Manual Chancador Primario en Ingles

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09-09-2011 J.PARADA
DATE: ________________ SIG.________________
TYPE “TS” AND “TSU”

GYRATORY CRUSHER
INSTRUCTION MANUAL
MANUAL NO.: 59001427

CUSTOMER: SIERRA GORDA
PROJECT: MINERA QUADRA CHILE LIMITADA
CONTRACT NO.: 11-20472-720
SIZE: 1100 x 1800
MODEL: Type “TS”
Gyratory Crusher
TYPE “TS” & “TSU”
upper portion of the crusher forms a stationary
crushing surface consisting of a cone-shaped chamber made up of the middle
and top shell sections. The chamber is lined with wear-resistant liners called
concaves. Inside the gyratory crushing surface is a moving shaft assembly,
called a main shaft. The main shaft is lined with a wear resistent liner called a
mantle. Relative movement between these surfaces creates the crushing
function.
At the top of the crusher is a support for the main shaft, referred to as the spider
assembly. The spider assembly incorporates a machined journal that positions
(restrains laterally) the upper end of the main shaft.
The spider is a cast-steel structure with the hub in the center and two integrally
cast arms. The ends of the arms are tapered and machined to fit into pockets in
the top shell. Bolts secure the spider to the rim of the top shell, seating the
spider in the tapered pocket.
The shell and the main shaft are covered with liners called concaves on the shell,
and mantles on the main shaft. Typically, when the mantle wears, the main shaft
assembly is removed and replaced with another rebuilt main shaft assembly.
The mantle on the removed main shaft can then be replaced, ready for the next
change-out. Concave replacement is carried out in place, with the main shaft
assembly removed. The concave liners are usually replaced as a complete set.
Concave liners may be installed individually or per row, via specialized
installation tooling.
Note that the part of the main shaft assembly in contact with the ore is the
mantle. The mantle is retained on the main shaft by a heavy head nut. This nut
is self-tightening due to the crushing action. The crushing head is supported
laterally at the top in the spider journal.
At the lower end of the crusher, the main shaft journal passes through the
eccentric. This arrangement offsets the lower end of the shaft with respect to the
centerline of the crusher. Therefore, when the eccentric is rotated by the gear
train, the lower end of the main shaft gyrates (moves back and forth in a small
circular path within the crushing chamber), progressively receding from and
approaching the stationary concave liners.
Air is used to pressurize the area above the eccentric. This area is created by an
enclosure called the dust seal bonnet. The core is sealed against the dust seal
bonnet by a dust seal ring located at the bottom of the core. This dust seal ring
runs against the outer periphery of the dust seal bonnet. By pressurizing the
area inside the dust seal bonnet, dust is prevented from entering the area and
contaminating the lubrication system and the eccentric.
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The OSS should be checked weekly, whenever there is reason to suspect

that the setting has changed, or after major crusher maintenance work
that may have affected the setting. The OSS is impossible to measure
while the crusher is operating, but the closed-side setting (CSS), or gap, is
easily measured. The crusher throw is defined as the offset distance of
the eccentric journal of the crusher. Knowing the throw and the closed-
side crusher gap, the open-side setting can easily be calculated by the
equation:
CSS + THROW = OSS
The closed-side setting is measured by passing a soft malleable metal,

such as a lead or foil ball, through the crusher. The ball is only slightly
larger than the crusher open-side setting, and it is attached to a rope or
wire so that it may be easily retrieved after it has passed through the
crusher. The ball is slowly lowered through the crusher and, as the ball
passes through the crusher, the crusher compresses it to a thickness
equal to the CSS. After the ball is retrieved, the operator can measure the
ball to determine the closed-side setting, and then perform the above
calculation to determine the OSS.
The primary crusher is adjusted by raising or lowering the mantle with the
hydraulic adjustment system. Lowering the mantle increases the OSS;
raising the mantle decreases the OSS. The crusher gap is checked and
set while the crusher is operating and the crusher chamber is empty.
PROCEDURE:
1) Ensure that the crusher is running empty.
THE CRUSHER SHOULD NEVER OPERATE MORE THAN

15 MINUTES WITHOUT LOAD OR TIRES.
2) Ensure that the operator performing the CSS measurement

is equipped with a safety harness and that the harness is
securely attached to a fixed object. The CSS measurement
requires the operator to stand at the edge of the crusher
dump pocket above the running crusher.
3) Tie a lead or foil ball to a rope and lower it through the
running crusher.
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4) Retrieve the ball and measure the smallest dimension. This

dimension is the closed-side setting (CSS).
5) Calculate the crusher open-side setting (OSS), and
determine how much, if any, the mantle height needs to be
adjusted.
6) If the OSS is not within the target range setting, the mantle
must be raised or lowered to attain the desired OSS. The
mantle height may be adjusted using the local hydraulic
adjustment system controls or using the controls in the
control room. The following steps describe how to adjust the
crusher mantle height. (NOTE: The crusher mantle height is
displayed in inches or mm.)
A. Approximate how far the mantle must be raised or

lowered to attain the desired crusher setting, and use
the calibration curve to determine the percent mantle.
B. With new crusher concaves and mantle, an upward
movement of of 1 inch (25 mm) the mantle gives an
OSS reduction of approximately .25 - .40 inch (6-10
mm) depending on machine size and crushing
chamber geometry. Always check any adjustment by
measuring OSS directly.
C. If the mantle must be raised, start the hydraulic
adjustment system motor. Allow the motor to run for
a couple of minutes to ensure the adjustment system
is filled with oil.
D. If the mantle needs to be raised, depress the Raise
pushbutton. Watch the mantle height on the mantle
height indicator, and release the pushbutton when the
mantle height has increased the desired amount.
E. If the mantle needs to be lowered, depress the Lower
pushbutton. Watch the mantle height on the mantle
height indicator, and release the pushbutton when the
mantle height has decreased the desired amount.
(NOTE: If the mantle needs to be lowered, the motor
does not have to be started.)
F. Measure the crusher CSS again, and calculate the
OSS.
G. If the OSS is not within the target range setting, adjust
the crusher mantle height again. If the OSS is within
the target range setting, turn off the hydraulic
adjustment system motor.
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5.7.3 – CLEARING THE CRUSHER
SPECIAL EQUIPMENT REQUIRED:

1) Barricades
2) Excavator
3) Special abrasion-resistant rope and lifting slings
4) Rigging gear
5) Body harness
6) Pry bars
7) Hooks
8) Primary crusher service crane
9) Primary crusher hydraulic rock breaker
During the course of normal crushing operations, there may be occasion

