-PDB1 1.0 EA 1.0
01.07 1-1/4 in NPT
08.01. Check valve, Connection 1-1/2 in 3696549-PDB1 1.0 EA 1.0
01.09 NPT
08.01. Pressure gauge 4051090-PDB1 1.0 EA 1.0
01.11


Part no. 1000606584 Rev .02
Page 43 of 57
Assembly, Oversize Mainshaft, Gyratory Crusher, Part no.: 1000714197

Rev. no.: 1
Drawing No: 1000714197, 1000135380, 1000024420, 1000198038 Parent assembly part no.: 1000606584
Total
Find
No.
kg.
10.01. Mainshaft, Integral 1000500074 1000135074 1.0 EA ASTM A668 24749

01.03 70007184-PDB1
1000024420
1000500074
10.01. Pin, dowel, Tolerance Tolerance e8, 4465803-PDB1 1.0 EA AISI 1018 1.0
01.07 Length 40 mm, Diameter 25 mm
10.01. Mantle, upper 1000406779 1000024420 1.0 EA Cast Mang 2456
01.13 1000406778
1000134858
1000024423
1000406811
1000406812
01.15
10.01. Mantle oversize, lower 1000406795 1000024420 1.0 kg SM 310 6416
01.17 1000406794
1000134858
1000406810
1000024423
01.19
10.01. Headnut 4819902-PDB1 13042508-PDB1 1.0 EA AISI 1045 187
01.21
10.01. Sleeve Cap Plate 1000503618 520530 1.0 EA 1100 35
01.23 13071825-PDB1
10.01. Filler ring 1000138304 1000138304 1.0 EA AISI 1045 41
02.01 1000024420
1000024422
1000135074
10.01. Bolt, 0213, d M30, L 100 mm 1334322-PDB1 16.0 EA CL 8.8 15
02.03
10.01. Pin, dowel, Length 65 mm, Diameter 4511393-PDB1 4.0 EA AISI 1018 4.0
02.05 25 mm
10.01. Dust Seal Ring Assembly 6168369-PDB1 13072248-PDB1 1.0 EA 61
02.07
10.01. Dust Seal Retainer 1000503620 520530 1.0 EA ASTM A36 131
02.09 70007195-PDB1
13071847-PDB1
02.11
10.01. Bar, Length 40 mm, Thickness 6 mm, 3645790-PDB1 12.0 EA AISI M1020 2.2
02.13 Width 20 mm
10.01. Lubricating Fitting 3223598-PDB1 2.0 EA 0.0
02.15
10.01. Shaft wear ring 1000503621 70008368-PDB1 1.0 EA Bronze 129
02.17 13071941-PDB1
520530
10.01. Threaded Bar 4511396-PDB1 13036445-PDB1 1.0 EA AISI 1018 1.0
02.19


Part no. 1000606584 Rev .02
Page 44 of 57
Total
Find
No.
kg.
10.01. Hexagon castle nut, 0142, d M24 477429-PDB1 1.0 EA 6 0.1

02.21
10.01. Cotter pin, Length 63 mm, Diameter 3645787-PDB1 1.0 EA Steel 1.2
02.23 3mm
10.01. Mainshaft Sleeve 1000503622 1000024420 1.0 EA AISI 1045 460
03.01 1000024422
1000503622
03.03


Part no. 1000606584 Rev .02
Page 45 of 57

Dust Seal Ring Assembly Rev. no.: 0
Unit Weight: 61 kg

Total
Find
No.
kg.
01.01. Dust Seal Upper 6168373-PDB1 13071873-PDB1 1.0 EA 1100 41

01.03
01.01. Dust Seal Lower 6168374-PDB1 13071893-PDB1 1.0 EA Nylatron 11
01.05
01.01. SCREW, CAP, HEX SOCKET 3713839-PDB1 24.0 EA 10.9, STEEL 0.2
01.07 BUTTON HEAD, Note DIN 7380,
Diameter M12, Length 35 mm, Pitch
1.75
01.09 C 44-51
01.01. Packing Seal 3248727-PDB1 2.0 EA 9.1
01.11
01.13


Part no. 1000606584 Rev .02
Page 46 of 57
Assembly, Concave Installation & Removal Tools, Part no.: 1000716863

Rev. no.: 1
Gyratory crusher, TS, 1300x1800 Unit Weight: 10728 kg
Drawing No: 1000024420 Parent assembly part no.: 1000606584
Total
Find
No.
kg.
11.01. Assembly, Concave Installation Ring 1000520967 1000520967 1.0 EA 5292

01.01 1000024420
11.01. Assembly, Concave Removal Pan 1000716626 1000716626 1.0 EA 5359
01.03 1000024420
11.13. Assembly, Bonnet cover 1000521941 1000521941 1.0 EA 77
01.01 1000024420


Part no. 1000606584 Rev .02
Page 47 of 57
Part no.: 1000520967

Assembly, Concave Installation Ring Rev. no.: 1
Drawing No: 1000520967, 1000024420

Total
Find
No.
kg.
11.02. Assembly, Lower Concave 1000521111 1000521111 1.0 EA 1792

01.01 Installation Ring 1000024420
11.04. Assembly, Middle Concave 1000521942 1000521942 1.0 EA 1518
01.01 Installation ring 1000024420
11.05. Assembly, Upper Concave 1000521945 1000521945 1.0 EA 1983
01.01 Installation Ring 1000024420


Part no. 1000606584 Rev .02
Page 48 of 57
Part no.: 1000521111

Assembly, Lower Concave Installation Ring Rev. no.: 1
Drawing No: 1000521111, 1000024420

Total
Find
No.
kg.
11.02. Installation Ring, Lower Concave 1000521112 1000521112 1.0 EA ASTM A36 St 1678
01.03 1000024422 eel
1000024420
11.02. Lifting bracket 1000672391 1000672391 16.0 EA ASTM A36 St 64
01.05 1000024422 eel
1000024420
11.02. Threaded Bar 1000563215 1000563215 16.0 EA AISI 4340 Steel 21
01.07 1000024420 , normalized
1000024422
01.09 teel
01.11 M20x200, 8.8 teel
01.13 4762, M24x60, 8.8 teel
11.02. Pin, cotter, linch, 3/16 x 1 1/4 in 1000543514 32.0 EA 3.2
01.15
11.02. Washer, ISO 7089, 30, 200 HV 1000002764 32.0 EA Plain Carbon S 1.7
01.17 teel
11.02. Nameplate Lifting Chart, Lower 1000680942 1000521111 2.0 EA AISI 316 0.8
01.19 Concave Installation Ring 1000680942
11.02. Nameplate, product 200x200 1000680950 1000680950 2.0 EA 302 SS 0.5
01.21
11.02. Screw, round head, metallic drive, 1000195679 16.0 EA Plain Carbon S 0.0
01.23 type U, ASME B18.6.3, No.4x3/8 teel
11.02. Label Lift Hook Point 120x80 Decal 9002P00005-BNE1 9002P00005- 8.0 EA Decal 0.1
02.01 BNE1


Part no. 1000606584 Rev .02
Page 49 of 57
Part no.: 1000521942

Assembly, Middle Concave Installation ring Rev. no.: 2
Drawing No: 1000521942, 1000024420

Total
Find
No.
kg.
11.04. Installation Ring, Middle Concave 1000521943 1000521943 1.0 EA ASTM A36 St 1381
01.03 1000024420 eel
1000024422
11.04. Lifting bracket, Concave 1000667643 1000024420 16.0 EA ASTM A36 St 64
01.05 1000024422 eel
1000137279
1000667643
01.07 1000024420 , normalized
1000024422
01.09 teel
01.11 M20x200, 8.8 teel
01.13 4762, M24x60, 8.8 teel
01.15
01.17 teel
11.04. Platform Grating Segment 1000523658 1000523658 1.0 EA Steel 23
01.19 1000024420
01.21 1000024420
11.04. Nameplate Lifting Chart, Middle 1000675717 1000675717 2.0 EA AISI 316 0.8
02.03 BNE1


Part no. 1000606584 Rev .02
Page 50 of 57
Part no.: 1000521945

Assembly, Upper Concave Installation Ring Rev. no.: 1
Drawing No: 1000521945, 1000024420

Total
Find
No.
kg.
11.05. Installation Ring, Upper Concave 1000522329 1000522329 1.0 EA ASTM A36 St 1734
01.03 1000024420 eel
11.05. Lifting bracket, Concave 1000667643 1000024420 16.0 EA ASTM A36 St 64
01.05 1000024422 eel
1000137279
1000667643
01.07 1000024420 , normalized
1000024422
01.09 teel
01.11 M20x200, 8.8 teel
01.13 4762, M24x60, 8.8 teel
01.15
01.17 teel
11.05. Platform Grating Segment 1000523670 1000523670 1.0 EA Steel 135
01.19 1000024420
01.21 1000024420
11.05. Nameplate Lifting Chart, Upper 1000674837 1000674837 2.0 EA AISI 316 0.8
02.03 BNE1


Part no. 1000606584 Rev .02
Page 51 of 57
Part no.: 1000716626

Assembly, Concave Removal Pan Rev. no.: 1
Drawing No: 1000716626, 1000024420

Total
Find
No.
kg.
11.09. Assembly, Lower Concave Removal 1000652444 1000652444 1.0 EA 1407

01.01 Pan 1000024420
11.11. Assembly, Middle Concave Removal 1000670704 1000670704 1.0 EA 1540
01.01 Pan 1000024420
11.12. Assembly, Upper Concave Removal 1000671390 1000671390 1.0 EA 2412
01.01 Pan 1000024420


