Instrucciones de Operación y Montaje SMCP 63x75

ThyssenKrupp Industrial Solutions
Assembly and Operating Instructions

Semi-mobile Crushing Plant
SMCP 63 x 75
Shougang Hierro II
Shougang Hierro S.A.A.
San Juan de Marcona, Peru
2-492-20980
05/2014 Rev 0
Year of manufacture 2013
2-492-20980
Revision level
Revision
status
0
Date
03.12.2013
26.06.2014
Changes
Original created (German)
Translation from original (English / Spanish)
Made by
Ritterbecks
Ritterbecks
1
2
3
ThyssenKrupp Industrial Solutions AG

P.O. Box 1463 D - 59306 Ennigerloh
Schleebergstrae 12 D - 59320 Ennigerloh
Telephone: +49 2524 30 0
Fax: +49 2524 2252
www.thyssenkrupp-industrial-solutions.com/
All parts protected by copyright. All rights reserved including those of translation into other languages. This
document may not be processed, reproduced or distributed by any means, including electronic systems, in
whole or in part without our express permission in writing.
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05/2014 Rev 0
Table of Contents
1
05/2014 Rev 0
User's guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 1
1.1
User groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 1
1.2
Structure of the safety notes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 2
1.3
Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 2
1.4
General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3
1.5
Liability and warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3
1.6
Copyright - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3
1.7
Technical modifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4
1.8
Stocking of spare parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4
Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 1
2.1
Material - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 1
2.2
Power supply system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 1
2.3
Process data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 1
2.4
Gyratory crusher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 2
2.4.1
Crusher type, dimensions, capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 2
2.4.2
Oil circulating lubrication and hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 3
2.4.3
Over-pressure ventilation of the dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 3
2.4.4
Grease lubrication for spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 3
2.4.5
Drive unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 4
2.5
Discharge conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 4
2.5.1
Drive unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 5
2.5.2
Belt weigher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 5
2.5.3
Metal detector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 5
2.5.4
Safety devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 6
2.6
Hydraulic hammer/rockbreaker - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 6
2.7
Sprinkling system with desalination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 7
2.8
Maintenance car with scissor-type elevating platform - - - - - - - - - - - - - - - - - - - - - - 2 - 8
2.8.1
Installation situation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 8
2.8.2
Dimensions and weights of the maintenance car (1) with elevating platform retracted (2) 2 - 9
2-492-20980
TOC - 1
TOC - 2
Scissors-type elevating platform(2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 9
2.8.4
Drive unit (3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 9
2.8.5
Detachable rail - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 10
2.8.6
Safety and monitoring equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 10
General safety notes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 1

3.1
Principles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 1
3.2
Modifications and spare parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 2
3.3
Personnel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 2
3.4
Noise hazard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 3
3.5
Information regarding residual risks during daily operation - - - - - - - - - - - - - - - - - 3 - 3
3.6
Fire protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 4
3.7
Disposal of consumables and process materials - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 4
Design and operating principle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 1

4.1
Scope of application and designated use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 1
4.2
Climatic conditions/ environmental conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 2
4.3
Functional description of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 2
4.4
Components of the semi-mobile crushing plant - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 3
4.4.1
Truck ramps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 3
4.4.2
Steel structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 4
4.5
Hydraulic hammer/rockbreaker - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 7
4.6
Sprinkling system for dust reduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 8
4.7
Maintenance car with scissor-type elevating platform - - - - - - - - - - - - - - - - - - - - - - 4 - 9
4.7.1
Installation situation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 9
4.7.2
Dimensions and weights of the maintenance car (1) with elevating platform retracted (2) - 4 10
4.7.3
Scissors-type elevating platform(2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 11
4.7.4
Drive unit (3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 11
4.7.5
Safety and monitoring equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 11
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2.8.3
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Transport, storage and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1

5.1
Transport instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1
5.2
Hoisting devices and slinging equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 3
5.2.1
Lifting gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 3
5.2.2
Lifting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 3
5.2.3
Lifting ropes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 5
5.2.4
Wire rope clamps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 7
5.2.5
Lifting chains - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 8
5.2.6
Hook - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 10
5.2.7
Screw-type lifting eyes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 10
5.2.8
Shackles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 12
5.2.9
Slinging equipment and load protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 14
5.2.10
Substructures for loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 14
5.3
Storage requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 15
5.3.1
General requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 15
5.3.2
Storage facilities & other details - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 16
5.3.3
Special requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 19
5.4
Installation planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 22
5.5
Preparation for installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 23
5.6
General information on assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 26
5.7
Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 28
5.7.1
Pontoons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 28
5.7.2
Discharge conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29
5.7.3
Discharge Hopper Platform - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 30
5.7.4
Support and Bracing (bottom shell) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.7.5
Bottom shell of the discharge conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 34
5.7.6
Maintenance platform - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 36
5.7.7
Discharge Hopper Upper Walls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40
5.7.8
Crusher platform - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 42
5.7.9
Support and Bracing (top part) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 47
5.7.10
Maintenance platform - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 48
5.7.11
Feed hopper and panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 50
5.7.12
Stair tower and catwalks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 52
5.7.13
Truck ramps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 54
5.7.14
Catwalk view (1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 56
5.7.15
Rockbreaker support (4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 58
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TOC - 3
TOC - 4
Main shaft stand (3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 60
5.7.17
Rockbreaker and crusher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 62
5.7.18
Electro-housing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 62
5.7.19
Periphery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 63
5.7.20
Continuation discharge belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 63
Commissioning and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1

6.1
General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1
6.2
Operator training - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 2
6.3
Safety instructions for operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 2
6.4
Power supply and control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 4
6.5
Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 5
6.5.1
Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 5
6.5.2
Emergency-stop system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 5
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 1
7.1
Important information on maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 1
7.1.1
Notes on cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 3
7.1.2
Information on maintenance and inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 4
7.1.3
Notes relating to repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 5
7.2
Screwed and bolted connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 6
7.2.1
Machine structures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 6
7.2.2
High-tensile bolted joints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 8
APPENDIX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 1
8.1
Drawings
8.2
Gyratory crusher
8.3
Discharge conveyor
8.4
Metal Detector
8.5
Cellular plastic buffer
8.6
Hydraulic hammer/rockbreaker
8.7
Sprinkling system with desalination
8.8
Compressor
8.9
Electrical equipment
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5.7.16
User's guide
The technical documentation (Assembly and Operating Instructions) is designed to
familiarise the user with the machine / plant and its designated use.
The Assembly and Operating Instructions must always be available at the service location
of the machine / plant.
1.1
User groups
Necessary or expected user skills (competence):
Use personnel qualified for the machine / system with special knowledge of the machine /
plant and the processes.
Qualified personnel are persons who, on account of their training, experience and
instruction as well their knowledge of the relevant standards, provisions, accident
prevention regulations and service conditions, are authorised to carry out the necessary
tasks and can recognise and avoid any potential hazards.
The operating personnel receive special instruction from the owner/operator of the
machine/plant. Operators must be conscious of the fact that they are in a hazardous area
during some manual tasks.
Two people always work temporarily on the machine / plant in accordance with the rules
of proper use. All operating, monitoring and servicing work is always carried out by at least
two people working together.
Those working on the machine/plant must be made familiar with the safety instructions
and layout of the emergency-stop systems as well as the related emergency-stop circuits.
05/2014 Rev 0
To exclude danger to other people, access to the machine/plant is prohibited for

unauthorised people. These people are not familiar with the process workflow and cannot
recognise potential hazards.
2-492-20980
1-1
1.2
Structure of the safety notes

The safety notes in the Assembly and Operating Instructions are highlighted as follows:
SIGNAL WORD
Type and source of danger
Possible consequence(s) of non-observance.
Measure(s) for prevention of the danger.
The following table shows the classification and significance of the signal words for safety
notes.
Pictogram
Signal word
Significance
Consequences of nonobservance
DANGER
Imminent danger
Death or severe bodily injuries
WARNING
Possible danger
Death or severe bodily injuries
CAUTION
Possible danger
Minor bodily injuries
NOTICE
Possible property damage
Damage to the machine / plant or

its environment
INFORMATION
Useful information or tip:

Simplifies the handling
!
!
General danger
!
specific danger, e.g.
electrocution
1-2
Definitions
right
on the right-hand side looking in the conveying direction
left
on the left-hand side looking in the conveying direction
Instructions for action (in the stated order)
Listing in the text
or
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1.3
1.4
General information
Dear Customer,
These Assembly and Operating Instructions are prepared by ThyssenKrupp Resource
Technologies and have to be observed in every detail by those responsible for the
transport, installation, commissioning, operation, maintenance as well as the disposal of
all consumables and process materials. Only if the responsible individuals follow the
instructions in these Assembly and Operating Instructions will errors in operating and
servicing the machine/plant be avoided and trouble-free operation ensured.
The Assembly and Operating Instructions contain important information on how to operate
the machine / plant safely, properly and efficiently. Observing this information helps to
avoid danger, to reduce repair costs and downtimes and to increase both the reliability and
the life of the machine/plant.
The Assembly and Operating Instructions include numerous instructions referring to
possible hazards. The user is responsible for training the operating staff at the machine/
plant or on site and ensuring that the safety regulations are observed.
The Assembly and Operating Instructions do not include instructions and guidelines for
major repair work.
ThyssenKrupp Resource Technologies can provide skilled and qualified personnel to
carry out inspections and repairs if required.
1.5
Liability and warranty

ThyssenKrupp Resource Technologies explicitly exclude all liability and warranty claims
for damage or operational malfunctions originating from:
Non-compliance with instructions in the Assembly and Operating Instructions
Incorrect operation
Any use of the machine other than the specified use
Faulty maintenance
Use of consumables (in particular lubricants) not explicitly permitted by the

manufacturer
Use of spare parts not approved by the manufacturer
Conversions and modifications not approved by the manufacturer.
05/2014 Rev 0
In addition, the conditions for liability and warranty as specified in the General Conditions
of Supply of ThyssenKrupp Resource Technologies are applicable.
1.6
Copyright
We reserve all rights in connection with this documentation, including those relating to
patent registration or provisional patent registration. This documentation may not be
disclosed to third parties or reproduced or used in any other way without our previous
consent in writing.
2-492-20980
1-3
1.7
Technical modifications
ThyssenKrupp Resource Technologies reserves the right to change designs in the course
of technical developments. Recent modifications may not yet have been included in the
drawings and texts of these Assembly and Operating Instructions.
1.8
Stocking of spare parts
NOTICE
The use of non-original spare parts
Damage to the machine/plant or its environment is possible
Only use original spare parts that are approved by ThyssenKrupp
Resource Technologies.
Damage caused by using products other than the original spare parts and
accessories is excluded from the liability and warranty.
We expressly point out that we cannot assume any liability for spare parts and
accessories which have not been supplied by us. In some cases the installation of
such products may alter and negatively affect the structural characteristics of the
machine/plant and therefore impair safety.
Continuous operation and operational readiness of the machine/ plant can only be
ensured if important spare and wear parts are held in stock.
Please order spare parts using the information contained in the spare parts list. The spare
parts drawings listed in the spare parts list furnish additional information.
Our warranty only covers genuine spare parts supplied by us.
05/2014 Rev 0
Please note that parts manufactured by us and non-company products are often subject
to special production and delivery specifications.
1-4
2-492-20980
Technical data
2.1
Material
Operating mode:
Loading using dumper with 170 t pay load
Feed material:
Iron ore
Feed material size ROM:
1200 mm - 100%
450 mm - 80%
2.2
05/2014 Rev 0
2.3
Moisture content:
max. 2.0%
Specific gravity:
3,3 - 4.5 t/m
Bulk density:
2,3 t/m
Power supply system
Medium voltage:
4,16 kV; 3-phase; 60Hz
Low voltage:
460 kV; 3-phase; 60Hz
Light:
400 V/ 230 V; 3-phase/ 1-phase; 60Hz
Control voltage:
24 V DC; 120 V DC
Process data
Capacity rating:
3050 mt/h
Product size:
0 - 250 (X) mm
Product size: P80:
175 mm
2-492-20980
2-1
2.4
Gyratory crusher
Figure 1
2-2
Crusher type, dimensions, capacity
Crusher type:
Gyratory crusher KB 63 - 75
Max. particle size feed:
1200 mm ROM
80% < 450 mm
Crushing:
0 - 250 (X) mm
P80 175 mm
Moisture content:
max. 2%
Hardness:
fmean = 150 MPa

fmax = 250 MPa
Bulk density:
2,3 t/m
2-492-20980
05/2014 Rev 0
2.4.1
2.4.2
2.4.3
2.4.4
Crusher work index:
10 kWh/t
Crushing gap OSS (design):
approx. 175 mm XXX
Crusher mouth opening:
approx. 1600 mm
Mantle diameter:
2030 mm
Stroke of the hydraulic cylinder:
max. 280 mm
Circumferential back lash between bevel gear/

bevel pinion:
suggested value +/- 15%
Oil circulating lubrication and hydraulic unit
Oil tank:
separate tank
Tank capacity lubricating oil:
approx. 1500 litres
Tank capacity hydraulic oil:
approx. 250 litres
Over-pressure ventilation of the dust sealing
Blower:
Gasring-compressor, single-stage
G 200 2BH1500-7AC19G with suction filter 2BX2102
Excess pressure:
approx. 0.15 bar
Air flow rate:
approx. 100 m/h
Electric motor
Voltage:
Capacity P:
Speed n:
Weight:
approx. 36 kg
460 V, 60 Hz
2.2 kW
1800 min-1
Grease lubrication for spider bearing
200 litres
05/2014 Rev 0
Pneumatic barrel pump:
2-492-20980
2-3
2.4.5
2.5
Drive unit
Motor:
750 kW, 60 Hz, 507 min-1
Safety coupling:
BWL 125 special
Multiple-disc steel clutch:
MTF 514
Discharge conveyor
Figure 2
Belt width:
2000 mm
Centre distance:
47,7 m
Belt speed:
max. 1.06 m/s
Angle of incline of belt:
approx. 5
Steel cord belt:
2000 DIN 22102-EP2500/4 25:10 Y open - GI
The length described in the purchase order refers to the continuous length.
The add-on for closing the continuous length of the belt is provided by the supplier:
05/2014 Rev 0
delivered quantity in metre = continuous length (order quantity) + add-on
2-4
2-492-20980
2.5.1
2.5.2
2.5.3
Drive unit
Type of gear:
Bevel spur gearbox with back stop