(such as a temporary power failure or an interlock trip condition) when the
crusher stops with ore in the dump pocket and crushing chamber. When
this occurs, the following procedure should be followed to restart the
crusher.
PROCEDURE:
1) Depress the hydraulic adjustment system mantle Lower
pushbutton until the mantle has dropped approximately ¾” to
1 inch (20 to 25 mm), as shown on the mantle position
indicator.
2) Energize the crusher motor.
3) Allow the crusher to clear itself.
4) Start the hydraulic adjustment system and allow it to run for
about 20 seconds. (NOTE: All crusher mantle adjustments
should only be made with the crusher stopped or running
empty.)
5) Depress the hydraulic adjustment system Raise pushbutton
to bring the mantle back to its normal position.
6) If the crusher cannot be cleared in this manner, lower the
mantle a little more and try again.
7) If successive attempts to lower the mantle and start the
crusher fail, the crusher may be overloaded or there may be
an uncrushable object such as a shovel tooth or drill bit
which is larger than the open-side setting wedged in the
crusher. It may be necessary to clear all material from the
crushing chamber to determine why the crusher cannot be
started. The crusher may be cleared by using an excavator
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to reach down into the crushing chamber to clear the

material. Attempts to start the crusher may be made as
more and more material is cleared. (NOTE: Ensure that
sufficient time is allowed between attempts to avoid
overheating and damaging the crusher motor.)
8) As the excavator is clearing the crushing chamber, a single
large rock that is preventing the crusher from starting may be
uncovered, or a piece of tramp metal wedged between the
mantle and the concaves may ultimately be uncovered.
A. If a large rock is uncovered, an attempt should first be

made to break the rock with the rock breaker. If this
is unsuccessful, the rock must be removed from the
crushing chamber with the service crane
B. If the crusher has been jammed with tramp metal, it
will be necessary to remove the object with a thermal
torch or an oxy-acetylene torch
5.7.4 – CLEARING TRAMP MATERIAL JAM

1) Lockout locks
2) Approved respirator
3) Work gloves
4) Safety harness
5) Work cage
6) Heat-resistant protective clothing
7) Face shield
8) Shaded welding goggles
9) Thermal cutting torch
10) Oxy-acetylene cutting torch with extensions
11) Oxygen
12) Acetylene
13) Rubber safety boots
14) Flashlight or suitable light source
Clearing tramp metal from a gyratory crusher is a major problem that

usually requires many hours of downtime to resolve. Accordingly, every
effort must be made to prevent uncrushable objects from entering
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the crusher. The normal remedy is to clear such jams with a thermal
cutting torch or an oxygen-acetylene cutting torch.
Each circumstance must be evaluated to determine the best and safest

course of action. Using a thermal cutting torch is considered a safe
method to remove tramp iron. Oxygen-acetylene cutting torches with
extra-long gas-mixing chambers (also called butts) are also used to cut
metals. Cutting and burning metals, such as tramp iron, is generally
slower with oxygen-acetylene torches.
The thermal cutting torch is a self-contained tool consisting of a

combination of special metal alloy wires inside a long steel pipe. Sections
are available in standard lengths (usually about 10 feet long), and two or
more lengths may be coupled together to reach into the crusher cavity.
The torch generates heat to temperatures exceeding 2,475ºC (4,487ºF)

when the alloys combine with pressurized oxygen forced through the pipe.
The intense, concentrated heat generated by the torch melts the tramp
iron with such speed that there is usually no structural damage to the
surrounding materials. The procedure is specific for a thermal cutting
torch. The techniques described are also applicable to an oxy-acetylene
cutting torch.
PROCEDURE:
1) Notify the mine or haul truck dispatch that the crusher is
shutting down and no more ore may be dumped into the
crusher. Turn the dump light to the NO DUMPING position.
2) Erect barricades to block access to the dump pocket area.
3) Post signs on the barricades that say, “No Dumping—
Workers in Crusher”.
4) Lock out the primary crusher and the rock breaker according
to lockout procedure.
5) Clear the crusher of ore.
Always work from the top of the crusher and never

enter the crushing cavity. Preferably, the cutting
torch operator should work from a suspended cage.
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6) The torch operator should either stand in a cage, lowered

into a position above and to the side of the tramp iron, or
stand on a temporarily constructed steel platform erected for
clearing the crusher. A thermal cutting torch pipe can be
easily lengthened and bent to reach the tramp iron without
placing a person in the crusher.
Do not attempt to dislodge or loosen the tramp

material with a sledgehammer, pry bar, or long
pipe. Serious personal injury could result.
Anyone working near the top of the crusher must
wear an approved safety harness with a line
securely fastened to a fixed object.
The tramp metal may be under stress. Relieving
the stress by heating may cause the tramp metal
to be forcibly ejected. Place the work platform in
a protected position.
7) Connect the cutting torch to an oxygen supply, and set the

oxygen pressure to permit a small amount of oxygen to flow
through the cutting torch.
8) Ignite the cutting torch while carefully following the
manufacturer’s operating instructions.
When working with torch cutting equipment, use

heat-resistant protective clothing and gloves,
shaded welding goggles, hardhat, and face shield.
9) Open the oxygen-regulating valve completely. The cutting

torch should now burn vigorously.
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When doing any torch cutting around a crusher,

wear a respirator. The noxious fumes produced
during the cutting process can be harmful if
breathed continuously in concentrated form. Avoid
inhaling fumes. Provide adequate ventilation.
Do not permit anyone to watch (i.e., to be in a line of
sight of) the operation. It is possible for material
released from the crusher to fly out with great force
and velocity.
10) After the tramp iron has been located, lower the cutting torch
into the crushing cavity and proceed to “wash” the tramp
metal away. Start at the top of the tramp iron and wash the
molten metal downward. It is very important that the molten
metals runs out freely and not forms a puddle on the tramp
iron. Slightly rotate the cutting portion of the torch to
accelerate the washing operation and to keep the tramp iron
from rewelding to itself.
Do not touch the tramp iron or put any pressure on

it with the torch. Always maintain a short gap when
cutting metals. Always keep the torch moving in
order to prevent it from being fused to the metal
being burned.
11) During the cutting operation, protect the discharge feeder

from sparks, molten slag, and metal by maintaining ore in
the crusher surge hopper or otherwise blocking material from
reaching the discharge belt feeder. It is possible for molten
slag to drop out of the crusher onto the belt feeder.
12) When using a thermal cutting torch, work quickly because
the burning time of a 10-foot-long thermal cutting torch is
only 3 to 5 minutes. Never start with a torch less than 10
feet long because the torch is consumed during burning.
The pipe portion of a thermal cutting torch is similar to a
conventional welding electrode in that the entire length of
pipe is self-consuming (it “disappears” during use). Save the
thermal torch remains and remove them from the crusher.
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Do not use a thermal cutting torch when the pipe

length is shorter than 5 feet (1.5 m). Either thread or
push on an additional 10-foot (3-m) length. The
cutting torches are designed for quick attachment
of additional lengths.
13) When the tramp metal is removed, inspect the crusher and
discharge conveyor for damage.
14) Remove the lockouts and barricades and restart the crusher.
5.8 – PROPER ROCK BREAKER INSTALLATION