Part no. 1000606584 Rev .02
Page 52 of 57
Part no.: 1000652444

Assembly, Lower Concave Removal Pan Rev. no.: 1
Drawing No: 1000652444, 1000024420

Total
Find
No.
kg.
11.09. Removal Pan, Lower Concave 1000652451 1000652451 1.0 EA A36 Steel 1210
01.02 1000024420
1000024422
1000137279
11.09. Plate, Support 1000652471 1000024422 8.0 EA ASTM A36 St 184
01.03 1000137279 eel
1000024420
1000652471
11.09. Screw, hexagon head, ISO 4017, 1000008572 24.0 EA Plain Carbon S 11
01.05 teel
11.09. Nameplate Lifting Chart, Lower 1000652474 1000652474 2.0 EA AISI 316 0.8
01.06 Concave Removal pan 1000024420
01.07 1000024420
01.08 BNE1


Part no. 1000606584 Rev .02
Page 53 of 57
Part no.: 1000670704

Assembly, Middle Concave Removal Pan Rev. no.: 1
Drawing No: 1000670704, 1000024420

Total
Find
No.
kg.
11.11. Removal Pan, Middle Concave 1000652502 1000652502 1.0 EA ASTM A36 St 1539
01.02 1000024422 eel
1000024420
1000137279
01.03 1000024420
11.11. Nameplate Lifting Chart 1000670708 1000670708 2.0 EA AISI 316 0.8
01.04 1000024420
01.05 BNE1


Part no. 1000606584 Rev .02
Page 54 of 57
Part no.: 1000671390

Assembly, Upper Concave Removal Pan Rev. no.: 1
Drawing No: 1000671390, 1000024420

Total
Find
No.
kg.
11.12. Removal Pan, Upper Concave 1000652932 1000652932 1.0 EA Steel 2410
01.02 1000024422
1000137279
1000024420
01.03 1000024420
11.12. Nameplate Lifting Chart 1000671391 1000671391 2.0 EA AISI 316 0.8
01.04 1000024420
01.05 BNE1


Part no. 1000606584 Rev .02
Page 55 of 57
Part no.: 1000521941

Assembly, Bonnet cover Rev. no.: 1
Unit Weight: 77 kg
Drawing No: 1000521941, 1000024420

Total
Find
No.
kg.
11.13. Bonnet cover 1000521939 1000521939 1.0 EA ASTM A36 St 73

01.03 1000024420 eel
11.13. Bonnet cover gasket 1000521940 1000521940 1.0 EA Rubber 0.2
01.05 1000024420
11.13. Gasket adhesive 3505650-PDB1 1.0 EA 3.4
01.07


Part no. 1000606584 Rev .02
Page 56 of 57
Assembly, Foundation bolt, Gyratory Crusher, TSU, Part no.: 1000633857

Rev. no.: 2
1300x1800 Unit Weight: 458 kg
Total
Find
No.
kg.
18.01. Threaded Rod, M80 x 2250 Lg 1000669311 4.0 EA 356

01.03
18.01. Nut, hexagon, M80x6, 8 1000165113 7.000304 16.0 EA Plain Carbon S 51
01.05 teel
18.01. Washer, Flat, M80, DIN 125-300HV, 1000160032 1000160071 4.0 EA Plain Carbon S 1.1
01.07 Plain Carbon Steel teel
18.01. Plate, 30mm x 230mm x 230mm 1000633913 4.0 EA 50
01.09


Part no. 1000606584 Rev .02
Page 57 of 57
Part no.: 1000614471

Assembly, Top Shell Seal Rev. no.: 1
Drawing No: 1000614471, 1000024420

Total
Find
No.
kg.
20.01. Top Shell Seal Plate 1000523427 1000523427 8.0 EA ASTM A36 1696
01.03 1000024420
20.01. Lower Seal Plate 1000523455 1000523455 8.0 EA ASTM A36 168
01.05 1000024420
20.01. Gasket adhesive 3505650-PDB1 1.0 EA 3.4
01.07
01.09 d M24
20.01. Hexagon nut, 0122, d M24 4095850-PDB1 16.0 EA 8 1.9
01.11
01.13
20.01. Top Shell Seal Gasket 1000523456 1000523456 16.0 EA See Notes 64
01.15 1000024420
20.01. Backer rod, Manufacturer type ø5/8 3505862-PDB1 1.0 EA 12
01.17 in x 1550ft. full coil length
20.01. Sealent, self leveling, 1 carton 1000517792 1.0 EA 0.6
01.19
20.01. Primer, paint, for steel, 1 quart 1000517787 4.0 EA 6.8
01.21
20.01. Primer, paint, for concrete,1 quart 1000517790 4.0 EA 6.8
01.23

239
Appendix F: Recommended
Spare Parts List
F.1 Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

240 Appendix F Recommended Spare Parts List
F.1 Recommended Spare Parts List
Recommended Spare Parts Lists

Recommended Start Up & Commssioning Spares
Part Number Descriptions QTY
4595902-PDB1 Spider Bushing Seal 1
100197812 Lube Filter element 12
FL30290-SLC1 Hydraulic Filter Element 4
4470560-PDB1 Countershaft Gasket 1
622054-PDB1 Voith Coupling Shear Tubes 20
3070900-PDB1 Safety Couling Oil 1
Recommended Second Year Operational Spares

1000406779
1000406787 Mantle Set w/Standard Lower Diameter 1
1000406779
Mantle Set w/Oversize Lower Diameter 1
1000519350 Set of Mn Concaves 1
1000138304 Burn Out Ring for Head Nut 1
100197812 Lube Filter Element 12
FL30290-SLC1 Hydaulic Filter Element 4
4595902-PDB1 Spider Bushing Seal 1
1000510906 Dust Seal Bonnet 1
1000524746 Dust Seal Bonnet Gasket 1
4453457-PDB1 Dust Seal Ring 1
4455357-PDB1 Split Contact Oil Seal Rings 1
1000494583 Set of Spider Shield (Set of 2) 2
1000494774
1000494779
1000494800 Set of Top Shell Wear Plates 2
1000495367 Set of Bottom Shell Liners 1
4562815-PDB1 Countershaft Wave Sing Set 1
4470560-PDB1 Countershaft Oil Seal Retainer Gaskets 1
Recommended Capital and Insurance Spares

1000496410 Eccentric Assemlby w/Bevel Gear 1
1000500157 Mainshaft Assemlby components 1
4422511-PDB1 Countershaft Assemlby w/Bevel Pinion & coupling half 1
1000494395 Spider Bushing 1
4453347-PDB1 Bottom Shell Outer Eccentric Bushing 1
1000531495 Center Wear Ring 1
1000496397 Inner Eccentric Bushing 1
4422294-PDB1 Upper Hydraulic Piston Bushing 1
4422292-PDB1 Lower Hydraulic Piston Bushing 1
4422297-PDB1 Bottom Piston Wearing Ring 1
1000503621 Shaft Wearing Ring 1

Appendix F Recommended Spare Parts List 241
Recommended Spare Parts List (Sheet 2)
4468495-PDB1 Countershaft Bearings 2

4455607-PDB1 Bevel Pinion 1
4455599-PDB1 Bevel Gear 1
1000503622
4819902-PDB1 Main Shaft Sleeve & Headnut Assembly 1
4406657-PDB1 Voith SafeSet Coupling 1
4281471-SLC1 Accumulator Bladder & Spring Package 1
60855-SLC1 TAK-Stik Sensor & Cable 1
3634845-SLC1 MPI-300 Magnet & Sensor 1

242 Appendix F Recommended Spare Parts List

243
Appendix G: Functional
Specification
G.1 1000656041: Functional Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

244 Appendix G Functional Specification
G.1 1000656041: Functional Specification
Functional Specification
Document No. 1000656041
Gyratory Crusher
1300 X 1800 TSU Gyratory Crusher
Ausenco Doc No: V-10496302-00020104

Appendix G Functional Specification 245
1000656041: Functional Specification (Sheet 2)
Gyratory Crusher
Table of Contents
1. Revision History ......................................................................................................................................................3
2. General ...................................................................................................................................................................4
3. Lubrication System .................................................................................................................................................9
4. Spider Lubrication System ..................................................................................................................................144
5. Hydraulic System ..................................................................................................................................................18
6. Other Crusher Equipment...................................................................................................................................233
7. Main Drive ..........................................................................................................................................................244
8. Crusher Feed Permission ....................................................................................................................................277
Interlocks 3.1 Tank Heater: 31-HE-511, 31-HE-512 & 31-HE-513 ..........................................................111

Interlocks 3.1 Lube Pump 1: 31-PU-651M.................................................................................................111
Interlocks 3.2 Lube Pump 2: 31-PU-652M.................................................................................................121
Interlocks 3.4 Heat Exchanger Stage 1: 31-FN-502M................................................................................132
Interlocks 3.5 Heat Exchanger Stage 2: 31-FN-503M................................................................................132
Interlocks 4.1 Grease Pump: 31-PU-654M.................................................................................................166
Interlocks 5.1 Hydraulic Pump 1:31-PU-653M..........................................................................................190
Interlocks 5.2 Tank Heater: 31-HE-514 & 31-HE-515 ..............................................................................200
Interlocks 5.3 Raise Solenoid: SV-1...........................................................................................................200
Interlocks 5.4 Lower Solenoid: SV-2 .........................................................................................................200
Interlocks 5.5 Mantle Calibration ...............................................................................................................211
Interlocks 7.1 Main Drive: 31-CR-501M ...................................................................................................265
Interlocks 8.1 Crusher Feed Permissive: 111GC101_FEEDPERM ...........................................................277