X4KR260HH/B
Transmission:
1:96
Oil quantity:
approx. 270 litres, ISO VG 320 HC
Flange coupling:
FC 775/275-S-M
Flexible coupling:
ADR 125
Electric motor:
355 L4, 400 kW, 1800 min-1, B3
Weight drive complete,

with motor:
approx. 9,500 kg
Mounting position - Drive:
Conveying direction RIGHT
Belt weigher
Model:
10-22-1 HD
Working temperature:
-40 C / +80 C
Accuracy:
+/- 0,03 %
Weight sensor:
Thermentically sealed, temperature-compensated

resistance strain gauges
Evaluation electronics:
MicroTech 2001
Metal detector
Oretronic III
05/2014 Rev 0
Model:
2-492-20980
2-5
2.5.4
2.6
Safety devices
Resistance thermometer:
PT100 41/5-3B
Pull-rope emergency switch:
NTS 002
Belt tracking switch:
SLS 011
Belt break monitoring switch:
BLS 011
Speed controller:
DI0001
05/2014 Rev 0
Figure 3
2-6
2-492-20980
Fixed boom system:
RK 6151
Boom:
8,3 m
Arm:
8m
Slewing angle:
180
Hydraulic unit:
HA 75 R
Capacity:
75/86 kW, 460 V, 50/60 Hz
Q:
200 l/min
Pmax:
320 bar
Hydraulic hammer:
BTI BXR65
Usage weight:
2200 kg
Oil flow rate:

159 227 l/min
Working
pressure:
150 190 bar
Shock
frequency:
335 684 1/min
Diameter of work
tool:
150 mm
2.7
Control and pump unit:
CU-2/0 + 7
Electronic gyratory pump MVIE-414
05/2014 Rev 0
Capacity:
max. 9.0 m3/h
Supply line:
1x min. 5 x 2.5 or 4 mm2
Input voltage:
460 V / 60 Hz I 3 phase N and PE,
On-site fuse protection:
6.5 kW for system
Water input pressure:
min. 1 bar to max. 5 bar
Water input:
for min. 1 %''
Water quality:
Drinking water, other qualities only as per agreement
2-492-20980
2-7
2.8
Maintenance car with scissor-type elevating platform
2.8.1
Installation situation
Figure 4
Park position (outside the crusher)
Position B
Working position (under the crusher outlet)

05/2014 Rev 0
Position A
2-8
2-492-20980
2.8.2
Dimensions and weights of the maintenance car (1) with elevating

platform retracted (2)
Length x Width:
7500 mm x 4750 mm
Overall height including railing
2.8.3
05/2014 Rev 0
2.8.4
with retracted elevating platform:
approx. 2600 mm
with protruded elevating platform:
approx. 4600 mm
Total weight:
approx. XXX kg
Scissors-type elevating platform(2)
Length x Width x Height:
approx. 3700 x 3600 x 950 mm
Useful lift:
2,000 mm
Drive power:
7.5 kW
Load bearing capacity:
19.000 daN surface load

14,500 daN of the hydraulic cylinders + 1,000 daN
accessories
Pressure generator:
Hydraulic pump
Operating pressure of the hydraulic pump:
140 bar
Hydraulic cylinder:
2 x D160 / 100
Weight:
XXX kg
Drive unit (3)
Motor:
Offset geared brake motor AFB 60 TD ZBA 90 AB 020
Capacity:
1,1 kW
Speed:
1400 min -1
Voltage:
Motor 525 V, 50 Hz, brake 230 V 50 Hz
Protection class:
IP 65 (brake IP 55)
2-492-20980
2-9
2.8.5
Detachable rail
After opening the discharge hopper make sure to use a detachable rail to prevent falling
into the hopper.
Figure 5
Safety and monitoring equipment

Safety locking device for the access door
Type:
AZM 200 SK - T - 1 P2 PW
Impulse generator for position recording

Type:
2 - 10
IIM 201
2-492-20980
05/2014 Rev 0
2.8.6
General safety notes
3.1
Principles
The machine/plant has been manufactured in accordance with the recognised safety
regulations. However, this does not preclude danger to life and limb for the user or others,
nor does it prevent harm to the machine/plant and/or other property.
These safety instructions must be observed by all persons responsible for the
transport, installation, commissioning, operation, maintenance as well as the
dismantling and disposal of consumables and process materials. We recommend
that the owner obtains a signed confirmation that the safety instructions have been
read and understood by his personnel.
The machine/plant may only be used in a technically perfect condition in accordance

with its designated use and the instructions set out in the Operating Instructions, and
only by safety-conscious persons who are fully aware of the risks involved in
operating the machine/plant! Any malfunctions, especially those affecting the safety
of the machine/plant, should therefore be rectified immediately.
In addition to the Operating Instructions, observe and instruct the user in all other
generally applicable legal and other mandatory regulations relevant to accident
prevention and environmental protection.
These compulsory regulations may also deal with the handling of hazardous substances,
issuing and/or wearing personal protective equipment (safety helmet, safety boots, safety
goggles, hearing protection, respiratory protection).
Observe all safety instructions and warnings attached to the machine/ plant!
Ensure that safety instructions and warnings attached to the machine/plant are
always complete and perfectly legible!
In the event of safety-relevant modifications or changes in the behaviour of the

machine/ plant during operation, stop the machine/ plant immediately and report the
malfunction to the responsible department!
Never make any modifications, additions or conversions to the machine/ plant which
might affect safety without the supplier's approval! This also applies to the mounting
and adjustment of safety devices and safety valves as well as to welding work on
load-bearing elements.
Replace hydraulic hoses within at appropriate intervals even if no safety-relevant

defects have been detected!
Comply with the prescribed intervals or those specified in the Operating Instructions
for routine checks and inspections!
05/2014 Rev 0
For the execution of maintenance work, tools and workshop equipment adapted to the
task on hand are absolutely indispensable.
The personnel must be familiar with the location and operation of fire extinguishers!
Observe all fire-warning and fire-fighting procedures!
2-492-20980
3-1
3.2
3.3
Modifications and spare parts
For safety reasons, conversions and modifications are prohibited unless previously
approved by ThyssenKrupp Industrial Solutions.
Use of accessories and spare parts not approved by

ThyssenKrupp Industrial Solutions can lead to unforeseeable dangers.
Personnel
Personnel entrusted with work on the machine/plant must have read the operating
instructions and in particular the chapter on safety before beginning work. Reading the
Instructions after work has begun is too late. This applies especially to persons working
only occasionally on the machine/plant, e.g. during setting up or maintenance.
For reasons of security, long hair must be tied back or otherwise secured, garments must
be close-fitting and no jewellery - such as rings - may be worn. Injury may result from being
caught up in the machinery or from rings catching on moving parts.
Use protective equipment wherever required by the circumstances or by law!
Any work on and with the machine/plant may only be carried out by reliable personnel.
Statutory minimum age limits must be observed!
Employ only trained or instructed staff and set out clearly the individual responsibilities of
the personnel for operation, set-up, maintenance and repair!
Define the machine operator's responsibilities - also with regard to observing traffic
regulations - giving the operator the authority to refuse to carry out instructions by
third parties which compromise safety!
Work on the electrical system and equipment of the machine/plant may only be carried out
by a skilled electrician or by instructed persons under the supervision and guidance of a
skilled electrician and in accordance with electrical engineering rules and regulations.
05/2014 Rev 0
Work on the hydraulic system must be carried out only by personnel with special
knowledge and experience of hydraulic equipment!
3-2
2-492-20980
3.4
Noise hazard
Information on the emissions level which is specific to the work station
No permanent work station has been assigned to the machine/ plant.
Depending on the material to be processed, noise emissions will occur: these may only
be measured during operation. The user has to ensure the measurement of the sound
power level of all operation positions (e.g. for maintenance and checking, control station)
immediately after commissioning.
CAUTION
Risk of injury when working without ear protection
Bodily injury possible
Directive 2003/10/EC of the European Parliament and of the Council dated 06/
02/2003 (17th individual directive in terms of Article 16 Paragraph 1 of the
Directive 89/391/EEC).
The plant operator must make suitable, correctly fitting ear protection available
to employees who must use this when noise emissions reach the upper limit
values 85 dB(A).
ThyssenKrupp Resource Technologies recommends that plant operators keep
suitable ear protection available for their employees for noise levels from
80 dB(A).
3.5
Information regarding residual risks during daily

operation
The safety requirements specified in the EC Machines Directive have been taken into
account in the machine/plant.
Residual risks can nevertheless still occur during operation.
Residual risks, which remain even after careful shutting off and with platforms
corresponding to the applicable safety requirements, are pointed out below.
05/2014 Rev 0
Mechanical hazard/material
Overcharging and discharge of crushing material on account of upstream conveying

equipment and/or congestion of material in the feed hopper.
Dusty operating conditions on account of the type of feeding material, material

feeding, the crushing procedure, the material discharge.
2-492-20980
3-3
3.6
Fire protection
The legal requirements regarding fire protection and fire prevention have to be
complied with and supplemented with in-company regulations. The fire-fighting
experts of the insurance companies should also be consulted in this process.
Appoint supervisors who are in charge of all the matters related to fire prevention and
fire fighting and provide them with the knowledge required for this task.
The management staff and the engineers have to support them in their task by
providing consultation to them.
The supervisor must check the fire extinguishing equipment at regular intervals, in order
to ensure that the equipment is always ready for use.
Rooms which are easily flammable require particular attention in this context!
The persons commissioned with supervision and fire fighting must have attended a first
aid course. First aid stations must be provided.
The fire protection regulations must be posted at different locations in the plant.
The personnel must be informed about the fire protection measures. Any case of fire
must be reported immediately.
The units and the assembly groups which heat up more strongly during operation on
account of the electrical and/or mechanical stress to which they are exposed must
be monitored by the responsible personnel. This applies e.g. to compressors, gear
units, bearings, motors, oil/hydraulic units.
The fire extinguishers must be easily accessible and may not be obstructed by objects.
The personnel must be familiarised with the use of the fire extinguishers to such a
degree that they are capable of fighting fire outbreaks with the appropriate fire
extinguishers.
Fire-fighting rules
Use fire-fighting water for burning wood, waste, fabric, jute, paper, belts, etc.
In case of burning liquids (mineral oil, petrol, oil, petroleum, paints, tar, etc.), always
use CO2 extinguishers and (powder type) fire extinguishers.
In case of burning cables, motors, electric plants, etc. only use (powder type) fire
extinguishers or CO2 fire extinguishers.
Disposal of consumables and process materials
3-4
The safe and environment-friendly disposal of all consumables and process

materials should be ensured. You should also make sure that all respective national
regulations for the protection of the environment are complied with.
2-492-20980
05/2014 Rev 0
3.7
05/2014 Rev 0
2-492-20980
3-5
05/2014 Rev 0
Blank page
3-6
2-492-20980
Design and operating principle
4.1
Scope of application and designated use
DANGER
Risk of injury through operating the machine/plant with unauthorised
modifications, conversions or spare parts
Imminent danger of death or severe bodily injuries
ThyssenKrupp Resource Technologies explicitly excludes all liability and
warranty claims if modifications/conversions are made without the express
permission in writing of the manufacturer.
Only operate the machine/plant in its original condition. Any deviations from the
original condition must be reported by the operator to the responsible
department.
NOTICE
System damage through use of the machine/plant contrary to its designated
use
The intended use of the machine/plant is regulated by contract. Any other use
contrary to its designated use is prohibited. ThyssenKrupp Resource Technologies
cannot be held liable for damage resulting from such misuse. The risk of such
misuse lies entirely with the user.
The gyratory crusher must be constantly fed with material to ensure that the
crushing chamber is always at least 80 % full.
The machine/plant must be used exclusively for the intended purpose agreed
upon with the manufacturer.
05/2014 Rev 0
Observe the Assembly and Operating Instructions.
2-492-20980
4-1