INTRODUCTION:
Hydraulic rock breakers are a common piece of equipment installed and used at
a primary gyratory crusher station. This equipment is commonly used to
manipulate over size and irregular shaped pieces of ore into the crusher and to
break the pieces of feed that can not be manipulated into the crusher into smaller
pieces that will enter the crushing chamber. Since the inception and
popularization of hydraulic rock breakers, the number of occasions in which
spider shields, spider caps, top shell wearing plates and the upper rows of
concaves have been dislodged from crushers has increased. Investigations of a
number of these occurrences has revealed the primary causes to be an
obstructed operator’s view and/or an overly aggressive use of the rock breaker.
The crusher operator must have an un-obstructed view of the pick end of the
rock breaker whenever hydraulic power is applied to the pick.
The view of the entire crusher dump pocket and crushing chamber should be
available from the rock breaker controls. The view of the dump hopper and
crushing chamber should not be obstructed by seemingly insignificant items such
as lighting, cameras, junction boxes, etc.
Closed circuit TV is a common way of providing an un-obstructed view.
When CC TV is used, the placement of the monitor is as important as the
placement of the camera(s). The TV monitor must be in a position that is visible
to the operator whenever the rock breaker is in use.
5.9 – PROPER ROCK BREAKER USE

INTRODUCTION:
The function of a rock breaker is to apply the amount of force required to break
any over sized rock located anywhere in the dump hopper and the crushing
chamber.
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This requirement often requires the use of the rock breaker in close proximity to
major crusher components.
Care should be used not to contact any part of the crusher with any part of the
rock breaker, including the rock breaker arm or rock breaker pick housing, during
the use of the rock breaker.
Improper use of the rock breaker can damage

crusher components. Avoid contact of any part of
the crusher with any part of the rock breaker.
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SECTION 6:
MAINTENANCE
Introduction 6.1
Manganese Steel Growth and

Trimming of Concaves and Mantles 6.2
Preventative Maint. Checksheets 6.3
Component and Subassembly Removal/Replacement 6.4
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A Teflon seal is installed in a groove in the gear cover assembly above the
eccentric. The seal rides against the journal of the main shaft and contains oil
splashed from the eccentric.
The main shaft is supported at its lower end by a thrust bearing. The thrust
bearing is, in turn, supported on a hydraulic piston and cylinder assembly. Oil is
trapped under the piston in the cylinder assembly. By varying the amount of oil,
the main shaft is raised or lowered to adjust the proximity of the mantle relative to
the crushing chamber.
When the crusher is empty, the main shaft and crushing head rotate, driven by
the oil shear friction within the eccentric journal.
1.3 - CONTACT INFORMATION

Our Website, www.flsmidth.com contains current, specific e-mail and telephone
information for our customer service managers and supervisors in each of our
global group company locations. If you prefer, the general information for each
of our regional group companies is listed below.
Note: If you call or e-mail one of the general numbers/addresses listed below,
make sure to inform the receptionist (or include something in the subject line of
the e-mail) that you wish to contact someone in the customer service, parts, or
field service department.
If you are unsure which FLSmidth group company is responsible to service your
plant, contact FLSmidth Inc., which is our global headquarters.
o FLSmidth Minerals Inc.(Global Headquarters)
Telephone: +1-610-264-6900
Telefax: +1-610-264-6996
E-mail: FLSM-US@flsmidth.com
o FLSmidth Minerals Pty Ltd. (Melbourn, Australia)

Telephone: +011-61-3-8336-1233
Telefax: +011-61-3-8336-1244
E-mail: FLSM-au @flsmidth.com
o FLSmidth Minerals Pty Ltd. (Perth, Australia)

Telephone: +011-61-8-9325-9990
Telefax: +011-61-8-9325-9991
E-mail: FLSM-au @flsmidth.com
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6.1 – INTRODUCTION
The purpose of this maintenance section is to provide the maintenance
technicians and planners with the information and procedures required to
effectively maintain, troubleshoot, and repair the crusher and its auxiliary
systems.
Specifications are provided to prepare for component repair and replacement, as
well as maintaining the crusher assembly while in operation and during shutdown
periods.
Preventive maintenance checksheets are provided to assist maintenance
personnel and crusher operators in maintaining and operating the crusher and its
systems. The checksheets specify recommended routine mechanical,
lubrication, electrical, and instrument inspection tasks. The checksheets can
also be used by operators for cursory running inspections and to report potential
and current problems to maintenance personnel.
Predictive maintenance forecasts and failure mode effect analysis provides
proactive and active guidelines for troubleshooting and maintaining the crusher
and its systems. The consistent and correct use of these maintenance tools is
intended to contribute to the optimum efficiency and economic life of the crusher
assembly.
The component replacement and repair instructions are provided to serve as a
baseline set of procedures for the replacement and/or repair of major wear
components. The intent of these procedures is to make the replacement/repair
effort consistent among work crews, and provide a basis for continued revision
and improvement. The ultimate goal is to improve the efficiency, productivity,
and economic life of the crusher and its auxiliary systems.
6.2 – MANGANESE STEEL GROWTH AND TRIMMING OF

CONCAVES AND MANTLES
During crushing of medium hard to hard ores the surface of manganese steel
concaves and mantles grow (peen). This surface growth flows into the gaps
between the concaves and mantles. As the growth continues, the concave gaps
peen shut. The surface growth continues, however, and large forces develop in
the concaves and mantles.
This force is transferred to the middle and upper shell sections and in cases
these forces have been great enough to cause shell failures.
The growth of manganese steel mantles can cause a large force to be applied to
the head nut threads making the removal of the head nut difficult and
occasionally damaging the threads on the main shaft.
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In mining applications, the abrasive wear rate of the mantle usually exceeds the
growth rate of the manganese and consequently the joints between the mantle
parts never close before the mantle parts are replaced. Occasionally, however,
the peening occurs at the joint between the upper mantle and the burn out ring.
The peening (growth) of the manganese during crushing is a condition that
affects only the surface of the concaves and mantle. Usually, the depth of this
growth zone is ½” to ¾” [12 mm to 16 mm].
To prevent damage to the crusher, it is necessary to periodically scarf (burn)
away any material that flows into the concave and mantle joints.
Care should be used during the scarfing not to damage the epoxy in the joints
between the concaves.
Usually, the scarfing is done at a 45 ° angle to allow for maximum growth before
the next scarfing.
Scarfing joints is accomplished by using a high-amperage welding machine (400
to 600 Amp) and carbon-arc rods.
The surface of alloy concaves does not work-

harden and grow, so there is no need to scarf the
joints of the alloy concaves.
6.3 – PREVENTATIVE MAINTENANCE CHECKSHEETS

The following preventive maintenance checksheets are included in this section:
Mechanical - Daily Section 6.3.1