Gyratory Crusher
1. Revision History
Revision Summary of changes Author Revision date
1 Initial release JGAMEZ 4-Dec-2020
2 Update per C&ID v2 and customer comments JGAMEZ 2-Sep-2021

Gyratory Crusher
2. General
Introduction
The purpose of this document is to specify the equipment protection and basic
operating requirements of the gyratory crusher control system. The target audience
of this document is a competent control system engineer with experience
developing control systems for industrial machinery and a basic understanding of
the operation of the gyratory crusher. The scope of this document does not include
the detailed design of the program architecture and operator interface.
This document is intended to be used in conjunction with the machine’s P&ID,
Instrument List and I/O List. The I/O List contains the value for all warning, alarm
and control settings for instruments. All warning, alarm, and control points
required by the I/O List shall be included in the program. Signals that are used for
warning and alarming only (not interlocking or control) are not discussed in this
document.
This document includes optional equipment and functions. The below table
identifies which options are applicable to this project.
Option Project (X)

Lubrication Tank Size No
Heat Exchanger Proportional Control No
Centrifuge Pump No
Oil Contamination Sensor No
Hydraulic Pump 2 No
Discharge Pocket Level Transmitter Yes

Gyratory Crusher
Motor Controls
This document assumes that a motor protection scheme that includes the
monitoring of the motor starter signals (Ready, Run, Fault) exists in the gyratory
crusher control system. The control system shall provide the operator with status
feedback of the motor control interface. Control system treatment of the motor
starter signals is not further described in this document.
Emergency Stop
This document assumes that an emergency stop circuit fulfilling all local
requirements is included with the motor control circuits. When an emergency stop
has been initiated by an operator, all power contactors are opened and the power
supply to all control system outputs is removed. The control system shall provide
the operator with status feedback and the ability to perform any required reset.
Control system treatment of the emergency stop signals is not further described in
this document.
Start Warning
This document assumes that a start warning scheme that includes visual and/or
audible warning signals for local personnel is in place at the crusher. A start warning
should sound for the crusher main drive. A start warning is not required when
crusher auxiliary subsystem motors (lubrication, spider lubrication and hydraulic)
are started. This includes moving the mantle as personnel cannot be in the area of
the moving mantle. Control system treatment of the start warning signals is not
further described in this document.

Gyratory Crusher
Control Modes
This document considers two modes of operation for the crusher, Automatic and
Manual. Automatic mode is defined as the operation of one or more units as
functional groups, in sequential operations or based on instrument feedback.
Manual mode is the operation of individual units by the operator with no
consideration for automated control based on functional groups, sequential
operations or instrument feedback.
Local control is only considered for functions where local control buttons are
provided by FLSmidth. Local start stop stations for motors are considered part of
the motor control scheme and are not further described in this document.
Interlocking
Interlocking for each unit or function is presented in an interlock table containing
all the interlocks for that item. Each interlock is identified with a unique index, a
description identifying the logical conditions required to make the interlock TRUE
and a Type and Mode per the below definitions. The Type and Mode identify when
an interlock is enabled. All enabled interlocks must be TRUE for the unit to operate.
Term Definition
Type: Start The interlock condition must be TRUE at the time the unit is started.
The interlock condition must be TRUE any time the unit is running, including at the time
Type: Run the unit is started.
Type: Stop The interlock condition must be TRUE before the unit is allowed to stop.
Mode: Auto The interlock condition must be TRUE when the unit is operated in Automatic mode.
Mode: Manual The interlock condition must be TRUE when the unit is operated in Manual mode.
The interlock condition must be TRUE when the unit is operated in either Automatic or
Mode: All Manual mode.
Mode: Special The interlock condition must be TRUE when the unit is operated in the specified condition.
Interlocks identified as ‘Optional’ are applicable only when the optional equipment
or instrument is present in the system and can be excluded from the interlocking
logic when not present.
6

Gyratory Crusher
Interlocks identified as ‘Conditional’ are applicable only when the operator has
enabled the function or feature associate with that interlock and can be excluded
from the interlocking logic when not enabled.
Automatic Control
Automatic Control or Auto Starting for each unit or function is presented in a control
table containing all the starting and stopping conditions for that item. Each
condition is identified with a unique index, a description identifying the logical
conditions and the associated control action.
Control loops are also presented in control tables with the P&ID identifier,
description, the process variable and the control variable.
Analog Instruments
The alarm and control points associated with each analog instrument are referenced
in interlocking and control tables per the below definitions. The numeric setpoints
associated with each of these alarm and control limit set points can be found on
Alarms and Control Limit Settings table of each section. Unless stated otherwise,
each analog alarm shall have a 1 second debounce timer.
Term Definition
H3 Alarm Limit High 3 is FALSE when the analog value is greater than the H3 setpoint.
H2 Alarm Limit High 2 is FALSE when the analog value is greater than the H2 setpoint.
H1 Warning Limit High 1 is FALSE when the analog value is greater than the H1 setpoint.
L1 Warning Limit Low1 is FALSE when the analog value is less than the L1 setpoint.
L2 Alarm Limit Low2 is FALSE when the analog value is less than the L2 setpoint.
L3 Alarm Limit Low3 is FALSE when the analog value is less than the L3 setpoint.
Operating Limit High 1 is a control point based on the value of the analog signal. LIM_H1
LIM_H1 is TRUE when the analog value is greater than the LIM_H1 setpoint.
Operating Limit Low 1 is a control point based on the value of the analog signal. LIM_L1
LIM_L1 is TRUE when the analog value is less than the LIM_L1 setpoint.
Operating Limit High 2 is a control point based on the value of the analog signal. LIM_H2
LIM_H2 is TRUE when the analog value is greater than the LIM_H2 setpoint.
Operating Limit Low 2 is a control point based on the value of the analog signal. LIM_L2
LIM_L2 is TRUE when the analog value is less than the LIM_L2 setpoint.

Gyratory Crusher
Document Organization
This functional specification is organized by sections for each machine subsystem.
Each section contains a short text description of the function followed by the below
content as required for each subsystem.
Starting Diagram
The starting diagram provides an overview of the typical staring and operation of
the subsystem. The diagram includes the operator commands for and interactions
among the units in the subsystem.
Additional Control Signals

This section identifies any control signals required for the subsystem that are not
already specified on the I/O List. This includes timers, counters, delayed alarms
and other logic determined control signals or alarms. A text description of each
signal is followed by a table of alarms and a table of settings including min/max
limits for each signal.
Calculations
This section specifies the equations for calculated values identified on the PID.
Units or Functions
Each subsystem is comprised of one or more units (motor, etc.) and logical
functions. The section for each unit contains a text description of the purpose of
the unit, its normal starting and operating conditions followed by interlock and
control tables.

Gyratory Crusher
3. Lubrication System
The purpose of the lubrication system is to provide a continuous supply of filtered
and temperature controlled lubricating oil to several lubrication points on the
crusher. The oil flow to each point and the temperature of the oil returning from
the crusher are monitored by the control system and used for main drive
interlocking.
Tank Heater Crusher Lubrication

Operator Operator
Start Start
Command Command
Tank Heater
Start
Auto Start per Lube Pumps
Control Limits
Heat Exchanger Centrifuge Pump

Drain Valve
Auto Start per Auto Start per
Close
Control Limits Control Limits
Figure 3.1 Lubrication Normal Startup

Tank Temperature L2 Delay
When the lubrication system is started, oil passing through a cold crusher can be
cooled significantly resulting in the tank temperature dropping below the
temperature of the start interlock. This delay time and associated interlock allow

Gyratory Crusher
operation below the start interlock temperature to continue while the crusher
warms.
Lubrication Run Time

Prior to starting the crusher main drive, the lubrication system shall run for a period
of time to warm the internal components to an acceptable operating temperature.
Lubrication Delayed Stop

After stopping the crusher main drive, the lubrication system shall run for a period
of time to remove heat from the internal components.
Timer Settings 3:1 Lubrication

Name Setting Min Max Comment
Tank Temperature L2
300 s - - Not adjustable
Delay Timer
Lubrication Run Timer 15 min 15 min - Can be set longer for ambient conditions
Lubrication Delayed Stop
30 min 30 min - Can be set longer for ambient conditions
Timer
Alarm and Control Limit Settings 3:2 Lubrication

Signal H3 H2 H1 L1 L2 L3 LIM_L2 LIM_L1 LIM_H1 LIM_H2
TI2 60 27 21 32 38
TI3 60 55 50
TI4 35 38 41 43
10

Gyratory Crusher
Calculations
The crusher lubrication oil differential temperature (TDY3) is defined as follows:

TDY3=TI3-TI4
Tank Heater
The tank heater shall be started by operator command and shall operate
automatically to heat the oil in the tank to the minimum operating temperature. It
is assumed that the tank heater control signal is used to control one or more
heating elements.
Interlocks 3.1 Tank Heater: 31-HE-511, 31-HE-512 & 31-HE-513

Index Description Type Mode Comment
HE1_INT01 LAL3 : Lube Tank Level Low Start Auto
HE1_INT02 N/A - -
HE1_INT03 TI2 : Lube Tank Temp < H2 Run All
HE1_INT04 LAL4 : Lube Tank Level Low Run All
HE1_INT05 N/A - -
HE1_INT06 N/A - -
Control 3.1 Tank Heater: 31-HE-511, 31-HE-512 & 31-HE-513

