Académique Documents
Professionnel Documents
Culture Documents
Gyratory crusher
KB 63 - 75
Iron ore
Shougang Hierro II
Shougang Hierro S.A.A.
San Juan de Marcona, Peru
2-492-20980
11/2013 Rev 0
Revision level
Revision
status
0
Date
Changes
Made by
11/10/2013
22/11/2013
Ritterbecks
Ritterbecks
25/03/2014
Chapter 2.2 Over-pressure ventilation of the dust sealing Voltage: Capacity P: Speed n:
Ritterbecks
11/2013 Rev 0
Table of Contents
1
11/2013 Rev 0
User's guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 1
1.1
User groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 1
1.2
1.3
Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3
1.4
General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3
1.5
1.6
Copyright - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4
1.7
Technical modifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 4
1.8
Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 1
2.1
2.2
2.3
2.4
Drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 3
Principles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 1
3.2
3.3
Personnel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 2
3.4
Noise hazard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 3
3.5
3.6
Fire protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 4
3.7
4.2
Main components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 2
4.3
Operating principle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 4
2-492-20980 (POS 01)
TOC - 1
TOC- 2
Assembly groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 6
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
Eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 18
4.4.6
4.4.7
4.4.8
4.4.9
4.4.10
4.4.11
Transport instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1
5.2
5.2.1
Lifting gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 4
5.2.2
Lifting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 5
5.2.3
Lifting ropes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 7
5.2.4
5.2.5
Lifting chains - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 12
5.2.6
Hook - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 13
5.2.7
5.2.8
Shackles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 16
5.2.9
5.2.10
5.3
Storage requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 20
5.3.1
General requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 20
5.3.2
5.3.3
Special requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 25
5.4
5.4.1
General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29
5.4.2
Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29
5.4.3
Pipes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29
5.4.4
5.4.5
Commission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31
5.4.6
Hydraulic fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31
5.4.7
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4.4
11/2013 Rev 0
5.4.8
Pressure settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31
5.4.9
Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.4.10
Cylinders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.4.11
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.4.12
Fluid level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.4.13
Filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33
5.4.14
Oil temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33
5.4.15
Oil change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33
5.4.16
Accumulators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33
5.4.17
Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33
5.4.18
Pipework - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33
5.4.19
Cooler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33
5.4.20
5.4.21
5.5
Installation planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 34
5.6
5.7
5.8
Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40
5.8.1
Pre-assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40
5.8.2
Weights: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40
5.8.3
Bottom shell - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 42
5.8.4
5.8.5
Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 46
5.8.6
5.8.7
5.8.8
5.8.9
5.8.10
Spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 60
5.8.11
Main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 62
5.8.12
5.8.13
5.9
5.9.1
5.9.2
5.9.3
Direct drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 74
5.9.4
5.9.5
TOC - 3
TOC - 4
5.9.7
5.10
General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1
6.2
6.3
6.4
Initial commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 5
6.5
Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6
6.5.1
Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6
6.5.2
6.6
Malfunctions, troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 7
6.6.1
6.6.2
6.7
Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11
6.7.1
Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11
6.7.2
Emergency-stop system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 12
6.8
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 1
7.1
7.1.1
7.1.2
7.1.3
7.2
Maintenance intervals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 8
7.3
7.3.1
7.3.2
7.3.3
Main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 16
7.3.4
7.3.5
Dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 22
7.3.6
7.3.7
Check the oil level and change the oil at the oil circulating lubrication unit - - - - - - - - - 7 - 28
7.3.8
Check the hydraulic oil level and change the hydraulic oil - - - - - - - - - - - - - - - - - - - - - 7 - 29
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5.9.6
7.3.10
7.4
Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 38
7.4.1
7.4.2
7.4.3
7.4.4
Checks to be made with the spider, main shaft and dust sealing housing dismantled - - 7 - 44
7.4.5
7.4.6
Wear parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 48
7.4.7
Main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 50
7.4.8
7.4.9
Dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 58
7.4.10
7.4.11
7.4.12
7.4.13
7.4.14
7.5
Screw connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 86
7.5.1
Machine structures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 86
7.5.2
Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 1
8.1
8.2
Storage of lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 - 2
8.3
8.3.1
Oil groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 - 3
8.3.2
8.3.3
Lubricant lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 - 5
8.4
8.4.1
Standard lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 6
8.4.2
Special lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 9
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7.3.9
72& - 5
8.5
ANNEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 - 1
9.1
Drawings
9.2
Couplings
9.3
9.4
9.5
9.6
Monitoring devices
9.7
9.8
Central lubrication
9.9
9.10
9.11
Tools
9.12
9.13
9.14
Fluid starter
9.15
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Lubricating instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 12
72& - 6
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.
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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.
1-1
1.2
SIGNAL WORD
Type and source of danger
Possible consequence(s) of non-observance.
Measure(s) for prevention of the danger.
The following table shows the classification and significance of the signal words for safety
notes.
Pictogram
Signal word
Significance
Consequences of non-observance
DANGER
Imminent danger
WARNING
Possible danger
CAUTION
Possible danger
CAUTION
INFORMATION
!
!
General danger
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1-2
1.3
1.4
Definitions
right
left
or
General information
Dear Customer,
These Assembly and Operating Instructions are prepared by ThyssenKrupp Resource
Technologies and have to be observed in every detail by those responsible for the transport, installation, commissioning, operation, maintenance as well as the disposal of all
consumables and process materials. Only if the responsible individuals follow the instructions in these Assembly and Operating Instructions will errors in operating and servicing
the machine / plant be avoided and trouble-free operation ensured.
The Assembly and Operating Instructions contain important information on how to operate
the machine / plant safely, properly and efficiently. Observing this information helps to
avoid danger, to reduce repair costs and downtimes and to increase both the reliability and
the life of the machine / plant.
The Assembly and Operating Instructions include numerous instructions referring to possible hazards. The user is responsible for training the operating staff at the machine / plant
or on site and ensuring that the safety regulations are observed.
The Assembly and Operating Instructions do not include instructions and guidelines for
major repair work.
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ThyssenKrupp Resource Technologies can provide skilled and qualified personnel to carry out inspections and repairs if required.
1-3
1.5
Incorrect operation
Faulty maintenance
Use of consumables (in particular lubricants) not explicitly permitted by the manufacturer
In addition, the conditions for liability and warranty as specified in the General Conditions
of Supply of ThyssenKrupp Resource Technologies are applicable.
1.6
Copyright
We reserve all rights in connection with this documentation, including those relating to patent registration or provisional patent registration. This documentation may not be disclosed to third parties or reproduced or used in any other way without our previous consent
in writing.
1.7
Technical modifications
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ThyssenKrupp Resource Technologies reserves the right to change designs in the course
of technical developments. Recent modifications may not yet have been included in the
drawings and texts of these Assembly and Operating Instructions.
1-4
1.8
CAUTION
The use of non-original spare parts
Damage to the machine/plant or its environment is possible
Only use original spare parts that are approved by ThyssenKrupp ResourceTechnologies.
Damage caused by using products other than the original spare parts and accessories is excluded from the liability and warranty.
We expressly point out that we cannot assume any liability for spare parts and
accessories which have not been supplied by us. In some cases the installation of
such products may alter and negatively affect the structural characteristics of the
machine / plant and therefore impair safety.
Continuous operation and operational readiness of the machine / plant can only be ensured if important spare and wear parts are held in stock.
Please order spare parts using the information contained in the spare parts list. The spare
parts drawings listed in the spare parts list furnish additional information.
Our warranty only covers genuine spare parts supplied by us.
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Please note that parts manufactured by us and non-company products are often subject
to special production and delivery specifications.
1-5
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Blank page
1-6
Technical data
Crusher type:
Gyratory crusher KB 63 - 75
1200 mm ROM
80% < 450 mm
Crushing:
0 - 250 (X) mm
P80 175 mm
Moisture content:
max. 2%
Hardness:
Bulk density:
2.3 t/m
10 kWh/t
approx. 175 mm
approx. 1600 mm
Mantle diameter:
2030 mm
max. 280 mm
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Figure 0
2-1
2.1
2.2
Oil tank:
separate tank
2.3
Blower:
Gasring-compressor, single-stage
G 200 2BH1500-7AC19G with intake filter 2BX2102
Excess pressure:
Electric motor
Voltage:
Capacity P:
Speed n:
Weight:
approx. 36 kg
460 V, 60 Hz
2.2 kW
1800 min-1
200 litres
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2-2
2.4
Drive
See ANNEX 9.2 "Couplings" and Chapter 4.4.9 "Crusher main drive motor and pinion assembly"
750 kW, 60 Hz, 507 min-1
Safety coupling:
MTF 514
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Motor:
2-3
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Blank page
2-4
3.1
Principles
The machine/plant has been manufactured in accordance with the recognised safety
regulations. However, this does not preclude danger to life and limb for the user or others,
nor does it prevent harm to the machine/plant and/or other property.
These safety instructions must be observed by all persons responsible for the transport, installation, commissioning, operation, maintenance as well as the dismantling
and disposal of consumables and process materials. We recommend that the owner
obtains a signed confirmation that the safety instructions have been read and understood by his personnel.
The machine/ plant may only be used in a technically perfect condition in accordance
with its designated use and the instructions set out in the manual, and only by safetyconscious persons who are fully aware of the risks involved in operating the machine/
plant! Any malfunctions, especially those affecting the safety of the machine/plant,
should therefore be rectified immediately.
In addition to the manual, observe and instruct the user in all other generally applicable
legal and other mandatory regulations relevant to accident prevention and environmental protection!
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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!
Never make any modifications, additions or conversions to the machine/ plant which
might affect safety without the supplier's approval! This also applies to the mounting
and adjustment of safety devices and safety valves as well as to welding work on loadbearing elements.
Comply with the prescribed intervals or those specified in the operating instructions for
routine checks and inspections!
For the execution of maintenance work, tools and workshop equipment adapted to the
task on hand are absolutely indispensable.
The personnel must be familiar with the location and operation of fire extinguishers!
3-1
3.2
3.3
Personnel
Personnel entrusted with work on the machine/ plant must have read the manual and in
particular the chapter on safety before beginning work. Reading the Instructions after work
has begun is too late. This applies especially to persons working only occasionally on the
machine/plant, e.g. during setting up or maintenance.
For reasons of security, long hair must be tied back or otherwise secured, garments must
be close-fitting and no jewellery - such as rings - may be worn. Injury may result from being
caught up in the machinery or from rings catching on moving parts.
Any work on and with the machine/plant may only be carried out by reliable personnel.
Statutory minimum age limits must be observed!
Employ only trained or instructed staff and set out clearly the individual responsibilities of
the personnel for operation, set-up, maintenance and repair!
Define the machine operator's responsibilities - also with regard to observing traffic
regulations - giving the operator the authority to refuse to carry out instructions by third
parties which compromise safety!
Work on the electrical system and equipment of the machine/plant may only be carried out
by a skilled electrician or by instructed persons under the supervision and guidance of a
skilled electrician and in accordance with electrical engineering rules and regulations.
11/2013 Rev 0
Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of hydraulic equipment!
3-2
3.4
Noise hazard
Information on the emissions level which is specific to the work station
No permanent work station has been assigned to the plant/machine.
Depending on the material to be processed, noise emissions will occur: these may only
be measured during operation. The user has to ensure the measurement of the sound
power level of all operation positions (e.g. for maintenance and checking, control station)
immediately after commissioning.
INFORMATION
Directive 2003/10/EC of the European Parliament and of the Council dated 6 February 2003 (17th individual directive in terms of Article 16 Paragraph 1 of the
Directive 89/391/EEC).
If other measures fail to prevent from risks due to noise hazards, a suitable and
properly adapted personal ear protection must be made available to the employee
and need be used by the employee.
Personal ear protection must be worn by the personnel if the noise hazard
reaches the threshold value (85 dB (A)).
3.5
11/2013 Rev 0
3-3
3.6
Fire protection
The legal requirements regarding fire protection and fire prevention have to be complied with and supplemented with in-company regulations. The fire-fighting experts of
the insurance companies should also be consulted in this process.
Appoint supervisors who are in charge of all the matters related to fire prevention and
fire fighting and provide them with the knowledge required for this task.
The management staff and the engineers must support them in their task in an advisory
capacity.
The supervisor must check the fire extinguishing equipment at regular intervals, in order
to ensure that the equipment is always ready for use.
Areas which are easily flammable require particular attention in this context!
The persons commissioned with supervision and fire fighting must have attended a first
aid course. First aid stations must be provided.
The fire protection regulations must be posted at different locations in the plant.
The personnel must be informed about the fire protection measures. Any case of fire
must be reported immediately.
The units and the assembly groups which heat up more strongly during operation on
account of the electrical and/or mechanical stress to which they are exposed must be
monitored by the responsible personnel. This applies e.g. to compressors, gear units,
bearings, motors, oil/hydraulic units.
The fire extinguishers must be easily accessible and may not be obstructed by objects.
The personnel must be familiarised with the use of the fire extinguishers to such a
degree that they are capable of fighting fire outbreaks with the appropriate fire extinguishers.
Fire-fighting rules
Use fire-fighting water for burning wood, waste, fabric, jute, paper, belts, etc.
In case of burning liquids (mineral oil, petrol, oil, petroleum, paints, tar, etc.), always
use CO2 extinguishers and powder type fire extinguishers.
In case of burning cables, motors, electric plants, etc. only use powder type fire extinguishers or CO2 extinguishers.
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.
11/2013 Rev 0
3.7
4.1
DANGER
Risk of injury through operating the machine/plant with unauthorised modifications, conversions or spare parts
Imminent danger of death or severe bodily injuries
ThyssenKrupp Resource Technologies explicitly excludes all liability and warranty claims if modifications/conversions are made without the express permission in writing of the manufacturer.
Only operate the machine/plant in its original condition. Any deviations from the
original condition must be reported by the operator to the responsible department.
CAUTION
System damage through use of the machine/plant contrary to its designated
use
Damage to the machine/plant or its environment is possible
The intended use of the machine/plant is regulated by contract. Any other use contrary to its designated use is prohibited. ThyssenKrupp Resource Technologies
cannot be held liable for damage resulting from such misuse. The risk of such misuse lies entirely with the user.
The gyratory crusher must be constantly fed with material to ensure that the
crushing chamber is always at least 80 % full.
The machine/plant must be used exclusively for the intended purpose agreed
upon with the manufacturer.
11/2013 Rev 0
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.
4-1
Frequent idle-running phases lead to uncontrolled movements of the main shaft in the spider head bearing and in the lower bearing bushing. At the same time, continuous re-filling
of the crushing chamber causes fluctuating loads and consequently uneven running under
load.
This impact-type method of operation destabilises the lubricating film between the bearing
components which can cause undesirable abrasion on the bearing positions.
This negative operating mode leads to an uneven wear patter with respect to the crushing
tools / wear parts.
INFORMATION
Prior to use of the machine/plant beyond this scope of application, consult the
after-sales service. Otherwise the warranty will lapse.
4.2
Main components
See Illustration 2
Crusher shells
(1)
Concaves
(2)
Wear parts
(3)
Base plate
(4)
(5)
Dust sealing
(6)
(7)
(8)
Spider bearing
(9)
10
11
12
13
14
15
16
17
18
19
4-2
(10)
(11)
(12)
Speed monitor
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Overpressure-ventilation
on the sub-structure
11/2013 Rev 0
11/2013 Rev 0
Oil circulating lubrication and hydraulic unit (main shaft adju- attached to the steel
stment)
structure
Figure 1
4-3
4.3
Operating principle
See Illustration 2
The material fed into the crusher is crushed between the fixed concaves (2) of the crusher
shells (1) and the wobbling mantle of the main shaft (5) .
The tumbling movement of the mains shaft (5) is driven by the eccentric bushing (7) . This
causes the gap between the concaves and the mantle to vary continuously at the circumference. The material is broken up by crushing and impact effects until it can leave the
crusher through the crushing gap.
The main shaft (5) is radially guided in the upper spider bearing (9) in the spider bushing
and in the lower eccentric bushing (7). Axial support of the main shaft (5) is provided by a
hydraulic cylinder (19) which can be used to adjust the crushing gap by moving the piston
and thus the main shaft (5).
11/2013 Rev 0
A hydraulic unit (for vertical adjustment of the main shaft/setting the crushing gap and protecting against overload) is integrated the unit for the oil circulating lubrication of the eccentric bushing and the axial bearing (= internal lubrication circuit) as well as the eccentric
bushing (= external lubrication circuit). The units are combined for reasons of accessibility
and maintenance but form separate circuits.
4-4
11/2013 Rev 0
Figure 1
4-5
4.4
Assembly groups
4.4.1
11/2013 Rev 0
Figure 2
4-6
11/2013 Rev 0
Figure 3
4-7
11/2013 Rev 0
The bottom flange of the bottom shell is used to mount the bottom shell on the
substructure/foundation.
4-8
11/2013 Rev 0
Figure 1
4-9
4.4.2
11/2013 Rev 0
The step bearing upper part (11) of the axial step bearing is mounted on the bottom front
face of the main shaft.
4 - 10
11/2013 Rev 0
Figure 4
4 - 11
4.4.3
11/2013 Rev 0
Figure 5
4 - 12
11/2013 Rev 0
Figure 6
4 - 13
11/2013 Rev 0
In the event of a failure, the crusher main drive motor can be switched off depending on
the interlocking system.
4 - 14
11/2013 Rev 0
Figure 2
4 - 15
4.4.4
11/2013 Rev 0
The lubricating oil is passed via a duct (6) in the sealing housing and bottom part and is
returned to the tank.
Figure 7
4 - 16
Starting from the compressor (1), the compressed air is passed to the hollow space of the
dust sealing via a hose/pipe system (2), the pressure transducer (3) (adjustable from 70 150 mbar) and the air ducts (4) in the hub of the bottom shell and in the dust sealing
housing.
The compressor is provided with an intake filter (5) and a pressure relief valve (6) and
mounted on a bracket on the steel structure.
In the event of a failure, the crusher main drive motor can be switched off depending on
the interlocking system.
11/2013 Rev 0
After the crusher has been switched off, the blower decelerates with a time delay.
Figure 8
4 - 17
4.4.5
Eccentric bushing
The eccentric bushing is driven by the pinion assembly. It guides the main shaft in the
inner eccentric bushing (4) and generates its wobbling (rotary/oscillating) motion.
The eccentric bushing consists of the eccentric bushing body (1) on which the bevel gear
(2) is mounted by means of a feather key (3) and bolts (7).