Mechanical - Weekly Section 6.3.2
Electrical - Weekly Section 6.3.3
Mechanical - Monthly Section 6.3.4
Electrical - Monthly Section 6.3.5
Mechanical – Annual Section 6.3.6
Electrical - Annual Section 6.3.7
Mechanical – Major Section 6.3.8
Instrument - Quarterly Section 6.3.9
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6.3.1 – Mechanical Preventative Maintenance (Daily)
EQUIPMENT:
¾ Crusher Assembly
¾ Lubrication System Skid
¾ Hydraulic System Skid
¾ Spider Bushing Lubrication System
SAFETY:
1) This is a running inspection. DO NOT reach behind or remove
safety guards. DO NOT work on running equipment except for
specified running inspections and adjustments.
2) Ensure that all personal protective equipment is being used.
3) Ensure that all test equipment is correctly calibrated and in good
operating condition.
4) After completion of the PM tasks, ensure that all safety guards,
labels, and signs are in place and properly secured.
COMMENTS:
The primary crusher is started, stopped, and operated from the control
console located in the control room. The primary crusher lubrication system,
hydraulic adjustment system, and spider lubrication system can also be
started from the control console in the control room. These units also have
local control panels normally used for maintenance purposes. Although the
operation of the primary crusher is accomplished almost entirely from the
control console, maintenance personnel can assist the control room operator
with field observations of ore movement to and through the crusher as well as
a variety of observations of the operation of the unit and its auxiliary systems.
Immediately notify a supervisor of any problems or potential problems
concerning safety or problems that might cause equipment downtime.
Document unusual conditions observed, measurements made, and any work
required.
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Item Task Repairs Required,

Date, Initial
Section 6.3.1 (con’t) MECHANICAL PREVENTATIVE MAINTENANCE (DAILY)
CRUSHER General Operating Conditions
ASSEMBLY Closely observe the operation of
the crusher for unusual conditions
such as sounds, odors, excessive
temperature, and vibration.
Spider Bushing
When visible, observe the area
between the spider and mantle for
excessive grease. When grease
delivery is correct, arrange for a
thorough inspection of the bushing
or excessive wear or damage.
Shell and Spider Bolts/Nuts
Inspect the shell and spider bolts
for missing items and signs of
looseness. Arrange for
adjustments and replacements as
required.
Countershaft Assembly
Inspect the countershaft assembly
mounting flange and countershaft
seal for signs of lubricant leakage.
Arrange for required repairs and
adjustment.
Countershaft Extension
Couplings
Observe the operation of the
countershaft extension for unusual
noises and vibration. Arrange for
required repairs.
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Date, Initial
CRUSHER Lube Oil Supply
ASSEMBLY Check the lube oil supply flow
(continued) meters to ensure the flow is steady
and is moving at the correct flow
rate. Check the hoses, pipelines,
and fittings for damage and leaks.
Arrange for required repairs.
Lube Oil Return
Check the return hoses, pipeline,
and fittings for damage and leaks.
Check the return oil temperature
through the DCS. Arrange for
more thorough inspections and
repairs as required.
LUBRICATION Lube Oil Pumps
SYSTEM SKID Check the operating oil pump for
unusual conditions such as
sounds, odors, excessive
Arrange for more thorough
inspection and repairs as required.
Reservoir
Check the level of the oil in the
reservoir with the sight gauge.
During normal operation the level
should be at the mark on the sight
gauge.
Pressure Relief Valve
Check that the pressure relief
valves are not chattering and are
not excessively hot. Check the
pressure in the lines downstream
of the valves for steady operation.
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Date, Initial
LUBRICATION Hoses, Pipe Lines, and Fittings
SYSTEM SKID Check all hoses, pipe lines,
(continued) gaskets, seals, and fittings for
leaks. Arrange for required repairs.
Oil Filter
Check the oil filter differential
pressure gauge. Switch to the
stand-by filter if the pressure
exceeds the maximum operating
pressure. Arrange to have the dirty
filter cleaned.
COOLERS Coolers (Radiators)
Check the coolers for damage and
Cooling Fans
Inspect the fans and their shrouds
for contact and damage. Arrange
for required repairs.
Hoses, Pipe Lines, and Fittings
Check all hoses, pipe lines,
gaskets, seals, and fittings for
Oil Temperature
Check the temperature of the oil
entering and leaving the coolers.
Record unusual conditions.
HYDRAULIC Oil Pumps
ADJUSTMENT Check the operating oil pump for
SYSTEM SKID unusual conditions such as
sounds, odors, excessive
Arrange for more thorough
inspection and repairs as required.
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Date, Initial
HYDRAULIC Reservoir
ADJUSTMENT Check the level of the oil in the
SYSTEM SKID reservoir with the sight gauge.
(continued) During normal operation the level
should be at the mark on the sight
gauge.
Check that the pressure relief
valves are not chattering and are
not excessively hot. Check the
pressure in the lines downstream
of the valves for steady operation.
Oil Filter
Check the oil filter differential
pressure gauge. Switch to the
stand-by filter if the pressure
exceeds the maximum operating
pressure. Arrange to have the dirty
filter cleaned.
SPIDER BUSHING Air Pressure (if air operated
LUBRICATION system is provided)
SYSTEM Ensure the inlet air pressure to the
pump is at or near plant air
pressure on the pressure gauge
near the regulator.
Regulator (if air operated system
is provided)
Check the air regulator for damage
or leaks. Arrange for required
repairs.
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Rev. 0
GYRATORY CRUSHER
Date, Initial
SPIDER BUSHING Air Filter (if air operated system

LUBRICATION is provided)
SYSTEM Check the condition of the filter
through the filter bowl. If the filter is
(continued)
not visible through the bowl,
arrange for cleaning of the filter
when the crusher is not operating.
Drain the filter with its valve if it is
not equipped with an automatic
drain valve.
Lubricator (if air operated
system is provided)
Check the oil-dispensing rate of
the air line lubricator; it should be
two drops per minute. Adjust as
required with the adjustment valve
on the lubricator. If the oil drops
are not visible arrange for cleaning
of the filter when the crusher is not
operating.
Grease Pump
Check the pump for unusual
conditions such as sounds, odors,
excessive temperature, and
vibration. Arrange for more
thorough inspection and repairs as
required.
Grease Drum
Check the level of the grease in
the drum either visually or with the
weight reading scale (if provided).
Arrange for a replacement drum as
required.
7.500762 M-9
Rev. 0
GYRATORY CRUSHER
6.3.2 – Mechanical Preventative Maintenance (Weekly)
EQUIPMENT:
¾ Crusher Assembly
PREVENTATIVE MAINTENANCE DESCRIPTION:
MECHANICAL WEEKLY – SHUTDOWN PREVENTATIVE MAINTENANCE

INSPECTION
SAFETY:
1) Ensure that the crusher drive motor, lubrication system, and hydraulic
adjustment system are inactive to avoid interference with their
operation due to mechanical inspection and tests.
2) Prior to proceeding with mechanical PM tasks, check for the presence
of main and control power at appropriate equipment. Control power
may be in the form of media pressure, temperature, or low- or high-
voltage electrical power.
5) After completion of the PM tasks, ensure that all safety guards, labels,
and signs are in place and properly secured. Remove locks and tags
from the appropriate equipment, and release the system or unit for
service according to established procedures.
COMMENTS:
with field observations of ore movement to and through the crusher as well as
a variety of observations of the operation of the unit and its auxiliary systems.
Document any and all unusual conditions observed, measurements made,
and any work required.
7.500762 M - 10
Rev. 0
GYRATORY CRUSHER