Index Description Operation Comment
HE1_CTRL01 TI2 : Lube Tank Temp < LIM L1 Turn ON Heater
HE1_CTRL02 TI2 : Lube Tank Temp > LIM H1 Turn OFF Heater
Lubrication Pumps
The lubrication pumps shall operate in a duty and standby configuration with one
pump in operation at a time. The selected lubrication pump shall be started by
operator command. The system shall be stopped to change to the standby pump.
Interlocks 3.2 Lube Pump 1: 31-PU-651M

31_PU_651M_INT01 LAL3 : Lube Tank Level Low Start Auto
31_PU_651M_INT02 TI2 : Lube Tank Temp > L2 Start Auto
31_PU_651M_INT03 31_PU_651M : Pump 1 Selected Run Auto
11

Gyratory Crusher
31_PU_651M_INT04 TI2 : Lube Tank Temp > L2 Delay Run Auto

31_PU_651M_INT05 31_PU_652M : Pump 2 not Running Run All
31_PU_651M_INT06 N/A - -
31_PU_651M_INT07 LAL4 : Lube Tank Level Low Run All
31_PU_651M_INT08 TI2 : Lube Tank Temp > L3 Run All
31_PU_651M_INT09 Lube Delayed Shutdown Complete Stop Auto
31_PU_651M_INT10 TI3 : Lube Return Oil Temp < H1 Stop Auto
Interlocks 3.3 Lube Pump 2: 31-PU-652M

31_PU_652M_INT01 LAL3 : Lube Tank Level Low Start Auto
31_PU_652M_INT03 31_PU_652M : Pump 2 Selected Run Auto
31_PU_652M_INT04 TI2 : Lube Tank Temp > L2 Delay Run Auto
31_PU_652M_INT05 31_PU_651M : Pump 1 not Running Run All
31_PU_652M_INT06 N/A - -
31_PU_652M_INT07 LAL4 : Lube Tank Level Low Run All
31_PU_652M_INT09 Lube Delayed Shutdown Complete Stop Auto
31_PU_652M_INT10 TI3 : Lube Return Oil Temp < H1 Stop Auto
Drain Valve
The drain valve provides a path for oil at the heat exchangers to drain by gravity
back to the tank. It shall operate automatically when the lubrication pump is
running to direct oil to the heat exchanger and crusher.
Control 3.2 Drain Valve: 31-DV-501

31_PU_651M, 31_PU_652M: Pump 1
31_DV_501M_CTRL01 Close Valve
Running OR Pump 2 Running
31_PU_651M, 31_PU_652M: Pump 1
31_DV_501M_CTRL02 Open Valve
Not Running AND Pump 2 Not Running
Heat Exchanger
The heat exchanger control stages shall operate automatically when the lubrication
pump is running to maintain the temperature of the oil supplied to the crusher
12

Gyratory Crusher
within the desired operating range. It is assumed that each stage is used to control
one or more heat exchanger fan motors.
Interlocks 3.4 Heat Exchanger Stage 1: 31-FN-502M
31_PU_651M, 31_PU_652M: Pump 1
STG1_INT01 Start Auto
Control 3.3 Heat Exchanger Stage 1: 31-FN-502M

STG1_CTRL01 TI4 : Supply Oil Temp > LIM_H1 Start Motor
STG1_CTRL02 TI4 : Supply Oil Temp < LIM_L1 Stop Motor
Interlocks 3.5 Heat Exchanger Stage 2: 31-FN-503M

31_PU_651M, 31_PU_652M: Pump 1
STG2_INT01 Start Auto
Control 3.4 Heat Exchanger Stage 2: 31-FN-503M

STG2_CTRL01 TIC4 : Supply Oil Temp > LIM_H2 Start Motor
STG2_CTRL02 TIC4 : Supply Oil Temp < LIM_L2 Stop Motor
Heat Exchanger Proportional Control (Optional Equipment)

The heat exchanger shall operate automatically when the lubrication pump is
running to maintain the temperature of the oil supplied to the crusher at the desired
setpoint. The control signal can be mapped to either heat exchanger fan variable
frequency drives (VFD) or a water flow control valve.
In either case, the interlocking is the same as described for the standard heat
exchanger.
Control 3.5 Heat Exchanger Proportional Control 111LQ106TIC4

PV: TI4 CV mapped to VFD or Flow
TIC4 Supply Oil Temperature Control valve command
CV: STG1C21
13

Gyratory Crusher
4. Spider Lubrication System

The purpose of the spider lubrication system is to periodically apply grease to the
crusher spider bushing. This periodic grease application is monitored by the control
system and is used for main drive interlocking.
Grease Pump
Operator
Start
Command
Grease Pump
Auto Start per

Control Limits
Figure 4.1 Spider Lubrication Normal Startup

Grease Cycle Period
A grease cycle is defined as starting the pump and upon receiving switch feedback
from the divider cycle switch, stopping the pump. The Grease Cycle Period is the
time between the start of one cycle and the start of the next cycle.
Grease Cycle Fault

The Grease Cycle Fault alarm indicates that the grease cycle did not end in the
expected time. The alarm is based on the Grease Cycle Fault Time. The grease
cycle fault timer starts at the beginning of the grease cycle. The timer is stopped
14

Gyratory Crusher
and reset on receipt of the divider cycle switch. If the divider cycle switch is not
received and the timer expires, the Grease Cycle Fault alarm shall be annunciated.
Spider Lube Fault

The Spider Lube Fault alarm indicates that crusher has been operating for an
extended period of time without a successful grease cycle. The alarm is based on
the Spider Lube Fault Time. The spider lube fault timer starts when the main drive
starts. The timer is reset on receipt of the divider cycle switch. The timer is stopped
and reset when the main drive is stopped. If the divider cycle switch is not received
and the timer expires, the Spider Lube Fault alarm shall be annunciated.
Timer Settings 4.1 Spider Lubrication

Grease Cycle Period 150 sec 60 sec 1500 sec
Grease Cycle Fault Time 10 sec - - Not adjustable
Spider Lube Fault Time 1800 sec - - Not adjustable
Alarm and Control Limit Settings 4:2 Spider Lubrication System

WI1 25
Alarms 4.1 Spider Lubrication

Name Condition Comment
Grease Cycle Fault Alarm Grease Cycle Fault Timer expired
Spider Lube Fault Alarm Spider Lube Fault Timer expired
Grease Pump
The grease pump shall be started by operator command and shall operate
automatically based on a timing cycle diagrammed below.
15

Gyratory Crusher
Cycle Timer
Pump Command
Cycle Switch
Cycle Fault
Cycle Period
Lube Fault
Figure 4.2 Spider Lubrication Cycle
Interlocks 4.1 Grease Pump: 31-PU-654M

31_CR_501M : Main Drive Motor
31_PU_654M_INT01 Running Run Auto
HI3B : Maintenance Field Switch
31_PU_654M_INT02 OFF Run All
Control 4.1 Grease Pump:31-PU-654M

31_PU_654M_CTRL01 Grease Period Timer Expired Start Motor
31_PU_654M_CTRL02 Cycle Switch On Stop Motor
31_PU_654M_CTRL03 Cycle Fault Timer Expired Stop Motor
Local Maintenance Panel

The local maintenance panel allows the spider lube system to be controlled locally
during routine maintenance procedures such as changing the grease drum. The
control switches at the local maintenance panel can be used at any time.
16

Gyratory Crusher
Maintenance Switch
The purpose of the maintenance switch (maintained) is to indicate to the control
system that the local grease pump motor starter is being turned off and locked out
for maintenance purposes.
When the maintenance switch input is ON,
x Grease cycle period timer and cycle fault timer shall be stopped and reset.
o The Spider Lube Fault timer shall continue timing.
x Grease pump motor control alarms shall be disabled.
x The grease pump run command shall not be turned on for any reason.
When the maintenance switch input is OFF, the normal grease cycle and alarm
handling shall resume.
Jog Switch
The purpose of the jog switch (momentary) is to run the grease pump motor locally
for maintenance purposes.
When the jog switch input is ON, the grease pump run command shall be turned
ON. When the jog switch input is OFF, the grease pump run command shall be
turned OFF.
Operation of the jog switch shall reset the grease cycle.
17

Gyratory Crusher
5. Hydraulic System
The purpose of the hydraulic system is to supply hydraulic oil as needed for
positioning the mantle.
Hydraulic Pump
Operator
Start
Command
Hydraulic Pump Operator Operator

Mantle Mantle
Auto Start per Raise Lower
Control Limits Command Command
Figure 5.1 Hydraulic Normal Startup

Hydraulic Pump Run Time
Each time the hydraulic pump is started, it shall be run for the time that it takes to
circulate the volume of the hydraulic tank through the circuit. This is done to ensure
that the hydraulic oil is regularly filtered.
Settings 5:1 Hydraulic
Hydraulic Pump Run Not Adjustable
Per Size - - See Hydraulic Tank Size Table
Time
Lubrication Skid Size 52GPM 65GPM 80GPM 100GPM 130GPM 160GPM 200GPM
Hydraulic Tank Size 100 gal 100gal 150 gal 150 gal 180 gal 180 gal 200 gal
Pump Run Time 25 min 25 min 35 min 35 min 40 min 40 min 45 min
18

Gyratory Crusher
Alarm and Control Limit Settings 5:2 Hydraulic

TI1 60 27 21 32 38
Hydraulic Pump
The hydraulic pump shall be started by operator command and operated
automatically when it is required.
Interlocks 5.1 Hydraulic Pump 1:31-PU-653M