The constant feeding ensures that the main shaft bearing is always uniformly loaded
("quiet load running").
At the same time a stable film of lubrication keeps wear to a minimum on all of the affected
bearing components.
This method also has a positive effect on the wear pattern of the crushing tools.
Frequent idle-running phases lead to uncontrolled movements of the main shaft in the
spider head bearing and in the lower bearing bushing. At the same time, continuous refilling of the crushing chamber causes fluctuating loads and consequently uneven running
under load.
This impact-type method of operation destabilises the lubricating film between the bearing
components which can cause undesirable abrasion on the bearing positions.
This negative operating mode leads to an uneven wear patter with respect to the crushing
tools / wear parts.
Prior to the use of the machine/ plant beyond this scope of application, consult the aftersales service. Otherwise the warranty will lapse.
4.2
Climatic conditions/ environmental conditions
Place of installation:
Peru
Altitude:
700 - 900 m above sea level
Min. temperature:
+ 7 C
Max. temperature:
+ 28.2 C
Average temperature:
+ 16.7 C
Relative humidity:
TBA
Wind velocity:
20 m/ s
Seismic factor:
UBC Zone 3
The manufacturer ThyssenKrupp Resource Technologies must be consulted when the

machine is operated at temperatures not within the above range. The expanded use must
be approved by ThyssenKrupp Resource Technologies.
Functional description of the system

Dump trucks with a capacity of 170 mt transport the material from the mining area to the
semi-mobile crushing plant.
The vehicles load the material directly into the feed hopper via two truck ramps. The
bunker is equipped with water pipes and nozzles for the suppression of dust.
4-2
2-492-20980
05/2014 Rev 0
4.3

From the discharge hopper the crushed material is loaded onto the speed-controlled
discharge conveyor below the crusher and transferred from there to the conveyor belt
system.
Metallic foreign bodies are detected by a metal detector and marked with a flag. The
metallic foreign bodies are then sorted out by hand.
The crushing plant is controlled from the control room near the crusher. The electrical
drive unit are locked so that maximum operational safety is ensured. The electrical
equipment is installed in air-conditioned containers, separated from the semi-mobile
crushing plant.
The system is equipped with a rockbreaker, which allows the crushing of oversized
stones.
The plant has a bridge crane with 80/20 t lifting capacity and an external maintenance
stand for servicing the main shaft.
A maintenance car with a hydraulic scissor lifting platform can be moved in and out of the
discharge hopper. It provides support disassembling the hydraulic cylinder below the
crusher.
4.4
Components of the semi-mobile crushing plant
4.4.1
Truck ramps
Two ramps for dump trucks with 170 mt loading capacity.
Made of corrugated, welded steel plates, including calotte storage and coupling link
for anchoring. (concrete by customer)
05/2014 Rev 0
Figure 6
2-492-20980
4-3
4.4.2
Steel structure
Figure 7
of the steel constructionThe feed hopper consists of thickly ribbed, welded steel
plates (25-mm plates plus 50-mm wear plates) and the necessary fasteners for
assembly of the bunker on to the carrying frame.
4-4
The discharge hopper consists of ribbed, welded steel plates with liner plates (15mm plates plus 20-mm liner plates) and the necessary fasteners for assembly of the
bunker on to the main frame.
... Pontoons with 4 stands
Platforms, walkways and stairs for access during maintenance and operation with
grid iron and corrugated sheet metal, as well as handrails for all stairs and walkways
2-492-20980
05/2014 Rev 0

The main frame consists of a welded box structure, in order to ensure maximum stability
when under enormous static and dynamic stresses during the crushing operation.
This main frame carries all of the equipment and all of the components.
The structures, platforms, walkways and stairs are made of sectional steel.
The entire configuration stands on two heavy pontoons based on a prepared bed of
gravel.
The primary gyratory crusher KB63-89 consists of:The heavy duty spider is made of
cast steel and consists of two heavy spider arms which are necessary for the central hub.
The spider arms are protected from wear by so-called arm liners.
The main shaft is supported and centred in the spider by the spider bearing. The spider
bearing is protected by the spider cap.
The spider cap is made of cast steel and contains the central hub and prevents
contaminants from entering into the spider bearing. The spider cap reduces maintenance
downtime and provides a service longer life.
The helmet is designed as a "slide-on" unit which requires no mounting screws.
Figure 8
The multi-part crusher housing also consists of the upper shell (1), the lower shell (2) and
the lower part (3).
The heat-treated cast steel constructions are reinforced with circumferential ribbing
between the upper and lower flange of each section and also with vertical bracing for
added strength during initial crushing.
Shells (1, 2) and lower section (3) are positioned using conical seats and bolted to the
external flanges.
The lower section is equipped with liner plates. It is connected to the internal hub via three
arms. One of the arms is suited for the installation of the pinion shaft assembly (pinion
assembly tunnel). The compressed air piping for the dust sealing and the lubrication oil
piping are installed in one arm and lead to the outer eccentric bushing of the external
lubrication circuit. The arms are protected against damage caused from impacting
material by liner plates.
The hub in the centre holds the outer eccentric bushing. The eccentric bushing is located
in the outer eccentric bushing. The dust sealing is mounted on top of the hub.
The base plate (including axial step bearing ring) is bolted to the lower section, which
supports the eccentric bushing in the axial direction. The hydraulic cylinder supports the
axial step bearing and is located under the base plate. The hydraulic cylinder is also bolted
to the lower section.
The lower section has two inspection opening covers. An inspection opening with a cover
is located on the lower section of the hub for checking the bevel gear and the pinion.
05/2014 Rev 0
The bottom flange of the lower section is used to mount the lower section on the
substructure / foundation.
The main shaft is made of forged steel. A protective nut with a burn protection ring is
screwed onto the main shaft.
The eye bolt is used to assemble/disassemble the main shaft.
The sealing ring of the dust sealing is bolted to the bottom side of the main shaft.
The upper section of the main shaft is protected by the main shaft sleeve.
The step bearing upper part is mounted on the lower face of the main shaft.
2-492-20980
4-5

The mantle is attached to the shaft cone. The mantle are held together on the shaft cone
with an external ring nut and an intermediate ring.
The outer ring nut is protected against wear by a cap and hard facing.
The mantle is backfilled with a special plastic sealing compound.
Concaves
The concave segments are made of manganese steel and arranged in four rows.
The bottom row is curved in order to increase resistance and the range of the mantle
adjustment.
If necessary the design of the concave surfaces can be modified in order to improve the
crushing performance.
The concaves are backfilled with a special plastic sealing compound.The dust sealing
protects the section of the oil circulating lubrication inside the gyratory crusher against the
ingress of dust from the crushing chamber.
The internal area is sealed with a plastic ring which is mounted with play between the top
and bottom sealing rings. A small amount of axial play exists between the plastic ring and
the sealing housing. The plastic ring follows the wobbling movement of the main shaft.
A separately arranged blower also generates a slight over-pressure inside the gyratory
crusher.
As a result, there is a continuous air flow from the interior of the crusher to the crushing
chamber. This prevents the ingress of dust and other pollutants.
Figure 9
The eccentric bushing is driven by the pinion assembly. It guides the main shaft in the
inner eccentric bushing and produces its wobbling (rotary/oscillating) motion.
The eccentric bushing is lubricated by the oil circulating lubrication internally (between the
inner eccentric bushing and the main shaft), externally (between the eccentric bushing
and the outer eccentric bushing) and on the underside (between the eccentric bushing and
the axial step bearing ring).
The circulating lubrication also supplies the teeth of the bevel gear.
The top device for compensating unbalance fixes the inner eccentric bushing in a vertical
(axial) direction.
The connection between the electric motor and the pinion assembly is the drive.
The multiple-disc steel clutch between pinion shaft and the electric motor is used to
compensate slight misalignment between the motor shaft journal and the pinion shaft
assembly.
The distance tube allows the pinion assembly to be removed without shifting the drive
motor.
The pinion assembly is arranged in the pinion assembly tunnel of the bottom shell of the
crusher.
The pinion shaft assembly sprocket for driving of the bevel gear of the eccentric bushing
is supported with roller bearings in the pinion assembly housing.
The bearings are lubricated by the oil filling in the pinion assembly housing (stand oil
lubrication).
By changing the thickness of the discs, the contact pattern of the bevel gear teeth and the
backlash can be adjusted.
4-6
2-492-20980
05/2014 Rev 0
The safety coupling is provided with a torque limiter with hydraulic torque setting. The
necessary releasing torque is set by varying the hydraulic pressure.
2000 mm
Centre distance:
47,7 m
Belt speed:
1,06 m/s at 60 Hz
Angle of incline of belt:
approx. 5
Steel cord belt:
Belt 2000 DIN 22102-EP2500/4 25:10 Y open - GI
Type of gear:
Bevel spur gearbox with back stop

X4KR260HH/B
Transmission:
1:96
Flange coupling:
FC 775/275-S-M
Flexible coupling:
ADR 125
Electric motor:
355 L4, 400 kW, 1800 min-1, B3
Mounting position - Drive:
Conveying direction RIGHT
05/2014 Rev 0
4.5
Belt width:
Figure 10
2-492-20980
4-7
Fixed boom system:
RK 6151
Boom:
8,3 m
Arm:
8m
Slewing angle:
180
Hydraulic unit:
HA 75 R
Capacity:
75 kW, 525 V, 50 Hz
Q:
200 l/min
Pmax:
320 bar
Hydraulic hammer:
BTI BXR65
Usage weight:
2200 kg
Oil flow rate:

159 227 l/min
Working
pressure:
150 190 bar
Shock
frequency:
335 684 1/min
Diameter of work
tool:
150 mm
4.6
Sprinkling system for dust reduction
Control and pump unit:
CU-2/0 + 7
Electronic gyratory pump MVIE-414
4-8
max. 9.0 m/h
Supply line:
1x min. 5 x 2.5 or 4 mm2
Input voltage:
400 V I 60 Hz I 3 phases N and PE,
On-site fuse protection:
6,5 kW for system
Water input pressure:
min. 1 bar to max. 5 bar
Water input:
for min. 1 %''
Water quality:
Drinking water, other qualities only as per agreement
2-492-20980
05/2014 Rev 0
Capacity:
4.7
Maintenance car with scissor-type elevating platform
4.7.1
Installation situation
Figure 11
Park position (outside the crusher)
Position B
Working position (under the crusher outlet)
05/2014 Rev 0
Position A
2-492-20980
4-9
4.7.2
Dimensions and weights of the maintenance car (1) with elevating

platform retracted (2)
Length x Width:
approx. 7470 mm x 4640 mm
Overall height including railing

approx. 2430 mm
with protruded elevating platform:
approx. 4400 mm
Total weight:
approx. 13,500 kg
05/2014 Rev 0
with retracted elevating platform:
Figure 12
4 - 10
2-492-20980
4.7.3
4.7.4
4.7.5
Scissors-type elevating platform(2)
Length x Width x Height:
approx. 3700 x 3600 x 950 mm
Useful lift:
approx. 1800 mm
Drive power:
7,5 kW
Load bearing capacity:
19,000 daN
Pressure generator:
Hydraulic pump
Operating pressure of the hydraulic pump:
140 bar
Hydraulic cylinder:
2 x D160 / 100
Weight:
5,800 kg
Drive unit (3)
Motor:
Electric motor
Capacity:
7,5 kW
Voltage:
460 V, 60 Hz
Protection class:
IP 55
Safety and monitoring equipment

Safety locking device for the access door
Type:
AZM 161 SK - 12/12RK-024
Limit switch stroke end, lowering

Type:
Schmersal ZV7H236-11Z-2138
Protective foot strip limit switch

Telemecanique XCKD2121P16
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Type:
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Blank page
4 - 12
2-492-20980
Transport, storage and assembly
5.1
Transport instructions
The machine/plant is transported in component parts or as assembly groups. Make sure
that suitable lifting tackle is used to unload the parts from the transport vehicles and move
them to the storage location.
The machine/plant must be transported with adequate care in order to prevent damage
and not endanger staff. In addition to the following information, the general and local
safety and accident prevention regulations must be observed. Overhead gantries and
mobile cranes or lifting tackle with a sufficient load bearing capacity must be available to
carry out the unloading, transport/loading safely and correctly.
05/2014 Rev 0
The transport and storage symbols on the machine packaging must be heeded.
Keep away from heat
Keep dry
Caution! Glass!
This way up
Sling here
Centre of gravity
Do not use hand

hooks
No hand truck here
Stacking limitation
Clamp here
Permissible
temperature range
Do not use fork lift

truck here
Electrostatic sensitive
device
Do not destroy barrier
Tear off here
Do not roll
When transporting the machine by crane, only use suitable loading devices.
When packing the machine, loading devices may only be attached at the marked points.
2-492-20980
5-1
DANGER
Risk of injury due to the improper transport of the machine/plant
Only transport the machine/plant on the designated slinging devices (lugs) and
slinging points.
The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
Make sure to use proper transportation equipment.
Do not walk under suspended loads.
Secure moveable components.
NOTICE
System damage from improper transport of the machine/plant
Do not attach any additional slinging points to the machine through welding,
torching or drilling (notching effects and the corresponding risk of crack
formation).
Do not push together the side walls or the attachment parts of the machine by
pulling lifting gear at an angle!
If transport securing devices have been furnished do not remove them until
installation has been completed.
05/2014 Rev 0
Check all components for transport damage after delivery to the site.
5-2
2-492-20980
5.2
Hoisting devices and slinging equipment
WARNING
Risk of injury through components that are improperly secured during
installation
Death or severe bodily injury is possible.
Make sure that moveable components are properly secured during installation
5.2.1
Lifting gear
Usually, cranes and lifting gear is used for transporting heavy assembly groups and
components. Slinging equipment such as ropes and hooks are critical elements between
the load and lifting equipment.
Safe lifting requires adequately dimensioned and suitably designed lifting gear and
slinging equipment to be used, as well as correct attachment and fixing to the load.
The weight of assembly groups and components is specified in the spare parts catalogue
/ in the Operating Instructions, so that equipment such as e. g. hoisting devices, winches,
cranes, lifting chains can be selected accordingly.
Check hydraulic winches for proper function before use. Only use winches with
adjustment ring. This allows loads to be supported mechanically and prevents their
lowering.
5.2.2
Lifting
INFORMATION
Before lifting heavy loads, attach a load cell to check the load.
Before lifting, determine the weight of the load.
Determine the size and shape of the load; two criteria which determine the following:
05/2014 Rev 0
the type of load securing, e. g. with slings, baskets or slings with special fixtures,
the slinging equipment / load securing fixtures, e. g. lifting rope, lifting chain, screw
eyes, yokes (see following chapters),
the load angle of the slinging equipment.
Determine the thickness of the slinging equipment to be used. Do not exceed the
permissible load bearing capacity of the slinging equipment.
2-492-20980
5-3
If any of the following points are unclear, consult the assembly supervisor
responsible:
correct attachment method,
selected thickness of slinging equipment,
type of slinging equipment.
Check the slinging equipment for damage / faults. Make sure that any faulty slinging
equipment is discarded immediately.
Do not overload slinging equipment and protect it against sharp corners and edges
of the load e. g. through edge/corner protection made of sacking or metal, boards
etc.
Protect high-gloss/finished surfaces of the load against damage caused by the

slinging equipment. Protective material that is intended to prevent the load/lifting
means slipping must be attached in such a way that it cannot slip if the slinging
equipment becomes loose.
When attaching slinging equipment at great heights:

Use the climbing aids provided. If no climbing aids have been provided or these
are not available, use an approved ladder.
Secure the ladder to prevent it slipping or falling over.
Use both hands for climbing. Have the slinging equipment to be attached brought
up by lifting tackle (e. g. crane).
After attaching the slinging equipment, tighten it as far as possible by hand. If the
slinging equipment has to be tightened by crane, make sure that no body parts get
between the load and the slinging equipment, and keep hands and fingers safe.
Give the crane driver fixed/agreed clear signals for moving the load.
5-4
Remove any material lying loosely on the load.
Secure unused rope/chain ends, e. g. by hooking them to the main ring/collecting

them in the shackle.
Instruct staff to leave the hazard area.
Check that the load is secured symmetrically at all points.
Make sure that the slinging equipment cannot damage the load (and vice versa).
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05/2014 Rev 0
Before lifting the load:

After the weight of the load has been picked up completely by the lifting tackle and
the load has been lifted a little:
Check the load brake.
Check again whether the load is secured at all points.
Transport the load over free areas as far as possible.
Warning signals must be given if there is anyone in the hazard zone.
Setting the load down:
5.2.3
Set the load down slowly on a respectively sturdy base. Align the base again before
the load is set down.
Remove slinging equipment from the load and check both for damage.
Lifting ropes
The number of sling points is equal to the number of rope strands connecting the crane
hook with the load. A load angle i. e. an angle between the horizontal surface of the load
and the lifting ropes is formed by several strands. The smaller the load angle, the smaller
the permissible load bearing capacity of the lifting ropes and thus the effectiveness.
Effectiveness of the load angle
Load angle
Load bearing
capacity
max. permissible load per strand in

relation to 1000 kg
%
50,0
(500 kg)
45
70,7
(707 kg)
60
86,6
(866 kg)
90
100,0
(1000 kg)
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30
2-492-20980
5-5

The load bearing capacity/wire rope strength is reduced by:
Splitting rope loops in the lifting ropes and splitting lifting ropes into continual
strands
Bending round corners
Using lifting ropes for clamping
Acceleration and slowing during lifting and lowering operation
General wear
High and low temperatures
Vibration
Corrosion
Use:
Although the weight of lifting ropes is lower than that of lifting chains of the same load
bearing capacity, they have a few disadvantages. They can become damaged more easily
and are more difficult to handle since their bending radius is smaller.
Lifting ropes are suitable for vertical lifting operation or for lifting operation where ropes
must be routed in a large radius around corners.
The thickness of a wire rope is given in relation to its outer diameter.
Protect lifting ropes from the influences of the weather, solvents, high temperatures
and chemicals.
Avoid knots forming in wire ropes. In the event of a knot, do not use the rope again.
Protect ropes against sharp-edged corners by enlarging the corner radius. This can
be by means of metallic corner protection devices or blocks. Sacking and wooden
boards can also be used.
The correct procedure for securing lifting ropes to the hook is as follows:
Secure each individual strand on the hook to prevent hitching at the hook.
Never wind the wire rope completely around the crane hook (i. e. by 360 degrees).
The low bending radius would damage the rope.
Check the lifting ropes for:

broken or cut strands,
rust and corrosion,
knots and kinked spots,
damaged eyes
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2-492-20980
05/2014 Rev 0
Never use one single slinging rope strand since this could lead to the load rotating.
The wire rope could be untwisted and thus the splice pulled out.
5.2.4
Do not bend the eyes of lifting ropes over corners.
When securing loads by winding the lifting ropes around the load, use shackles (1).
Wire rope clamps

Attach wire rope clips in such a way that the lower part of the clip (6) is pushed against the
long end (5) of the rope, and the yoke of the clip (2) against the dead end (4) of the rope.
Always attach a rope thimble (1). The correct number of clips and distance (3) between
them is given in the following table.
Tighten clamping nuts using the given torques.
Once the rope has been put into operation and is tensioned, tighten the clamping nuts
again. Check the clamping nuts regularly and tighten if necessary. This compensates rope
expansion and the related reduction of rope radius.
05/2014 Rev 0
Rope diameter
Diameter of the clamping

yoke
Distance between clips
Required minimum
number of clips
Inches
mm
Inches
mm
Inches
mm
3/16
4,76
11/32
8,73
76
1/4
6,35
7/16
11,11
3-1/4
83
5/16
7,94
1/2
12,70
3-1/4
83
3/8
9,53
9/16
14,29
102
7/16
11,11
5/8
15,88
4-1/2
114
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5-7

Rope diameter
Diameter of the clamping

yoke
Distance between clips
Required minimum
number of clips
Inches
mm
Inches
mm
Inches
mm
1/2
12,70
11/16
17,46
127
5/8
15,88
3/4
19,05
5-3/4
146
3/4
19,05
7/8
22,23
6-3/4
172
7/8
22,23
25,40
203
25,40
1-1/8
28,58
8-3/4
222
1-1/8
28,58
1-1/4
31,75
9-3/4
248
1-1/4
31,75
1-5/16
36,51
10-3/4
273
1-3/8
34,93
1-1/2
38,10
11-1/2
292
1-1/2
38,10
1-23/32
43,66
12-1/2
318
1-5/8
41,28
1-3/4
44,45
13-1/4
337
1-3/4
44,45
1-15/16
49,21
14-1/2
368
50,80
2-1/8
53,98
16-1/2
419
2-1/4
57,15
2-5/8
66,68
16-1/2
419
2-1/2
63,50
2-7/8
69,85
17-3/4
451
5.2.5
Lifting chains
Use:
Lifting chains are made of alloyed steel and are sturdier and more flexible than lifting
ropes, but they are not as resistant to impact loads as ropes are. The thickness of a chain
is determined in relation to the diameter (1) of a chain link.
Avoid knots forming in lifting chains. They weaken the chain strand and can lead to
deformation or other damage to the chain links.
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5-8
2-492-20980
Shorten lifting chains by hooking them back into the chain or into the main line with
the aid of a gripper hook. Never shorten a chain by twisting, knotting or through bolts.
Protect lifting chains against sharp corners and edges that could deform the chain
links. Use suitable flexible boards or metallic corner protection devices.
If the chain for lifting operation is to be wound around the load to be lifted, always turn
the hook opening away from the direction in which the slings are to be pulled. This
prevents the hook slipping out when the slings are tightened.
Check lifting chains for:

notches, cracks, exact dimensions and wear
deformed chain links, welding burr, bent or open hooks, elongation
rust and corrosion
If all the strands of a lifting chain can be hooked back into the main line, the
permissible load bearing capacity of the whole sling can be increased by 50 %.
05/2014 Rev 0
2-492-20980
5-9
5.2.6
Hook
The load bearing capacity is usually stamped into the hook.
5.2.7
If possible, use a hook with spring-loaded snap-in locking devices. If such hooks are
not available, the hook has to be secured temporarily as shown in the diagram.
Screw-type lifting eyes

The size of screw-type lifting eyes is determined in relation to the diameter of the shank of
the threaded section. A distinction is made between simple screw-type eyes and screwtype eyes with shoulder.
For vertical lifting operation, use simple screw-type eyes (without shoulder).
Screw-type eyes with shoulder are used when loads are to be lifted at certain angles
(e. g. lifting operation with several lifting ropes).
The permissible load bearing capacity that has already been reduced by the load angle,
is reduced even further by the use of screw-type eyes.
05/2014 Rev 0
An eye bolt with a shoulder, which is used for example at an angle of 45, can only be used
for up approximately 10 % of the permissible load for vertical lifting.
5 - 10
2-492-20980

Permissible loads for eye bolts with shoulders:
Shank diameter
Vertical lifting
operation
Tension at 60 to
the shoulder level
Tension at 45 to
the shoulder level
Tension at 90 or
loose side pull
per screw-type eye
per screw-type eye
per screw-type eye
per screw-type eye
Inches
mm
Pounds
kg
Pounds
kg
Pounds
kg
Pounds
kg
1/4
6,4
300
136
50
23
30
14
40
18
1/2
12,7
1300
590
200
91
140
64
150
68
3/4
19,3
3000
1361
400
181
250
113
300
136
25,4
6000
2722
800
363
500
227
600
272
1-1/4
31,8
9000
4082
1300
590
800
363
900
408
1-1/2
38,1
13000
5897
1800
816
1200
544
1300
590
50,8
23000
10433
3300
1497
2100
953
2300
1043
2-1/2
63,5
37000
16783
6000
2722
3500
1724
4300
1950
05/2014 Rev 0
Eyes must be screwed in completely to prevent the shank becoming bent.
2-492-20980
5 - 11
5.2.8
Use screw-type eyes of a suitable size.
Check the condition of the thread to make sure the screw-type eye fits tightly and that
there is flush and complete contact between the shoulder and the load. Never use
screw-type eyes with cracked or flawed threads.
Only use screw-type eyes the load bearing capacity of which is suitable for the load,
i. e. shanks with threads that fit exactly in standard boring holes.
Check shanks of the screw-type eyes for deformation or crack formation.
Use hardened washers to make sure the edges of the screw-type eye are a tight fit.
The washers must not be thicker than two threads.
Shackles
DANGER
Danger caused through the use of improper slinging equipment
Never replace shackle bolts by conventional bolts. Danger of breaking!
Shackles are closed safety devices that cannot be hooked out. Their size is determined in
relation to the diameter of the main part (1) and not in relation to the diameter of the bolt.
A distinction is made between anchor load shackles (on the left of the diagram) and chain
load shackles (on the right).
Do not expose the main part of the shackle to side tensile loads.
Ensure the shackle bolt is a perfect fit.
The permissible load for anchor load and chain load shackles as well as for screwtype or socket pin is always the same.
05/2014 Rev 0
5 - 12
2-492-20980
05/2014 Rev 0
Diameter
If shackles are used at load angles other than 90, the permissible load bearing
capacity is reduced; see table:
Single shackle
vertical
Two shackles 60
Two shackles 45
Two shackles 30
Inches
mm
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
1/4
6,4
1/3
0,3
3/4
0,7
1/2
0,5
1/3
0,3
5/16
7,9
1/2
0,5
0,9
0,7
1/2
0,5
3/8
9,5
3/4
0,7
1-1/4
1,1
0,9
3/4
0,7
7/16
11,1
0,9
1-3/4
1,6
1-1/2
1,4
0,9
1/2
12,7
1-1/2
1,4
2-1/2
2,3
1,8
1-1/2
1,4
5/8
15,9
1,8
3-3/4
3,4
2,7
1,8
3/4
19,3
2,7
5-1/2
4-1/2
4,1
2,7
7/8
22,2
5-1/2
25,4
5-1/2
10
7,2
5,4
1-1/8
28,6
6-1/2
5,9
11-1/2
10,5
9-1/2
8,5
6-1/2
5,9
1-1/4
31,8
7,2
14
12,7
12
10,8
7,2
1-3/8
24,9
10
17
15,4
14
12,7
10
1-1/2
38,1
12
10,8
20
18,1
17
15,4
12
10,8
1-3/4
44,5
16
14,5
28
25,4
23
20,9
16
14,5
50,8
21
19
36
32,6
30
27,1
21
19
2-1/4
57,2
27
24,5
46
41.7
38
34,5
27
24,5
2-1/2
63,5
34
31
58
52,6
48
44
34
31
2-3/4
70,1
40
36,2
69
62,9
57
51,9
40
36,2
76,2
80
45,3
87
78,8
71
64.4
50
45,3
101,6
100
90,7
173
156,9
142
128,7
100
90,7
2-492-20980
5 - 13
5.2.9
Protect lifting ropes against sharp edges/corners. Use materials to enlarge the
radius, e. g. metallic corner protection devices (left and right), belts, wooden blocks,
sacking, steel bushings/sleeves. This protects finished load surfaces from the wire
rope too.
Protect lifting chains against sharp edges/corners. Use materials to enlarge the
radius, e. g. metallic corner protection devices (left and right), belts, wooden blocks,
sacking, steel bushings/sleeves. This protects finished load surfaces from the chain
too.
Substructures for loads
Make sure that the base has a sturdy and level surface and can bear the whole
weight of the load. Only use hard wood with (approx.) square cross-section as a
base.
Protect finished surfaces by cushioning the base, e. g. with sacking, pressboard,

belts.
Use wedges to prevent the load rolling away or moving (e. g. handles, round forged
parts and rings). When using wedges be careful with your hands and make sure they
do not get crushed if the load moves.
05/2014 Rev 0
5.2.10
Slinging equipment and load protection
5 - 14
2-492-20980
When using several supports as substructures, only use supports of the same height.
Place supports under the load so that they are stable and level. Do not use supports
that have rounded edges, are fragile or damaged.
Compensate unevenness under the supports.
Use the supports to create a cavity under the load, enabling the slinging equipment
to be attached and removed easily.
5.3
Storage requirements
5.3.1
General requirements
NOTICE
System damage from improper storage/assembly of the machine/plant
If the machine/plant is to be stored, it has to be left in the delivery condition. The
manufacturer is not liable for damage caused by improper repeated assembly of
the machine/plant.
NOTICE
System damage from improper storage of the machine/plant
05/2014 Rev 0