Date, Initial
Section 6.3.2 (con’t) MECHANICAL PREVENTATIVE MAINTENANCE (WEEKLY)
CRUSHER Daily PM Tasks
ASSEMBLY Complete the daily PM tasks
specified in PM Checksheet
Correct all abnormal conditions
observed and measured.
Mantle
Check the mantle for excessive
wear and cracks. Repair or
replace as required.
Head Nut
Check the space between the
head nut and the bottom of the
spider to determine the amount of
wear and remaining shaft
adjustment. Record observations.
Concave Surfaces
Check the concaves for excessive
wear and cracks. Repair or
Manganese Steel Concave and
Mantle Joints
Concaves:
Check the concave joints to make
sure that they have not peened
shut.
NOTE: Concave joints
peening shut may cause great
pressure to accumulate in the
concaves, transferring this
pressure to the middle and upper
shell sections.
7.500762 M - 11
Rev. 0
Gyratory Crusher
o FLSmidth ABON Pty Ltd. (Melbourne, Australia)
Telephone: +011-61-3-9338-7011
Telefax: +011-61-3-9338-3765
E-mail: ABON@flsmidth.com
o FLSmidth Ltda. (Sorocaba, Brasil)

Telephone: +011-55-15-2101-7878/3224-3080
Telefax: +011-55-15-2101-7860
E-mail: FLSM-br@flsmidth.com
o FLSmidth Minerals Ltd. (Toronto, Canada)

Telephone: +1-416-284-8200
Telefax: +1-416-284-8348
E-mail: FLSM-ca@flsmidth.com
o FLSmidth Minerals Ltd. (Montreal, Canada)

Telephone: +1-514-489-9311
Telefax: +1-514-485-9188
E-mail: diane.dewey-young@flsmidth.com
o Technequip Division (Ontario, Canada)

Telephone: +1-416-749-3991
Telefax: +1-416-749-9767
E-mail: Technequip@flsmidth.com
o FLSmidth Minerals S.A. (Santiago, Chile)

Telephone: +011-56-2-328-2900/2999
Telefax: +011-56-2-341-0484
E-mail: FLSM-cl@flsmidth.com
o FLSmidth Minerals Inc. - China Representative

Office (Beijing)
Telephone: +011-86-10-6431-7905
Telefax: +011-86-10-6431-8916
E-mail: info@flsmidth.com.cn
o FLSmidth Minerals A/S (Copenhagen, Denmark)

Telephone: +011-45-36-18-3600
Telefax: +011-45-36-18-3618
E-mail: FLSM-dk@flsmidth.com
o FLSmidth Möller GmbH (Germany)

Telephone: +011-49-4101-788-0
Telefax: +011-49-4101-788-140
E-mail: moller@flsmidth.com
o FLSmidth Minerals Pvt. Ltd. (Chennai, India)

Telephone: +011-91-44-2815-0801, 0802/2815-2840, 2841
Telefax: +011-91-44-2815-0803
E-mail: FLSM-in@flsmidth.com
7.500757 GI - 5
Rev. 0
GYRATORY CRUSHER

Date, Initial
CRUSHER The peening (growth) of the

ASSEMBLY manganese during crushing is a
(continued) condition that affects only the
surface of the concaves and
mantle.
Usually, the depth of this growth
zone is ½” to ¾” [12 mm to 16
mm]. During scarfing only this zone
of surface growth has to be
removed.
Care should be used during the
scarfing not to damage the epoxy
in the joints between the concaves.
Usually, the scarfing is done at a
45 ° angle to allow for maximum
growth before the next scarfing.
Scarfing joints is accomplished by
using a high-amperage welding
machine (400 to 600 Amp) and
carbon-arc rods.
NOTE: The surface of Alloy
concaves does not work-
harden and grow, so there
is no need to scarf their
joints
Mantles:
The growth of manganese steel
mantles can cause excessive force
to be applied to the head nut
threads making the removal of the
head nut difficult and occasionally
damaging the threads on the main
shaft.
7.500762 M - 12
Rev. 0
GYRATORY CRUSHER
Date, Initial
CRUSHER In mining applications, the abrasive
ASSEMBLY wear rate of the mantle usually
(continued) exceeds the growth rate of the
manganese and consequently the
joints between the mantle parts
never close before the mantle
parts are replaced.
Occasionally, however, the joint
between the upper mantle and the
burn out ring grows and it is
necessary to scarf this joint ½” by
45°.
Dust Seal
Check the dust seal for excessive
wear. Replace as required, or
record observations when wear is
minimal or normal.
Lubricate the dust seal with grease
using the grease fittings in the dust
seal retainer.
Dust Seal Retainer

Check the dust seal retainer for
tightness to prevent bolt breakage.
Tighten or replace as required.
Counter Shaft Seals

Lubricate the counter shaft seal
with grease using the grease
fittings in the counter shaft seal
retainer
7.500762 M - 13
Rev. 0
GYRATORY CRUSHER
6.3.3 – Electrical Preventative Maintenance (Weekly)
EQUIPMENT:
¾ Crusher Main Drive Motor
¾ Lubrication System
¾ Hydraulic Support System
¾ Spider Bushing Lubrication System
¾ Main Shaft Position Indication System
ELECTRICAL WEEKLY – ELECTRICAL RUNNING PREVENTATIVE

MAINTENANCE INSPECTION
SAFETY:
1) This is a running inspection. DO NOT reach behind or remove safety
guards. DO NOT work on running equipment except for specified
running inspections and adjustments.
and signs are in place and properly secured.
COMMENTS:
with field observations of the crusher, auxiliary systems, and its drive motor.
required.
7.500762 M - 14
Rev. 0
GYRATORY CRUSHER

Date, Initial
Section 6.3.3 (con’t) ELECTRICAL PREVENTATIVE MAINTENANCE (WEEKLY)
Main Drive Motor Bearing Temperature:
Check bearing area temperature
with a portable thermal detector;
temperatures should be in the
range of 75° to 90°C (167° to
194°F), depending on ambient
temperature. Confirm unusually
high temperatures through the
distributed control system (DCS).
Excessive temperature of the
bearings may be due to damaged
or worn bearings, loose mounting
bolts, excessively worn coupling
elements, or misalignment.
Motor Housing: Check the

temperature of motor housing with
a portable thermal detector;
temperature should not exceed
65.5°C (150°F). Excessive
temperature of the housing may be
due to overload, mechanical
defect, or phase imbalance.
7.500762 M - 15
Rev. 0
GYRATORY CRUSHER