31_PU_653M_INT01 LAL1 : Hyd Tank Level Low Start Auto
31_PU_653M_INT03 31_PU_653M : Pump 1 Selected Run Auto Optional
31_PU_653M_INT04 Spare (Not Used)
31_PU_653M_INT05 Spare (Not Used)
31_PU_653M_INT06 LAL2 : Hyd Tank Level Low Run All
31_PU_653M_INT08 SV2 : Lower Solenoid Not Energized Run All
31_PU_653M_INT09 Minimum Run Time Complete Stop Auto
Control 5.1 Hydraulic Pump 1:31-PU-653M

31_PU_653M_CTRL01 Raise Mantle Command Start Motor
Optional
31_PU_653M_CTRL02 Oil Contamination > H1 Start Motor Any of the 3 particle sizes.
31_PU_653M_CTRL03 Lower Mantle Command Stop Motor
19

Gyratory Crusher
Tank Heater
The tank heater shall be started by operator command and shall operate
automatically to heat the oil in the tank to the minimum operating temperature. It
is assumed that the tank heater control signal is used to control one or more
heating elements.
Interlocks 5.2 Tank Heater: 31-HE-514 & 31-HE-515

HE1_INT01 Spare (Not Used)
HE1_INT02 LAL1 : Hyd Tank Level Low Start Auto
HE1_INT05 LAL2 : Hyd Tank Level Low Run All
HE1_INT06 TI1: Hyd Tank Temp < H2 Run All
Control 5.2 Tank Heater: 31-HE-514 & 31-HE-515

HE1_CTRL01 TI1 : Lube Tank Temp < LIM L1 Turn ON Heater
HE1_CTRL02 TI1 : Lube Tank Temp > LIM H1 Turn OFF Heater
Mantle Solenoids
The mantle solenoids are operated manually to control the position of the mantle.
Interlocks 5.2 Raise Solenoid: SV-1

SV1_INT01 ZI1 : Mantle Position < H2 Run Special Main Drive Running
31_PU_651M, 31_PU_652M: Lube
SV1_INT02 Pump 1 or 2 Running Run All
SV1_INT03 SV2 : Lower Solenoid Command OFF Run All
Interlocks 5.3 Lower Solenoid: SV-2

SV2_INT01 ZI1 : Mantle Position > L2 Run Special Main Drive Running
31_PU_651M, 31_PU_652M: Lube
SV2_INT02 Pump 1 or 2 Running Run All
SV2_INT03 SV1 : Raise Solenoid Command OFF Run All
20

Gyratory Crusher
Mantle Position Calibration

Due to manufacturing variations of the crusher components, the measured position
of the mantle varies; the mantle is mechanically stopped before the instrument
reads zero. This difference between the actual zero position and the instrument
zero position necessitates a calibration procedure.
The procedure for mantle position calibration is specified in the below diagram. All
control actions of the calibration procedure are operator initiated.
Interlocks 5.4 Mantle Calibration

31_CR_501M: Main Drive Motor Not
CAL_INT01 Running Run All
Operator Initiated Interlocks satisfied

Calibration
Lower Mantle to Raise Mantle to

Physical Stop Physical Stop
Instrument position Set the 100% Instrument position

Set the 0% Position
saved as 0% position. Position saved as 100% position.
Calibration Complete.
Figure 5.2 Mantle Calibration
21

Gyratory Crusher
The calibrated mantle position shall be used for all mantle position alarming and
interlocking.
Local Maintenance Panel

The local maintenance panel allows the mantle solenoids to be controlled locally
during maintenance procedures. The control switches at the local maintenance
panel can be used when permission is granted by the crusher operator.
Mantle Position Indicator

The mantle position indicator displays the calibrated mantle position.
Maintenance Permission Lamp

The maintenance permission lamp indicates to the local operator that local mantle
control permission has been granted and the raise and lower switches will operate
the solenoids.
Mantle Raise and Lower Switches

When the mantle raise switch input is ON, the mantle raise command shall be
turned ON. When the mantle raise switch input is OFF, the mantle raise command
shall be turned OFF.
When the mantle lower switch input is ON, the mantle lower command shall be
turned ON. When the mantle lower switch input is OFF, the mantle lower command
shall be turned OFF.
22

Gyratory Crusher
6. Other Crusher Equipment

Dust Seal Fan
The purpose of the dust seal fan is to provide positive air pressure inside the crusher
to prevent dust from entering.
The dust seal fan is typically started with the lubrication system.
There are no interlocks for 31-FN-501M.
Dust Seal Fan

Operator
Start
Command
Start Dust Seal Fan
Figure 6.1 Dust Seal Normal Startup
Countershaft Speed
The countershaft speed is measured by a proximity switch and a target on the
shaft. The control system shall convert the frequency of this digital signal to
revolutions per minute for alarming. This conversion can be done either by
hardware (frequency to current converter) or by software.
23

Gyratory Crusher
7. Main Drive
The purpose of the main drive or main motor is to supply the input power to the
machine’s countershaft which is converted by the machine into the crushing forces
that act upon the feed material.
Main Drive
Operator
Start
Command
Start Main Drive
Figure 7.1 Main Drive Normal Startup

Downstream Interlock Definition
A signal from the process control system indicating that the equipment downstream
of the gyratory crusher is operating and ready to receive crushed product.
Main Drive Stop Delay Time

The delayed stop function is designed to allow the crushing chamber to empty
before the main drive is stopped following a delayed stop interlock.
Extended Idle Time (Optional)
24

Gyratory Crusher
An alarm to indicate that the crusher main drive is running but not crushing for a
period of time. This alarm can be configured by the operator as an interlock on
the main drive.
Timer Settings 7:1 Main Drive

Main Drive Delayed Stop
15s 15s 120s
Time
Extended Idle Time 60 min 30 min -
Alarm and Control Limit Settings 7:2 Main Drive

FI3 179.9 102.8

FI6 21.14 12.08
FI7 179.9 102.8
SI3 100
TI6 90 85
TI11 90 85
ZI1 287.5 275 50 25
Main Drive
The main drive shall be started by operator command.
Motor Protective Relay
This document assumes that the main drive motor is protected by a motor
protective relay. All motor protection instruments are connected directly to this
relay and it performs all motor protection functions including starting limitations.
Control system treatment of the motor protective relay is not further described in
this document.
Interlocks identified as Delayed Stop are used to start the Stop Delay timer. The
main drive shall stop when the Stop Delay timer reaches zero.
25

Gyratory Crusher
Interlocks 7.1 Main Drive: 31-CR-501M

31_CR_501M_INT01 LAL3 : Lube Tank Level Low Start Auto
31_CR_501M_INT02 LAL1 : Hyd Tank Level Low Start Auto
31_CR_501M_INT03 TI3 : Lube Return Oil Temp < H2 Start Auto
31_CR_501M_INT04 FI3 : Outer Eccentric Flow > L2 Start Auto
31_CR_501M_INT05 Spare (Not used)
31_CR_501M_INT06 FI7 : Inner Eccentric Flow > L2 Start Auto
31_CR_501M_INT08 FI6 : Countershaft Flow > L2 Start Auto
TI6 : Countershaft Outboard
31_CR_501M_INT09 Bearing Temp < H2 Start Auto
TI11 : Countershaft Inboard Bearing
31_CR_501M_INT10 Temp < H2 Start Auto
31_CR_501M_INT11 ZI1 : Mantle Position < H2 Start Auto
31_CR_501M_INT12 ZI1 : Mantle Position > L2 Start Auto
31_CR_501M_INT13 Mantle Calibration Not Active Start All
31_CR_501M_INT14 Lube Pump Minimum Run Time Start All
31-FN-501M : Dust Seal Blower
31_CR_501M_INT15 Running Start All
31_CR_501M_INT16 LAL4 : Lube Tank Level Low Run Auto Delayed Stop
31_CR_501M_INT17 TI3 : Lube Return Oil Temp < H3 Run Auto Delayed Stop
31_CR_501M_INT18 FI3 : Outer Eccentric Flow > L2 Run Auto Delayed Stop
31_CR_501M_INT20 FI7 : Inner Eccentric Flow > L2 Run Auto Delayed Stop
31_CR_501M_INT22 FI6 : Countershaft Flow > L2 Run Auto Delayed Stop
TI6 : Countershaft Outboard
31_CR_501M_INT23 Bearing Temp < H3 Run Auto Delayed Stop
TI11 : Countershaft Inboard Bearing
31_CR_501M_INT24 Temp < H3 Run Auto Delayed Stop
31-FN-501M : Dust Seal Blower
31_CR_501M_INT25 Running Run Auto Delayed Stop
31_CR_501M_INT26 Spider Lubrication OK Run Auto Delayed Stop
31_CR_501M_INT27 Downstream Equipment OK Run Auto
31_CR_501M_INT28 Extended Idle Time OK Run Auto Configurable
31_CR_501M_INT29 FI3 : Outer Eccentric Flow > L3 Run All
31_CR_501M_INT31 FI7 : Inner Eccentric Flow > L3 Run All
31_CR_501M_INT33 FI6 : Countershaft Flow > L3 Run All
31_CR_501M_INT34 SI3 : Countershaft Speed > L2 Run All
26

Gyratory Crusher
31_CR_501M_INT35 ZI1 : Mantle Position < H3 Run All

31_CR_501M_INT36 ZI1 : Mantle Position > L3 Run All
31_CR_501M_INT37 LI6 : Discharge Pocket Level < H2 Run All Optional
31_CR_501M_INT38 LSHH4 : Discharge Pocket Level OK Run All Optional
31_CR_501M_INT39 LSHH5 : Discharge Pocket Level OK Run All Optional
31_CR_501M_INT40 Delayed Stop Timer Complete Stop Auto
8. Crusher Feed Permission