All the delivered machine and plant components must be stored on suitable
supports to keep them dry. The storage place must be free from vibration.
The stored machine and plant components must be protected from water, sea
water, aggressive vapour or gas and increased ozone concentration.
2-492-20980
5 - 15

If the storage time is exceeded by a lengthy period (i.e. more than 2 months), all the
bearings of the machine and plant components must be completely filled with suitable
grease. The shafts in the bearings must be turned several times once a month. They must
be subsequently topped up with grease. The bearings and housings are thereby protected
from condensation water and rust. After storage, i.e. before the plant component is
commissioned, the grease must be removed and the bearings cleaned and regreased
(approx. 1/3 of the volume of bearing and housing).
All the machine and plant components must be stored at temperatures between minimum
+ 5C and maximum + 45C. Electrical equipment is t o be stored dry and frost-free,
temperatures between minimum + 5 C and maximum + 4 5 C.
All unpainted surfaces must be provided with suitable protection against corrosion.
The storage location must be dry. If equipment is stored in a shipping container, a
"desiccant material" must be placed in the container prior to storage. The equipment must
be covered and good ventilation provided in the storage place.
The packing climate must be protected from environmental influences, in order to maintain
rust prevention and the effectiveness of siccatives.
The storage area must be clean and free from dust and other contaminants.
Equipment must be stored in the original crates or on the original transport skids provided
by ThyssenKrupp Resource Technologies. Equipment on transport skids must be loosely
covered with tarpaulins, in order to keep it clean and to allow the air to circulate.
Stored equipment may not be exposed to direct sunlight.
Plant components made of plastic or rubber may not be exposed to direct sunlight. The
storage temperature must be + 5 C minimum and + 45 C maximum. It must be protected
from contamination by grease or oil. Rubber parts, such as the belts of troughed belt
conveyors and the filter belts of vacuum belt filters, are normally delivered on coils. The
coils must be stored vertically and not horizontally. Furthermore, the coils may not be
stored directly on the floor. They must be stored vertically on a firm base surface. Pallets
or similar must be used for moisture protection. The coils may not be stacked.
The stored equipment must be secured against damage and loss. Secured storage areas
may only be accessed by authorised personnel.
5.3.2
Storage facilities & other details
5.3.2.1
"Open-air" storage
Please note that roofed storage is to be preferred (Chapter 5.3.2.2 ""Roofed" storage"),
however large-volume, painted plant components showing a small proportion of
mechanically machined surface compared to the volume as well as wear-out parts, where
surface corrosion does not affect the function, could be stored in the open air (provided
that there is no indication to the contrary on the packing, e.g. protect from heat, protect
from moisture or similar.) (see Chapter 5.1 "Transport instructions").
5 - 16
2-492-20980
05/2014 Rev 0
Insurance with sufficient coverage for damage caused by third parties, transport and
weather damage (lightning, flooding, and storms) and theft must be concluded for the
entire handling/storage period until the machine/plant has been accepted.

Examples: "Large-volume plant components"
Mills (mechanically machined parts such as bearings, retaining flanges on the gear
rim must be provided with protection against corrosion and mechanical damage e.g.
by anti-corrosive grease, plastic foil and wooden banding)
Gear rim cover
Mill outlet case
Chutes
Ducts for material transport and dedusting
Crusher frame
Apron conveyor supporting frame/chain conveyor supporting frame (without drive

units)
Supporting frame for troughed belt conveyor
Bed plates
Structural steelwork elements
Examples: "Wear parts whose surface has no effect on the functional capability"
Grinding media, rods and balls
Mill and shell lining
Slotted plates and rear panel plates for intermediate and discharge diaphragms
Crusher rolls for RollSizer
Systematic organisation of the material warehouse is strongly recommended, i.e. storage

should correspond to the assembly planning (Example: bed plates and base plates should
be placed at the outer edge of the storage area, etc). Route plans must be provided in
the store. The store must also be accessible to heavy trucks, mobile cranes and forklifts.
Drainage systems for discharge of surface water must be present.
Items must always be stored on a support such as timber planks, pallets, or similar,
preferably on a level, drained and gravelled base surface. Contact with surface water and
the ground must be avoided. All parts must be stored in such a way that no water can
accumulate.
The effectiveness of the protection of machined surfaces (protection against corrosion
and mechanical damage) must be checked and repaired or renewed if necessary.
Markings on plant components must be readable without the part having to be moved. If
water accumulates on a plant component through visible markings, the component must
be provided with new visible markings at suitable points.
05/2014 Rev 0
5.3.2.2
"Roofed" storage
Plant components which have to be protected from direct sunlight as well as those which
have to be protected from rain as a result of mechanically machined surfaces, rubber or
plastic seals, ventilation holes, or similar.
2-492-20980
5 - 17

Examples:
Rubber belts for troughed belt conveyors. Please note that the belts are delivered on
coils and must be stored in a vertical position.
Rubber and plastic seals (e.g. for gear rim protection cover, mill outlet casing,
material guide bar of troughed belt conveyors, etc.).
Components with a high proportion of mechanically machined surfaces, e.g. gear

rims, pinions with bearings, gear units, gear motors, motors, fans, parts of filter plant
housings, rotary gate valves, control and shut-off valves, large-volume couplings,
bearing housings and bearing segments for the slide shoe bearings.
Idlers for troughed belt conveyors, drive stations and pulleys, mechanical parts of
belt weighers.
Plant components with ventilation holes e.g. gear units, gear motors and bearings
equipped with openings for air pressure compensation.
All compact hydraulic units and compressors which have to be protected against dirt
by plastic foil. The covering on the bottom must remain open, in order to prevent the
accumulation of condensation water.
Operating fluids such as lubricants, grease and oil as well as sealants such as
silicone, paints, thinners and cleansers.
Items must always be stored on a support such as timber planks, pallets, or similar,
preferably on a level, drained and gravelled base surface. Contact with surface water and
the ground must be avoided.
5.3.2.3
Storage "in closed, partially air-conditioned rooms"

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

05/2014 Rev 0
5 - 18
2-492-20980

5.3.2.4
Storage in closed lockable rooms

High-quality, sensitive and valuable components.
Examples:
Measuring instruments
Sensors
PCs
Screens
Laboratory equipment e.g. test screens, scales, etc.
5.3.3
Special requirements
5.3.3.1
Electric motors
Motors must be stored in the original crates if they are not mounted on the equipment.
The storage area must be free of vibration.
Bearings:
Balls and rollers (regreasable roller bearings). Bearings going into extended storage
must be completely greased beforehand. Motor shafts must be manually rotated
once a month and bearing grease must be topped up. Rotate the shaft by hand
before putting it into service.
Balls (roller bearings, regreasing not possible). No other provisions are necessary for
the bearings.
All drain openings must be operable and the drain plugs removed during storage. The
motors must be stored so that the drain opening is at the lowest point. All breathers and
automatic drains must be operable via T-safety screws, so that breathing can take place
at a different location from the bearing seats.
Windings must be measured when they are put into storage. When they are removed from
storage, the resistance reading may not be more than 50 % below the original value. Any
values below this value necessitate electrical or mechanical drying. Where a large quantity
of motors is stored, an inspection or sampling should be made by removing the end
brackets and visually inspecting for the presence of water in the grease or rust on the
bearing. If present, replace the bearings and relubricate.
05/2014 Rev 0
All external parts and motors subjected to corrosion to be protected by corrosive resistant
coating.
Where motors are not stored in the original containers, but are removed and mounted on
other pieces of machinery, the mounting must be such that the drains and breathers are
fully operable. In this respect, the drains must be located at the lowest point of the motor
and the drain plugs removed, so that condensation water can drain out by itself. All other
storage conditions apply, including rotation of the motor shafts. If such conditions cannot
be complied with, the equipment must be treated as if it were mounted in its normal
position and all protective devices such as heaters, breathers and drains were fully
operable.
2-492-20980
5 - 19

5.3.3.2
Gear unit
Oil and grease lubrication:
The oil recommended by the manufacturer must be used for the oil change.
All gear openings such as flanges for oil lubrication, openings for holding thermometers
and pressure and flow sensors must be checked for proper sealing. Replace the seals if
necessary. Breathing or venting: Pressure compensation between the pressure inside the
gear unit and the atmosphere must be provided. The inside of the gear must be protected
against humidity and/or nesting insects or birds.
5.3.3.3
Gear motors
If gear motors, e.g. SEW, are placed in storage, a volatile corrosion inhibitor (VCI) is
added to the lubricant of these gear units.
Some of the gear units are delivered with a higher oil level for long-time storage.
The storage period is a maximum of 3 years in compliance with the documentation
supplied by the manufacturer.
NOTICE
Gear damage from improper storage of the machine/plant
Gear units must be kept sealed until commissioning, in order to prevent
volatilisation of the VCI corrosion inhibitor.
Before these gear motors are commissioned, the operating oil level must be
restored using dipstick/oil-inspection glass/oil-level plug.
5.3.3.4
Electrical control systems
Cover the motor control centre with heavy duty plastic or similar material to prevent
the ingress of foreign matter.
Motor control centres which are not installed and used immediately must be stored
in a clean and dry area. The storage temperature should be constant and between
+ 5 C and + 45 C. If the storage temperature flu ctuates or if humidity exceeds 60
%, space heaters must be used to prevent condensation. Control centres must be
stored in an air-conditioned building with adequate air circulation and be protected
from dirt and water.
Control centres which are designed for indoor applications do not have packaging
which is suitable for outdoor storage. They should therefore be provided with
additional packaging for protection from outside elements and a temporary electric
heater to prevent condensation. A space heater rated at 200 watts per section is
adequate for the average control centre. All loose packaging or flammable material
must be removed before switching on space heaters.
Control centres which are for outdoor use and are not being used must be kept dry
internally by installing temporary heaters or by means of self-contained space heaters.
5 - 20
2-492-20980
05/2014 Rev 0
Control centres (MCC):

DC drive units:
Drive motors are enclosed. Ensure that all covers are tightly fitted.
Keep the temperature between + 5 C and + 45 C.
Gear case and operator's station -- Keep the housing and the operator's station dry
by means of siccatives. Ensure that both are closed. If any openings are cut, they
must be sealed with duct sealant or duct tape.
Keep the temperature between + 5 C and + 45 C.
Process control equipment:

Process control equipment should be stored indoors in a heated/air-conditioned room.
Control valves:
The normal storage conditions are valid for all products. "Normal" means away from heat
and frost-free (storage temperature between + 5 C and + 45 C ), dry and protected from
dust. Other products may not be stacked on them.
5.3.3.5
Other mechanical equipment