Date, Initial
Main Drive Motor Motor Vibration—Feel the motor
(continued) for excessive vibration. If vibration
feels excessive, confirm with a
portable vibration detector.
Vibration velocity should not
exceed 2 mm (80 mils)/sec at 1X
frequency. Excessive vibration
may be due to damaged or worn
bearings, loose mounting bolts, a
mechanical defect, misalignment,
or phase imbalance.
Motor Noise
Listen to the motor for excessive
and unusual noise. Excessive
noise may indicate mechanical or
electrical defects or loose
mounting bolts.
Main Lead Junction Box Cover
Check the temperature of the
junction box cover. Excessive
temperature may be caused by
loose power terminal connections.
Motor Bearings
Visually inspect the motor bearing
areas for signs of excessive heat,
such as leaking lubricant and
discolored paint. Check bearing
area temperature with a portable
thermal detector; temperatures
should not exceed 82°C (180°F).
7.500762 M - 16
Rev. 0
GYRATORY CRUSHER

Date, Initial
Main Drive Motor Excessive temperature of the
(continued bearings may be due to damaged
Lubrication System Motor Housing

Pump Motors Check temperature of motor
housing with a portable thermal
detector; temperature should not
exceed 65.5°C (150oF). Excessive
temperature of the housing may be
due to overload, mechanical
defect, or phase imbalance.
Motor Vibration
Feel the motor for excessive
vibration. If vibration feels
excessive, confirm with a portable
vibration detector. Vibration
velocity should not exceed 2 mm
(80 mils)/sec at 1X frequency.
Excessive vibration may be due to
damaged or worn bearings, loose
mounting fasteners, mechanical
defect, misalignment, or phase
imbalance.
Motor Noise .
mounting fasteners.
7.500762 M - 17
Rev. 0
GYRATORY CRUSHER

Date, Initial
Lubrication System Motor Vibration
Cooler Pump Feel the motor for excessive
Motors (continued) vibration. If vibration feels
(80 mils)/sec at 1X frequency.
imbalance.
Motor Noise
mounting fasteners.
Junction Box Cover
Check the temperature of the
junction box cover. Excessive
loose power terminal
connections.
Cooler Fan Motor(s) Motor Bearings
Visually inspect the motor bearing
areas for signs of excessive heat,
7.500762 M - 18
Rev. 0
GYRATORY CRUSHER
Date, Initial
Cooler Fan Motor(s) Excessive temperature of the
(continued) bearings may be due to
damaged or worn bearings,
loose mounting bolts,
excessively worn coupling
Motor Housing
Check temperature of motor
exceed 65.5° C (150° F).
housing may be due to overload,
mechanical defect, or phase
imbalance.
Motor Vibration
80 mils)/sec at 1X frequency.
imbalance.
Motor Noise
mounting fasteners.
7.500762 M - 19
Rev. 0
GYRATORY CRUSHER

Date, Initial
Cooler Fan Motor(s) Junction Box Cover
(continued) Check the temperature of the
junction box cover. It should be
warm to the touch, cooler than
the housing. Excessive
loose power terminal
connections.
Lubrication System Junction Box Cover
Sump Tank Heaters Check the temperature of the
junction box cover. It should be
warm to the touch. Excessive
Hydraulic Motor Bearings
Adjustment System Visually inspect the motor bearing
Pump Motors areas for signs of excessive heat,
bearings may be due to damaged
Motor Housing
Check temperature of motor
exceed 65.5° C (150° F).
imbalance.
7.500762 M - 20
Rev. 0
GYRATORY CRUSHER

Date, Initial
Hydraulic Motor Housing
Adjustment System Check temperature of motor
Pump Motors housing with a portable thermal
(continued) detector; temperature should not
exceed 65.5° C (150° F).
imbalance.
Motor Vibration
80 mils)/sec at 1X frequency.
imbalance.
Motor Noise
mounting fasteners.
7.500762 M - 21
Rev. 0
Gyratory Crusher
o FLSmidth Minerals (Pty) Ltd. (Vecor, Johannesburg, SA)
Telephone: +011-27-11-470-9700
Telefax: +011-27-11-475-7666
E-mail: FLSM-za@flsmidth.com
o FLSmidth Buffalo (Pty) Ltd. (Witbank)

Telephone: +011-27-13-699-8900
Telefax: +011-27-13-699-8907
E-mail: Buffalo@flsmidth.com
7.500757 GI - 6
Rev. 0
GYRATORY CRUSHER

Date, Initial
Hydraulic Junction Box Cover
Adjustment System Check the temperature of the
Pump Motors junction box cover. Excessive
(continued) temperature may be caused by
Hydraulic Junction Box Cover
Adjustment System Check the temperature of the
Sump Tank Heaters junction box cover. Excessive
7.500762 M - 22
Rev. 0
GYRATORY CRUSHER
6.3.4 – Mechanical Preventative Maintenance (Monthly)
EQUIPMENT:
¾ Crusher Assembly
¾ Coolers
¾ Hydraulic Adjustment System
MECHANICALMONTHLY—CRUSHER SHUTDOWN PREVENTATIVE

MAINTENANCE PM INSPECTION
SAFETY:
operation due to mechanical inspection and tests.
2) Prior to proceeding with mechanical PM tasks, check for the presence
COMMENTS:
with field observations of the crusher, auxiliary systems, and its drive motor.
required.
7.500762 M - 23
Rev. 0
GYRATORY CRUSHER

Date, Initial
Section 6.3.4 (con’t) MECHANICAL PREVENTATIVE MAINTENANCE (MONTHLY)
Crusher Assembly Daily and Weekly PM Tasks
Complete the daily and weekly PM
tasks specified in PM
Checksheets:
• DAILY -MECHANICAL
• WEEKLY - MECHANICAL
Bottom Shell Liners

Inspect the bottom shell liners for
cracks, missing pieces, unusual
wear patterns, and excessive
wear. Replace liners as required.
Spider Bushing
Check the clearance between the
spider bushing and the main shaft.
Replace the spider bushing if
clearance is excessive, or record
measurements if the clearance is
within normal limits.
Lube Oil System Daily and Weekly PM Tasks
Skid Complete the daily and weekly PM
tasks specified in PM
Checksheets:
Oil Sample Take an oil sample
from the reservoir in an approved
container. Write the source and
the date of the sample on the label
of the container, and submit it for
analysis.
7.500762 M - 24
Rev. 0
GYRATORY CRUSHER
\Item Task Repairs Required,
Date, Initial
Lube Oil System Pumps
Skid (con’t) Inspect the pumps and piping for
signs of leakage. Repair as
required. Clean the pump
housings. Ensure all guards are
securely in place.
Mounting Bolts
Check all equipment mounting
bolts for tightness and missing
units. Replace and tighten as
required.
Coolers (Radiators)
Coolers Check the radiators for damage
and leaks. Clean the exterior
cooling surfaces as required.
Mounting Bolts
required.
Fans
Clean and inspect the fans for
cracks and erosion. Replace as
required.
7.500762 M - 25
Rev. 0
GYRATORY CRUSHER
Date, Initial
Hydraulic Daily and Weekly PM Tasks
Adjustment System Complete the daily and weekly PM
Skid tasks specified in PM
Checksheets:
Oil Sample
Take an oil sample from the
reservoir in an approved container.
Write the source and the date of
the sample on the label of the
container, and submit it for
analysis.
Pumps
Inspect the pumps and piping for
signs of leakage. Repair as
required. Clean the pump
housings. Ensure all guards are
securely in place.
Mounting Bolts
required.
Hydraulic Accumulator Pressure
Adjustment System Lower the main shaft to the full
Accumulator down position (hydraulic pressure
will be zero) and measure the
nitrogen pressure in the
accumulator bladder . Recharge
the accumulator as required.
7.500762 M - 26
Rev. 0
GYRATORY CRUSHER
6.3.5 – Electrical Preventative Maintenance (Monthly)
EQUIPMENT:
¾ Crusher Assembly
¾ Coolers
¾ Main Shaft Position Indication System
ELECTRICAL MONTHLY — CRUSHER SHUTDOWN PREVENTATIVE