The inner eccentric bushing (4) is made of bearing metal and is secured against rotation
by a feather key (5).
The eccentric bushing is lubricated by the oil circulating lubrication internally (between the
inner eccentric bushing and the main shaft), externally (between the eccentric bushing
and the outer eccentric bushing) and on the underside (between the eccentric bushing and
the axial step bearing ring).
The circulating lubrication also supplies the teeth of the bevel gear.
11/2013 Rev 0
The top device for compensating unbalance (6) fixes the inner eccentric bushing in a vertical (axial) direction.
4 - 18
11/2013 Rev 0
Figure 9
4 - 19
4.4.6
11/2013 Rev 0
The sealing cord (7) prevents oil losses (lubrication space - external bearing) and the ingress of pollutants into the interior of the crusher.
Figure 3
4 - 20
4.4.7
11/2013 Rev 0
The boundaries of the bearing components are supplied with lubrication oil by the internal
lubrication oil circuit.
Figure 10
4 - 21
4.4.8
11/2013 Rev 0
The three adjustable pressure relief valves (8) are used to limit the working pressure and
thus serve as an overload protection.
4 - 22
11/2013 Rev 0
Figure 11
4 - 23
4.4.9
max. 85 C
Warning
max. 92 C
Depletion of crusher
The fluid switch (12) monitors the oil level of the pinion assembly housing.
11/2013 Rev 0
Accelerometers (optional) (13) (including evaluation unit) monitor the condition of the roller
bearings of the pinion assembly.
4 - 24
11/2013 Rev 0
Figure 12
(similar illustration)
4 - 25
4.4.10
Filter clogging
Monitoring of lubricating oil flow rate (flow meters for supply and return flow)
Shaft position via distance sensor, see Chapter 4.2 "Main components".
See also ANNEX "9.9 Oil circulating lubrication and hydraulic unit".
Grease lubrication unit for spider bearing
Filling level of reservoir, see Chapter 4.4.3 "Spider bearing with grease lubrication"
Flow function via a pulse counter in the grease lubrication line of the top axle mounting,
see Chapter 4.4.3.
Accelerometer (optional).
11/2013 Rev 0
The speed monitor (1) is arranged on a bracket (2) which is screwed to the flange of the
transmission. Two diametrically opposite sheet metal strips (3) and (4) which function as
cam switches are mounted on the flange of the multiple-disc clutch.
4 - 26
11/2013 Rev 0
Figure 13
4 - 27
4.4.11
11/2013 Rev 0
The separately arranged balance unit (10) is connected to the hydraulic cylinder (2) via
pipes. It consists of a compressed air tank and a compensation cylinder and prevents the
main shaft from lifting off the axial step bearing under particular conditions of operation.
See also Chapter 4.4.8.
4 - 28
11/2013 Rev 0
Figure 14
4 - 29
11/2013 Rev 0
Blank page
4 - 30
5.1
Transport instructions
The machine/plant is transported in component parts or as assembly groups. Make sure
that suitable lifting tackle is used to unload the parts from the transport vehicles and move
them to the storage location.
The machine/plant must be transported with adequate care in order to prevent damage
and not endanger staff. In addition to the following information, the general and local
safety and accident prevention regulations must be observed. Overhead gantries and
mobile cranes or lifting tackle with a sufficient load bearing capacity must be available to
carry out the unloading, transport/loading safely and correctly.
11/2013 Rev 0
The transport and storage symbols on the machine packaging must be heeded.
Keep dry
Caution! Glass!
This way up
Sling here
Centre of gravity
Stacking limitation
Clamp here
Electrostatic sensitive
device
Do not roll
5-1
When transporting the machine by crane, only use suitable loading devices.
When packing the machine, loading devices may only be attached at the marked points.
DANGER
Risk of injury due to the improper transport of the machine/plant
Imminent danger of death or severe bodily injuries
Only transport the machine/plant on the designated slinging devices (lugs) and
slinging points.
The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
Make sure to use proper transportation equipment.
Do not walk under suspended loads.
Secure moveable components.
CAUTION
System damage from improper transport of the machine/plant
Damage to the machine/plant or its environment is possible
Do not attach any additional slinging points to the machine through welding,
torching or drilling (notching effects and the corresponding risk of crack formation).
Do not push together the side walls or the attachment parts of the machine by
pulling lifting gear at an angle!
11/2013 Rev 0
If transport securing devices have been furnished do not remove them until
installation has been completed.
5-2
CAUTION
System damage from improper storage/assembly of the machine/plant
Damage to the machine/plant or its environment is possible
If the machine/plant is to be stored, it has to be left in the delivery condition. The
manufacturer is not liable for damage caused by improper repeated assembly of
the machine/plant.
11/2013 Rev 0
Check all components for transport damage after delivery to the site.
5-3
5.2
WARNING
Risk of injury through components that are improperly secured during
installation
Death or severe bodily injuries are possible
Make sure that moveable components are properly secured during installation
5.2.1
Lifting gear
Usually, cranes and lifting gear is used for transporting heavy assembly groups and components. Slinging equipment such as ropes and hooks are critical elements between the
load and lifting equipment.
Safe lifting requires adequately dimensioned and suitably designed lifting gear and slinging equipment to be used, as well as correct attachment and fixing to the load.
The weight of assembly groups and components is specified in the spare parts catalogue
/ in the Operating Instructions, so that equipment such as e. g. hoisting devices, winches,
cranes, lifting chains can be selected accordingly.
Check hydraulic winches for proper function before use. Only use winches with adjustment ring. This allows loads to be supported mechanically and prevents their lowering.
INFORMATION
11/2013 Rev 0
Before lifting heavy loads, attach a load cell to check the load.
5-4
5.2.2
Lifting
Determine the size and shape of the load; two criteria which determine the following:
the type of load securing, e. g. with slings, baskets or slings with special fixtures,
the slinging equipment / load securing fixtures, e. g. lifting rope, lifting chain, screw
eyes, yokes (see following sections),
the load angle of the slinging equipment.
Determine the thickness of the slinging equipment to be used. Do not exceed the permissible load bearing capacity of the slinging equipment.
If any of the following points are unclear, consult the assembly supervisor responsible:
correct attachment method,
selected thickness of slinging equipment,
type of slinging equipment.
Check the slinging equipment for damage / faults. Make sure that any faulty slinging
equipment is discarded immediately.
Do not overload slinging equipment and protect it against sharp corners and edges of
the load e. g. through edge/corner protection made of sacking or metal, boards etc.
Protect high-gloss/finished surfaces of the load against damage caused by the slinging
equipment. Protective material that is intended to prevent the load/lifting means slipping must be attached in such a way that it cannot slip if the slinging equipment becomes loose.
11/2013 Rev 0
5-5
Give the crane driver fixed/agreed clear signals for moving the load.
Secure unused rope/chain ends, e. g. by hooking them to the main ring/collecting them
in the shackle.
Make sure that the slinging equipment cannot damage the load (and vice versa).
After the weight of the load has been picked up completely by the lifting tackle and
the load has been lifted a little:
Remove slinging equipment from the load and check both for damage.
11/2013 Rev 0
5-6
5.2.3
Lifting ropes
The number of sling points is equal to the number of rope strands connecting the crane
hook with the load. A load angle i. e. an angle between the horizontal surface of the load
and the lifting ropes is formed by several strands. The smaller the load angle, the smaller
the permissible load bearing capacity of the lifting ropes and thus the effectiveness.
Effectiveness of the load angle
Effectiveness
Load angle
50,0
(500 kg)
45
70,7
(707 kg)
60
86,6
(866 kg)
90
100,0
(1000 kg)
11/2013 Rev 0
30
5-7
Protect lifting ropes from the influences of the weather, solvents, high temperatures
and chemicals.
Avoid knots forming in wire ropes. In the event of a knot, do not use the rope again.
Protect ropes against sharp-edged corners by enlarging the corner radius. This can be
by means of metallic corner protection devices or blocks. Sacking and wooden boards
can also be used.
The correct procedure for securing lifting ropes to the hook is as follows:
Secure each individual strand on the hook to prevent hitching at the hook.
11/2013 Rev 0
Never use one single slinging rope strand since this could lead to the load rotating.
The wire rope could be untwisted and thus the splice pulled out.
5-8
Never wind the wire rope completely around the crane hook (i. e. by 360 degrees). The
low bending radius would damage the rope.
When securing loads by winding the lifting ropes around the load, use shackles (1).
11/2013 Rev 0
5-9
5.2.4
11/2013 Rev 0
Once the rope has been put into operation and is tensioned, tighten the clamping nuts
again. Check the clamping nuts regularly and tighten if necessary. This compensates rope
expansion and the related reduction of rope radius.
5 - 10
Rope diameter
Required minimum
number of clips
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
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
11/2013 Rev 0
Inches
5 - 11
5.2.5
Lifting chains
Use:
Lifting chains are made of alloyed steel and are sturdier and more flexible than lifting
ropes, but they are not as resistant to impact loads as ropes are. The thickness of a chain
is determined in relation to the diameter (1) of a chain link.
Avoid knots forming in lifting chains. They weaken the chain strand and can lead to
deformation or other damage to the chain links.
Shorten lifting chains by hooking them back into the chain or into the main line with the
aid of a gripper hook. Never shorten a chain by twisting, knotting or bolting.
Protect lifting chains against sharp corners and edges that could deform the chain
links. Use suitable flexible boards or metallic corner protection devices.
11/2013 Rev 0
5 - 12
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.
5.2.6
If all the strands of a lifting chain can be hooked back into the main line, the permissible
load bearing capacity of the whole sling can be increased by 50 %.
Hook
The load bearing capacity is usually stamped into the hook.
11/2013 Rev 0
5.2.7
If possible, use a hook with spring-loaded snap-in locking devices. If such hooks are
not available, the hook has to be secured temporarily as shown in the diagram.
For vertical lifting operation, use simple screw-type eyes (without shoulder).
Screw-type eyes with shoulder are used when loads are to be lifted at certain angles
(e. g. lifting operation with several lifting ropes).
2-492-20980 (POS 01)
5 - 13
The permissible load bearing capacity that has already been reduced by the load angle,
is reduced even further by the use of screw-type eyes.
A screw-type eye with shoulder that is used e. g. at an angle of 45, can only used for up
to a load of about 10 % of the permissible load for vertical lifting operation.
Permissible loads for eye bolts with shoulders:
Shank diameter
Tension at 60 to
the shoulder level
Tension at 45 to
the shoulder level
Tension at 90 or
loose side pull
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
5 - 14
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.
11/2013 Rev 0
Eyes must be screwed fully in, this ensures the shaft cannot be bent.
Only use screw-type eyes the load bearing capacity of which is suitable for the load,
i. e. shanks with threads that fit exactly in standard boring holes.
Use hardened washers to make sure the edges of the screw-type eye are a tight fit.
The washers must not be thicker than two threads.
11/2013 Rev 0
5 - 15
5.2.8
Shackles
DANGER
Danger caused through the use of improper slinging equipment
Imminent danger of death or severe bodily injuries
Never replace shackle bolts with standard bolts. Danger of breaking!
Shackles are closed safety devices that cannot be hooked out. Their size is determined in
relation to the diameter of the main part (1) and not in relation to the diameter of the bolt.
A distinction is made between anchor load shackles (on the left of the diagram) and chain
load shackles (on the right).
Do not expose the main part of the shackle to side tensile loads.
The permissible load for anchor load and chain load shackles as well as for screw-type
or socket pin is always the same.
If shackles are used at load angles other than 90, the permissible load bearing capacity is reduced; see table:
11/2013 Rev 0
5 - 16
Diameter
Two shackles 60
Two shackles 45
Two shackles 30
mm
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
Americ.
tonnes
tonnes
1/4
6,4
1/3
0,3
3/4
0,7
1/2
0,5
1/3
0,3
5/16
7,9
1/2
0,5
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
11/2013 Rev 0
Inches
5 - 17
Protect lifting ropes against sharp edges/corners. Use materials to enlarge the radius,
e. g. metallic corner protection devices (left and right), belts, wooden blocks, sacking,
steel bushings/sleeves. This protects finished load surfaces from the wire rope too.
Protect lifting chains against sharp edges/corners. Use materials to enlarge the radius,
e. g. metallic corner protection devices (left and right), belts, wooden blocks, sacking,
steel bushings/sleeves. This protects finished load surfaces from the chain too.
11/2013 Rev 0
5.2.9
5 - 18
Make sure that the base has a sturdy and level surface and can bear the whole weight
of the load. Only use hard wood with (approx.) square cross-section as a base.
Protect finished surfaces by cushioning the base, e. g. with sacking, pressboard, belts.
Use wedges to prevent the load rolling away or moving (e. g. handles, round forged
parts and rings). When using wedges be careful with your hands and make sure they
do not get crushed if the load moves.
When using several supports as substructures, only use supports of the same height.
Place supports under the load so that they are stable and level. Do not use supports
that have rounded edges, are fragile or damaged.
Use the supports to create a cavity under the load, enabling the slinging equipment to
be attached and removed easily.
11/2013 Rev 0
5.2.10
5 - 19
5.3
Storage requirements
5.3.1
General requirements
CAUTION
System damage from improper storage of the machine/plant
Damage to the machine/plant or its environment is possible
All the delivered machine and plant components must be stored on suitable supports to keep them dry. The storage place must be free from vibration.
The stored machine and plant components must be protected from water, sea
water, aggressive vapour or gas and increased ozone concentration.
If the storage time is exceeded by a lengthy period (i.e. more than 2 months), all the bearings of the machine and plant components must be completely filled with suitable grease.
The shafts in the bearings must be turned several times once a month. They must be subsequently topped up with grease. The bearings and housings are thereby protected from
condensation water and rust. After storage, i.e. before the plant component is commissioned, the grease must be removed and the bearings cleaned and regreased (approx. 1/3
of the volume of bearing and housing).
All the machine and plant components must be stored at temperatures between + 5 C
and + 45 C. Electrical equipment is to be stored dry and frost-free, temperatures between
minimum + 5 C and maximum + 45 C.
All unpainted surfaces must be provided with suitable protection against corrosion.
The storage location must be dry. If equipment is stored in a shipping container, a "desiccant material" must be placed in the container prior to storage. The equipment must be
covered and good ventilation provided in the storage place.
11/2013 Rev 0
The packing climate must be protected from environmental influences, in order to maintain
rust prevention and the effectiveness of siccatives.
5 - 20
The storage area must be clean and free from dust and other contaminants.
Equipment must be stored in the original crates or on the original transport skids provided
by ThyssenKrupp Resource Technologies. Equipment on transport skids must be loosely
covered with tarpaulins, in order to keep it clean and to allow the air to circulate.
Stored equipment may not be exposed to direct sunlight.
Plant components made of plastic or rubber may not be exposed to direct sunlight. The
storage temperature must be + 5 C minimum and + 45 C maximum. It must be protected
from contamination by grease or oil. Rubber parts, such as the belts of troughed belt conveyors and the filter belts of vacuum belt filters, are normally delivered on coils. The coils
must be stored vertically and not horizontally. Furthermore, the coils may not be stored
directly on the floor. They must be stored vertically on a firm base surface. Pallets or similar must be used for moisture protection. The coils may not be stacked.
The stored equipment must be secured against damage and loss. Secured storage areas
may only be accessed by authorised personnel.
Insurance with sufficient coverage for damage caused by third parties, transport and
weather damage (lightning, flooding, and storms) and theft must be concluded for the entire handling/storage period until the machine/plant has been accepted.
5.3.2
5.3.2.1
"Open-air" storage
11/2013 Rev 0
Please note that roofed storage (Chapter 5.3.2.2 "Storage in "covered areas"") is to be
preferred, however large-volume, painted plant components showing a small proportion
of mechanically machined surface compared to the volume as well as wear-out parts,
where surface corrosion does not affect the function, could be stored in the open air (provided that there is no indication to the contrary on the packing, as e.g. protect from heat,
protect from moisture or similar.) See Chapter 5.1 "Transport instructions".
5 - 21
11/2013 Rev 0
Markings on plant components must be readable without the part having to be moved. If
water accumulates on a plant component through visible markings, the component must
be provided with new visible markings at suitable points.
5 - 22
5.3.2.2
11/2013 Rev 0
Items must always be stored on a support such as timber planks, pallets, or similar, preferably on a level, drained and gravelled base surface. Contact with surface water and the
ground must be avoided.
5 - 23
5.3.2.3
5.3.2.4
11/2013 Rev 0
5 - 24
5.3.3
Special requirements
5.3.3.1
Electric motors
Motors must be stored in the original crates if they are not mounted on the equipment.
The storage area must be free of vibration.
Bearings:
Balls and rollers (regreasable roller bearings). Bearings going into extended storage
must be completely greased beforehand. Motor shafts must be manually rotated once
a month and bearing grease must be topped up. Rotate the shaft by hand before putting it into service.
Balls (roller bearings, regreasing not possible). No other provisions are necessary for
the bearings.
All drain openings must be operable and the drain plugs removed during storage. The
motors must be stored so that the drain opening is at the lowest point. All breathers and
automatic drains must be operable via T-safety screws, so that breathing can take place
at a different location from the bearing seats.
Windings must be measured when they are put into storage. When they are removed from
storage, the resistance reading may not be more than 50 % below the original value. Any
values below this value necessitate electrical or mechanical drying. Where a large quantity
of motors is stored, an inspection or sampling should be made by removing the end brakkets and visually inspecting for the presence of water in the grease or rust on the bearing.
If present, replace the bearings and relubricate.
All external parts and motors subjected to corrosion to be protected by corrosive resistant
coating.
11/2013 Rev 0
Where motors are not stored in the original containers, but are removed and mounted on
other pieces of machinery, the mounting must be such that the drains and breathers are
fully operable. In this respect, the drains must be located at the lowest point of the motor
and the drain plugs removed, so that condensation water can drain out by itself. All other
storage conditions apply, including rotation of the motor shafts. If such conditions cannot
be complied with, the equipment must be treated as if it were mounted in its normal position and all protective devices such as heaters, breathers and drains were fully operable.
5 - 25
5.3.3.2
Gear unit
Oil and grease lubrication:
The oil recommended by the manufacturer must be used for the oil change.
All gear openings such as flanges for oil lubrication, openings for holding thermometers
and pressure and flow sensors must be checked for proper sealing. Replace the sealing
if necessary. Breathing or venting: Pressure compensation between the pressure inside
the gear unit and the atmosphere must be provided. The inside of the gear must be protected against humidity and/or nesting insects or birds.