The purpose of the crusher feed permission is to signal the Process Control System
(PCS) that the crusher is ready to receive feed material. This signal shall be
included in the PCS logic that is used to control any upstream equipment that allows
feed to enter the crusher dump pocket.
When the Crusher Feed Permission signal is FALSE, no additional feed material shall
be supplied to the crusher dump pocket.
Alarm and Control Limit Settings 8:1 Crusher Feed Permission

LI6 95 55 13 17
Interlocks 8.1 Crusher Feed Permissive: 111GC101_FEEDPERM

31_CR_501M : Main Drive Motor
CFP_INT01 Running Run All
CFP_INT02 Feed Permission Timer Complete Run All
CFP_INT03 Not Delayed Stop Timer Run All
27

Gyratory Crusher
Control 8.1 Crusher Feed Permissive: 111GC101_FEEDPERM

CFP_CTRL01 LI6 : Discharge Pocket Level > LIM_H1 Permissive OFF Optional
CFP_CTRL02 LI6 : Discharge Pocket Level < LIM_L1 Permissive ON Optional
28


273
Appendix H: Drawing
Package
H.1 1000614305: Crusher General Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
H.2 1000614318: Foundation Load and Clearance Requirements . . . . . . . . . . . . . . .277
H.3 1000633857: Foundation Bolt Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
H.4 1000660387: Mainshaft Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
H.5 1000660800: Spider Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
H.6 1000660799: Top Shell Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
H.7 1000660798: Middle Shell Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
H.8 1000660797: Bottom Shell Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
H.9 1000494407: Spider Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
H.10 1000494882: Top Shell Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
H.11 1000614471: Top Shell Seal Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
H.12 13072581: Middle Shell Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
H.13 13037588: Bottom Shell Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
H.14 1000495367: Bottom Shell Liner Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
H.15 1000497921: Dust Bonnet Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
H.16 1000496410: Eccentric Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
H.17 1000531721: Hydraulic Cylinder Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
H.18 1000500157: Mainshaft Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
H.19 1000519350: Concave Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
H.20 1000520967: Concave Installation Ring Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
H.21 1000521111: Installation Ring Assy, Lower Concave . . . . . . . . . . . . . . . . . . . . . . 296
H.22 1000521942: Installation Ring Assy, Middle Concave . . . . . . . . . . . . . . . . . . . . .297
H.23 1000521945: Installation Ring Assy, Upper Concave . . . . . . . . . . . . . . . . . . . . . 298
H.24 1000716626: Concave Removal Pan Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
H.25 1000652444: Removal Pan Assy, Lower Concave . . . . . . . . . . . . . . . . . . . . . . . 300
H.26 1000670704: Removal Pan Assy, Middle Concave . . . . . . . . . . . . . . . . . . . . . . . . 301
H.27 1000671390: Removal Pan Assy, Upper Concave . . . . . . . . . . . . . . . . . . . . . . . . 302
H.28 1000521941: Bonnet Cover Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
H.29 13036470: Countershaft Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
H.30 1000608222: Lube and Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
H.31 1000636190: Spider Lubrication GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

274 Appendix H Drawing Package
H.32 1000614472: Countershaft Extension Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307

H.33 1000614634: Drive Guard Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
H.34 13072248: Dust Seal Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
H.35 3.507050: Mantle Position Indicator Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
H.36 10453395: Hydraulic Jack Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
H.37 1000614463: Mantle Relief Valve and Accumulator Assy . . . . . . . . . . . . . . . . . . 313
H.38 1000614466: Blower Assy Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
H.39 13035139: Gear & Pinion Assy, Field Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 315
H.40 1000730476: Erection and Maintenance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
H.41 7.500234: Acceptable Epoxy Grouts for Installation . . . . . . . . . . . . . . . . . . . . . 320
H.42 1000637275: Instrument List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
H.43 1000636813: Electrical Load List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
H.44 1000627226: Control and Instrumentation Diagram . . . . . . . . . . . . . . . . . . . . . . 331
H.45 1000681661: Interconnection Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
H.46 1000606868: Lubrication Unit Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 341
H.47 1000614108: Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
H.48 1000637276: I/O List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346


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H.41 7.500234: Acceptable Epoxy Grouts for Installation
Acceptable Epoxy Grouts for

Gyratory Crusher Installation
Engineering Instruction
Created by: M.Daniel

Approved by: M.Ford
FLSmidth, 7.500234-3.0

7.500234: Acceptable Epoxy Grouts (Sheet 2)
Acceptable Epoxy Grouts for Crusher Installation

7.500234-3.0
Page 2 of 5
Foreword
The present instructions are concerned with the situations which, according to the
experience of FLSmidth, are the most likely to occur during manufacture, installa-
tion, operation and maintenance of the equipment. An exhaustive enumeration of
all conceivable situations, which may occur, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in
the instructions, and which the operator is/or feels unable to handle, it is recom-
mended that FLSmidth is contacted without undue delay for advice on appropriate
action.
Reference by seller to any international or national standard does not incur an

obligation on seller to provide any recipient, reader or user of the documentation
with samples or copies of the said standard(s).
Hence, any recipient, reader or user of the documentation is expected – at his own
cost – to obtain necessary knowledge of the contents of any of the standards
referred to.
Legend
Warning
This symbol indicates dangers which, in case of non-observance, may cause fatal or
serious personal injuries!
Warning text is concluded with a filled black triangle to symbolize end of warning
text. S
Attention
This symbol indicates important information where specific attention and caution is
needed. For example to avoid damage to or destruction of the equipment and/or
parts of the installation.
Attention text is concluded with a filled black square to symbolize end of attention
text.
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.


7.500234-3.0
Page 3 of 5
Table of contents
1.0 Scope ..................................................................................................... 4
2.0 Purpose .................................................................................................. 4
3.0 Epoxy Grouts ........................................................................................... 4


7.500234-3.0
Page 4 of 5
1.0 Scope
This document pertains to FLSmidth Gyratory Crushers.
2.0 Purpose
To define the epoxy grouts instruction for subject equipment.
3.0 Epoxy Grouts
Non-shrink epoxy grouts with a minimum compressive strength at least 99 MPa are
acceptable for use for gyratory crushers. The following epoxy grouts are a few
examples of acceptable grouts. Grout installation specialist should be employed to
ensure grout is poured correctly so the maximum bearing area is achieved.
For thickness from 5 mm to 25 mm
FIVE STAR HP EPOXY GROUT - HIGH FLOW

7 day compressive strength 110 MPa (16000 psi)
MASTER BUILDERS MASTERFLOW 649 GROUT

MICOROX STANDARD GROUT

CHOCKFAST RED GROUT

EPOGROUT 758 GROUT

REDBAC DEEP POUR 3CE GROUT

For thickness from 15 mm to 100 mm
(Epoxies must be used in conjunction with an aggregate. The quantity of aggregate

depends on grout thickness and method of pour; contact the manufacturer for
details.)


7.500234-3.0
Page 5 of 5
FIVE STAR HP EPOXY GROUT - HIGH FLOW

MASTER BUILDERS MASTERFLOW 649 GROUT (WITH AGGREGATE)

MICOROX DEEP POUR GROUT

CHOCKFAST RED GROUT

EPOGROUT 758 GROUT

REDBAC DEEP POUR 3CE GROUT


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9/7/21
1000637275: Instrument List (Sheet 3)
#\
327
9232510974 — 1000702743 1
328
Original
Load List
1300 X 1800 TSU Gyratory
Project number: 9232510974
Document Type: Control and instrumentation

Reference Documents:

Client Document No.: V-10496302-0002-0067 S.No Document Number Description Rev Date
1 1000627226 Piping And Instrumention Diagram 2 4-Dec-20
9/7/21
3 15-Dec-20 RKRIS ARAAH JGAMEZ Revised Doc: 1000636813
2 8-Dec-20 RKRIS ARAAH JGAMEZ Revised CERTIFIED FINAL Rev: 3
1 18-Sep-20 RKRIS ARAAH JGAMEZ Preliminary
Rev Date Created By Checked By Approved By Description
15-DEC-2020
H.43 1000636813: Electrical Load List
Property of FLSmidth A/S. This drawing contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this drawing is not permitted
without the prior written permission of FLSmidth A/S.
9232510974 — 1000702743 1
Electrical Load List
Doc: 1000636813 Rev: 3

Page 2 of 3
MOTOR VOLTAGES ABBREVIATIONS FOR MOTOR TYPE COLUMN:
System Voltage level SCHB = HV Squirrel Cage, Foot Mounted Motor

Variable Speed motors >300kW 6000V 3 phase 50Hz 3 wire, resistance earthed SCHF = HV Squirrel Cage, Flange Mounted Motor
Fixed speed DOL motors >150kW 6000V 3 phase 50Hz 3 wire, resistance earthed SCLB = LV Squirrel Cage, Foot Mounted Motor
Fixed speed DOL Motors up to 150kW 415V 3 phase 50Hz 3 wire solidly earthed SCLF = LV Squirrel Cage, Flange Mounted Motor
Variable Speed motors up to 300kW 415V 3 phase 50Hz 3 wire solidly earthed SRHB = HV Slip Ring, In-Direct Air-Cooled Motor
Electric Heaters up to 3kW 220V 1 phase, 50Hz solidly earthed SRHC = HV Slip Ring, Direct Air-Cooled Motor

Electric Heaters above 3kW 415V 3 phase 50Hz 3 wire solidly earthed SRHW = HV Slip Ring, Water Cooled Motor
VSCHB = Variable HV Squirrel Cage, Foot Mounted Motor
VSCLB = Variable LV Squirrel Cage, Foot Mounted Motor
VSCLF = Variable LV Squirrel Cage, Flange Mounted Motor
ABBREVIATIONS FOR STARTER TYPE COLUMN: GENERAL ABBREVIATIONS:
CB = Circuit Breaker A/C = Air Conditioning