SAFETY:
operation due to electrical inspection and tests.
2) Prior to proceeding with electrical PM tasks, check for the presence of
main and control power at appropriate equipment. Control power may
be in the form of media pressure, temperature, or low- or high-voltage
electrical power.
COMMENTS:
console located in the control room. The primary crusher lubrication
system, hydraulic adjustment system, and spider lubrication system can
also be started from the control console in the control room. These units
also have local control panels normally used for maintenance purposes.
Although the operation of the primary crusher is accomplished almost
entirely from the control console, maintenance personnel can assist the
control room operator with field observations of the crusher, auxiliary
systems, and its drive motor. Immediately notify a supervisor of any
problems or potential problems concerning safety or problems that might
cause equipment downtime.
Document unusual conditions observed, measurements made, and any
work required.
7.500762 M - 27
Rev. 0
GYRATORY CRUSHER

Date, Initial
Section 6.3.5 (con’t) ELECTRICAL PREVENTATIVE MAINTENANCE (MONTHLY)
Main Drive Motor Weekly PM Tasks
Complete the weekly PM tasks
specified in the PM Checksheets:
• WEEKLY - ELECTRICAL
Power Terminals
Ensure the motor has been
isolated from its main and control
power sources at the MCC, and try
to start it from its local control
panel. Open the main lead
junction box and check the main
power terminals and the heater
terminals for signs of excessive
heat. Disconnect and clean loose
terminals, and reconnect securely.
Junction Box Seal
Inspect the junction box cover
seals for signs of leakage and
damage. Replace as required.
Vacuum-clean the junction box
interior, and replace the cover.
Motor Assembly
Correct all abnormal temperature,
vibration, and noise conditions
observed and measured during
weekly PM inspections.
Local Controls
Inspect local control panel for
damaged or missing buttons,
switches, and indicators. Repair or
7.500762 M - 28
Rev. 0
GYRATORY CRUSHER
Date, Initial
Main Drive Motor Conduit and Cable
(continued) Inspect power cable and conduit
for signs of excessive heat and
physical damage. Repair or
Lubrication Oil Weekly PM Tasks
Pump Motors Complete the weekly PM tasks
Motor Current Draw
With the lube oil system operating
normally, measure and record the
total current draw of operating
pump motor and the current in
each phase at the MCC. Compare
the phase currents. Each should
be at least 93 percent of the
greatest current reading. Low
phase current measurements
indicate a motor phase unbalance
and may require motor
replacement.
Power Terminals
Shut down the lubrication system,
lock out and tag at the MCC, and
try to start from the local control
panel.
With the pump motor isolated from
its power and control circuits,
check the power terminals for
signs of excessive heat.
Disconnect and clean loose
terminals until their contact
surfaces are bright, and reconnect
securely.
7.500762 M - 29
Rev. 0
GYRATORY CRUSHER
Date, Initial
Lubrication Oil Junction Box Seal
Pump Motors Inspect the junction box cover
(continued) seals for signs of leakage and
Vacuum-clean the Vacuum-clean
the junction box interiors, and
replace the covers.
Motor Assembly
Local Controls
Inspect the local control panel for
Conduit and Cable
Inspect power cable and conduit
Prepare for Service
Clean motor housing surfaces to
assist cooling.
Cooler Pump Weekly PM Tasks
Motors Complete the weekly PM tasks
7.500762 M - 30
Rev. 0
GYRATORY CRUSHER
Date, Initial
Cooler Pump Motor Current Draw
Motors (continued) With the lube oil system operating
indicate a motor phase unbalance
replacement.
Power Terminals
panel.
securely.
Junction Box Seal
vacuum-clean the Vacuum-clean
replace the covers.
7.500762 M - 31
Rev. 0
Gyratory Crusher
SECTION 2:
SAFETY
General Safety Instructions 2.1
Slip, Trip, and Fall Hazards 2.2
Pressurized Hydraulics 2.3
Lifting and Moving Heavy Components 2.4
Flying or Falling Objects 2.5
Confined Spaces 2.6
Respiratory Concerns 2.7
High Noise Levels 2.8
Crusher Control System

Operating and Safety Interlocks 2.9
General Safety Concerns 2.10
7.500758 S-1
Rev. 0
GYRATORY CRUSHER
Date, Initial
Cooler Pump Motor Assembly
Motors (continued) Correct all abnormal temperature,
Local Controls
Conduit and Cable
Prepare for Service
Clean motor housing surfaces to
assist cooling.
Weekly PM Tasks
Cooler Fan Motors Complete the weekly PM tasks
Motor Current Draw
With the lube oil system operating
indicate a motor phase imbalance
replacement.
7.500762 M - 32
Rev. 0
GYRATORY CRUSHER