Belts and seals:
These components must be protected from moisture and stored in a dry environment. The
environment must be ozone free and the belts and seals kept out of direct sunlight, in order
not to adversely affect the performance characteristics.
Bright metal components (e.g. pistons, bushes or the sealing surfaces of valves) must be
conserved by smearing them with a VCI corrosion inhibitor such as rust-inhibiting oil or
wrapped in oiled paper (these additives are referred to internally as VCI = volatile
corrosion inhibitors). Volatile corrosion inhibitors permanently emit small amounts of
protective additives. Rust-inhibiting oil or oiled paper therefore protect surfaces with or
without metal contact and are particularly suitable for irregular shapes such as hollow
parts, tapped holes, pipes and machines.
05/2014 Rev 0
VCI additives can be used for steel, iron, chrome, cast iron and aluminium. There are also
special VCI additives for copper and copper alloys and for both materials. The VCI method
is not applicable for the conservation of zinc, tin, cadmium, magnesium, lead and alloys of
these metals.
2-492-20980
5 - 21
5.4
Installation planning
When planning the installation, please note the following:
Please refer to the relevant foundation and installation drawings for the main
dimensions of the machine/plant and the associated secondary units.
See APPENDIX 8.1 "Drawings".
Provide additional ladders, walkways, platforms and safety railings for maintenance
work and indicate the permissible traffic loads.
Provide sufficient space to accommodate the periphery equipment as well as to

arrange the feeding units and conveyors to unload the material to be crushed.
Provide suitable lifting gear for the installation and for the exchange of spare and
wear parts. It should be possible to position the lifting tackle/load hook vertically on
top of the machine/plant.
Comply with the specified loading values for the design of foundations and the
calculation of the girder/platform structures.
The movement of the machine/plant generates horizontal and vertical forces which
must be absorbed by suitable shear braces.
Ensure that the machine is accessible for cleaning.
Initiate measures against dangerous environmental influences, e.g. dangerous

dusts, uncontrolled oil leaks, noise.
Integrate the machine/plant in the existing/planned control system, including

interlocking system, protective and monitoring devices, e.g. emergency stop
switches, local switches, speed monitors, filling level monitors. Integrate optical and
acoustic starting alarms in the control system.
If the conditions at the place of installation vary from those in the installation drawing,
please consult ThyssenKrupp Frdertechnik.
INFORMATION
The construction contractor is responsible for the correct dimensioning of

foundations, steel platforms, load-bearing ceilings and their supports as well as
for the execution of the construction work and compliance with the official
regulations, even if an erecting engineer of ThyssenKrupp Frdertechnik erects
the machine/plant.
Align the machine / plant with a level.
05/2014 Rev 0
For installation on a concrete foundation, grout the foundation bolts and the base
frame by concrete mortar 1:2 (1 portion cement; 2 portions sand) after alignment.
Prior to this, carefully clean the surface of the foundation and saturate it with
water.
5 - 22
2-492-20980
5.5
Preparation for installation
WARNING
The use of untrained personnel or equipment that does not comply with
safety standards poses additional danger
When carrying out overhead assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms. Never use machine
parts as a climbing aid! Wear fall protection when carrying out maintenance work
at a higher level.
WARNING
Risk of injury through components that are improperly secured during
installation
Make sure that moveable components are properly secured during installation.
WARNING
Danger from working on electrical systems without proper technical
knowledge
05/2014 Rev 0

Work on the electrical systems or equipment may only be carried out by a skilled
electrician or by specially trained personnel under the supervision of an
electrician and in compliance with the applicable regulations required for
electricians.
2-492-20980
5 - 23

INFORMATION
The manufacturer accepts no liability for damage resulting from incorrect

installation of the machine!
Careful selection of the tools and appliances used and the installation personnel
is important for correct execution of the assembly work.
It is recommendable to have the assembly work supervised from start to finish by
assembly specialists from ThyssenKrupp Frdertechnik.
05/2014 Rev 0
Our warranty is based on the assumption that an assembly specialist from

ThyssenKrupp Frdertechnik will carry out the final assembly and assembly
inspection.
5 - 24
2-492-20980
05/2014 Rev 0
2-492-20980
5 - 25
5.6
General information on assembly
WARNING
Risk of injury through improper assembly and transport
Make sure that moveable components are secured, also during installation
Use proper transportation equipment
Do not walk under suspended loads
Fasten and lift components properly
Only transport the machine/plant on the designated slinging devices (lugs) and
slinging points.
WARNING
Risk of injury during assembly work at great heights
other suitable and safe climbing aids and working platforms.
Never use machine parts as a climbing aid!
Wear fall protection when carrying out maintenance work at a higher level.
WARNING
Risk of injury when working on electrical systems
Work on the electrical system or equipment may only be carried out by a skilled
electrician or by specially instructed personnel under the control and supervision
of a skilled electrician and in accordance with the applicable electrical
engineering rules.
5 - 26
2-492-20980
05/2014 Rev 0
NOTICE
System damage through improperly executed welding work
Always take note of the pre-heating temperature of all components to be welded
and tack-welded. The pre-heating temperatures specified for welding work to be
performed on the individual materials can be found in the respective assembly
drawings in APPENDIX 8.1 "Drawings" if required.
Never conduct welding current through slide or roller bearings or other moveable
connections or measuring equipment.
Carry out welding work on individual machine components prior to their
installation.
INFORMATION
The manufacturer accepts no liability for damage resulting from incorrect

installation of the machine!
Careful selection of the tools and appliances used and the installation personnel
is important for correct execution of the assembly work.
It is recommendable to have the assembly work supervised from start to finish by
assembly specialists from ThyssenKrupp Frdertechnik.
Our warranty is based on the assumption that an assembly specialist from
ThyssenKrupp Frdertechnik will carry out the final assembly and assembly
inspection.
Initial assembly must be carried out by trained personnel.
05/2014 Rev 0
The respective layout plan and assembly drawings must be carefully studied (see
APPENDIX 8.1 "Drawings"). All guidelines and notes must be observed.
2-492-20980
5 - 27
5.7
Assembly
5.7.1
Pontoons
Install and adjust pontoons.
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5.7.2
Discharge conveyor
Install and adjust the reversing station, bend pulley and part 1 of the conveyor frame.
For assembly, see the documentation of the discharge belt.
05/2014 Rev 0
Figure 15
2-492-20980
5 - 29
5.7.3
Discharge Hopper Platform
Pre-assemble and fix the discharge hopper platform (1), set it on the pontoons and
weld it.
Mount the platform plankings (2).
Assemble the railing (3).
05/2014 Rev 0
Figure 16
5 - 30
2-492-20980

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05/2014 Rev 0
2-492-20980
5 - 31
5.7.4
Support and Bracing (bottom shell)
Pre-assemble and fix the support and bracing (bottom shell) (1)
Level and adjust the heights of the head plates,
and guy the struts (2).
Install steps with railing on the discharge conveyor platform (3).
05/2014 Rev 0
Figure 18
5 - 32
2-492-20980

05/2014 Rev 0
2-492-20980
5 - 33
5.7.5
Bottom shell of the discharge conveyor
Assembly the bottom shell of the discharge conveyor (Discharge Hopper Lower
Walls).
INFORMATION
Use the lateral filler plates.
05/2014 Rev 0
Figure 21
5 - 34
2-492-20980

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05/2014 Rev 0
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2-492-20980
5 - 35
5.7.6
Maintenance platform
Maintenance platform (1, Figure 23) pre-assemble and align then fix and weld
according to the assembly drawings.
Adjust and assemble the platform plankings (2, Figure 23) and railings (3).
05/2014 Rev 0
Figure 23
5 - 36
2-492-20980

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2-492-20980
5 - 37
INFORMATION
Assemble the hydraulic units before installing the steel structure.
Pre-assemble the hydraulic spaces for the hydraulic unit of the crusher (1, conveying
direction left) and for the hydraulic unit of the Rockbreaker (2, conveying direction
right) without cladding.
Position the hydraulic unit as per the drawing.
LxBxH 2747x875x85
152,0 kg
Welded assembly 3
4523321
Welded assembly 6
4523321
Welded assembly 4
4523321
Welded assembly 6
4523321
Welded assembly 5
4523321
Welded assembly 1
4523321
Welded assembly 8
4523321
LxBxH 2730x920x220
190,6 kg
Welded assembly 19 (8x)
4523321
LxBxH 220x305x60
10,9 kg
Welded assembly 13
4523321
LxBxH 1425x176x480
44,6 kg
Welded assembly 7
4523321
LxBxH 2730x920x300
Welded assembly 4
4523321
194,5 kg
4523321
LxBxH 3075x140x195
64,8 kg
Welded assembly 6
4523321
Welded assembly 4
4523321
Welded assembly 6
4523321
Welded assembly 17
4523321
LxBxH 2747x875x135
154,1 kg
Welded assembly 3
4523321
Welded assembly 19
4523321
Welded assembly 11
4523321
Angle
4523321 item 50
Welded assembly 11
4523321
Combined Power
4523321 item 100 (2x)
provision TKF
Welded assembly 19
4523321
Welded assembly 11
4523321
Welded assembly 6
4523321
Welded assembly 19
4523321
Profile
4523321 item 28

4523321
LxBxH 2730x920x300
194,5 kg
Plate
4523321 item 14

4523321
LxBxH 2862x220x90
75 kg
Doorway
4523321 item 102
Welded assembly 19
4523321
Welded assembly 15
4523321
Welded assembly 11
4523321
Welded assembly 10
4523321
LxBxH 2747x875x85
152,0 kg
Welded assembly 3
4523321
E
Doorway
4523321 item 101
Welded assembly 14
4523321

4523321
LxBxH 1425x140x195
32,3 kg

4523321
LxBxH 1490x140x195
33,3 kg
Welded assembly 9
4523321
LxBxH 7460x2406x160
457,1 kg
Welded assembly 12
4523321
LxBxH 8800x140x140
298,4 kg
2110
Welded assembly 16
4523321
Plate
4523321 item 24
1 11
Doorway (2x)
4523321 item 101
DIN 18100-1125x2125

4523321
LxBxH 2537x2907x100
273,6 kg
Profile (6x)
4523321 item 28
U 120x9970
132,9 kg
Welded assembly 11
4523321
Welded assembly 2
4523321
LxBxH 2747x875x135
154,1 kg
Z
Plate (2x)
4523321 item 14
LxBxH 9970x200x10
156,1 kg
Plate (2x)
4523321 item 24
LxBxH 320x220x20
7,9 kg
Combined Power
4523321 item 100
provision TKF
Angle (4x)
4523321 item 50
L 60x60x6x85
0,4 kg
Welded assembly 11
4523321
Plate (30x)
4523321 item 2
LxBxH 190x140x5
1 kg
Z ( 1 : 10 )
Welded assembly 11
4523321
Welded assembly 9
4523321
Doorway (2x)
4523321 item 102
DIN 18100-1125x2125

4523321
LxBxH 2537x2907x100
273,6 kg
Welded assembly 15
4523321
LxBxH 2862x220x90
75,0 kg
(2x)
K
(2x)

4523321
LxBxH 2842x220x220
176,4 kg
General tolerances for

welded assemblies
DIN EN ISO 13920 tolerance class

machined surfaces
DIN ISO 2768 part 1/2 tolerance class
Welds
non-destructive testing DR 10.01
external findings DIN EN 25817
Tolerances
ISO 8015
assessment category
assessment category
05/2014 Rev 0
5 - 38
2-492-20980
05/2014 Rev 0
Figure 27
2-492-20980
5 - 39
5.7.7
Discharge Hopper Upper Walls
Pre-assemble the panels and doors
INFORMATION
If required, use the lateral filler plates.
After assembly lubricate the hinges.
Adjust and assembly the door seals.
Seal the columns and the corners of the entire discharge hopper (Upper and Lower
Walls).
05/2014 Rev 0
Figure 28
5 - 40
2-492-20980
( 1 : 50 )
The reproduction, distribution and utilization of this

document as well as the communication of its contents to others without explicid authorization is
prohibited. Offenders will be held liable for the
payment of damages. All rights reserved in the event
of the grant of a patent, utility model or design.
Weitergabe sowie Vervielfltigung diese Dokuments,
Verwertung und Mitteilung seines Inhalts sind ver-
Werkstckkanten ohne Angaben nach DIN 6784

Chamfers w/o dimension acc to
DIN 6784
Auenkante
outer edges
-0,5
-0,3
Innenkante
inner edges
vereinfach.
Eintragung
simplified
symbols
gemittelte Rauhtiefe Rz
EN-ISO 1302
average roughness Rz
value acc to EN-ISO
1302
=
Auengewinde bis auf Kern- n Innengewinde
Rz=100

welded assemblies
DIN EN ISO 13920 tolerance class

machined surfaces
DIN ISO 2768 part 1/2 tolerance class
Stckl.-Nr.:
list o. Mat.
D
Oberflce
Surface
KN 912235.11
EN ISO 1302
No. of features
Name dept..
Date
edited.
09.08.2012
We/AUN
reviewed
statics
Welds
non-de
extern
Tolerances
Mastab/Scale
Werkstoff/Mater
Disch
upper pa
Align, adjust and assemble the pre-assembled hydraulic spaces.
05/2014 Rev 0
+0,5
+0,3
Figure 30
2-492-20980
5 - 41
5.7.8
Crusher platform
Pre-assemble, fix and weld the platform parts.
INFORMATION
Adhere to the welding sequence and the specifications for welding.
05/2014 Rev 0
Figure 31
5 - 42
2-492-20980
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Assemble the drive platform.
Package gratings
4602299 Item 12
total weight 929,2 kg
teelwork WA 2
4602299
H 2018x2110x780
173,6 kg
Plate
4602299 Item 3
Plate
4602299 Item 28
Wind Bracing
4602299 item 8,9
Plate
4602299 Item 28
LxBxH 500x408x30
32,2 kg
Steelwork WA 1
4602299
LxBxH 8720x4475x1115
6774,0 kg
Wind Bracing (2x)

4602299 item 8,9
139,7x6,3x2588
55,0 kg
05/2014 Rev 0
Plate (2x)
4602299 Item 3
LxBxH 740x608x20
56,0 kg
Steelwork WA 3
4602299
LxBxH 2018x2110x780
173,6 kg
2-492-20980
5 - 43
3BJMJOH(-

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LH
3BJMJOH(-

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LH
Adjust and assemble the platform plankings and the railing on the drive platform.
3BJMJOH(-

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LH
3BJMJOH(-

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LH
3BJMJOH(-

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LH
3BJMJOH(-

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LH
3BJMJOH(-

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LH
3BJMJOH(-

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LH
3BJMJOH(-

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LH
3BJMJOH(-

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LH
05/2014 Rev 0
5 - 44
2-492-20980
05/2014 Rev 0
Figure 35
2-492-20980
5 - 45
Adjust and assemble the platform plankings and the railing on the crusher platform.
Figure 36
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5 - 46
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2-492-20980
05/2014 Rev 0

5.7.9
Support and Bracing (top part)
Measure, pre-assemble, fix and weld the steel structure. here, pay attention to the
position and height of the head plates.
Figure 38
05/2014 Rev 0

2-492-20980
5 - 47
5.7.10
Maintenance platform
Assemble the maintenance platform (1, Figure 42).
Install the steps.
Assemble the platform plankings and the railing.