FVC = Full Voltages Contactor AM = Ammeter
FVLC = Full Voltage Lighting Contactor AT = Auto Transformer
FVNR = Full Voltage Non Reversing Starter BDT = Breakdown Torque
FVR = Full Voltage Reversing Starter CB = Circuit Breaker
9/7/21
RVNR = Reduced Voltage Non Reversing Starter CH = Constant HP
2S2W = 2 Speed 2 Winding CT = Constant Torque
2S1W = 2 Speed 1 Winding EM = Electromagnetic
AFD = Adjustable Frequency Drive GM = Gear Motor
H = Hydraulic Drive
HST = High Starting Torque
HTR = Heater (Space Heater, Lube Heater, Etc.)
LVCB = Low Voltage Circuit Breaker
RS = Reactor Start
SF = Service Factor
ST = Starting Torque
STB = Standby
T/R = Transformer Rectifier
T/S = Transfer Switch
VT = Variable Torque
TEFC = Totally Enclosed, Fan Cooled
1000636813: Electrical Load List (Sheet 2)
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth. This drawing contains confidential and proprietary information of FLSmidth A/S and
may only be used for the limited purposes of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this drawing is not permitted without the prior written permission of FLSmidth A/S.
9232510974 — 1000702743 1
329
Electrical Load List
330
Doc: 1000636813 Rev: 3

Page 3 of 3
OPERATING SPEED DUTY/STANDBY/

EQUIPMENT TAG POWER RATING LOAD VOLTAGE FREQUENCY RESPONSIBILITY
REV P&ID EQUIPMENT DESCRIPTION MOTOR TYPE STARTER TYPE NO OF POLES RANGE INTERMITTENT REMARKS
NUMBER (KW) (V) (Hz) FOR STARTER
(RPM) LOAD
3 1000627226, Sh.03 31-FN-501M Primary Crusher Dust Seal Fan Motor SCLB 1.5 kW FVNR 415 50 4 3000 Continuous By Others
3 1000627226, Sh.04 31-CR-501M Primary Crusher Main Motor SCLB 450 kW FVNR 6000 50 4 600 Continuous By Others
3 1000627226, Sh.04 31-HE-510 Primary Crusher Main Motor Space Heater - 0.5 kW CB 220 50 - - Intermittent By Others
2 1000627226, Sh.05 31-PU-653M Primary Crusher Hydraulic Oil Pump 1 Motor - Operating SCLB 5.5 kW FVNR 415 50 4 1000 Continuous By Others
3 1000627226, Sh.06 31-PU-654M Primary Crusher Spider Bushing Lube System Grease Pump Motor - 0.37 kW CB 220 50 - Continuous By Others
3 1000627226, Sh.06 31-HE-517 Primary Crusher Spider Lube System Drum Heater - 1000W CB 220 50 - - Intermittent By Others
2 1000627226, Sh.07 31-FN-502M Primary Crusher Heat Exchanger 1 Fan Motor VSCLB 11 kW AFD 415 50 4 1000 Continuous By Others AFD Supplied by Client
2 1000627226, Sh.07 31-FN-503M Primary Crusher Heat Exchanger 2 Fan Motor VSCLB 11 kW AFD 415 50 4 1000 Stand-by By Others AFD Supplied by Client
2 1000627226, Sh.05 31-HE-514 Primary Crusher Hydraulic Oil Reservoir Heater 1 - 2 kW FVC 415 50 - - Intermittent By Others

2 1000627226, Sh.05 31-HE-515 Primary Crusher Hydraulic Oil Reservoir Heater 2 - 2 kW FVC 415 50 - - Intermittent By Others
2 1000627226, Sh.07 31-HE-511 Primary Crusher Lube Oil Reservoir Heater 1 - 2 kW FVC 415 50 - - Intermittent By Others
3 1000627226, Sh.07 31-DV-501M Primary Crusher Lube Oil Drain Motor SCLF 10A FVNR 24VDC - - Intermittent By Others
2 1000627226, Sh.07 31-PU-651M Primary Crusher Lube Oil Pump 1 Motor - Operating SCLB 15 kW FVNR 415 50 4 1500 Continuous By Others
2 1000627226, Sh.07 31-PU-652M Primary Crusher Lube Oil Pump 2 Motor - Stand By SCLB 15 kW FVNR 415 50 4 1500 Stand-by By Others
9/7/21
1000636813: Electrical Load List (Sheet 3)
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth. This drawing contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes of evaluating proposals or
installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this drawing is not permitted without the prior written permission of FLSmidth A/S.
9232510974 — 1000702743 1
H.44 1000627226: Control and

Instrumentation Diagram
©
CERTIFIED FINAL
04-DEC-20

1000627226: C&ID (Sheet 2)
©
CERTIFIED FINAL
04-DEC-20

1000627226: C&ID (Sheet 3)
©
CERTIFIED FINAL
04-DEC-20

1000627226: C&ID (Sheet 4)
©
CERTIFIED FINAL
04-DEC-20

1000627226: C&ID (Sheet 5)
©
CERTIFIED FINAL
04-DEC-20

1000627226: C&ID (Sheet 6)
©
CERTIFIED FINAL
04-DEC-20

1000627226: C&ID (Sheet 7)
©
CERTIFIED FINAL
04-DEC-20

1000627226: C&ID (Sheet 8)
©
CERTIFIED FINAL
04-DEC-20

1000627226: C&ID (Sheet 9)
©
CERTIFIED FINAL
04-DEC-20

340
PRIMARY CRUSHER
FIELD INSTRUMENTS INSTRUMENT MARSHALLING PANEL
31-IM-502
WH1 31-TE-8008-J1 WH1
PRIMARY CRUSHER COUNTERSHAFT OUTBOARD BEARING 1 1 + 31-TIT-8008-J1 1
31-31-TE-8008 2 BK1 BK1 2 31-TIT-8008
TEMPERATURE ELEMENT BK2 (By Others) (By Others)
3 BK2 3 - 2
3
WH1 31-TE-8007-J1 WH1
PRIMARY CRUSHER COUNTERSHAFT INBOARD BEARING 1 1 31-TIT-8007-J1 4
31-31-TE-8007 2 BK1 BK1 2 31-TIT-8007 +
3 BK2 3 - 5
31-FIT-8009 + 31-FIT-8009-J1 7
PRIMARY CRUSHER OUTER ECCENTRIC LUBE FLOW TRANSMITTER - (By Others)
8

31-FIT-8011 + 31-FIT-8011-J1 10
PRIMARY CRUSHER INNER ECCENTRIC LUBE FLOW TRANSMITTER - (By Others)
Drawing
11
12
31-FIT-8010 + 31-FIT-8010-J1 13
PRIMARY CRUSHER COUNTER SHAFT SUPPLY LINE FLOW TRANSMITTER - (By Others)
14
15
1 WH1 31-TE-8012-J1 WH1 1
PRIMARY CRUSHER OUTER ECCENTRIC UPPER BK1 + 31-TIT-8012-J1 16
31-TE-8012 2 (By Others)
BK1 2 31-TIT-8012 (By Others)
TEMPERATURE ELEMENT 3 BK2 BK2 3 - 17
18
WH1 31-TE-8013-J1 WH1
PRIMARY CRUSHER OUTER ECCENTRIC WEAR RING 1 1 + 31-TIT-8013-J1 19
31-TE-8013 2 BK1 BK1 2 31-TIT-8013
3 BK2 3 - 20
21
WH1 31-TE-8014-J1 WH1
PRIMARY CRUSHER OUTER ECCENTRIC LOWER 1 1 + 31-TIT-8014-J1 22
31-TE-8014 2 BK1 BK1 2 31-TIT-8014
3 BK2 3 - 23
9/7/21
24
PRIMARY CRUSHER
MANTLE POSITION INDICATOR PANEL
31-VP-502
31-HS-8004 14 31-VP-502-J1 25
(By Others)
PRIMARY CRUSHER MANTLE POSITION RAISE PUSHBUTTON 15 26
16 27
31-HS-8005 17 28
PRIMARY CRUSHER MANTLE POSITION LOWER PUSHBUTTON 18 31-VP-502-J2 29
(By Others)
19 30
31-ZT-8003 20 31
PRIMARY CRUSHER MANTLE POSITION TRANSMITTER 21
H.45 1000681661: Interconnection
LEGEND
CABLE SUPPLY AND TERMINATION BY FLS

BY OTHERS
CERTIFIED FINAL
23-Aug-2021 ®
©
9232510974 — 1000702743 1
H.46 1000606868: Lubrication Unit

Electrical Schematic

1000606868: Lube Unit Schematic (Sheet 2)

®
²
≥
©
NO MORE THAN ONE WIRE SHALL BE TERMINATED IN ANY ONE TERMINAL
WIRE LABELS SHALL BE ORIENTATED SUCH THAT THEY READ LEFT TO

WIRE NUMBER LABELS SHALL BE BLACK ON WHITE GRAFOPLAST SI2K
²
²
²
²
RIGHT ORBOTTOM TO TOP

STYLE
BLOCK
-


LEGEND
GYRATORY CRUSHER BLOCK DIAGRAM BY FLS

BY OTHERS
COMMUNICATION CABLE BY OTHERS
MAIN BEARING
LUBE INSTRUMENTS
LUBE & HYDRAULIC SYSTEM

JUNCTION BOX
JB01
MAIN DRIVE
VFD
HYDRAULIC OIL E-STOP

SYSTEM INSTRUMENTS

EtherNet/IP
CUSTOMER
DCS
SPIDER BUSHING
LUBRICATION SYSTEM
9/7/21
INSTRUMENTS
EtherNet/IP
CRUSHER SPEED
INSTRUMENTS MACHINE
JUNCTION BOX
JB02
LV MCC
GYRATORY CRUSHER
INSTRUMENTS
E-STOP
MANTLE POSITION
INDICATION
H.47 1000614108: Block Diagram
Ausenco Doc No: V-10496302-0002-0040

CONTROL EQUIPMENT DETAILS
LUBE & HYDRAULIC SYSTEM JUNCTION BOX : TBD

MACHINE JUNCTION BOX : TBD
®
9232510974 — 1000702743 1
345
346
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1000637276: I/O List (Sheet 2)

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9232510974 — 1000702743 1
347

349
Appendix I: Final
Mechanical Inspection
I.1 Final Mechanical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

350 Appendix I Final Mechanical Inspection
I.1 Final Mechanical Inspection

Serial Number:
Sign off by initialing and dating each inspection made. When the final mechanical checklist is completed, both the
FLSmidth representative and the installer and erector must sign and date this checklist, and must return one copy of the
checklist for each furnished 1300 × 1800 Top Service Ultra Duty (TSU) Gyratory Crusher to the FLSmidth project
management department to ensure warranty coverage.