5.3.3.3
Gear motors
If gear motors, e.g. SEW, are placed in storage, a volatile corrosion inhibitor (VCI) is added to the lubricant of these gear units.
Some of the gear units are delivered with a higher oil level for long-term storage.
The storage period is a maximum of 3 years in compliance with the documentation supplied by the manufacturer.
CAUTION
Gear damage from improper storage of the machine/plant
Damage to the machine/plant or its environment is possible
Gear units must be kept sealed until commissioning, in order to prevent volatilisation of the VCI corrosion inhibitor.
11/2013 Rev 0
Before these gear motors are commissioned, the operating oil level must be
restored using dipstick/oil-inspection glass/oil-level plug.
5 - 26
5.3.3.4
11/2013 Rev 0
Control valves:
The normal storage conditions are valid for all products. "Normal" is defined as conditions
free from heat or cold (+ 5 C to + 45 C storage temperature), and where the products
are kept dry and protected from dust. Other products may not be stacked on them.
5 - 27
5.3.3.5
11/2013 Rev 0
VCI additives can be used for steel, iron, chrome, cast iron and aluminium. There are also
special VCI additives for copper and copper alloys and for both materials. The VCI method
is not applicable for the conservation of zinc, tin, cadmium, magnesium, lead and alloys of
these metals.
5 - 28
5.4
5.4.1
General
The reliable functioning of oil hydraulic systems is primarily dependent on careful maintenance. The service life of the hydraulic components is generally longer than that of mechanical components (e.g. ball bearings).
The following general instructions may were appropriate be replaced by special instructions.
5.4.2
Installation
At assembly particular attention is to be paid to utmost cleanliness.
5.4.3
Pipes
The pipes must be sawn off square. Cutting the pipes with cutting rollers is not permissible. Special instructions apply to the welding of pipes.
During all welding operations, it must be ensured that the welding current does not flow
through any hydraulic devices, otherwise internal components may be welded together.
The pipes must be cleaned of dirt before mounting.
The pipes must be laid in such a way that they are unstressed.
Sealants such as hemp and putty are not permitted.
11/2013 Rev 0
Pump suction lines must be carefully sealed against the ingress of air. Leak oil lines are
to be laid in a manner that the pumps and motor housing always remain filled with oil. They
must not have any connection to pressure lines and drain lines.
5 - 29
5.4.4
WARNING
Risk of injury through leakage or fractures of the hose lines and leaking
pressure medium
Death or severe bodily injuries are possible
Stop the machine/ plant using the emergency-stop switch.
Shield the machine/ plant in such a way that the pressure medium cannot injury
any persons or cause a fire hazard.
CAUTION
Plant damage through fluttering hose lines during pressure build-up
Damage to the machine/plant or its environment is possible
Fix the hose in place
The hydraulic hose lines must be mounted in such a way that
the length required to prevent kinking and tensile load of the hose is provided during
operation;
twisting of the hose caused by faulty installation or occurring during operation (e.g.
through the blocking of a rotary joint or unfavourable movements of the connecting
points) is reduced to a minimum;
it is properly fixed in place should the weight of the hose line potentially cause an
impermissible loading.
11/2013 Rev 0
5 - 30
5.4.5
Commission
Before filling with hydraulic fluid, check the tank and pipes once again for cleanliness. The
test must be made directly prior to filling.
Faulty pipework or incorrect wiring is generally not noticed until the plant is being commissioned and the required functions are not available.
Any modification at this stage normally proves to be extremely difficult.
Careful checking of the pipings and the wiring on basis of the circuit diagram is therefore
urgently recommended before filling the pressure fluid into the tank.
Solenoid-operated valves and pressure switches must be checked for the type of current
and voltage.
Pumps and the associated electric motors must be aligned with each other. Any misalignment between the motor and the pump may cause premature destruction of the pump.
Pumps and their motors must not be distorted by any incorrect pipe connection.
Unless they have been delivered ready for operation, accumulators must be properly provided with the specified nitrogen charge before they are installed in the plant. It is advisable to mark the gas precharge pressure on the accumulator (e.g. with a sticker) and also in
the circuit diagram, so that an easy comparative check can subsequently be made if required.
5.4.6
Hydraulic fluid
HLP oils or HVLP oils selected to meet the respective climatic conditions or ambient temperatures are to be used.
The hydraulic oil must always be filtered when being filled.
5.4.7
5.4.8
Pressure settings
11/2013 Rev 0
The pressure setting of the limit valves must initially be kept low at start-up. Type-tested
pressure relief valves for hydraulic accumulator systems which do not permit any variation
because of their fixed-value adjustment are an exception.
5 - 31
5.4.9
Start-up
DANGER
Risk of injury through faults in the control system or operating errors
Imminent danger of death or severe bodily injuries
Ensure that no unauthorised persons are located in the danger zone
Wherever practical, variable-delivery pumps and motors should be set to a small swivelling angle, in order to facilitate the initial priming.
The electric motors can now be switched on for a short time (approx. 5 to 10 sec.). Check
the direction of rotation in the process. At the same time it need be checked whether couplings or other connection parts have become loose.
Before the operating pressure setting can gradually be increased, check whether the
pump discharges quietly and steadily. Any leaks must be remedied immediately. The plant
must be vented when it is operated at a low-pressure setting. The fluid level in the tank
must be monitored and fluid (of the same type) must be added if necessary.
After the operating pressure has been reached and the functional test has been successfully passed, pressure switches, level switches, thermostats, etc. must be adjusted.
5.4.10
Cylinders
Cylinders must be mounted in such a way that they are unstressed and above all free of
transverse forces, otherwise malfunctions and premature wear may occur.
5.4.11
Maintenance
The frequency of maintenance cannot be specified. It is a pure matter of experience. Only
the regularity with which it is performed is important. The following points must be regularly
checked at intervals recommended by the manufacturer or gained from experience.
5.4.12
Fluid level
11/2013 Rev 0
The fluid level must be checked constantly during the commissioning period; after commissioning it must be initially checked daily and then weekly.
5 - 32
5.4.13
Filters
During the commissioning period, the filters must be checked at intervals of 2 to 3 hours
and must be exchanged if necessary. In the initial 150 - 250 operating hours, the filters
must be serviced considerably more frequently than afterwards. If visual or electrical clogging indicators are provided, the filter elements must be exchanged according to these
indicators. Actuation of the clogging indicators at cold start is insignificant and is terminated after a short time if the filter elements are clean.
Breathers must be regularly checked and the filter element exchanged if necessary.
5.4.14
Oil temperature
The operating temperature must not only be measured in the oil tank but also at the bearing points of the pumps, amongst other places. A temperature rise indicates wear. (Growing friction and leakage by converting hydraulic energy into heat).
5.4.15
Oil change
The frequency of the system fluid change depends on several operating factors and is
governed by the degree of ageing and pollution.
Regular laboratory tests of the hydraulic oil must be carried out, especially in case of large
oil quantities of oil.
5.4.16
Accumulators
If necessary, the precharge pressure of the nitrogen side of accumulators must be chekked at regular intervals. When doing so, the oil side of the accumulator must be absolutely
unpressurised.
5.4.17
Alignment
At adequate intervals we recommend to check the correct alignment of the energy converters (pumps, motors, cylinders etc.) at operating temperature and, as far as possible,
under operating pressure. This includes erection bolts, screws, connections, pipes, couplings, etc.
5.4.18
Pipework
11/2013 Rev 0
The hydraulic pipe system must be checked for leaks at regular intervals. Bolted joints
must be retightened when the plant is unpressurised.
5.4.19
Cooler
The fins of oil/air coolers must be cleaned at regular intervals depending on the environmental conditions.
Oil/water coolers must be descaled from time to time.
The frequency depends on the hardness of the cooling water used.
2-492-20980 (POS 01)
5 - 33
5.4.20
5.4.21
2 years
6 years
11/2013 Rev 0
5 - 34
5.5
Installation planning
When planning the installation, please note the following:
Please refer to the relevant foundation and installation drawings for the main dimensions of the machine/plant and the associated secondary units.
See ANNEX 9.1 "Drawings".
Provide additional ladders, walkways, platforms and safety railings for maintenance
work and indicate the permissible traffic loads.
Provide sufficient space to accommodate the periphery equipment as well as to
arrange the feeding units and conveyors to unload the material to be crushed.
Provide suitable lifting gear for the installation and for the exchange of spare and wear
parts. It should be possible to position the lifting tackle/load hook vertically on top of the
machine/plant.
Comply with the specified loading values for the design of foundations and the calculation of the girder/platform structures.
The movement of the machine/plant generates horizontal and vertical forces which
must be absorbed by suitable shear braces.
Ensure that the machine is accessible for cleaning.
Initiate measures against dangerous environmental influences, e.g. dangerous dusts,
uncontrolled oil leaks, noise.
Integrate the machine/plant in the existing/planned control system, including interlokking system, protective and monitoring devices, e.g. emergency stop switches, local
switches, speed monitors, filling level monitors. Integrate optical and acoustic starting
alarms in the control system.
If the conditions at the place of installation vary from those in the installation drawing, please consult ThyssenKrupp Resource Technologies.
INFORMATION
The construction contractor is responsible for the correct dimensioning of foundations, steel platforms, load-bearing ceilings and their supports as well as for the
execution of the construction work and compliance with the official regulations,
even if an erecting engineer of ThyssenKrupp Resource Technologies erects the
machine/plant.
Align the machine / plant with a level.
11/2013 Rev 0
For installation on a concrete foundation, grout the foundation bolts and the base
frame by concrete mortar 1:2 (1 portion cement; 2 portions sand) after alignment.
Prior to this, carefully clean the surface of the foundation and saturate it with
water.
5 - 35
5.6
WARNING
The use of untrained personnel or equipment that does not comply with
safety standards poses additional danger
Death or severe bodily injuries are possible
The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
When carrying out overbelt assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms. Never use machine
parts as a climbing aid! Wear fall protection when carrying out maintenance work
at a higher level.
WARNING
Risk of injury through components that are improperly secured during
installation
Death or severe bodily injuries are possible
Make sure that moveable components are properly secured during installation.
WARNING
Danger from working on electrical systems without proper technical knowledge
Work on the electrical systems or equipment may only be carried out by a skilled
electrician or by specially trained personnel under the supervision of an electrician and in compliance with the applicable regulations required for electricians.
5 - 36
11/2013 Rev 0
INFORMATION
The manufacturer accepts no liability for damage resulting from incorrect installation of the machine!
A careful selection of the tools and appliances used and the assembly personnel
employed is important for the correct execution of the assembly work.
It is recommendable to have the assembly work supervised from start to finish by
assembly specialists from ThyssenKrupp Resource Technologies.
11/2013 Rev 0
Our warranty is based on the assumption that an assembly specialist from ThyssenKrupp Resource Technologies will carry out the assembly and assembly
inspection.
5 - 37
5.7
WARNING
Risk of injury through improper assembly and transport
Death or severe bodily injuries are possible
Make sure that moveable components are secured, also during installation
Use proper transportation equipment
Do not walk under suspended loads
Fasten and lift components properly
Only transport the machine/plant on the designated slinging devices (lugs) and
slinging points.
WARNING
Risk of injury through assembly work at a higher level
Death or severe bodily injuries are possible
When carrying out overbelt assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms.
Never use machine parts as a climbing aid!
Wear fall protection when carrying out maintenance work at a higher level.
WARNING
Risk of injury through work on electrical systems
Work on electrical systems or equipment may only be carried out by a skilled electrician or by specially instructed personnel under the control and supervision of a
skilled electrician and in accordance with the applicable electrical engineering
rules.
5 - 38
11/2013 Rev 0
CAUTION
System damage through improperly executed welding work
Damage to the machine/plant or its environment is possible
Always take note of the pre-heating temperature of all components to be welded
and tack-welded. The pre-heating temperatures specified for welding work to be
performed on the individual materials can be found in the respective assembly
drawings in ANNEX 9.1.
Never conduct welding current through slide or roller bearings or other moveable
connections or measuring equipment.
Carry out welding work on individual machine components prior to their installation.
INFORMATION
The manufacturer accepts no liability for damage resulting from incorrect installation of the machine!
A careful selection of the tools and appliances used and the assembly personnel
employed is important for the correct execution of the assembly work.
It is recommendable to have the assembly work supervised from start to finish by
assembly specialists from ThyssenKrupp Resource Technologies.
Our warranty is based on the assumption that an assembly specialist from ThyssenKrupp Resource Technologies will carry out the assembly and assembly
inspection.
11/2013 Rev 0
The respective layout plan and assembly drawings must be carefully studied, see
ANNEX 9.1 "Drawings". All guidelines and notes must be observed.
5 - 39
5.8
Installation
See ANNEX 9.1 "Drawings"
INFORMATION
Tightening torques for all relevant bolts, see Chapter 5.10 and Chapter 7.5 "Screw connections".
5.8.1
Pre-assembly
The gyratory crusher is delivered in sub-assemblies and component parts.
The assembly groups and individual components can be assembled and adapted to the
relevant crane capacities at the place of installation.
Suspension points and drawings, see drawings in ANNEX 9.1.
5.8.2
Weights:
INFORMATION
5 - 40
approx. 52.000 kg
Lower shell:
approx. 26.600 kg
Upper shell:
approx. 46.500 kg
approx. 38.500 kg
approx. 49.780 kg
Hydraulic cylinder:
10000 kg
1800 kg
2000 kg
1150 kg
550 kg
2600 kg
Drive:
11/2013 Rev 0
Since casting parts have higher manufacturing tolerances, their weight may deviate by +/- 15% from the specified value.
10800 kg
185 kg
Protective nut:
131 kg
385 kg
approx. 7.600 kg
Spider cap:
4670 kg
652 kg
approx. 3.400 kg
approx. 9.000 kg
approx. 13.500 kg
11/2013 Rev 0
Mantle:
5 - 41
5.8.3
Bottom shell
Also see drawings in the ANNEX 9.1
Install, align, tack-weld and weld liner plates (5) on to the bottom shell. The instructions
provided in the drawing 4609235 in ANNEX 9.1 must be followed.
Align, tack-weld and weld the liner plates (6) on to the conical part of the hub. The
instructions provided in the drawing 4609235 in ANNEX 9.1 must be followed.
Place wearing caps (7) on the arms of the bottom shell and tack-weld.
INFORMATION
Align the protective cap (8) with the through bore for mounting the base plate and weld
oil-tight.
Check welded disk (9) in the bore (over-pressure ventilation) for oil-tightness.
CAUTION
System damage from improper tightening of screws
Damage to the machine/plant or its environment is possible
Take the clearance of bolts in the through holes into account!
Mark the position of the retaining ring in relation to the hub for subsequent assembly
and disassembly work.
Lower the outer eccentric bushing (11) into the hub and turn it until the bottom recesses
of the outer eccentric bushing rest on the retaining ring (10).
Jack up the bottom shell (1) in such a way that the eccentric bushing (2), the base plate
(3) and the hydraulic cylinder (4) can be mounted from below.
11/2013 Rev 0
5 - 42
11/2013 Rev 0
Figure 18
5 - 43
5.8.4
Place the spacer plate (2) (1, 2, 3 and 5 mm - to set the backlash of the gears of the
bevel pinion and bevel gear) onto the bottom plate.
Insert cylindrical pin (3) and position the axial bearing ring (4).
Thoroughly oil all the running surfaces of the axial step bearing ring (4), the outer
eccentric bushing in the bottom shell and the eccentric bushing.
Place the complete eccentric bushing on the axial step bearing ring (4) of the base
plate (1).
Fix the bottom shell and carefully allow the outer eccentric bushing to slide on to the
eccentric bushing, then continue lowering to the base plate.
Ensure that the sealing cord (6) is not damaged when lowering into the bottom seat.
11/2013 Rev 0
5 - 44
11/2013 Rev 0
Figure 19
5 - 45
5.8.5
Transmission
See drawing 4521963 Sheets 1 + 2 in ANNEX 9.1
Clean and slightly oil the contact surfaces of the pinion assembly tunnel/pinion assembly.
Insert the complete pinion assembly (1) with sealing cord (2) in the pinion assembly
tunnel (3) of the bottom shell (4).
Arrange disks (5) (5 mm thickness; for correct backlash) between the pinion assembly
flange and tunnel and screw the pinion assembly to the bottom shell.
INFORMATION
11/2013 Rev 0
The final check of the torsional backlash can be made after the hydraulic cylinder
has been installed and the main shaft inserted.
5 - 46
11/2013 Rev 0
Figure 20
5 - 47
Warning
Depletion of crusher
11/2013 Rev 0
5 - 48
11/2013 Rev 0
Figure 20
5 - 49
5.8.6
Position hydraulic cylinder on the scissors lift of the maintenance car and secure in
place.
Insert sealing cord (1) in the cylinder flange of hydraulic cylinder (2).
Place oil ring (3) on the piston of the hydraulic cylinder and bolt on.
Place the sliding ring (5) and the lower part (6) of the step bearing on the piston.
Position the hydraulic cylinder with the maintenance car below the hub of the bottom
shell.
For the operation of the maintenance car see separate documentation.
WARNING
Danger of crushing due to maintenance car moving
Death or severe bodily injuries are possible
Make sure no unauthorised persons are near the maintenance car.
Leave the area of danger!
With the maintenance car at a standstill, raise the hydraulic cylinder using the scissors
lift.
Pay attention to the correct position of the oil connections. Do not damage the sealing
cord (1).
Mount the hydraulic cylinder on the bottom shell.
INFORMATION
11/2013 Rev 0
The final check of the torsional backlash can be made after the hydraulic cylinder
has been installed and the main shaft inserted.
5 - 50
11/2013 Rev 0
Figure 21
5 - 51
5.8.7
Insert O-ring (1) in the bottom shell to seal the air duct.
INFORMATION
Use additional sealing agent to enhance the flange sealing effect, e.g. Hylomar.
Attach the seal housing (3) to lifting gear, lower to the bottom shell and align the oil and
air ducts with each other.
Place the seal housing on the hub of the bottom shell and bolt on.
Mount the air (6) and oil lines (7) in the bottom shell, so that they are oil- and air-tight.
During the further assembly process, seal the lines with caps to prevent dust from entering. Further important assembly instructions provided in drawing 4609197 in
ANNEX 9.1 must be followed.
Pay attention to the clearance between the housing (1) and the bearing bush (8), follow
the instructions in drawing 4350716 in ANNEX 9.1.
11/2013 Rev 0
5 - 52
11/2013 Rev 0
Figure 22
5 - 53
5.8.8
Attach and connect the lower shell to the prepared bottom shell.
See Chapter 5.9.
Place the upper shell on the lower shell and connect them.