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Assemble and align the steps (2, Figure 42).
05/2014 Rev 0
"2#%*$$2-,/
5 - 48
2-492-20980
g G4
60
4620x2050x1210
kg
Graiting
05/2014 Rev 0
Figure 42
2-492-20980
5 - 49
5.7.11
Feed hopper and panels

Assemble the feed hopper (1, Figure 44) in the following sequence:
Pre-assemble, fix and weld the hopper base.
Screw the hopper modules,
adapt, fix and weld the side panels.
Assemble the support for the "Main Shaft Stands."
Lift, adjust and screw 4 hopper parts on the scaffold.
Assemble the side walls (2, Figure 44).

"#"#''

"#"#'

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+ ,!
05/2014 Rev 0
5 - 50
2-492-20980
Figure 44
Fasten the dust sealing and dust chute at the crusher inlet opening.
INFORMATION
05/2014 Rev 0
Assemble the splitter only after installing the crusher.
2-492-20980
5 - 51
5.7.12
Stair tower and catwalks
Install the stair tower on the feed hopper
05/2014 Rev 0
Figure 45
5 - 52
2-492-20980

Attach catwalk to dedusting and also:
Assemble the bearing frame,
Assemble the steps and platforms,
Assemble and install the transitions to the individual platforms.
Figure 47

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*
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05/2014 Rev 0
2-492-20980
5 - 53
5.7.13
Truck ramps
Prepare the ring bearing, for that:
Position the half parts of the ramps,
Assemble the calotte bearing on the steel structure and the ramps,
Align and fix the ring bearing on the base with the steel plate provided by the
customer.
Insert the partitioned bearing plate (sheet 40 mm) into the half parts of the ramps,
and align and fix it.
Insert the bearing plate into the second half of the ramp and screw and fix it with the
ring bearing.
Assemble and screw the half parts of the ramp,
Weld the bearing plates.
Place filler plates under the ramps and secure the filler plates.
Adjust and screw side barrier walls.
05/2014 Rev 0
5 - 54
2-492-20980
Attach catwalk truck ramp with railings and coverings onto the ramp.
05/2014 Rev 0
Figure 50
2-492-20980
5 - 55
5.7.14
Catwalk view (1)

Attach catwalk, and also:

#$&'(

&'(

%)*'+

05/2014 Rev 0
5 - 56
2-492-20980
05/2014 Rev 0
Figure 52
2-492-20980
5 - 57
5.7.15
Rockbreaker support (4)
Pre-assemble, fix and weld the steel structure
and assemble on the rear of the hopper.
Align and fix the upper platform for work on the rockbreaker.
Assemble the railing and the plankings.
Align and secure the lower platform.
Attach the catwalk rockbreaker (2), and also:
$ %&# ' # ((,

-
- )
- #
05/2014 Rev 0
- (
5 - 58
2-492-20980
05/2014 Rev 0
Figure 54
2-492-20980
5 - 59
5.7.16
Main shaft stand (3)
Assemble, fix, and weld the structural steel on the installation location,
!
!
05/2014 Rev 0
5 - 60
2-492-20980
05/2014 Rev 0
Figure 56
2-492-20980
5 - 61
5.7.17
Rockbreaker and crusher
Refer to the specific documentation of the components for the assembly of

rockbreaker and the crusher.
Figure 57
Electro-housing
Assemble and secure the steel construction for the electro-housing.
Assemble the steel construction for the operator cab.
Assemble the access platforms with handrails and coverings.
Assemble the access platforms, railings and stairs.
Install the transformers, electric container and operator's cab.

05/2014 Rev 0
5.7.18
5 - 62
2-492-20980

!" " #

$%
&

5.7.19
Place the drive for the gyratory crusher on the drive platform and connect to the cone
crusher.
Assemble the maintenance car with scissors lift.
Continuation discharge belt
Assemble and align part 2 of the belt frame.
Assemble and align the drive station and the driving pulley.
For assembly, see the documentation of the discharge belt.
05/2014 Rev 0
5.7.20
Periphery
2-492-20980
5 - 63
05/2014 Rev 0
Blank page
5 - 64
2-492-20980
Commissioning and operation
6.1
General information
For many reasons we highly recommended you call for the assistance of
ThyssenKrupp Resource Technologies staff in the commissioning process. This is not
only for reasons relating to the warranty, but also for the purpose of:
having the machine/plant checked
determining the optimum capacity
training the operating personnel
passing on additional advice on operation, maintenance and upkeep.
For the initial commissioning routine note the instructions relating to the components
APPENDIX 8.2 "Gyratory crusher"
APPENDIX 8.3 "Discharge conveyor"
APPENDIX 8.6 "Hydraulic hammer/rockbreaker"
APPENDIX 8.7 "Sprinkling system with desalination"
05/2014 Rev 0
2-492-20980
6-1
6.2
Operator training
These installation and operation instructions to operate the machine/plant does not
replace training and instructions.
Previous technical and safety knowledge is required for operation of the machine/plant!
The owner must prepare a directive for regulating the internal operation, maintenance and
repair of the machine/plant.
These installation and operation instructions include the requisite operating instructions
for the operating personnel.
Always make sure to observe the intended use of the machine/system (see Chapter 4.1).
The operating staff must be familiar with the arrangement and function of the safety
devices.
6.3
Safety instructions for operation
DANGER
Risk of injury from damaged insulation on the connecting cable and
missing terminal box covers
The electrical connections to the drives must be adequately protected.
WARNING
Risk of injury from larger oscillation amplitudes
Do not reach into the spaces between fixed components and oscillating
components.
05/2014 Rev 0
Repair incorrect oscillation before feeding material.
6-2
2-492-20980
CAUTION
Risk of injury when operating the drive units without protective clothing
The machine must never be operated without the guards in position over the
drive units.
Operate the machine / plant only if all protective and safety-oriented devices, such
as removable safety devices and emergency shut-off equipment, sound-proofing
elements and exhausters, are in place and fully functional!
Check the machine/ plant at least once every shift for obvious damage and defects!
Report any changes (including changes in the operating performance) to the
responsible department immediately! If necessary, stop the machine/ plant
immediately and lock it!
In the event of malfunctions, stop the machine/ plant immediately and lock it!
Have any defects remedied immediately!
Follow the start-up and shutdown procedures and control displays as set out in the
manual!
Before starting up/putting the the machine/ plant into operation, make sure that
nobody is at risk!
If abnormal vibrations suddenly occur in the equipment supporting structure the

operation of which is corresponding with vibrations and unbalances, these abnormal
vibrations must be eliminated prior to feeding the machine with material.
Only work with the prescribed lighting under darkness and with poor visibility.
Switch off the plant/machine immediately if people are at risk, e.g. due to careless
working near belt conveyor systems and material transfer points.
Local operation of individual drives is allowed only during inspection, maintenance

and repair work.
Work may only be carried out if the worker is properly qualified and/or has been
authorised to do so.
Do not carry out maintenance and repair work without authorization.
05/2014 Rev 0
2-492-20980
6-3
6.4
Power supply and control system

Power is supplied via mains and feeder circuits.
Gyratory crushers may only be operated in an electrically interlocked condition for safety
reasons and as a protection against overloading.
The start-up and shutdown procedures of the gyratory crusher and the upstream and
downstream units/equipment must be executed in a defined sequence for functional and
safety reasons. To this end, the crusher and these units are electrically interlocked
internally and with each other. The control system, all drives as well as the monitoring
devices/local transmitters connected to the control system are included in the interlocking
system.
Any faults are signalled to the control station/control cabin.
Depending on the type of failure, only a message is output or the upstream units/the
crusher are switched off.
The drives can also be operated separately, i.e. locally, for inspection, maintenance and
repair work as well as for test runs.
NOTICE
System damage through use of the machine/plant contrary to its designated
use
The intended use of the machine/plant is regulated by contract. Any other use
contrary to its designated use is prohibited. ThyssenKrupp Resource Technologies
cannot be held liable for damage resulting from such misuse. The risk of such
misuse lies entirely with the user.
Electrical interlocking systems may only be switched off by qualified personnel.
All drives must be interlocked during normal operation!
INFORMATION
GYRAMATIC is a compact and reliable control and monitoring system that has been
specially designed for the ThyssenKrupp gyratory crusher. It provides all the control
functions as regards operation, calibration and overloads which are necessary for reliable
and problem-free operation of the gyratory crusher. The device is designed as a touch
screen terminal and enables control and gearing of all motors connected to the gyratory
crusher. Here, the pressure, temperature and oil flow in the lubricant/hydraulic system and
in the hydraulic system of the automatic traverse tension are displayed.
6-4
2-492-20980
05/2014 Rev 0
The safety-related parts of control systems for the gyratory crusher meet the
required Performance Level "D" - Category 2.
The delivery scope of ThyssenKrupp Resource Technologies-Busines Unit
Processing does not include the control unit "MCC," but only the
GYRAMATIC.
6.5
Shutting down
6.5.1
Normal operation
The material feed must always be interrupted before the crushing plant is stopped. The
crushing plant can then run "empty."
When the crushing plant is stopped, make sure that sufficient material remains in the feed
hopper to protect the conveyor covering.
NOTICE
Plant damage through false material feeding after emptying the feed
conveyor
If the feed hopper is run empty, ensure that small-sized pieces of material are
again initially fed to the feed hopper when material feeding resumes. This serves
to protect the conveyor covering against the impact load of lump material.
6.5.2
Emergency-stop system
NOTICE
System damage from material overfilling when using emergency-stop
switch
When using an emergency-stop switch, there is a danger of material overfilling at
the transfer points, as all upstream and downstream parts of the plant are switched
off with no specific shutdown sequence.
The emergency-stop switches must not be used for normal shutdown.
05/2014 Rev 0
Several emergency-stop switches must be installed on the machine/plant.

The emergency-stop switches are identified by red impact surfaces on yellow background.
The switches engage on actuation.
2-492-20980
6-5

The whole electrical system is switched off by the emergency stop.
Ascertain the danger or damage, and provide first aid if necessary.
Have any defects rectified.
In order to restart the plant after having rectified the emergency case, the actuated
switch is to be unlocked by turning the impact surface to the right-hand side.
Acknowledge the fault.
Switch the main electrical supply back on.
05/2014 Rev 0
6-6
2-492-20980
Maintenance
7.1
Important information on maintenance
WARNING
Risk of injury through cleaning, inspection, maintenance and repair work
during operation
Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off and secured against restarting.
Do not get into the machine/plant's interior unless it is supplied with fresh air and
has sufficiently cooled down. Make sure that there is enough oxygen in the
interior and that no hot gas can get in.
The machine/plants interior must continuously be fed with fresh air during works
(by blowing-in or exhausting) thus keeping the inhaled air free from components
injurious to health. Do not ventilate with pure oxygen. Wear dust protective
masks in case of possible dust formation.
The following activities may only be carried out by qualified personnel:
Note the information in the Operating Instructions on adjusting, maintenance and

inspection work and observe the intervals set out, including information on the
replacement of parts and equipment!
Inform the operating personnel before starting service and maintenance work!
Appoint a person to supervise the work!
When carrying out any work concerning the operation, conversion or adjustment of
the machine/ plant and its safety-oriented devices or any work related to
maintenance, inspection and repair, always follow the start-up and shutdown
procedures described in the Operating Instructions and the information on
maintenance work!
As a general principle, all work on the machine/ plant should only be carried out when
the machine/ plant is at a standstill.
05/2014 Rev 0
If the machine/ plant has been completely shut down for maintenance and repair work, it
must be secured against inadvertent restart by:
Locking the principal control elements and removing the ignition key and/ or
attaching a warning sign to the main switch.
Before restarting the machine/plant after repair work, check that all safety devices
have been attached.
After electrical installation or repair work, test the protection systems (e.g. earth
resistance) used.
2-492-20980
7-1
7-2
To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting gear and secured. Only
use suitable and technically perfect lifting gear and suspension systems with an
adequate carrying capacity! Never work or stand under suspended loads!
When carrying out overhead assembly work, always use specially designed or other
suitable and safe climbing aids and working platforms. Never use machine parts as
a climbing aid! Wear fall protection when carrying out maintenance work at a higher
level.
Keep all handles, steps, handrails, platforms, landings and ladders free of dirt, snow
and ice!
Always tighten up any bolted connections which have been loosened during
maintenance and repair work!
Any safety devices removed for setting up, maintenance or repair purposes must be
refitted and checked immediately upon completion of the maintenance and repair
work.
Ensure that all consumables and process materials and replaced parts are disposed
off safely and in an environmentally friendly manner!
Only use original fuses with the specified current rating! Shut down the machine/
plant immediately if faults occur in the electrical power supply!
Work on the electrical system or equipment may only be carried out by a skilled
electrician or by specially instructed personnel under the control and supervision of
a skilled electrician and in accordance with the applicable electrical engineering
rules.
If prescribed, the power supply to parts of machines and plants on which inspection,
maintenance and repair work is to be carried out must be disconnected. Check that
the isolated parts have been disconnected from the supply, then earth and shortcircuit them and insulate any adjacent live parts!
The electrical equipment of the machine/plant must be inspected at regular intervals.