Applicable)
Spider and Top Shell Pockets (if spider pockets are not received
N/A
poured)
Spider End A – spider vertical location shim thickness
Spider End B – spider vertical location shim thickness
Spider End A (left side) – spider radial location feeler thickness
Spider End A (right side) – spider radial location feeler thickness
Spider End B (left side) – spider radial location feeler thickness
Spider End B (right side) – spider radial location feeler thickness
Spider End A (left side) – spider and spider pocket gap
Spider End A (middle) – spider and spider pocket gap
Spider End A (right side) – spider and spider pocket gap
Spider End B (left side) – spider and spider pocket gap
Spider End B (middle) – spider and spider pocket gap
Spider End B (right side) – spider and spider pocket gap
Spider End A - Temperature of spider and spider pocket at time of epoxy

pour
Spider End A - time and date of epoxy pour
Spider End B - Temperature of spider and spider pocket at time of epoxy

pour
Spider End A - time and date epoxy pour completed
Amount of epoxy used - Spider Pocket A
Amount of epoxy used - Spider Pocket B
Time and date spider removed from spider pockets
Mainshaft Component Assembly N/A
Temperature of core and mainshaft at time of epoxy pour
Core epoxy amount
Time and day core epoxy pour completed
Temperature of lower mantle and core at time of epoxy pour
Lower mantle epoxy amount
Time and day lower mantle epoxy pour completed
Gap between lower mantle and middle or upper mantle
Horizontal offset between lower mantle and middle or upper mantle
Temperature of lower mantle and core at time of epoxy pour
Lower mantle epoxy amount
Table I-1: Final Mechanical Inspection

Appendix I Final Mechanical Inspection 351

Applicable)
Time and day lower mantle epoxy pour completed
Gap between lower mantle and middle or upper mantle
Horizontal offset between lower mantle and middle or upper mantle
Temperature of middle or upper mantle and core at time of epoxy pour
Middle or upper mantle epoxy amount
Time and date middle or upper mantle epoxy pour completed
Gap between lower or middle mantle and upper mantle
Horizontal offset between lower or middle mantle and upper mantle
Temperature of upper mantle and core at time of epoxy pour
Upper mantle epoxy amount
Time and date upper mantle epoxy pour completed
Gap between bottom of head nut and top of upper mantle – measure at
four equally spaced locations
Gap between the top of the mainshaft and the bottom of the flange on
the mainshaft sleeve – measure at four equally spaced locations
Number of welds and the length of welds between the mainshaft and the
mainshaft sleeve
Bottom shell level
Gear Set N/A
Backlash
Number and thickness of gaskets between bottom plate and bottom

shell
Number and thickness of gaskets between countershaft housing and

bottom shell
Bottom Shell to Middle Shell N/A
Initial gap between bolting flanges at four 90 degree spaces
Final gap between bolting flanges at the same locations as the initial
N/A
measurements
Middle Shell to Top Shell N/A
Initial gap between bolting flanges at four 90 degree spaces
Final gap between bolting flanges at the same locations as the initial
N/A
measurements
Bottom, Middle, and Top Shells N/A
Horizontal offsets (ledges) at the middle to top shell joint N/A
(Record values – include plan view sketch of location and radial extent of
offset)
Concaves N/A
(With one concave from each row stacked inside the shells) measure the
N/A
distance from upper concave lug to top surface of top shell lug groove
Vertical gap between the lower row of concaves
Temperature of lower concaves and shell at the time of epoxy pour
Lower row of concaves epoxy amount
Epoxy pour completed

352 Appendix I Final Mechanical Inspection

Applicable)
Horizontal gap between lower and lower intermediate concaves
Vertical gap between the lower intermediate row of concaves
Temperature of lower intermediate concaves and shell at the time of

epoxy pour
Lower intermediate row of concaves epoxy amount
Time and date lower intermediate concave epoxy pour completed
Horizontal gap between lower intermediate and intermediate concaves
Vertical gap between the intermediate row of concaves
Temperature of intermediate concaves and shell at the time of epoxy

pour
Intermediate row of concaves epoxy amount
Time and date intermediate concave epoxy pour completed
Horizontal gap between lower intermediate (or intermediate) and upper

intermediate concaves
Vertical gap between the upper intermediate row of concaves
Temperature of upper intermediate concaves and shell at the time of

epoxy pour
Upper intermediate row of concaves epoxy amount
Time and date intermediate concave epoxy pour completed
Horizontal gap between intermediate (or upper intermediate) and upper

concaves
Vertical gap between the upper row of concaves
Temperature of upper concaves and shell at the time of epoxy pour
Upper row of concaves epoxy amount
Time and date upper concave epoxy pour completed
Spider Bolt Tightness N/A
Mainshaft Stroke N/A
Measure the distance between the top of the head nut and the bottom of
the spider. (measure with the mainshaft in the lowest position – no
pressure in the hydraulic support system)
Countershaft Extension (if purchased) N/A
Measure the countershaft extension endplay.
Controlled Torque Coupling (if purchased) N/A
Measure the compressed height of the springs
Verify the main drive alignment with the countershaft. N/A
Lubrication and Cooling System Lines for Heat Tracing N/A
Hydraulic System Lines for Heat Tracing N/A
Lubrication System Return Piping N/A
Measure the pitch of the lubrication oil return line from the crusher to the
reservoir
Lubrication and Hydraulic Lines Beneath the Crusher N/A
Ensure protection from the discharged ore N/A

Appendix I Final Mechanical Inspection 353

Applicable)
Countershaft Housing N/A
Verify location of bearing seal grease fitting N/A
Lubrication and Cooling System Piping N/A
Inspect piping for leaks N/A
Hydraulic System Piping N/A
Inspect piping for leaks N/A
Countershaft Seal N/A
Inspect seal for leaks N/A
Countershaft Housing N/A
Bottom Plate N/A
Hydraulic Bottom to Bottom Shell N/A
_________________________________ _________________
(Installer or Erector) (Date)
_________________________________ _________________
(FLS Service Representative) (Date)

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Copyright 2021 FLSmidth. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth.
FLSmidth is constantly striving to improve its products and must therefore reserve the right to change
designs, materials, specifications, and price without notice.

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INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702743 1

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702743 1

3.1.2 Storing OEM Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Chapter 4: Equipment Overview

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702743 1

5.6 Bottom Shell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702743 1

Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. 9/7/21 9232510974 — 1000702743 1

7.9.1 Mainshaft Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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7.15 Countershaft Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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A.6.1 Oil Sampling Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Appendix B: Pre-Installation Inspection

Appendix D: Maintenance Schedule

Appendix E: Parts List/Bill of Materials

Appendix F: Recommended Spare Parts List

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F.1 Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Appendix G: Functional Specification

Appendix H: Drawing Package

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H.36 10453395: Hydraulic Jack Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Appendix I: Final Mechanical Inspection

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1.1 Important Safety Information

Follow all governing safety standards and local jobsite procedures.

1.1.1 Hazard Signal Indicators

Hazard Symbol Symbol Description

“Danger” indicates an imminently hazardous situation which, if not avoided,

“Warning” indicates a potentially hazardous situation which, if not avoided,

“Caution” indicates a potentially hazardous situation which, if not avoided,

“Notice” is used to draw attention to detailed instructions. These notes are

Table 1-1: Hazard Signal Indicators

1.1.2 Safety Signs and Symbols

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1.1.2.1 Mandatory Action Symbols

Mandatory Action Description Mandatory Action Description

General Mandatory Action Wear Protective Clothing

Refer to Instruction Manual Use Handrail

Wear Ear Protection Wear a Face Shield

Wear Eye Protection Wear Head Protection

Connect an Earth Terminal to the

Disconnect Plug from Outlet Wear a Mask

Wear Opaque Eye Protection Wear a Safety Harness

Disconnect Before Carrying Out

Wear Protective Gloves Use This Walkway

Table 1-2: Mandatory Action Symbols

1.1.2.2 Prohibition Symbols

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Prohibition Description Prohibition Description

General Prohibition No Pushing

No Open Flame, Fire, Open

No Thoroughfare Do Not Use Lift in Event of Fire

No Access for People with Active

No Metallic Articles or Watches Do Not Use Lift for People

Do Not Touch No Running

No Heavy Load No Climbing

No Reaching In Do Not Enter

Table 1-3: Prohibition Symbols