Longitudinally align the receiving pockets for the spider in the direction of loading (pay
attention to the position of the grease lubrication connection for the spider bearing).
Tightening torques of bolts see Chapter 5.10.
Clean and remove the grease from the contact surfaces of the shells and concaves.
When back-filling synthetic resin and cement-bonded Betec sealing compound, do not
apply separating agent to the concaves and the internal surfaces of the crusher shells.
For preparation and processing of the sealing compound see ANNEX 9.4.
Weld round steel bars (2; spacer bars for horizontal joint) to the lower concaves (3).
Put the lower row of concaves (3) into the lifting gear using the transport lugs, insert
and distribute evenly across the circumference. Comply with the vertical distances.
Check that all bearing points of each concave are close-fitting. If necessary, insert
shims.
INFORMATION
11/2013 Rev 0
5 - 54
11/2013 Rev 0
Figure 23
5 - 55
Use assembly rings for securing and as assembly aids where necessary.
Drive in wooden wedges (10) between the concaves and the auxiliary assembly ring
(14).
Figure 24
5 - 56
11/2013 Rev 0
CAUTION
Seal all horizontal and vertical joints of the concaves (3, 8, 9, 5) with hemp ropes (4) or
plaster of Paris.
Backfill the row of concaves (3) by inserting synthetic resin sealing compound(7) in the
openings provided for each concave. Ensure that all the concaves are backfilled completely. See ANNEX 9.4.
Put the next rows of concaves (8, 9, 5) into the lifting gear using the transport lugs, centre and align them. Pay attention to the vertical joints.
Weld the round steel bars (2) to the upper sides of the concaves (8,9) beforehand.
Possibility (see Figure 24): Insert the next auxiliary assembly rings (11) and secure the
concaves with wooden wedges (12).
11/2013 Rev 0
Figure 25
5 - 57
Backfill each row of concaves (8, 9, 5) with synthetic resin sealing compound (7).
After hardening, remove the transport lugs, sealants, wooden wedges and auxiliary
assembly rings.
11/2013 Rev 0
Figure 25
5 - 58
5.8.9
Insert liner plates (1) on the transport lugs (2) into the upper shell, align and bolt into
place. Tightening torques of bolts see Chapter 5.10.
Figure 26
INFORMATION
11/2013 Rev 0
5 - 59
5.8.10
Spider bearing
See Figure 27 and drawing 4609216 in ANNEX 9.1
Clean all the contact surfaces, prepare the conical spider bushing (1a) and wear insert
(1b) for installation.
INFORMATION
The spider bushing must slide into the seat of the spider without force.
Do not press in or cool the bushing under any circumstance: rework the spider
bushing if necessary.
Pre-mount the sealing ring (2) and radial seals for the shaft (3) and fix the plate in place
using bolts (5).
Lay the leather packing in a warm oil bath before inserting it.
Pre-mount the leather packing (4).
To fit the wear insert (1b) screw the eye bolts into the threaded holes (14) of the wear
insert.
To fit the wear spider bushing (1a) screw the eye bolts into the threaded holes (13) of
the spider bushing.
Follow the assembly instructions for calculating the required washer thickness (6) in drawing no. 4609216 in ANNEX 9.1 "Drawings".
Screw bolts (8) with washers (9) into the holes (7) and tighten them.
Unscrew the eye bolts from the threaded holes (13) of the spider bushing (1a).
Install filling level sensor (11) with bracket and route the cables through the cable duct,
so that they are oil-tight.
The two holes (12) must be securely sealed with sealing screws (screw plugs and seals).
These screw plugs must be removed immediately before disassembling the spider bushing (1a). Two oil pumps (provided by the customer) must then be attached to both R 1/
4" threaded connections. Applying an oil film between the surfaces of the spider bushing
and the spider with suitable overpressure will facilitate the subsequent disassembly of the
spider bushing. After having disassembled the rolling contact bush (1a), securely lock the
cleaned R 1/4 threaded connections in the spider by the cleaned lock screws with the appropriate seals.
5 - 60
2 pieces
2 pieces
11/2013 Rev 0
11/2013 Rev 0
Figure 27
5 - 61
5.8.11
Main shaft
See Figure 28 and drawing 4609199 in ANNEX 9.1
INFORMATION
The stop plates (10) are welded to the mantle. Remove after fitting.
Bolt protective nut (8) to the shaft and secure using Loctite 277.
Place the mantle (2) on the cone of the main shaft (1) and measure the protrusion of
the main shaft cone towards the mantle.
Heat up the mantle (2) by approx. 50 C above ambient temperature and shrink it 5 mm
lower than the protrusion length.
CAUTION
System damage through improper assembly
Damage to the machine/plant or its environment is possible
5 - 62
Before the mantle has cooled during the shrinking process, insert the intermediate ring
(5) and tighten the ring nut (6) slightly.
After the mantle (2) has cooled, remove the ring nut (6) with intermediate ring (5) again.
Replace the intermediate ring, screw on the ring nut and tighten it up securely. Tackweld the intermediate ring to the ring nut and mantle. To do this, use different filler
materials. Follow the welding instructions in drawing 4609199.
Clean the wear insert (3) and the top shaft of the main shaft.
Screw eye bolts into the wear insert, pre-heat the wear insert by 80 C above the ambient temperature.
11/2013 Rev 0
Never shrink the mantle to less than 5 mm lower than the protrusion length.
11/2013 Rev 0
Figure 28
5 - 63
5.8.12
Screw the top and bottom sealing rings (2) and (3) together and measure the distance
between them.
To ensure this clearance, determine the required thickness of the shims (4).
Separate the top and bottom sealing rings. Screw the top sealing ring into the main
shaft.
Arrange the plastic sealing ring on the bottom sealing ring, position the shims and
screw the top and bottom sealing rings in place.
11/2013 Rev 0
Figure 29
5 - 64
5.8.13
11/2013 Rev 0
Bolt the step bearing upper part (1) to the main shaft:
Insert the upper positioning cylindrical pin (2) in the step bearing upper part.
Screw the step bearing upper part (1) of the axial step bearing to the main shaft.
Figure 30
5 - 65
5.9
5.9.1
Place the filler plates for the requisite grouted joint on the steel structure/foundation.
Place the bottom shell of the crusher (1) on the steel structure/foundation and align the
pinion assembly tunnel with the motor.
Horizontally align the bottom shell and screw it firmly to the sub-structure (steel
structure/foundation) using anchor bolts/stone bolts (2). See drawing no. 4470461
Sheets 1 - 5.
Cover the crusher feet with BETEC cement mortar, allow to harden and re-tighten the
nuts. (See ANNEX 9.4)
Clean the flange faces and conical seats of the bottom shell and the shells (3, 4).
Place the lower shell (3) on the bottom shell and align it horizontally so that an even
flange joint is obtained.
11/2013 Rev 0
5 - 66
11/2013 Rev 0
Figure 31
5 - 67
Attach the upper shell (4) and align it horizontally so that a uniform flange joint is obtained.
INFORMATION
Longitudinally align the receiving pockets of the upper shell for the spider (5) in
the direction of loading.
Pay attention to the installation position of the grease lubrication line.
Install the concaves and the liner plates before the assembly of the main shaft and spider.
See Chapter 5.8.8 and Chapter 5.8.9.
Clean and grease the bottom shaft of the main shaft (6), the eccentric bushing (7) and
the components of the axial step bearing (8).
CAUTION
System damage through improper assembly
Damage to the machine/plant or its environment is possible
When inserting the main shaft, do not damage the oil seal (9), the axial step
bearing (8), the dust sealing (10) or the eccentric bushing (7).
11/2013 Rev 0
When positioning the spider (5), do not damage the shaft sealing (11) and the
spider bushing (12).
To facilitate fitting, slightly turn the main shaft by means of the eccentric bushing
(7).
5 - 68
11/2013 Rev 0
Figure 31
5 - 69
Attach a hoist to the eye bolt of main shaft, lift the main shaft and allow it to slide into
the eccentric bushing.
Check the correct position of the oil seal (9), the step bearing lower part of the axial
step bearing (8) and the dust sealing (10) for installing the main shaft.
Pre-assemble the grease lubrication and sensor line on the spider (5).
See Chapter 5.8.
INFORMATION
When positioning and aligning the spider (5), pay attention to the routing of the
grease lubrication line for the spider bearing. Insert eye bolts into the 4 bores of
the spider (5) for transport. After the spider has been set down, remove the eye
bolts and seal the bores with the screw plugs.
Attach the spider (5) and align it horizontally so that a uniform flange joint is obtained.
Do not forget to grease the contact surfaces to the sealing compound beforehand.
INFORMATION
To release the connection, only loosen the bolts, do not remove them. Loosen
them evenly and gradually.
Backfill the gap (16) between the spider and the upper shell (4) with sealing compound.
See instructions ANNEX 9.4.
Fill the spider bearing with grease as per the table of lubricants.
Mount the arm liners (14). See drawing 4609235 in ANNEX 9.1
11/2013 Rev 0
5 - 70
11/2013 Rev 0
Figure 31
5 - 71
5.9.2
INFORMATION
Place the arm liners (1) onto the two arms (2) of the spider.
Align the arm liners (1) and fix in place using bolts at the side (3).
Bolt the arm liners (1) to the spider using bolts (4).
Tightening torque of the bolts (4): 4227 Nm.
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5 - 72
11/2013 Rev 0
Figure 32
5 - 73
5.9.3
Direct drive
See Figure 33
Take the further important assembly instructions on the drawing 4609407 in ANNEX 9.1
and video in Chapter 7.4.14 "Crusher main drive motor and pinion assembly" into account.
Slide the distance ring (1) and the feather keys (2) and (3) on to the shaft butt ends of
the pinion assembly and motor.
The crusher, pinion assembly and crusher main drive motor must be precisely aligned.
Align the components accordingly and secure them. If possible, backfill up with suitable
sealing compound.
Mount multiple-disc clutches (4), distance tube (5) and safety coupling (6).
See ANNEX 9.2
CAUTION
Plant damage through improper assembly of the clutches
Damage to the machine/plant or its environment is possible
Mount the multiple-disc steel clutch (4) so that it is unstressed. If necessary,
the motor must be axially displaced during assembly, in order not to exceed the
permissible load.
Comply with the tightening torques!
In order to protect the safety clutch (6) from damage/destruction, the following
oil filling process must be followed during fitting:
First fill the lubrication chambers with oil. This takes approx. 45 minutes.
The pressure chambers must only be filled with lubrication oil after the lubrication chambers have been filled. See also ANNEX 9.2
Mount the bracket (7) for the speed monitor (8) on the pinion assembly flange.
Screw the 4 cam switches (9) on the flange of the multiple-disc clutch.
11/2013 Rev 0
5 - 74
11/2013 Rev 0
Figure 33
5 - 75
5.9.4
Connect the hose/pipe system (3) between the compressor (2) and air pipe (4) in the
bottom shell.
11/2013 Rev 0
Figure 34
5 - 76
5.9.5
Mount the high-pressure hoses (5) and pipelines (6) as per drawing 4613053.
11/2013 Rev 0
Figure 35
5 - 77
5.9.6
Set up the oil tank with the oil circulating lubrication unit and the hydraulic unit in an
easily accessible place near the crusher which is as dust-free and protected from the
elements as possible.
If the crusher is installed in enclosed inside areas, provide good ventilation to prevent
heat accumulation.
Connect the pressure lines of the lubrication pump unit to the lubrication oil supply on
the hydraulic cylinder (internal lubrication) and the oil supply of the crusher (external
lubrication).
Connect the electric motors of lubrication pumps of the hydraulic unit and the oil cooler
and check the directions of rotation.
11/2013 Rev 0
Figure 36
5 - 78
5.9.7
Mount the filling level sensor (2) in the head of the spider and pass the cables through
the cable duct in the spider.
Mount the grease lubrication pump (3) on the filled grease reservoir (4). Mount the
lubricant line of the grease lubrication pump for the spider bearing.
Clean all grease and air pipes by air prior to the final connection.
Rinse the lubricating grease lines by hand with grease until clean grease flows. Then
assemble the connection to the grease lubrication unit of the spider bearing.
Pump grease into the cap until the filling level sensor actuates.
11/2013 Rev 0
Figure 37
5 - 79
5.10
INFORMATION
For bolted connections without specified tightening torques see ANNEX 7.5
Position
Bolt
Superbolt
Ma (Nm)
Clamping nut
Stress bolts
ANNEX 9.1
M 72 x 6 x 380
130001
M 72 x 6 x 380
130002
M 160 x 6 x 925
M 160 x 6
M 20
5003
M 12 x 40
38
M 24 x 80
310
M 56x 460
4227
M 42 x 5 x 280
1746
M 30 x 100
1200
M 30 x 90
625
10
M 30 x 90
625
11
M 20 x 200
180
12
M 30 x 160
500
13
M 30 x 240
1400
5 - 80
4609197
4609235
4470280
4609204
11/2013 Rev 0
Drawing
11/2013 Rev 0
Figure 38
5 - 81
Position
Bolt
Superbolt
Ma (Nm)
Clamping nut
Stress bolts
Drawing
ANNEX 9.1
M 36 x 140
1100
15
M 16 x 40
100
16
M 12 x 25
50
17
M 24 x 100
230
18
M 24 x 80
710
19
M 24 x 70
300
20
M 30 x 130
1000
21
M 20 x 70
300
22
M 16 x 65
295
23
M 30 x 95
1090
24
M 36 x 90
630
25
M 30 x 140
1600
26
M 56 x 280
4500
27
M 16 x 40
100
4609216
4207101
4521963 Sheets 1
+2
4609407
4207648
4613028
11/2013 Rev 0
14
5 - 82
11/2013 Rev 0
Figure 38
5 - 83
11/2013 Rev 0
Blank page
5 - 84
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:
For the initial commissioning routine note the instructions relating to the components included in the ANNEX 9.
6.2
DANGER
Risk of injury from damaged insulation on the connecting cable and missing terminal box covers
Imminent danger of death or severe bodily injuries
The electrical connections to the drives must be adequately protected.
WARNING
Risk of injury from larger oscillation amplitudes
11/2013 Rev 0
6-1
CAUTION
Risk of injury when operating the drive units without protective clothing
Bodily injury possible
The machine must never be operated without the guards in position over the
drive units.
Operate the machine / plant only if all protective and safety-oriented devices, such as
removable safety devices and emergency shut-off equipment, sound-proofing elements and exhausters, are in place and fully functional!
Check the machine/ plant at least once every shift for obvious damage and defects!
Report any changes (including changes in the operating performance) to the responsible department immediately! If necessary, stop the machine/ plant immediately and
lock it!
In the event of malfunctions, stop the machine/ plant immediately and lock it!
Have any defects remedied immediately!
Follow the start-up and shutdown procedures and control displays as set out in the
manual!
Before starting up/actuating the machine/ plant, make sure that nobody is at risk!
If abnormal vibrations suddenly occur in the equipment supporting structure the operation of which is corresponding with vibrations and unbalances, these abnormal vibrations must be eliminated prior to feeding the machine with material.
Only work with the prescribed lighting under darkness and with poor visibility.
Switch off the machine/plant immediately if people's lives are at risk, e.g. due to careless working near belt conveyor systems and material transfer points.
Local operation of individual drives is allowed only during inspection, maintenance and
repair work.
Work may only be carried out if the worker is properly qualified and/or has been authorised to do so.
Do not carry out maintenance and repair work without authorization.
11/2013 Rev 0
6-2
6.3
CAUTION
System damage through use of the machine/plant contrary to its designated
use
Damage to the machine/plant or its environment is possible
The intended use of the machine/plant is regulated by contract. Any other use contrary to its designated use is prohibited. ThyssenKrupp Resource Technologies
cannot be held liable for damage resulting from such misuse. The risk of such misuse lies entirely with the user.
11/2013 Rev 0
6-3
INFORMATION
The safety parts of controllers for the gyratory crushers correspond to the
necessary performance level "d" - category 2.
The scope of supply of ThyssenKrupp Resource Technologies-Business
Unit Processing does not include the "MCC" control unit but only the GYRAMATIC.
11/2013 Rev 0
GYRAMATIC is a compact and reliable control and monitoring system that has been specially designed for the ThyssenKrupp gyratory crusher. It provides all the control functions
as regards operation, calibration and overloads which are necessary for reliable and problem-free operation of the gyratory crusher. The device is designed as a touch screen terminal and enables control and gearing of all motors connected to the gyratory crusher.
Here, the pressure, temperature and oil flow in the lubricant/hydraulic system are displayed.
6-4
6.4
Initial commissioning
Check that
the oil circulating lubrication for the eccentric and axial step bearing,
the hydraulic system with the balance unit,
the grease lubrication for the spider bearing and
the stand oil lubrication unit of the pinion assembly shaft
the safety coupling
are sufficiently filled with the lubricant and/or hydraulic oil as specified in the relevant table
of lubricants (Chapter 8.4).
Check that the monitoring, heating and cooling systems of the oil circulating lubrication
have been set correctly and electrically connected/interlocked, so that the crusher cannot be started without lubrication.
Switch on the hydraulic unit. Place the balance unit in a state of readiness for operation.
Pump up the safety clutch between the electric motor and the crusher to 90 MPa (900
bar) as per the instructions. (See ANNEX 9.3).
CAUTION
Plant damage through incorrect oil pressure
Damage to the machine/plant or its environment is possible
11/2013 Rev 0
Check the oil pressure in the pressure chamber of the safety coupling again after
the run-in period.
Allow the gyratory crusher to test run for approx. 2 hours without material. Check that
the control equipment, e.g. flow meters, thermostats, level indicators of lubrication
units and the hydraulic unit of the crusher, is functioning correctly. Remedy any faults/
failures immediately or have them remedied.
Increase the feed rate of the material over a period of approx. 8 hours thereby steadily
increasing the load on the gyratory crusher (no maximum size of feed material to start
with).
6-5
6.5
Normal operation
6.5.1
Requirements
Sufficient lubricant and/or hydraulic oil levels (see previous section).
The associated ball valves upstream/downstream of the pump provided for operation
(one of the two pumps) must be opened.
The ball valves of the second pump (standby pump) must be closed.
The oil pump must be switched on.
The oil circulation rate of the external bearing (radial) must be 165 l/min and that of the
internal bearing (axial) 195 l/min.
The return temperature may not exceed approx. 55 C.
The tank heating system and the air/oil cooler must be operative. The lubricating oil
must have a temperature of approx. 35 C on start-up of the crusher.
Activation of the heating system at 34 C.
Switch off of the heating system at 38 C.