Any defects such as loose connections or scorched cables must be rectified
immediately.
If work on live parts is necessary, it may only be carried out in the presence of a
second person who can disconnect the power supply in an emergency by actuating
the emergency stop button or main power switch. Cordon off the working area with
a red-and-white safety chain and a warning sign. Only use insulated tools!
Before starting work on high-voltage assemblies and after disconnecting the power
supply, the supply cable must be earthed and components such as capacitors shortcircuited with an earthing rod!
Carry out welding, flame-cutting and grinding work on the machine/ plant only if this
has been expressly authorised, as there may be a risk of explosion and fire!
2-492-20980
05/2014 Rev 0
7.1.1
Before carrying out welding, flame-cutting and grinding work, clean dust and other
inflammable substances from the machine/ plant and its surroundings and provide
adequate ventilation (risk of explosion)!
Check all lines, hoses and bolted connections regularly for leaks and obvious
damage. Repair any damage immediately! Splashing oil may cause injury and fires.
Depressurise all system sections and pressure pipes which are to be opened in
accordance with the instructions for the assembly group concerned before carrying
out any repair work!
Hydraulic lines must be laid and connected in line with good professional practice!
Do not mix up any exchange connections! The fittings, lengths and quality of the
hoses must comply with the technical requirements.
Follow the applicable safety regulations when handling oil, grease and other
chemical substances!
Be careful when handling hot consumables and process materials (risk of burning or
scalding)!
Notes on cleaning
CAUTION
Risk of injury when working without personal safety equipment
Always wear a face protector when carrying out cleaning work with highpressure or steam jet cleaners.
Check the degree of soiling of the machine/plant every day. Do not allow material to
accumulate or cake. The mechanical interaction of the plant components may be
interfered with and malfunctions and increased wear occur.
Always clean the assembly group in question before commencing maintenance

work.
Before cleaning the machine/ plant with water or steam jet (high-pressure cleaners)
or other cleaning agents close/tape up all openings into which water, steam and
detergents should not be allowed to penetrate for safety or operational reasons.
Electric motors and switch cabinets are at particular risk.
Do not use corrosive detergents.
Do not direct the spray jet at electrical devices, relay boxes and switch cabinets,
intake and breather filters or greased surfaces.
05/2014 Rev 0
2-492-20980
7-3
7.1.2
Always hold the spray jet a sufficiently large distance away from the surface being
cleaned and do not direct the spray jet at these surfaces at right angles.
Clean places which are difficult to reach with suitable equipment e.g. special brooms.
The covers and adhesions must be removed completely after cleaning.
After cleaning, check all lubricant and hydraulic oil lines for leaks, loose connections,
friction areas and damage! Eliminate any deficiencies immediately!
Information on maintenance and inspection
WARNING
Risk of injury by neglecting proper maintenance intervals
All pending maintenance work must be completed according to schedule. The
manufacturer does not accept liability for damage resulting from maintenance
work which has not been carried out or has not been carried out according to
schedule.
NOTICE
System damage through improper maintenance
Damage to the machine/plant or its environment is possible.
Check the machine / plant at least once per shift for obvious damage and
defects! Report any changes (including changes in the operating performance)
to the responsible department immediately!
In the event of malfunctions, stop the machine / plant immediately and lock it!
Have any defects remedied immediately!
Functional safety, trouble-free operation and the service life of the machine/ plant depend
on proper cleaning, inspection and maintenance.
7-4
2-492-20980
05/2014 Rev 0
Failures arising from inadequate or improper maintenance may cause high repair costs
and long downtimes. Regular maintenance is therefore indispensable.

Check the machine/ plant at the specified intervals (inspection intervals, maintenance
periods) for proper operation, lubrication condition and wear.
Replace or repair all damaged/ worn parts.
Check the paintwork for corrosion at regular intervals but no later than every 6
months. Touch up all damaged areas in line with good professional practice.
Have the function of all instrumentation and control devices/ electrical interlocks
checked by qualified personnel at regular intervals.
INFORMATION
Downtimes for repairs can also be used for scheduled maintenance work.
The required frequency of checks for wear, inspection, maintenance and repair cannot be
specified beforehand owing to the variety of service conditions. An appropriate routine
inspection schedule must be prepared making allowance for the operating conditions.
The maintenance table is a guideline for inspection and maintenance work.
For maintenance and repair work strictly follow the general safety notes included in
(Chapter 3).
As recommended during commissioning you are advised to have initial repairs carried out
by the personnel from ThyssenKrupp Industrial Solutions. Your maintenance staff will
have the opportunity to take part in an intensive training course.
7.1.3
Notes relating to repairs
WARNING
Risk of injury due to improper fastening
05/2014 Rev 0
Individual parts and large assemblies being moved for replacement purposes
should be carefully attached to lifting gear and secured so that they do not pose
any danger. Only use suitable and technically perfect lifting gear and suspension
systems with an adequate carrying capacity! Never work or stand under
suspended loads!
other suitable and safe climbing aids and working platforms. Never use machine
parts as a climbing aid! Wear fall protection when carrying out maintenance work
at a higher level.
2-492-20980
7-5
7.2
Immediately replace worn components with new components.

With worn components, strength is reduced and the risk of fracture is increased!
Do not re-use seals and safety elements that have been removed.
When re-using assembly groups and parts, always use new bolts, nuts and washers.
Do not leave any tool or other device in the machine/plant.
Observe the welding instructions for the prevention of accidents whenever carrying
out welding work.
During electric welding, secure the earthing cable near the part being welded. Do not
route the welding current return line over movable machine elements (e.g. shafts,
bearings). For bridging, fit a cable with a cross-section adequate for the strength of
the welding current and for the length over which current must be carried.
Restore the machine/plant to its original state on the completion of the repair work.
Remount protective and safety devices again. Make sure that the machine/plant is
working properly by carrying out a test run.
Screwed and bolted connections

Always protect all screwed and bolted connections against corrosion.
7.2.1
Machine structures
For machine structures:
Standard
Quality
Hexagon bolt (thread up to head)
DIN EN ISO 4017
8.8 / 10.9 / 12.9
Hexagon socket head cap bolt
DIN EN ISO 4762
8.8 / 10.9 / 12.9
DIN 7984
8.8 / 10.9 / 12.9
DIN EN ISO 4032
8 / 10 / 12
Washer
DIN 6916
C 45 hardened
Hexagon fitted bolts
DIN 609
8.8 / 10.9 / 12.9
Hexagon socket head cap bolt with short head

Hexagon nut
Screw grade:
Nut grade
7-6
8.8
10.9
12.9
10
12
2-492-20980
05/2014 Rev 0
Use only the following bolts and nut qualities together:

Tightening torques for machine structures
Calculated with k = 0.14 (new bolts, without post-treatment) in accordance with VDI 2230
Tightening torque MA (Nm)

Class
Bolt diameter
8.8
10.9
12.9
M6
11
15
18
M8
26
36
43
M10
51
71
86
M12
88
123
148
M16
211
300
358
M20
412
579
697
M24
711
1000
1196
M30
1422
2010
2403
M36
2481
3491
4197
M42
3991
5609
6727
M48
6021
8473
10150
M56
9650
13582
16279
M64
14416
20300
24320
INFORMATION
05/2014 Rev 0
Only use the tightening torques listed in the table when no special tightening
torques are indicated in the relevant section.
2-492-20980
7-7
7.2.2
High-tensile bolted joints

In the case of high-tensile (friction-type bolted connections), the force is transmitted by
friction between the contact faces and depends on the pretensioning force of the bolts.
The contact faces must be bright. They must be cleaned by sandblasting, flame cleaning
or chemical detergents (DIN 18800, DIN V 18800-7 - Appendix D.1.6).
Use bolts, nuts and washers from one manufacturer only. A uniform protection
against corrosion is compelling.
Only use properly oiled bolts in perfect condition.
Use a torque wrench to produce the required bolt pretensioning force.
Components are marked as

follows
Material data
Manufacturer
data
Marked HSFG
Hexagon bolt HSFG

as per DIN 6914
10.9
yes
HSFG
Hexagon nut HSFG

as per DIN 6915
10
yes
HSFG
yes
HSFG
Washer
as per DIN 6916
Use only the following bolts and nut qualities together:

Screw grade:
Nut grade
10.9
12.9
10
12
For steel structures:
Quality
Hexagon bolt
DIN 6914
10.9 / 12.9
Hexagon nut
DIN 6915
10 / 12
Washer
DIN 6916
C 45 hardened
Use the required pretensioning forces indicated in the table below or in the drawing.
05/2014 Rev 0
Standard
7-8
2-492-20980

Pretensioning forces and tightening torques applicable to torque methods for sets corresponding to
tensile strength class 10.9 according to table 5, DIN V 18800-7.
Torque method
Basic pretensioning
force Fv in kN
Dimensions
1.
Required tightening torque to achieve the basic

pretensioning force
MA in Nm
Hot-galvanised and
lubricated1
As manufactured and
slightly oiled
M 12
50
100
120
M 16
100
250
350
M 20
160
450
600
M 22
190
650
900
M 24
220
800
1100
M 27
290
1250
1650
M 30
350
1650
2200
M 36
510
2800
3800
Nuts lubricated with molybdenum disulphide or equivalent lubricants.
Check the friction grip connection immediately following installation and at least once a year:
Pre-stressed bolted connections (DIN V 18800-7 1.2.2.2)
(1216) When using the torque method, at least 5 % of the sets of the connection must be
checked (at least 2 bolted connections for connections with less than 20 bolts). A test
torque which is a maximum of 10% higher than the applied tightening torque is transmitted
to the set on the side on which it was tightened. Proceed as described in Table 7
depending on the angle of rotation that is achieved till the torque wrench is activated. If
necessary, retain the element not to be turned in order to prevent it from turning.
Checking the pre-stressing force according to the torque method
(DIN V 18800-7 Table 7)
Angle of additional
rotation
Measures
none, pretensioning is adequate
30 to 60
pretensioning is adequate, check two adjac ent bolts of the same connection
> 60
replace the bolt, check two adjacent bolts of t he same connection
05/2014 Rev 0
< 30
2-492-20980
7-9
05/2014 Rev 0
Blank page
7 - 10
2-492-20980
APPENDIX
8.1
Drawings
8.2
Gyratory crusher
8.3
Discharge conveyor
8.4
Metal Detector
8.5
8.6
8.7
8.8
Compressor
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Instrucciones de Operación y Montaje SMCP 63x75

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Instrucciones de Operación y Montaje SMCP 63x75

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ThyssenKrupp Industrial Solutions

Assembly and Operating Instructions

Year of manufacture 2013

ThyssenKrupp Industrial Solutions

ThyssenKrupp Industrial Solutions AG

ThyssenKrupp Industrial Solutions

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

Liability and warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3

Stocking of spare parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4

Power supply system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 1

Crusher type, dimensions, capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 2

Oil circulating lubrication and hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 3

Over-pressure ventilation of the dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 3

Grease lubrication for spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 3

Sprinkling system with desalination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 7

Maintenance car with scissor-type elevating platform - - - - - - - - - - - - - - - - - - - - - - 2 - 8

ThyssenKrupp Industrial Solutions

Scissors-type elevating platform(2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 9

Drive unit (3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 9

Safety and monitoring equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 10

General safety notes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 1

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

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

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

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

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

Climatic conditions/ environmental conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 2

Functional description of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 2

Components of the semi-mobile crushing plant - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 3

Sprinkling system for dust reduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 8

Maintenance car with scissor-type elevating platform - - - - - - - - - - - - - - - - - - - - - - 4 - 9

Scissors-type elevating platform(2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 11

Drive unit (3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 11

Safety and monitoring equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 11

ThyssenKrupp Industrial Solutions

Transport, storage and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1

Hoisting devices and slinging equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 3

Wire rope clamps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 7

Screw-type lifting eyes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 10

Slinging equipment and load protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 14

Substructures for loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 14

Storage facilities & other details - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 16

Preparation for installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 23

General information on assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 26

Discharge Hopper Platform - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 30

Support and Bracing (bottom shell) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32

Bottom shell of the discharge conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 34

Discharge Hopper Upper Walls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40

Support and Bracing (top part) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 47

Feed hopper and panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 50

Stair tower and catwalks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 52

Catwalk view (1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 56

Rockbreaker support (4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 58

ThyssenKrupp Industrial Solutions

Main shaft stand (3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 60

Rockbreaker and crusher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 62

Continuation discharge belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 63

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

Safety instructions for operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 2

Power supply and control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 4

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

Information on maintenance and inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 4

Notes relating to repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 5

Screwed and bolted connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 6