The oil filters must be operative, i.e. excessively clogged filters must be cleaned and/
or replaced.
The ball valve between the tank and the pump and between the pump and the oil/air
cooler must be open on the pump for the oil cooling circuit.
6.5.2
Measure the position of the piston in the hydraulic cylinder and thus the position of the
main shaft by the distance sensor starting from the bottom position
Monitor the main shaft / check the overload protection for actuation:
In case of overload, the operating pressure is exceeded.
Open two pressure relief valves for a short period of time.
A negligible amount of oil leaks from the hydraulic cylinder:
The main shaft is lowered and the crushing gap is increased to empty the crushing
chamber.
The lowering of the main shaft on overload can be seen on the display of the main shaft
adjustment in the control station/control cabin.
Check the temperature of the lubricating oil.
If the temperature of the lubricating oil is too high, an alarm signal is actuated by thermostats. The crusher main drive motor is switched off if the max./ max. oil temperature is exceeded.
Monitoring is via flowmeter. If the oil circulating quantity is too low, an acoustic and visual
warning is output and the crusher main drive motor is switched off.
6-6
11/2013 Rev 0
The lubricating oil is cleaned by a switchable pressure filter in the supply line. As soon as
one of the filters is clogged, the second (bypass) filter is switched over to and the filter element of the first filter can be replaced.
The heating system in the lubricating oil tank is monitored by a temperature controller.
The air/oil cooler and the pump of the cooling circuit of the oil circulating lubrication are
controlled via a temperature controller in the return line.
If the oil temperature is above 45 C, the cooler and the pump motor switch on.
If the oil temperature is below 40 C, the cooler and the pump motor switch off.
Monitoring is by a magnet level switch. An alarm is output as soon as the level decreases
to the minimum oil level.
The crusher motor is switched off at min.min. after an idling time of 5 minutes.
Monitoring is via pressure controller. An acoustic and visual warning is output and the
crusher main drive motor is switched off as soon as the pressure is lower than the min.
pressure.
Monitor the pilot lamps/displays and arrange for the necessary maintenance work after
warning messages.
After a failure has been displayed/signalled, acknowledge the failure and arrange for
the cause of failure to be remedied.
Switch off the gyratory crusher by pressing the emergency-stop button in the case of
danger.
11/2013 Rev 0
Due to progressive wear of the crushing tools, the product grain size no longer corresponds to the originally set crushing gap after a certain period of operation.
6.6
Reduce the crushing gap by lifting the cylinder according to the condition of wear.
Malfunctions, troubleshooting
Failures/faults are displayed in the control station/control cabin.
The crusher is switched off automatically depending on the failure/fault.
The cause of failures/faults which are not displayed must be found and remedied.
6-7
Fault
Gyratory crusher comes
to a standstill
Cause
Overload, accumulation of material in
the crushing chamber, the safety coupling has actuated.
Check the function of the oil coolers, temperature controllers and cooling circuit
pump.
Check the flow rate and the operating pressure of the oil circulating lubrication.
Message - Operating
pressure of oil circulating lubrication too low
6-8
Remedy
11/2013 Rev 0
6.6.1
Fault
Cause
Leaky oil lines/bolted connections
Eliminate leaks
Message - Increased
return temperature of
lubricating oil
Replace if damaged/worn.
Insufficient lubrication
Check the flow rate and the operating pressure of the oil circulating lubrication.
Repair compressor
Check bottom spherical disk of axial bearing/ bevel gear or pinion of transmission
shaft.
11/2013 Rev 0
Remedy
by bronze coloured
metal deposits
Replace if damaged/worn.
6-9
Frequent readjustment
of the crushing gap
required
Cause
Remedy
Replace if damaged/worn.
Continuous topping up
of oil in the pinion
assembly required
Grease consumption of
spider bearing too high
Hoses defective
Replace hoses.
Alignment inaccurate
Streaks of grease on
the wear insert of the
main shaft
6 - 10
11/2013 Rev 0
Fault
Fault
Cause
Remedy
Replace pump.
6.6.2
Lower the main shaft, several times if necessary, in order to clear it.
Switch on the crusher drive in the bottom axle position during lowering (3 trials/h possible).
6.7
Shutting down
6.7.1
Normal operation
The material feed must always be interrupted before the crushing plant is stopped. The
crushing plant can then run "empty."
When the crushing plant is stopped, make sure that sufficient material remains in the feed
hopper to protect the conveyor covering.
CAUTION
Plant damage through false material feeding after emptying the feed conveyor
11/2013 Rev 0
6 - 11
6.7.2
Emergency-stop system
CAUTION
System damage from material overfilling when using emergency-stop
switch
Damage to the machine/plant or its environment is possible
When using an emergency-stop switch, there is a danger of material overfilling at
the transfer points, as all upstream and downstream parts of the plant are switched
off with no specific shutdown sequence.
The emergency-stop switches must not be used for normal shutdown.
Several emergency-stop switches must be installed on the machine/plant.
The emergency-stop switches are identified by red impact surfaces on yellow background.
The switches engage on actuation.
6.8
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.
11/2013 Rev 0
Handling of oil hydraulic systems (see Chapter 5.4 "Handling of oil hydraulic systems").
6 - 12
Maintenance
7.1
WARNING
Risk of injury through cleaning, inspection, maintenance and repair work
during operation
Death or severe bodily injuries are possible
Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off and secured against restarting.
Inform the operating personnel before starting service and maintenance work! Appoint
a person to supervise the work!
When carrying out any work concerning the operation, conversion or adjustment of the
machine/ plant and its safety-oriented devices or any work related to maintenance,
inspection and repair, always follow the start-up and shutdown procedures described
in the Operating Instructions and the information on maintenance work!
As a general principle, all work on the machine/ plant should only be carried out when
the machine/ plant is at a standstill.
If the machine/ plant has been completely shut down for maintenance and repair work,
it must be secured against inadvertent restart by:
Locking the main control elements and removing the key and/or
11/2013 Rev 0
7-1
Before restarting the machine/plant after repair work, check that all safety devices have
been attached.
After electrical installation or repair work, test the protection systems (e.g. earth resistance).
To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting gear and secured. Only
use suitable and technically perfect lifting gear and suspension systems with an adequate carrying capacity! Never work or stand under suspended loads!
The fastening of loads and the instruction of crane operators should only be entrusted
to experienced persons! The marshaller must be within eyesight of the operator or
have verbal communication with him.
When carrying out overbelt assembly work, always use specially designed or other suitable and safe climbing aids and working platforms. Never use machine parts as a climbing aid! Wear fall protection when carrying out maintenance work at a higher level.
Keep all handles, steps, handrails, platforms, landings and ladders free of dirt, snow
and ice!
Always tighten up any bolted connections which have been loosened during maintenance and repair work!
Any safety devices removed for setting up, maintenance or repair purposes must be
refitted and checked immediately upon completion of the maintenance and repair work.
Ensure that all consumables and process materials and replaced parts are disposed
off safely and in an environmentally friendly manner!
Only use original fuses with the specified current rating! Shut down the machine/ plant
immediately if faults occur in the electrical power supply!
Work on the electrical system or equipment may only be carried out by a skilled electrician or by specially instructed personnel under the control and supervision of a
skilled electrician and in accordance with the applicable electrical engineering rules.
If prescribed, the power supply to parts of machines and plants on which inspection,
maintenance and repair work is to be carried out must be disconnected. Check that the
isolated parts have been disconnected from the supply, then earth and short-circuit
them and insulate any adjacent live parts!
11/2013 Rev 0
7-2
If work on live parts is necessary, it may only be carried out in the presence of a second
person who can disconnect the power supply in an emergency by actuating the emergency stop button or main power switch. Cordon off the working area with a red-andwhite safety chain and a warning sign. Only use insulated tools!
Before starting work on high-voltage assemblies and after disconnecting the power
supply, the supply cable must be earthed and components such as capacitors shortcircuited with an earthing rod!
Only carry out hot work (welding, flame-cutting and grinding) on the plant if this has
been expressly authorised. For example there may be a risk of fire or explosions.
Before carrying out welding, flame-cutting and grinding work, clean dust and other
inflammable substances from the machine/ plant and its surroundings and provide
adequate ventilation (risk of explosion)!
Check all lines, hoses and bolted connections regularly for leaks and obvious damage.
Repair any damage immediately! Splashing oil may cause injury and fires.
Depressurise all system sections and pressure pipes which are to be opened in accordance with the instructions for the assembly group concerned before carrying out any
repair work!
Hydraulic lines must be laid and connected in line with good professional practice!
Ensure that no connections are interchanged! The fittings, lengths and quality of the
hoses must comply with the technical requirements.
Follow the applicable safety regulations when handling oil, grease and other chemical
substances!
Be careful when handling hot consumables and process materials (risk of burning or
scalding)!
11/2013 Rev 0
7-3
7.1.1
CAUTION
Risk of injury when working without personal safety equipment
Bodily injury possible
Always wear a face protector when carrying out cleaning work with high-pressure or steam jet cleaners.
Check the degree of soiling of the machine/plant every day. Do not allow material to
accumulate or cake. The mechanical interaction of the plant components may be interfered with and malfunctions and increased wear occur.
Always clean the assembly group in question before commencing maintenance work.
Before cleaning the machine/ plant with water or steam jet (high-pressure cleaners) or
other cleaning agents close/tape up all openings into which water, steam and detergents should not be allowed to penetrate for safety or operational reasons. Electric
motors and switch cabinets are at particular risk.
Do not direct the spray jet at electrical devices, relay boxes and switch cabinets, intake
and breather filters or greased surfaces.
Always hold the spray jet a sufficiently large distance away from the surface being cleaned and do not direct the spray jet at these surfaces at right angles.
Clean places which are difficult to reach with suitable equipment e.g. special brooms.
After cleaning, check all lubricant and hydraulic oil lines for leaks, loose connections,
friction areas and damage! Eliminate any deficiencies immediately!
11/2013 Rev 0
7-4
7.1.2
WARNING
Risk of injury by neglecting proper maintenance intervals
Death or severe bodily injuries are possible
All pending maintenance work must be completed according to schedule. The
manufacturer does not accept liability for damage resulting from maintenance
work which has not been carried out or has not been carried out according to
schedule.
CAUTION
System damage through improper maintenance
Damage to the machine/plant or its environment is possible.
Check the machine / plant at least once per shift for obvious damage and
defects! Report any changes (including changes in the operating performance)
to the responsible department immediately!
In the event of malfunctions, stop the machine / plant immediately and lock it!
Have any defects remedied immediately!
Failures arising from inadequate or improper maintenance may cause high repair costs
and long downtimes. Regular maintenance is therefore indispensable.
11/2013 Rev 0
Functional safety, trouble-free operation and the service life of the machine/ plant depend
on proper cleaning, inspection and maintenance.
Check the machine/ plant at the specified intervals (inspection intervals, maintenance
periods) for proper operation, lubrication condition and wear.
Check the paintwork for corrosion at regular intervals but no later than every 6 months.
Touch up all damaged areas in line with good professional practice.
Have the function of all instrumentation and control devices/ electrical interlocks chekked by qualified personnel at regular intervals.
7-5
INFORMATION
Downtimes for repairs can also be used for scheduled maintenance work.
The required frequency of checks for wear, inspection, maintenance and repair cannot be
specified beforehand owing to the variety of service conditions. An appropriate routine inspection schedule must be prepared making allowance for the operating conditions.
The maintenance table (Chapter 7.2) is a guideline for inspection and maintenance work.
For maintenance and repair work strictly follow the general safety notes included in
(Chapter 3).
INFORMATION
11/2013 Rev 0
As recommended during commissioning, you are advised to have initial repairs carried out
by ThyssenKrupp Resource Technologies staff. Your maintenance staff will have the opportunity to take part in an intensive training course.
7-6
7.1.3
WARNING
Risk of injury due to improper fastening
Death or severe bodily injuries are possible
To avoid the risk of accidents, individual parts and large assemblies being
moved for replacement purposes should be carefully attached to lifting gear and
secured. Only use suitable and technically perfect lifting gear and suspension
systems with an adequate carrying capacity! Never work or stand under suspended loads!
The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
When carrying out overbelt assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms. Never use machine
parts as a climbing aid! Wear fall protection when carrying out maintenance work
at a higher level.
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.
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.
11/2013 Rev 0
7-7
7.2
Maintenance intervals
Maintenance intervals are:
defined periods of time (maintenance periods) or
a certain number of operating hours (approx. 8000 operating hours/a and the maintenance intervals derived from this).
The following table provides an overview of the maintenance intervals with the abbreviations D (= daily), W (= weekly), and M (= monthly) used in the maintenance tables.
Maintenance interval
Maintenance period
approx. 24
weekly
approx. 165
M1
monthly
approx. 720
M3
quarterly
approx. 2200
M6
half-yearly
approx. 4400
M12
annually
approx. 8800
Carry out the relevant inspection/maintenance work as soon as the first of the two possible
maintenance intervals is reached.
The maintenance intervals (maintenance periods and operating hours) for carrying out
maintenance work are suggestions and recommendations of ThyssenKrupp Resource
Technologies.
However the frequency with which maintenance work should be carried out depends on
the particular operating conditions existing on site, such as
Operating time
Operating condition and
Wear.
Therefore the operating conditions must be observed and taken into account. It
may be necessary to change or adapt the maintenance intervals over the course of
time.
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7-8
Maintenance interval
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Inspection/maintenance work
Note
M1
M3
M6
M12
7-9
Maintenance interval
Note
M1
7 - 10
M3
M6
M12
after every 15
releases of the safety
clutch or after 12
months
11/2013 Rev 0
Inspection/maintenance work
Maintenance interval
Inspection/maintenance work
Note
M1
M3
M6
M12
Annual inspection
11/2013 Rev 0
7 - 11
7.3
7.3.1
Check the positions of the concaves from above through the loading opening for completeness and obvious damage with the crusher empty and at standstill.
INFORMATION
The continuous wear from operation can be detected because the main shaft
height must be increased. For replacing the concaves, see Chapter 7.4.5.
Check the spider cap (2) for damage with the crusher empty and at standstill. The wear
of the wall thickness can only be checked with the cap dismantled (see Chapter 7.4.8).
Check the thickness and condition of the arm liners (3) on the cross bar. Replace worn
arm liners.
Check the thickness and condition of the liner plates (4, 5). Check the attachment of
the liner plates. Replace worn plates.
Check the attachment of the liner plates (6) on the conical part of hub (crusher outlet)
- weld seams - re-weld liner plates if necessary; replace worn plates.
Check the position and condition of the arm liner (7) on the arms (bottom shell of the
hub), realign/replace if necessary.
7 - 12
11/2013 Rev 0
Check the spider cap, spider, upper shell, lower shell and bottom shell
11/2013 Rev 0
Figure 39
7 - 13
7.3.2
CAUTION
Plant damage through loose fastening bolts
Damage to the machine/plant or its environment is possible.
Check the following bolts/ screws:
Anchor bolts/fastening bolts of the bottom shell of crusher
Fastening bolts (1) between bottom sheet of crusher and the lower shell
Fastening bolts (2) between the upper and the lower shells
Fastening bolts (3) between upper shell and cross bar
Flange screws (4) of the hydraulic cylinder.
Re-tighten lose bolts to the tightening torque specified in Chapter 5.10 or if not
indicated in accordance with the table in Chapter 7.5.
Check the secure attachment of the ring nut (5) for securing the mantle on the main
shaft.
Re-tighten any loose ring nuts. To do so, weld a knocking cam on the ring nut.
11/2013 Rev 0
7 - 14
11/2013 Rev 0
Figure 40
7 - 15
7.3.3
Main shaft
See Illustration 41
Check the crushing gap
The height of the main shaft (1) can be vertically adjusted to change the crushing gap locally/centrally.
The crushing gap increases and must be re-adjusted due to increasing wear of the crushing tools (concaves and main shaft).
Check the actual size/width of the crushing gap with the crusher empty and at standstill.
For this purpose:
Measure the crushing gap (X) at two opposite points and calculate using the following
equation:
OSS= (measuring value1 + measuring value2)/2 + eccentricity
OSS= (measuring value1 + measuring value2)/2 - eccentricity
Check the mantle (3) from above through the feed opening for obvious damage with
the crusher empty and at standstill.
The continuous wear from operation can be detected because the main shaft height
must be increased.
For replacing the concaves, see Chapter 7.4.7 "Main shaft".
Check the secure attachment of the mantle. Re-knock the outer ring nut (4) if necessary.
Check the main shaft sleeve (5) of the main shaft for wear/damage, e.g. wear marks,
longitudinal grooves. Replace the main shaft sleeve if excessively worn/visibly damaged (see Chapter 7.4.7 "Main shaft").
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7 - 16
11/2013 Rev 0
Figure 41
7 - 17
7.3.4
INFORMATION
The following checks must be carried out with the main shaft fully lowered (before
switching off the crusher). Always check all components of the spider bearing with
the spider and main shaft dismantled (e.g. replacement of the concaves and mantle).
Clean the top part of the spider, dismantle the spider cap (1) and remove the lubricating
grease.
Check the clearance (2) between the wear insert (4) and the main shaft sleeve (3).
Press the main shaft on the wear insert by means of a hydraulic device.
Measure the clearance between the wear insert of the top bearing and the wearing
bushing of the crusher axle by means of a feeler gauge. The clearance may be a max.
of 3.5 mm. If this is exceeded, replace the wear insert (see Chapter 7.4.8).
If the clearance exceeds the permissible value to a large extent, the inclination of the main
shaft will change in a way causing abrasion to the inner eccentric bushing due to a wrong
inclination angle.
The main shaft will elevate when exchanging the main shaft sleeve and the wear insert.
This results in an edge pressure in the inner eccentric bushing. The main shaft may seize
during crushing through the action of the operating pressure.
Check the inner eccentric bushing for run-in marks and cracks caused by edge pressure.
CAUTION
Plant damage through worn eccentric insert
Damage to the machine/plant or its environment is possible
Check the condition of the leather packing (5), shaft sealing rings (6) and toroidal
sealing ring (7).
Use a grease pump to fill the space above the spider bearing with grease (see
Chapter 8.5 "Lubricating instructions").
Re-mount the spider cap. Ensure that no dirt to gets into the spider bearing.
7 - 18
11/2013 Rev 0
When replacing a worn wear insert, also replace the eccentric insert (see
Chapter 7.4.11).
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Figure 42
7 - 19
CAUTION
Plant damage due to insufficient lubricant
Damage to the machine/plant or its environment is possible.
11/2013 Rev 0
Check the grease level one month after commissioning. To do so, remove the
cap.
7 - 20
11/2013 Rev 0
Figure 42
7 - 21
7.3.5
Dust sealing
See Illustration 43 and Illustration 44
Check the dust sealing preferably with fully lifted crusher axle.
INFORMATION
Always check all components of the dust sealing for wear with the spider and the
main shaft dismantled.
With the main shaft installed, this check may be carried out either
through access A, whereby all dimensions can be checked
through access B (inspection flap), whereby a visual check from outside can be carried out .
11/2013 Rev 0
Figure 43
7 - 22
Check the wear of the sealing housing and the clearance of the sealing ring:
Check the sealing housing (1) for run-in grooves, which can be caused by the polyamide sealing ring (2). If the run-in grooves are deep, the sealing housing must be
replaced.
Check the condition of the polyamide sealing ring (2) and measure the radial clearance
(3) between the polyamide sealing ring (2) and the sealing housing (1). If the radial
clearance is considerably larger than 2 mm, replace the polyamide sealing ring (2).
Ensure that the polyamide sealing ring (2) can slide between the upper (4) and lower
sealing ring (5). The axial clearance may be 1.0 - 1.5 mm. If necessary, change the
clearance by adding other shim packages (6).
11/2013 Rev 0
Figure 44
7 - 23
Carry out a visual check for the secure attachment of bolted joints and damage to
hoses. Re-tighten loose bolted joints, replace damaged hoses.
After the crusher has been switched off, check that the compressor (1) switches off with
a time delay.
As a preventive measure, check the intake air filter (2) of the compressor for clogging.
Clean/replace if necessary.
Check the connection piping for accumulated oil, e.g. due to splash oil below the dust
sealing. Otherwise the free passage of the compressed air for the dust sealing cannot
be guaranteed.
Unscrew the hose connection (3) to the air pipe and check whether oil flows out.
11/2013 Rev 0
For maintenance work on the compressor, see ANNEX "9.5 Compressor (over-pressure
ventilation)".
7 - 24
11/2013 Rev 0
Figure 45
7 - 25
7.3.6
INFORMATION
Direct checks/inspection of the axial step bearing (1) and the eccentric bushing
(2) are not possible without dismantling the spider, the main shaft and dust sealing
beforehand. Thus, always check and if necessary, replace the axial step bearing
and the eccentric insert in case of dismantled cross bar and main shaft (see
Chapter 7.4.2, Chapter 7.4.3 and Chapter 7.4.4).
Performing maintenance on the oil circulating lubrication system indirect conclusions regarding potential wear or damage of the axial bearing or eccentric bush can be drawn from
signals generated by the control system and visual inspections of plant components:
Control messages:
Silver to grey metal deposits indicate possible damage to the axial bearing, the bevel
gear, the bevel pinion, the eccentric bushing or the main shaft.
11/2013 Rev 0
7 - 26
11/2013 Rev 0
Figure 46
7 - 27
7.3.7
Check the oil level and change the oil at the oil circulating lubrication unit
See also Chapter 7.2 "Maintenance intervals"
Carry out a visual check of the oil circulating lubrication system for leaks. Only re-tighten/replace leaky bolted joints in an unpressurised condition.
Check the oil level on the oil inspection glass of the tank with the crusher and lubrication pumps switched off.
Switch off the crusher and the oil circulating lubrication unit for an oil change. Drain
the oil when it is at operating temperature.
Provide an adequately sized tank (used oil quantity approx. 2,500 l).
Drain and collect the used oil and dispose of it according to the regulations.
Open the maintenance cover of the tank and clean the tank. Only use non-linting cloth
for cleaning (no cotton waste).
Check the tubular steel protective casings of the heating inserts for damage.
Fill with new filtered lubricating oil (filter fineness 25 m). Oil quantity and quality, see
Chapter 8.5 "Lubricating instructions".
Check the screen insert of the screen basket with the cone crusher at standstill and the
oil circulating lubrication switched off; clean, if clogged.
Check that the cooling air can flow freely in and out.
Clean the cooling fins or blow them out by means of compressed air.
11/2013 Rev 0
7 - 28
7.3.8
Check the hydraulic oil level and change the hydraulic oil
See also Chapter 7.2 "Maintenance intervals"
Check the hydraulic oil level on the inspection glass of the tank. The hydraulic oil
level must be at the max. mark.
If the oil level is too low, top up with filtered oil (25 m) until the max. mark is reached.
In this respect, also unscrew the cover on the cylinder bottom of the hydraulic cylinder
and check the connection of the distance sensor.
WARNING
Risk of injury due to leaky connections / bolted connections
Death or severe bodily injuries are possible
Tighten / replace only when unpressurised.
CAUTION
Plant damage due to mixing of hydraulic oil with lubricating oil of circulating
lubrication
Damage to the machine/plant or its environment is possible.
Replace the piston seals of the hydraulic cylinder
If hydraulic oil has to be topped up several times a week without there being any
obvious leaks, this may be an indication of wear on the piston seals of the
hydraulic cylinder.
11/2013 Rev 0
To change the hydraulic oil, lower the main shaft completely and switch off the crusher and the hydraulic unit.
Drain and collect the used oil and dispose of it according to the regulations.
7 - 29
Open the maintenance cover of the hydraulic oil tank and clean the tank. Only use nonlinting cloth for cleaning (no cotton waste).
Fill with new filtered oil (filter mesh 25 m). The max. filling level has been reached as
soon as the oil level is at the top edge of the inspection glass.
Oil quantity and quality, see Chapter 8.5 "Lubricating instructions".
Check the preload pressure on the pressure gauge of the air tank. The pressure
should be between 6 and 8 bar. If the pressure is too low, use the compressed air
system to re-fill with air.
7.3.9
For checks of the multiple-disc clutch and safety coupling, see ANNEX 9.
Read the oil level on the oil inspection glass (1) with the crusher switched off.
If the oil level is too low, unscrew the breather (2) and top up with filtered oil (filter mesh
25 m) through the filter opening. Use the oil according to Chapter 8.5 "Lubricating
instructions".
Unscrew the breather and fill with filtered oil (filter mesh 25 m) via the filter opening.
Oil quantity and quality, see Chapter 8.5 "Lubricating instructions". Check the oil level
on the inspection glass.
7 - 30
11/2013 Rev 0
Figure 47
7 - 31
11/2013 Rev 0
7 - 32
11/2013 Rev 0
Figure 47
7 - 33
7.3.10
Turn the multiple-disk clutch and thus the bevel pinion to the right until the teeth of the
bevel pinion and the bevel gear contact each other.
Attach the pipe clip and the auxiliary measuring rod to the multiple-disk clutch and align
vertically towards the dial gauge.
Turn the multiple-disk clutch to the left until the teeth contact each other again. Read
off and record the value on the dial gauge. Swing the dial gauge away.
Since approx. 4 rotations of the bevel pinion correspond to one rotation of the bevel
gear, turn the multiple-disc clutch by another 4 full rotations. Repeat the measuring
process after each single rotation. This is to account for the possible influence on the
measured values of the changing clearance between the eccentric bushing and the
outer eccentric bushing.
Average the four measurements and convert to the actual backlash. If the calculated
average value is below/above these values, readjust the backlash.
11/2013 Rev 0
7 - 34
11/2013 Rev 0
Figure 48
7 - 35
Open the inspection opening (8) in the bottom shell with the crusher at standstill.
Carry out a visual check of the bevel pinion (1) and bevel gear (2) for jamming, grooves
and tooth breakage.
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7 - 36
11/2013 Rev 0
Figure 48
7 - 37
7.4
Repairs
WARNING
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation
Death or severe bodily injuries are possible
Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off and secured against restarting.
INFORMATION
Have an annual general plant inspection carried out by responsible qualified personnel
and management staff. If necessary, consult ThyssenKrupp Resource Technologies.
Have any defects and damage remedied immediately!
Co-ordinate the time and location of repair work with the regular maintenance and
inspection work.
Spare parts must comply with the technical requirements specified by the manufacturer. This is always ensured when using original spare parts - see spare parts lists.
Provide a complete set of wear parts - see spare parts lists. Replace when necessary
and re-machine worn parts if possible.
Workshop equipment is required for the repair of assembly groups. Remove and
install assembly groups in the workshop.
The assembly groups and individual components can be assembled and adapted to
the relevant crane capacities at the place of installation.
11/2013 Rev 0
The standards and tightening torques for machine bolts are included in Chapter 7.5.1.
7 - 38
INFORMATION
Always use these tightening torques unless special tightening torques are stated.
11/2013 Rev 0
Specific repair work, e.g. disassembly and assembly of structural units, assembly
groups and components are described in separate sections. These descriptions do not exclude the use of other possibilities which may be appropriate from time to time. However,
the safety of the repair personnel and the machine /plant may not be adversely affected.
7 - 39
7.4.1
7.4.2
Dismantle the spider cap (6) and remove the grease over the spider bush (7) and dispose of it in an environmentally-friendly manner.
Detach the control cable (8) and grease line (9). (They are located on the upper shell).
Also see drawings in the ANNEX 9.1
Screw eye bolts into the transport holes of the spider (3).
Attach the spider to the crane. Undo the connecting bolts and carefully lift the spider
together with the control cable and grease line.
INFORMATION
To detach the spider from the sealing compound (if necessary), insert hydraulic
cylinders (provided by the customer) in the threaded holes in the upper shell.
Lift the spider with the crane and place it down on the floor. Check the sealing elements
and spider bushing, replace if necessary (see Chapter 7.4.8).
11/2013 Rev 0
7 - 40
11/2013 Rev 0
Figure 49
7 - 41
7.4.3
CAUTION
Plant damage due to sticking of the step bearing when lifting the axle
Damage to the machine/plant or its environment is possible
Make sure the middle spherical disk of the axial bearing does not adhere to the
upper spherical disk (15) when lifting out the crusher axle (4).
Attach crane to the eye bolts (10) of the main shaft (4) and lift the main shaft out of the
inner eccentric bushing (11). Ensure that the oil seal (14) in the sealing housing (13) of
the dust sealing does not catch on the main shaft. Possible safety hazard through falling off!
Protect the step bearing upper part (14) of the axial step bearing from damage and
place the main shaft in a supporting device/shaft stand on the floor.
Cover the sealing housing of the dust sealing, thereby protecting the eccentric bushing
and axial step bearing against the ingress of dust.
Carry out checks with the spider and main shaft dismantled. See Chapter 7.4.4.
Check the liner plates (15) and wearing caps (16) in the bottom shell. Replace them if
necessary.
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7 - 42
11/2013 Rev 0
Figure 49
7 - 43
7.4.4
Checks to be made with the spider, main shaft and dust sealing
housing dismantled
See Illustration 50
Certain assembly groups of the crusher must be dismantled, in order to exchange the concaves, mantle and other wearing parts in the crusher.
After dismantling, the following crusher components which are normally inaccessible
should always be checked for wear.
Checks for wear with the spider and main shaft dismantled:
Main shaft sleeve (3) and lower shaft of the main shaft.
For the exchange, see Chapter 7.4.7.
Step bearing upper part (4) of the axial step bearing.
For the exchange of the axial step bearing, see Chapter 7.4.10.
Check polyamide sealing ring (5) between top and bottom sealing ring of dust
sealing for wear and clearance. For replacing the polyamide sealing ring, see
Chapter 7.4.7.
Other checks:
Free passage of air duct to the sealing housing.
If necessary, detach the air connection from the bottom shell of the crusher and
blow compressed air through the air duct.
Check the bottom sealing ring (6) for secure attachment.
Check the sealing housing for damage through the polyamide sealing ring (5). For
the exchange of the sealing housing, see Chapter 7.4.9.
Checks for wear with the spider, main shaft and dust sealing housing dismantled:
Inner eccentric bushing (7) of the eccentric bushing. For the exchange, see
Chapter 7.4.11.
Clearance between the outer eccentric bushing and the eccentric bushing. To
check, turn the eccentric bushing, so that it contacts one side of the outer eccentric
bushing.
For the exchange of the outer eccentric bushing, see Chapter 7.4.13.
Check the step bearing lower part (8) and slide bearing plate (9) of the axial step
bearing for damage.
For the exchange of the axial step bearing, see Chapter 7.4.10.
7 - 44
11/2013 Rev 0
Other checks:
11/2013 Rev 0
Figure 50
7 - 45
7.4.5
Weld lifting eye to the concaves (1 to 4) and attach the concave to be dismantled to the
crane.
Remove the concaves in rings from top to bottom. For this purpose:
Separate/flame cut one crushing jaw of the relevant crushing jaw ring.
Loosen and lift out the concaves by means of a hydraulic hammer or pneumatic
hammer.
WARNING
Risk of injury due to dust loading
Death or severe bodily injuries are possible
Ensure proper ventilation.
Wear a respirator as protection against dust of the grouting compound.
Remove old grouting compound from spider and bowl and clean the latter.
For mounting the concaves, see Chapter 5.8.8 and drawings in ANNEX 9.1.
INFORMATION
11/2013 Rev 0
7 - 46
11/2013 Rev 0
Figure 51
7 - 47
7.4.6
Wear parts
See Illustration 51
To replace the liner plates:
Separate (grind off, flame-cut, gouge) the weld seams which join the liner plates to the
crusher shells, and dismantle the liner plates in rings from top to bottom.
Position, press on, tack-weld and weld new liner plates (horizontal weld seams at top,
bottom and plug weld).
Pay attention to the notes in the drawings in ANNEX 9.1 when welding!
INFORMATION
Check, exchange and re-position the arm liners (7) on the arms in the bottom shell.
Check, exchange and re-position the arm liners on the cross bar (9).
11/2013 Rev 0
For mounting the liner plates and the arm liners, see Chapter 5.8.3, Chapter 5.8.9 and
Chapter 5.9.2.
7 - 48
11/2013 Rev 0
Figure 51
7 - 49
7.4.7
Main shaft
Exchange of the main shaft sleeve
Screw eye bolts into the threaded holes of the main shaft sleeve (1), attach to lifting
gear and pull sling ropes tight.
To remove the main shaft sleeve (1) from the main shaft, proceed as follows if possible:
Heat the main shaft sleeve to approx. 100 C above the ambient temperature.
Quickly withdraw the main shaft sleeve from the main shaft and set it down immediately. If the main shaft sleeve cools down too rapidly during the pulling process and reshrinks on the main shaft, reheat it.
If the main shaft sleeve (1) cannot be pulled off this way:
Cut main shaft sleeve (1) lengthways and then insert for disassembly.
CAUTION
Plant damage due to damage to the axle when cutting
Damage to the machine/plant or its environment is possible.
Do not cut through wearing bushing (1) completely.
Clean the seat of the main shaft sleeve and the shaft of the main shaft.
Attach a new main shaft sleeve to a hoist and heat it up to approx. 100 C above ambient temperature.
Quickly place the main shaft sleeve on the shaft. If necessary, continue to heat the
main shaft sleeve during installation.
After the installation, clean and grease the main shaft sleeve.
7 - 50
In order to avoid damage to the dust sealing when replacing the mantles (2) and (3),
remove the bottom sealing ring (3), the polyamide sealing ring (4) and the top sealing
ring (5) from the main shaft.
In order to avoid damage, remove the step bearing upper part (6).
Detach the protective cap (7) and outer ring nut (8). If this is not possible, the intermediate ring (9) must be separated by a horizontal flame cut to relieve the pretension in
the thread.
Lift the crushing mantle (2) off. To do so, weld on 4 lifting eyes (10) offset by 90
(mantle made of austenitic manganese steel).
Pre-heat the bottom third of the mantle (2) to approx. 50 C above ambient temperature
and loosen it by hitting it around the entire circumference; then lift it off.
11/2013 Rev 0
11/2013 Rev 0
Figure 52
7 - 51
Screw top spherical disk (6) of the axial bearing back onto the crusher axle.
We recommend checking the complete axial step bearing. Also check the dust sealing before mounting the main shaft.
Re-mount the dust sealing. Check the bolts on the sealing housing for secure attachment/re-tighten if necessary.
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7 - 52
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Figure 52
7 - 53
7.4.8
Clean the spider cap (1) and spider (2). Remove the spider cap.
Remove the grease filling over the spider bushing (4) and dispose of it in an environmentally-friendly manner.
Unscrew the bolts (5) of the spider bushing. Screw in four forcing screws into the
threaded bores (6) and press off the rolling contact bush from the seat of the spider.
For this purpose use the forcing hydraulics (12) and/or (14).
INFORMATION
For removal of the spider bushing (4) and installation of the sealing ring (9) see
Chapter 5.8.10 "Spider bearing" and ANNEX 9.1 "Drawings".
Use an appropriate hoist to lift out and set down the spider bushing (4) with spacer (13).
Replace sealings
Screw eye bolts into the threaded bores (8) of the sealing ring (9) and withdraw sealing
ring.
Replace the leather packing (10) and shaft sealing rings (11). Soak the new leather
package in oil beforehand.
Coat the outside edge of this area (2) of the spider with sealing gel Loctite 574.
11/2013 Rev 0
7 - 54
11/2013 Rev 0
Figure 53
7 - 55
Screw eye bolts into the threaded holes (7) in the spacer (13).
INFORMATION
If it is not possible to remove the spacer this way, rip the spacer (13).
For installation of the new wear insert (13) see Chapter 5.8.10 "Spider bearing".
Installation
INFORMATION
The spider bushing must slide into the seat of the spider without force. Do not
press in or cool the bushing under any circumstances. Rework the spider bushing
if necessary.
11/2013 Rev 0
If the delivery rate of the grease pump is too low and no other causes are detected, the
grease lubrication pump is defective and must be replaced (see ANNEX 9).
7 - 56
11/2013 Rev 0
Figure 53
7 - 57
7.4.9
Dust sealing
See Illustration 54
Dismantle the spider and the main shaft (see Chapter 7.4.2 and Chapter 7.4.3) and
replace the worn components of the dust sealing.
Unscrew the bottom sealing ring (1) from the top sealing ring (2) on the dismantled
main shaft and remove the plastic sealing ring (3).
Apply a small amount of grease to the new plastic sealing ring. Re-insert the spacer
disks (4). The plastic sealing ring must slide radially (clearance 1.0 to 1.5 mm) and may
not jam.
To replace the sealing housing (5), remove the oil seal (6), undo the bolts and remove
the sealing housing.
INFORMATION
Check the clearance (max. 3 mm) between the outer eccentric bushing in the bottom shell of the crusher and the eccentric bushing with the sealing housing dismantled. If the clearance is excessive, remove the outer eccentric bushing and
replace it.
Clean the bearing face of the sealing housing on the bottom shell of the crusher. Insert
a new toroidal sealing ring (7) and O-ring (8).
Place a new sealing housing in the seat of the bottom shell of the crusher and bolt it in
place. Ensure that the holes of the air and oil duct are on top of each another.
Insert the oil seal (6) and reinstall the main shaft and spider.
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7 - 58
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Figure 54
7 - 59
7.4.10
To dismantle the axial step bearing, remove the oil seal (4) and dismantle the sealing
housing (5) of the dust sealing. We also recommend removing the inner eccentric
bushing (6) (see Chapter 7.4.11).
Screw eye bolts into the threaded holes of the slide bearing plate (3) and attach the
slide bearing plate to a hoist.
Lift out the slide bearing plate and the step bearing lower part resting on it (2) through
the eccentric bushing. Tilt the slide bearing plate if it cannot be lifted off the piston of
the hydraulic cylinder.
Unscrew the step bearing upper part (8) from the main shaft. See Chapter 7.4.7.
Place the components of the axial bearings on top of each another and measure them,
i.e. determine the wear. The overall height of the new axial step bearing is approx. 200
mm.
The depth of the lubrication grooves in the step bearing upper part and the slide bearing plate is 8 mm in each case. If the overall height is less than approx. 185 mm (depth
of lubrication grooves only approx. 1 mm ) or if there is other damage, replace all the
components of the axial step bearing.
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7 - 60
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Figure 55
7 - 61
7.4.11
Check the inner eccentric bushing (and the main shaft) for grooves, cracks, run-in
marks caused by an excessive edge pressure and increased bearing temperatures.
Check the dimensional accuracy.
CAUTION
Plant damage due to damage to the eccentric insert
Damage to the machine/plant or its environment is possible.
Check the spider bushing of the upper spider bearing and replace them in case
of wear (see Chapter 7.4.8).
When mounting a new inner eccentric bushing, also replace the spider bushing.
Unscrew the device for compensating unbalance (2) from the eccentric bushing (3) and
screw eye bolts into the inner eccentric bushing (1).
Remove the inner eccentric bushing including the feather key (4) from the eccentric
bushing by means of a hoist.
Insert a new inner eccentric bushing and feather key in the groove of the eccentric
bushing and re-mount the device for compensating unbalance.
11/2013 Rev 0
7 - 62
11/2013 Rev 0
Figure 56
7 - 63
7.4.12
Empty the crusher, change over to local operation, lift the main shaft. Switch off the
crusher.
Open the inspection hole cover (4) on the bottom shell and place supporting trestles
(5) on the three arms of the bottom shell.
Lower the crusher axle so that the crushing mantle rests safely on the three supporting
trestles.
Lower the piston (5) of the hydraulic cylinder to the full extent.
Switch off the hydraulic unit and depressurise the hydraulic system.
Drive the maintenance car (with scissor-type elevating platform) under the hydralic
cylinder.
The hydraulic cylinder (2) and the ground (3) can be improved.
WARNING
Danger of crushing due to maintenance car moving
Death or severe bodily injuries are possible
Make sure no unauthorised persons are near the maintenance car.
Leave the area of danger!
11/2013 Rev 0
7 - 64
11/2013 Rev 0
Figure 57
7 - 65
Drain and collect residual oil from the lines, cylinder and the surface of the piston.
Remove the pipes of the hydraulic system (7) and (8) and the oil circulation lubrication
(9) and protect them from the ingress of dust.
Mark the position of the hydraulic cylinder with respect to the bottom shell.
11/2013 Rev 0
7.4.12.1
Figure 57
7 - 66
Position and use the maintenance car to dismantle the hydraulic cylinder (2) and the
ground (3) and the eccentric insert (1). See the documentation of the maintenance car.
Figure 58
INFORMATION
11/2013 Rev 0
Do not support the hydraulic cylinder (2) on the remaining pipes (7).
Move the scissor-type elevating platform with sub-structure under the hydraulic cylinder, see Illustration 59 (Video)
Lower the hydraulic cylinder (2) with the help of the scissor-type elevating platform and
move the maintenance car back to its initial position.
7 - 67
INFORMATION
Check the axial step bearing after the hydraulic cylinder has been removed and
replace it if necessary (see Exchanging the axial step bearing, Chapter 7.4.10).
11/2013 Rev 0
7 - 68
7.4.12.2
WARNING
Risk of squeezing due to moving maintenance car or scissor-type elevating
platforms
Death or severe bodily injuries are possible
Make sure no unauthorised persons are near the maintenance car.
Leave the area of danger!
Pay attention to the separate documentation in ANNEX 9.15 "Maintenance car
with scissor-type elevating platform".
WARNING
Risk of injury due to uncontrolled movements of the eccentric insert on the
base plate
Bodily injury possible
Lower the base plate and eccentric bushing, so that the eccentric bushing is still
guided in the bottom shell.
Secure the eccentric bushing against lateral sliding from the base plate.
11/2013 Rev 0
Persons may not stand on the upper scissor-type elevating playforn during the
lowering process
7 - 69
Drive the maintenance car with scissor-type elevating platform under the base plate.
Prepare the carrying device (6) with suitable fixing equipment (4) for lifting with the
crane. Also see Chapter 5.2 "Hoisting devices and slinging equipment"
Retract the scissor-type elevating platform slowly till end stop (A).
Lift the carrying device with the crane and insert the upper part of the carrying device
into the eccentric insert (1) (B). Here, adjust the carrying device (6) such that the fastening bolts of the base plate (2) are not covered.
Lift the carrying device further till it is located on the base plate (2) (C).
Secure the base plate (2) against sliding laterally by screwing it (5) on to the dismantling device (6).
11/2013 Rev 0
Figure 60
7 - 70
Unscrew the fastening bolts (3) of the secured base plate (2).
Remove and keep the spacer plates in sets for reuse (710) - important for setting the
backlash between the bevel pinion and the bevel gear.
Position the base plate (2) and the eccentric insert (1) on the scissor-type elevating
platform (D).
Lower the scissor-type elevating platform and move the maintenance car to the starting
position.
11/2013 Rev 0
7 - 71
Lift the eccentric bushing from the base plate and the axial bearing ring (4) using a
crane and set it down.
Heat the damaged/worn bevel gear (max. 150 C) and lift it off the eccentric bushing
(which can be re-used) by means of a hoist.
Replace the feather key (12) and install a new warm bevel gear.
CAUTION
Plant damage due to uneven wear
Damage to the machine/plant or its environment is possible.
When replacing the bevel gear, also replace the bevel pinion of the pinion
assembly (see Chapter 7.4.14.1).
11/2013 Rev 0
7 - 72
11/2013 Rev 0
Figure 62
7 - 73
See Illustration 63
Mounting the eccentric bushing:
Replace all the sealing rings and clean and oil the sliding surfaces before mounting the
eccentric bushing (3). Replace the sealing cord (4) of the base plate.
Place the maintenance car with scissor-type elevating platform under the crusher to
install the ground (5), axial step bearing ring (6) and eccentric insert (3). Secure the
components against sliding.
Move the eccentric insert (3) into the bushing (2) of the lower shell using the carrying
device (see Chapter 7.4.12.2 "Dismantling of the ground and the eccentric insert").
Place and align the spacer plate (710) on the base plate.
Lift the base plate and the eccentric bushing up further. Slightly turn the drive coupling/
pinion assembly shaft, so that the teeth of the bevel gear can engage the pinion.
Press the base plate into the seat of bottom shell; do not damage the sealing cord (4).
Screw on the base plate (5) by means of bolts (11).
Replace the O-rings and sealings on the flange of the hydraulic cylinder before mounting the hydraulic cylinder.
When mounting the hydraulic cylinder, ensure that the bores (residual oil drain) in the
base plate and the cylinder flange are on top of each other.
Re-connect the lubricating oil lines, hydraulic lines and distance sensor.
Close the revision opening for visual inspection of the provided backlash.
Lift the main shaft, remove the supporting trestles (12), close the inspection hole cover.
11/2013 Rev 0
7 - 74
11/2013 Rev 0
Figure 63
7 - 75
7.4.13
WARNING
Danger of crushing due to maintenance car moving
Death or severe bodily injuries are possible
Make sure no unauthorised persons are near the maintenance car.
Leave the area of danger!
Place the maintenance car with scissor-type elevating platform under the crusher (also
see the documentation of the maintenance car).
Secure the flange ring (2) of the outer eccentric bushing (1).
Unscrew the bolts and detach the flange ring of the outer eccentric bushing by means
of jack screws.
Lower the outer eccentric bushing and the flange ring, remove them from the working
area and replace them.
For mounting, oil the new outer eccentric bushing and re-mount in the reverse order.
11/2013 Rev 0
7 - 76
11/2013 Rev 0
Figure 63
7 - 77
7.4.14
7.4.14.1
7 - 78
Remove the protective hood over the crusher main drive motor.
Remove the hose connection (6) of the fluid switch (7) and drain and collect the oil from
the pinion assembly and dispose of it.
Attach the distance tube (8) to ropes, mark the flanged connections.
Push back the multiple-disc clutch (3) towards the motor (2) until the centerings of
distance tube are exposed.
Set down the distance tube and remove/set down the multiple-disc clutch (3) with
safety coupling (9) from the clutch hub (on the pinion assembly shaft) (4).
11/2013 Rev 0
11/2013 Rev 0
Figure 65
7 - 79
Unscrew the pinion assembly. Remove the shims (10) and keep them in a safe place
- they are important for setting the back lash between the bevel pinion and the bevel
gear.
Remove the pinion assembly partially from the pinion assembly tunnel using a cable
winch - keep it horizontal.
Again fix the rope pull and place the transmission with the pinion showing upwards into
a stable supporting unit.
Unscrew the end disk (11), screw in eye bolts and attach the pinion to a hoist.
INFORMATION
The roller bearings of the pinion assembly can be exchanged in this dismantled
state (see the following section).
Screw in the eye bolts before mounting the new bevel pinion. Preheat the new bevel
pinion to a max. 150 C in the oil bath and install it.
11/2013 Rev 0
7 - 80
11/2013 Rev 0
Figure 65
7 - 81
CAUTION
Plant damage due to uneven wear
Damage to the machine/plant or its environment is possible.
When replacing the bevel gear of the transmission, also replace the bevel pinion
(see Chapter 7.4.12.2 "Dismantling of the ground and the eccentric insert").
Insert the pinion assembly in the pinion assembly tunnel by means of cable winches.
Slightly turn the pinion assembly shaft (4) so that the pinion can engage in the bevel
gear.
Re-mount the distance tube (8), multiple-disc clutch (3) and safety coupling (9).
See Chapter 5.9.3 and ANNEX 9.3.
Fill with Chapter 8.5 "Lubricating instructions" filtered oil (25 m) according to the and
check the oil level on the oil level indicator (13).
11/2013 Rev 0
7 - 82
11/2013 Rev 0
Figure 65
7 - 83
7.4.14.2
Unscrew the bolts (1) and remove the bearing cover (2).
Place transmission shaft (3) vertically with the pinion side downward in a stable supporting device. Attach the pinion assembly shaft (4) to a hoist (A).
Detach the locking plate (5) and unscrew the shaft nut (6).
Unscrew the bolts (9) and remove the bearing cover (10) with helical compression
springs (11), spacer plates (24) and shaft sealing ring (12).
Remove the pinion assembly shaft (4) together with the bearings (16), inner race of the
bearing (17) and spacer sleeve (18) from the pinion assembly housing; place it horizontally on a support.
Remove the outer race of the bearing (17) from the housing (3).
Installation
Check all the spacer sleeves for grooving, replace if necessary.
Lower the pinion assembly shaft (4) into the housing together with the bearings (16).
Exchange the O-ring (22) and push the spacer sleeve (15) on the shaft.
Insert (9) bearing cover (10) with helical compression springs (11) and shaft sealing
ring (12).
Attach the locking plate (5) and tighten and secure the shaft nut (6).
Insert the shaft sealing ring (23) and tighten the bearing cover (2) by means of bolts (1).
11/2013 Rev 0
7 - 84
11/2013 Rev 0
Figure 66
7 - 85
7.5
Screw connections
Always protect all screwed and bolted connections against corrosion.
7.5.1
Machine structures
Standard
Quality
DIN 7984
8 / 10 / 12
Washer
DIN 6916
C 45 hardened
DIN 609
8.8
10.9
12.9
Nut quality:
10
12
11/2013 Rev 0
7 - 86
Bolt diameter
8,8
10,9
12,9
M6
11
15
18
M8
26
36
43
M10
51
71
86
M12
88
123
148
M16
211
300
358
M20
412
579
697
M24
711
1000
1196
M30
1422
2010
2403
M36
2481
3491
4197
M42
3991
5609
6727
M48
6021
8473
10150
M56
9650
13582
16279
M64
14416
20300
24320
INFORMATION
11/2013 Rev 0
Only use the tightening torques listed in the table when no special tightening torques are indicated in the relevant section.
7 - 87
7.5.2
Use bolts, nuts and washers from one manufacturer only. A uniform protection against
corrosion is compelling.
Material data
Manufacturer
data
Marked HSFG
10,9
yes
HSFG
10
yes
HSFG
yes
HSFG
Washer
as per DIN 6916
10.9
12.9
Nut quality
10
12
Quality
Hexagon bolt
DIN 6914
10.9 / 12.9
Hexagon nut
DIN 6915
10 / 12
Washer
DIN 6916
C 45 hardened
Use the required pretensioning forces indicated in the table below or in the drawing.
11/2013 Rev 0
Standard
7 - 88
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
As manufactured and
slightly oiled
M 12
50
100
120
M 16
100
250
350
M 20
160
450
600
M 22
190
650
900
M 24
220
800
1100
M 27
290
1250
1650
M 30
350
1650
2200
M 36
510
2800
3800
1)
Check the friction grip connection immediately following installation and at least once a year:
Pre-stressed bolt connections (DIN V 18800-7 1.2.2.2)
(1216) When using the torque method, at least 5 % of the sets of the connection must be
checked (at least 2 bolted connections for connections with less than 20 bolts). A test torque which is a maximum of 10% higher than the applied tightening torque is transmitted
to the set on the side on which it was tightened. Proceed as described in Table 7 depending on the angle of rotation that is achieved till the torque wrench is activated. If necessary, retain the element not to be turned in order to prevent it from turning.
Checking the pre-stressing force according to the torque method
(DIN V 18800-7 Table 7)
Angle of additional
rotation
Measure
none, pretensioning is adequate
30 to 60
> 60
replace the bolt, check two adjacent bolts of the same connection
11/2013 Rev 0
< 30
7 - 89
11/2013 Rev 0
Blank page
7 - 90
Lubrication
8.1
WARNING
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation
Death or severe bodily injuries are possible
Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off.
Maintaining the operating reliability and an adequate service life calls for orderly lubrication with lubricants which are most suitable for the individual application. It is not possible
to determine the complete characteristics of the lubricants by means of the reference values stated in the table of lubricants. The supplier of the lubricant is solely responsible for
the correct selection of the lubricant with due consideration given to the local conditions
and conditions of application of such industrial systems as well as the state-of-the art-in
the field of lubrication engineering.
The lubricants are provided by the owner on-site.
We will not accept any claim for defects or damage which can be attributed to incorrectly
selected lubricants.
In summary, we recommend the exclusive use of high-quality lubricants which have been
selected by reputable companies in accordance with our guiding values.
INFORMATION
All of the mineral oil companies stated in the table of lubricants offer a lubrication
service, and their technicians are available to our customers to answer any questions about appropriate lubrication.
11/2013 Rev 0
CAUTION
System damage through improper lubrication
Damage to the machine/plant or its environment is possible
Lubrication and any work in connection with lubrication must be carried out at
operating temperature with the machine/ plant at a standstill.
8-1
Storage of lubricants
Carefully close the container immediately after removing lubricant. Store the containers in enclosed dry indoor areas. You thereby avoid contamination of the lubricants.
Ensure that lubricants are stored, used and disposed of in an environmentally friendly
manner and comply with the relevant national environmental regulations when handling lubricants.
Observe the relevant national occupational safety, health and fire protection regulations when storing and handling lubricants.
Mark drums, canisters, oil cans and grease guns with different colours according to
their content. Mixing of lubricants is not allowed.
11/2013 Rev 0
8.2
8-2
8.3
8.3.1
Oil groups
The oil types listed in Chapter 8.4 "Table of lubricants (Index 8)" are broken down into the
following oil groups:
Mineral oils
CLP
Polyglycols
Poly-a-olefins
Hydraulic oils
HLP
Hydraulic oils
INFORMATION
Gear unit
To select oils, refer to the viscosity indicated on the ID plate of the gear unit.
Comply with the oil quality required by the manufacturer. If necessary, have the
quality confirmed by your supplier. Every lubricant manufacturer or supplier is
responsible for the quality of its products.
The required quantity depends on the oil level measured on the inspection glass,
the dipstick or the oil overflow opening.
Change the oil in accordance with the intervals stipulated by the gear unit manufacturer. In addition, check the oil level regularly and top-up, if necessary.
When the oil type is changed, as little old oil as possible may remain in the gear
unit. As a rule, small residues do not cause any problems. Gear oils of different
types and from different manufacturers may not be mixed together. If necessary,
have the compatibility of the new oil with the residues of the old oil confirmed by
the manufacturer.
11/2013 Rev 0
When changing from polyglycols to other gear oils or vice versa, always thoroughly purge the gear unit with the new oil. Residues of the old oil must be completely removed from the gear unit.
Carry out regular relubrication at appropriate intervals. Poor lubrication may cause
damage to the machine components.
When purging, use a low-viscosity oil type of the same basis and from the same manufacturer; never mix mineral oil with synthetic oil.
Rinse out and dry the bearing and bearing housing if a grease with different soap properties is to be used.
Completely fill the bearings with grease. Only partially fill the free space in the housing
with grease (around 30-50 %). Then mount the bearings.
8-3
After lubricating:
CAUTION
System damage from contamination in the grease
Damage to the machine/plant or its environment is possible
Work in a clean manner! Even minor contamination in the grease will affect the
service life of the bearing points.
8.3.2
DANGER
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation
Imminent danger of death or severe bodily injuries. Open toothed rim drives and
toothed racks may draw in and crush parts of the body
Never lubricate the machine while it is in operation.
11/2013 Rev 0
Thoroughly clean open toothed rim drive units and toothed racks before lubrication. Apply
lubricant in a thin and even layer.
8-4
8.3.3
Lubricant lines
11/2013 Rev 0
Ensure that the lubricant lines are thoroughly cleaned before commissioning and that they
are filled with the prescribed lubricant.
8-5
8.4.1
Standard lubricants
8.4.1.1
Lubricating oils
Index
number
Used for
Class
Aral
BP
ESSO
Fuchs
Europa
Mobil
Shell
Texaco
Klber
A1
ISO VG 32
HLP
Vitam
GF 32
Energol
HLP-HM
32
Nuto
H 32
Renolin
B 10
DTE 24
Tellus 32
Rando
HD 32
LAMORA
HLP 32
ISO VG
46 HLP
Vitam
GF 46
Energol
HLP-HM
46
Nuto
H 46
Renolin
B 15
DTE 25
Tellus 46
Rando Oil
HD 46
LAMORA
HLP 46
A3
ISO VG
68 HLP
Vitam
GF 68
Energol
HLP-HM
68
Nuto
H 68
Renolion
B 20
DTE 26
Tellus 68
Rando Oil
HD C-68
LAMORA
HLP 68
B1
ISO VG
32 HVLP
Vitam
HF 32
Bartran
HV 32
Univis
N 32
Renolin
MR 32 MC
DTE 13 M
Tellus
T 32
Rando Oil
HD AZ 32
ISO VG
46 HVLP
Vitam
HF 46
Bartran
HV 46
Univis
N 46
Renolin
MR 46 MC
DTE 15 M
Tellus
T 46
B3
ISO VG
68 HVLP
Bartran
HV 68
Univis
N 68
Renolin
MR 68 MC
DTE 16 M
Tellus
T 68
Rando Oil
HD CZ 68
C1
ISO VG
150 CLP
Degol
BG 150
Energol
GR-XP
150
Spartan
EP 150
Renolin
CLP 150/
Plus
Mobilgear
600 x P150
Omala
150
Meropa
150
Klberoil
GEM
1-150 N
C2
ISO VG
220 CLP
Degol
BG 220
Energol
GR-XP
220
Spartan
EP 220
Renolin
CLP 220/
Plus
Mobilgear
600 x P220
Omala
220
Meropa
220
Klberoil
GEM
1-220 N
ISO VG
320 CLP
Degol
BG 320
Energol
GR-XP
320
Spartan
EP 320
Renolin
CLP 320/
Plus
Mobilgear
600 x P320
Omala
320
Meropa
320
Klberoil
GEM
1-320 N
C4
ISO VG
460 CLP
Degol
BG 460
Energol
GR-XP
460
Spartan
EP 460
Renolin
CLP 460/
Plus
Mobilgear
600 x P460
Omala
460
Meropa
460
Klberoil
GEM
1-460 N
C5
ISO VG
680 CLP
Degol
BG 680
Energol
GR-XP
680
Spartan
EP 680
Renolin
CLP 680/
Plus
Mobilgear
600 x P680
Omala
680
Meropa
680
Klberoil
GEM
1-680 N
D1
ISO VG
150 CLP
HC
Degol
PAS 150
Renolin
Unisyn
CLP 150
Mobilgear
SHC XMP
150
Omala
HD 150
Pinnacle
EP 150
Klbersynth
GEM
4-150 N
D2
ISO VG
220 CLP
HC
Degol
PAS 220
Enersyn
EP-XF 220
(is no
longer produced)
Renolin
Unisyn
CLP 220
Mobilgear
SHC XMP
220
Omala
HD 220
Pinnacle
EP 220
Klbersynth
GEM
4-220 N
D3
ISO VG
320 CLP
HC
Degol
PAS 320
Enersyn
EP-XF 320
Renolin
Unisyn
CLP 320
Mobilgear
SHC XMP
320
Omala
HD 320
Pinnacle
EP 320
Klbersynth
GEM
4-320 N
D4
ISO VG
460 CLP
HC
Degol
PAS 460
Renolin
Unisyn
CLP 460
Mobilgear
SHC XMP
460
Omala
HD 460
Pinnacle
EP 460
Klbersynth
GEM
4-460 N
D5
ISO VG
680 CLP
HC
Renolin
Unisyn
CLP 680
Mobilgear
SHC XMP
680
Omala
HD 680
Klbersynth
GEM
4-680 N
A2
Hydraulic systems
B2
C3
Hydraulic systems
8-6
11/2013 Rev 0
8.4
Index
number
Class
Aral
BP
ESSO
Fuchs
Europa
Mobil
Shell
Texaco
Klber
E1
ISO VG
150 CLP
PG
Degol
GS 150
Renolin
PG 150
Tivela
S 150
Synlube
CLP 150
Klbersynth
GH 6-150
E2
ISO VG
220 CLP
PG
Degol
GS 220
Enersyn
SG-XP
220
Glycolube 220
Renolin
PG 220
Glycoyle
HE 220
Tivela
S 220
Synlube
CLP 220
Klbersynth
GH 6-220
ISO VG
320 CLP
PG
Degol
GS 320
Enersyn
SG-XP
320
Renolin
PG 320
Glycoyle
HE 320
Tivela
S 320
Synlube
CLP 320
Klbersynth
GH 6-320
E4
ISO VG
460 CLP
PG
Degol
GS 460
Enersyn
SG-XP
460
Glycolube 460
Renolin
PG 460
Glycoyle
HE 460
Tivela
S 460
Synlube
CLP 460
Klbersynth
GH 6-460
E5
ISO VG
680 CLP
PG
Degol
GS 680
Enersyn
SG-XP
680
Renolin
PG 680
Glycoyle
HE 680
Tivela
S 680
Klbersynth
GH 6-680
ISO VG
46 CL
Degol
CL 46
Energol
CS 46
Teresso
46
DTE Oil
Medium
Tellus Oil
C 46
Rando
Oil 46
ISO VG
100 CL
Degol
CL 100
Energol
CS 100
Renolin
DTA 100
Morlina
100
Rando
Oil EE
ISO VG
150 CL
Degol
CL 150
Energol
CS 150
Renolin
DTA 150
Morlina
150
Rando
Oil F
G3
ISO VG
220 CL
Degol
CL 220
Energol
CS 220
Renolin
DTA 220
Morlina
220
Ursa Oil
P 45
G4
ISO VG
320 CL
Degol
CL 320
Energol
CS 320
Renolin
DTA 320
Morlina
320
Viscoma
Oil 144
E3
Used for
F1
Non-return
devices
G1
G2
Neck bearings
and
Slide bearings
H1
Rollers
Motor oil
SAE 30
Kowal
Motor Oil
- VanellusT
-Energol
HDS
ESSOLUBE
-XD-3
-HDX
TITAN
Universal
HD SAE 30
Delvac
Super
Rimula
X 30
Ursa
Super LA
Ursatex
Klberoil
GEM
1-100 N
J1
Gear unit
chain links
API GL 4
SAE 90
EP
Gear Oil
Hyp 90
Gear Oil
EP SAE
90
Gear oil
GX-D 90
TITAN
Gear MP
SAE 90
Mobilube
HD 90-A
Spirax
G 80 W
90
Multigear
SAE
85 W-90
Klbersynth
GEM
4-220 N
Index
number
Pour point
- 24 C to - 27 C
- 42 C
- 9 C to - 24 C
- 30 C to - 48 C
- 27 C to - 45 C
F+G
11/2013 Rev 0
8-7
8.4.1.2
Lubricating greases
Marking to DIN 51502 / 51825
Base oil: Mineral oil
Saponification type: Lithium-12-hydroxystearate
Application temperature range: - 20 C to 120 C
Index
number
Used for
Class
Aral
BP
ESSO
Fuchs
Europa
Mobil
Shell
Texaco
Klber
K1
Grease lubrication
unit for spider bearing
NLGI
000
Aralub
GFP 000
Energrease
HT 000 EP
Low-viscosity
grease
000
Mobilux
EP 023
Simnia
Grease 000
CENTOPLEX
GLP 500
K2
Tooth couplings of
main shaft bearings
NLGI
00
Aralub
FDP 00
Energrease
HT-EP 00
Low-viscosity
gear
grease
Renolit
SO-D8024
Mobilplex
44
Alvania
GL 00
Marfak
00
MICROLUBE
GB 00
K3
Tooth couplings
and grease lubrication systems
NLGI 0
KPO K-20
Energrease
LS 0
Beacon
EP 0
Alvania
grease
EP ROEP1
Multifak
EP 0
MICROLUBE
GB 0
K4
Grease lubrication
systems
NLGI 1
KP1K-20
Energrease
LS-EP 1
Beacon
EP 1
Renolit
FEP 2
Mobilux
EP 1
Alvania
Grease EP
1
MICROLUBE
GL 261
K5
NLGI 2
KP2K-20
Aralub
H-LP 2
Energrease
LS-EP 2
Beacon
EP 2
Renolit
FEP 2
Mobilux
EP 2
Alvania
Grease EP
(LF) 2
Multifak
EP 2
CENTOPLEX
2 EP
K6
Roller bearings
(normal-duty type)
NLGI 3
K3K-20
Aralub
HL 3
Energrease
LS 3
Beacon 3
Renolit
FWA 220
Mobilux 3
Alvania
Grease RL
3
Glissando
FT 3
CENTOPLEX 3
8.4.1.3
Used for
Class
Aral
BP
ESSO
Fuchs
Mobil
Shell
Texaco
Klber
L1
Roller bearings
(high temperature
load)
NLGI 2
Mobiltemp
SHC 100
11/2013 Rev 0
Index
number
8-8
Used for
Class
Aral
BP
ESSO
Fuchs
Mobil
Shell
Texaco
L2
Roller bearings
(high temperature
load)
NLGI 2
Mobilith
SHC 220
Albida
PPS 2
Used for
Class
Aral
BP
ESSO
Fuchs
Mobil
Shell
Texaco
L3
Roller bearings
(high temperature
load)
NLGI 1,5
Mobiltemp
SHC 32
8.4.2
Special lubricants
8.4.2.1
Index
number
M1
Klber
Fuchs
Lubritech
transparent
GRAFLOSCON
A - G1 ULTRA
Klberplex
AG 11-462
Ceplattyn 300
M2
Inlet process
GRAFLOSCON
B - SG-00 ULTRA
Klberfluid
B-F 2 ULTRA
Inlet Ceplattyn - RN
M3
Operating lubrication
(Adhesive lubricant with good EP characteristics.)
FZG special test A/2, 76/50 > 12th Degree of
load,
Wear < 0.2 mg/kWh
GRAFLOSCON
C - SG-0 Ultra
Klberfluid
C-F 8 ULTRA
Ceplattyn KG 10 HMF
M4
GRAFLOSCON
C - SG-1000 Ultra
Klberfluid
C-F 4 ULTRA
M5
GRAFLOSCON
C - SG-2000 Ultra
Klberfluid
C-F 3 ULTRA
11/2013 Rev 0
black
8-9
8.4.2.2
Index
number
Used for
CASTROL
Class
CASTROL
ISO VG
32 HLP
Tribol 943 AW 32
ISO VG
46 HLP
Tribol 943 AW 46
N3
ISO VG
68 HLP
Tribol 943 AW 68
N4
ISO VG
100 CLP
Tribol 1100/100
ISO VG
150 CLP
Tribol 1100/150
ISO VG
220 CLP
Tribol 1100/220
N1
N2
N5
Hydraulic unit
Axle adjustment and overload protection.
Pinion assembly of the V-belt drive
Oil unit
Oil circulating lubrication
N6
BIO TOP
Greases
Index
number
Used for
P1
CASTROL
NLGI 000
Tribol 3020/1000-000
GP 000K-40
NLGI 00
Tribol 3020/1000-00
GP 00K-40
NLGI 2
KP2K-20
Tribol 3020/1000-2
Molub-Alloy
Bio Top 9488-1
BIO TOP
11/2013 Rev 0
P3
CASTROL
Class
8 - 10
8.4.2.3
Hydrodynamic couplings
Application range: Power transmission oils
Pour point down to -42 C
Index
number
Used for
Class
Aral
BP
ESSO
Fuchs
Europa
Mobil
Shell
Texaco
Q1
Hydraulic couplings
(Voith)
ISO VG 32
HLP
Degol BG
32
Energol
HLP-HM 32
Torque
Fluid N 45
Renolin
MR 10
Mobilfluid
125
Tegula
32
Rando
HD 32
8.4.2.4
Index
number
Used for
Class
Castrol
Klber
Mobil
Q2
Hydraulic couplings
(Voith)
ISO VG 32
Hyspin
AWH-M 32
Summit
HySyn
FG 32
SHC 524
Pour point - 42 C
Pour point - 45 C
Pour point - 63 C
8.4.2.5
Index
number
Used for
Class
Shell
R1
Hydraulic systems
ISO VG 32
Tellus
Arctic 32
11/2013 Rev 0
Used for
Class
Fuchs Europa
Quintolubric
S1
Hydraulic systems
ISO VG 46
PLANTOFLUX AT-S
VG 46
Quintolubric
888-46
S2
Hydraulic systems
ISO VG 68
PLANTOFLUX AT-S
VG 68
Quintolubric
888-68
8 - 11
8.5
Lubricating instructions
CAUTION
System damage due to incorrect indications of oil quantities and/or oil classes
Damage to the machine/plant or its environment is possible
The specifications on the type plates of gears, motors etc. referring to the oil
quantity and oil class to be filled take priority over the specifications in these
lubricating instructions.
Observe the lubricating instructions for components given in ANNEX 9.
Num
ber
Lubricant
acc. to
Chapter 8.4
index number
Oil circulating
lubrication system
Eccentric bearing:
Eccentric bearing
and eccentric
bushing, eccentric
insert and main
shaft, bevel gear
and drive pinion,
axial bearing main
shaft
C2,
recommendation D2
Transmission
C1
8 - 12
Hydraulic system
Axle adjustment
and overload protection
B2
Relubrication
We recommend
that oil checks
are carried out
every 3 months.
Without these
regular oil analyses, change the
oil every 2000 h,
but no later than
every 6 months.
Always check
the oil level in
the tank
before startup
We recommend
that oil checks
are carried out
every 3 months.
Without these
regular oil analyses, change the
oil every 2000 h,
but no later than
every 6 months.
Always check
the oil level in
the tank
before startup
Lubricant quantity
Oil change
Relubrication
approx.
1500 litres
and approx.
300 litres in
the system
Inspection
glass and
min./ max.
signal to control station
approx.
50 litres
Inspection
glass
approx.
250 litres and
approx.
40 litres in the
system
Inspection
glass and
min./ max.
signal to control station
11/2013 Rev 0
Lubricating point
Lubricating point
HYGUARD
Safety coupling
type BWL 125
Spec.
Lubricant
acc. to
Chapter 8.4
index number
K1,
Recommendation P1
Replenish
grease level
A1,
Recommendation N1
After every
15 releases or
after 12 months
at the latest:
Change oil
Relubrication
Lubricant quantity
Oil change
approx.
200 kg in the
grease tank of
Setting at
the grease
level indicator
pump and
approx. 50 60 litres in
the system
Relubrication
0.067 litres
11/2013 Rev 0
Grease lubrication
unit for spider
bearing
Spider bushing of
the spider and
wear insert of the
main shaft
Num
ber
8 - 13
11/2013 Rev 0
Blank page
8 - 14
11/2013 Rev 0
ANNEX
9.1
Drawings
9.2
Couplings
9.3
9.4
9.5
9.6
Monitoring devices
9.7
Central lubrication
9.8
9.9
9.10
Tools
9.11
9.12
9.13
Fluid starter
9-1
11/2013 Rev 0
9-2
9.1
Drawings
Name
Drawing No.
4602798
Installation plan
4470461 Sheets 1 - 5
4609197
Concaves, complete
4609240
4609235
Base, complete
4350085
Shaft, complete
4609199
4470280
4609204
4613028
Hydraulic cylinder
4207648
Spider bearing
4609216
4207101
4521963 Sheets 1 + 2
Drive, complete
4609407
Balancing device
4207649
Balancing cylinder
4207624
On-site piping
4613053
4350050
4350926 Sheets 1 + 2
Blower, complete
4350373
4207338
Cooler piping
4613051
Cylinder piping
4613052
Hydraulic unit
4358834
Hydraulic diagram
4473148
11/2013 Rev 0
9-3
11/2013 Rev 0
Blank page
9-4
9.2
Couplings
Multi-plate clutch
11/2013 Rev 0
Safety clutch
9-5
11/2013 Rev 0
Blank page
9-6
9.3
11/2013 Rev 0
9-7
11/2013 Rev 0
Blank page
9-8
9.4
11/2013 Rev 0
9-9
11/2013 Rev 0
Blank page
9 - 10
11/2013 Rev 0
9.5
9 - 11
11/2013 Rev 0
Blank page
9 - 12
Monitoring devices
11/2013 Rev 0
9.6
9 - 13
11/2013 Rev 0
Blank page
9 - 14
11/2013 Rev 0
9.6.1
9 - 15
11/2013 Rev 0
Blank page
9 - 16
11/2013 Rev 0
9.6.2
9 - 17
11/2013 Rev 0
Blank page
9 - 18
Fluid switch for monitoring the oil filling of the pinion assembly
11/2013 Rev 0
9.6.3
9 - 19
11/2013 Rev 0
Blank page
9 - 20
11/2013 Rev 0
9.6.4
9 - 21
11/2013 Rev 0
Blank page
9 - 22
11/2013 Rev 0
9.6.5
9 - 23
11/2013 Rev 0
Blank page
9 - 24
Central lubrication
11/2013 Rev 0
9.7
9 - 25
11/2013 Rev 0
Blank page
9 - 26
11/2013 Rev 0
9.8
9 - 27
11/2013 Rev 0
Blank page
9 - 28
11/2013 Rev 0
9.9
9 - 29
11/2013 Rev 0
Blank page
9 - 30
Balancing device
11/2013 Rev 0
9.9.1
9 - 31
11/2013 Rev 0
Blank page
9 - 32
Hydraulic cylinder
11/2013 Rev 0
9.9.2
9 - 33
11/2013 Rev 0
Blank page
9 - 34
Tools
11/2013 Rev 0
9.10
9 - 35
11/2013 Rev 0
Blank page
9 - 36
11/2013 Rev 0
9.11
9 - 37
11/2013 Rev 0
Blank page
9 - 38
11/2013 Rev 0
9.12
9 - 39
11/2013 Rev 0
Blank page
9 - 40
Fluid starter
11/2013 Rev 0
9.13
9 - 41
11/2013 Rev 0
Blank page
9 - 42
11/2013 Rev 0
9.14
9 - 43
11/2013 Rev 0
Blank page
9 - 44