Date, Initial
Power Terminals
Cooler Fan Motors Shut down the lubrication system,
(continued) lock out and tag at the MCC, and
panel.
securely.
Junction Box Seal
vacuum-clean the Vacuum-clean
replace the covers.
Motor Assembly
Local Controls
Conduit and Cable
7.500762 M - 33
Rev. 0
GYRATORY CRUSHER
Date, Initial
Prepare for Service
Cooler Fan Motors Clean motor housing surfaces to
(continued) assist cooling.
Lubrication System Heating Elements
Reservoir Heaters Check the continuity and
resistance of each heater.
Record results and compare
with previous measurements.
Replace the elements as
required.
Power Terminals
With the heaters isolated from their
power and control circuits, check
the power terminals for signs of
excessive heat. Disconnect and
clean loose terminals until their
contact surfaces are bright, and
reconnect securely.
Junction Box Seal
interiors, and replace the covers.
Conduit and Cable
Inspect power cables and
conduit for signs of excessive
heat and physical damage.
Repair or replace as required.
Prepare for Service
Remove the locks and tags at the
MCC according to established
procedure when all maintenance
and repair work has been
completed, and release the system
for service.
7.500762 M - 34
Rev. 0
GYRATORY CRUSHER
Date, Initial
Hydraulic Weekly PM Tasks
Adjustment Pump Complete the weekly PM tasks
Motors specified in the PM Checksheets:
Motor Current Draw
With the lube oil system
operating normally, measure
and record the total current
draw of operating pump motor
and the current in each phase at
the MCC. Compare the phase
currents. Each should be at
least 93 percent of the greatest
current reading. Low phase
current measurements indicate
a motor phase unbalance and
may require motor replacement.
Power Terminals
panel.
securely.
7.500762 M - 35
Rev. 0
GYRATORY CRUSHER
Date, Initial
Hydraulic Junction Box Seal
Adjustment Pump Inspect the junction box cover
Motors (continued) seals for signs of leakage and
Vacuum-clean the Vacuum-
clean the junction box interiors,
and replace the covers.
Motor Assembly
Correct all abnormal
temperature, vibration, and
noise conditions observed and
measured during weekly PM
inspections.
Local Controls
Inspect the local control panel
for damaged or missing buttons,
switches, and indicators. Repair
or replace as required.
Conduit and Cable
Prepare for Service
Remove the locks and tags at the
MCC according to established
procedure when all maintenance
completed, and release the system
for service.
Hydraulic System Heating Elements
Reservoir Heaters Check the continuity and
resistance of each heater. Record
results and compare with previous
measurements. Replace the
elements as required.
7.500762 M - 36
Rev. 0
GYRATORY CRUSHER
Date, Initial
Hydraulic System Power Terminals
Reservoir Heaters With the heaters isolated from
(continued) their power and control circuits,
surfaces are bright and
reconnect securely.
Junction Box Seal
interiors, and replace the covers.
Conduit and Cable
Inspect power cables and
conduit for signs of excessive
heat and physical damage.
Prepare for Service
Remove the locks and tags at
the MCC according to
established procedure when all
maintenance and repair work
has been completed, and
release the system for service.
Main Shaft Position Sensing Unit
Indication System Inspect the sensing unit for signs
of oil leaks. If oil is observed, trace
the cause and correct. The
position indicator sensing unit is
located at the bottom of the
crusher.
7.500762 M - 37
Rev. 0
GYRATORY CRUSHER
Date, Initial
Main Shaft Position Conduit
Indication System Check the power and signal
(continued) conduit for impact damage.
Replace as required.
Converter Box Seal
Inspect the converter box cover
Vacuum-clean the converter box
interior, and replace the covers.
Indicator Box Seal
Inspect the indicator box cover
Vacuum-clean the indicator box
interior, and replace the covers.
7.500762 M - 38
Rev. 0
GYRATORY CRUSHER
6.3.6 – Mechanical Preventative Maintenance (Annual)
EQUIPMENT:
¾ Coolers
MECHANICAL ANNUAL—CRUSHER SHUTDOWN PREVENTATIVE

SAFETY:
1) Ensure that the crusher drive motor, lubrication system, and

hydraulic adjustment system are inactive to avoid interference with
their operation due to mechanical inspection and tests.
2) Prior to proceeding with mechanical PM tasks, check for the
presence of main and control power at appropriate equipment.
Control power may be in the form of media pressure, temperature,
or low- or high-voltage electrical power.
labels, and signs are in place and properly secured. Remove locks
and tags from the appropriate equipment, and release the system
or unit for service according to established procedures.
COMMENTS:
systems, and its drive motor.
Document unusual conditions observed, measurements made, and any
work required.
7.500762 M - 39
Rev. 0
GYRATORY CRUSHER
Date, Initial
Section 6.3 - MECHANICAL PREVENTATIVE MAINTENANCE (ANNUAL)
Lube Oil System Daily, Weekly, and Monthly PM
Skid Tasks
Complete the daily, weekly, and
monthly PM tasks specified in PM
Checksheets:
• MECHANICAL – DAILY
• MECHANICAL- WEEKLY
• MECHANICAL- MONTHLY
Filters and Housings
Check filter elements and housings
for dirt and sludge. Check filter
housings and fittings for signs of
leakage and damage. Replace
damaged components as required.
Screens
Remove and inspect the reservoir
screens. Record observation of
the material in the screens. Clean
the screens. Inspect for damage
and holes in the screen material
and its seals. Replace the screens
as required.
Reservoir
Drain and clean the reservoir.
Remove all traces of sludge and
sediment from both compartments
of the reservoir and its dividers.
Gaskets and Seals
Closely inspect all gaskets and
seals. Replace aged or leaking
components as required.
7.500762 M - 40
Rev. 0
GYRATORY CRUSHER
Date, Initial
Section 6.3.6 (con’t) MECHANICAL PREVENTATIVE MAINTENANCE (ANNUAL)
Lube Oil System Prepare for Service
Skid (continued) Fill with the correct grade and type
of new oil to the mark on the sight
gauge. Close and secure the
openings. Clean the exterior of the
reservoir.
Coolers Daily, Weekly, and Monthly PM
Tasks
Checksheets:
Exterior
Check the coolers for signs of
leakage and physical damage.
Clean the exterior of the coolers
with strong detergent and water.
Inspect the coolers again. Repair
Interior
Inspect the top tube sheet for
corrosion, sediment, and sludge. If
sludge is observed, drain and
clean the cooler.
Pipe, Hose, and Fittings
Inspect the piping, hoses, and their
fittings for leakage and damage.
Replace components as required.
Fan
Clean and inspect the fan for
cracks. Replace the fan as
required.
7.500762 M - 41
Rev. 0
Gyratory Crusher
2.1 - GENERAL SAFETY INFORMATION

This instruction manual discusses only the basic safety concerns related to the
installation, operation, and maintenance of the “TS” and “TSU” Gyratory Crusher.
As with all machinery with moving components, attention to personal safety is of
the utmost importance. The “TSU” Gyratory Crusher is designed with safety
factors in mind, with respect to structural steel, high pressure hydraulic
components, electrical components and drive components. All moving parts or
potential pinch points are provided with safety guards. FLSmidth Minerals
provides all of the static and dynamic load requirements, as well as the clearance
dimensions necessary to the design a safe and sound platform for the operation
and maintenance of the Crusher. The actual installation of the Crusher with
respect to plant layout is the responsibility of the customer or agents of the
customer.
The Safety Section of this Instruction Manual is not to be construed to supersede

any of the safety policies of the customer and applicable government agencies.
Instead, the safety topics and recommendations should only be regarded as an
aid in assisting the customer to write their own safety procedures pertaining to
the installation, operation, and maintenance of the “TS” and “TSU” Gyratory
Crusher. There are specific safety concerns related to the installation, operation,
and maintenance of the “TS” and “TSU” Gyratory Crusher, and FLSmidth
Minerals has outlined these concerns in the following paragraphs.
Moving Components and Potential Pinch Points: As with all mechanical

equipment with exposed movable components, workers must be made aware of
the dangers and adequately protected from these dangers. Following is a list of
areas must be guarded:
The “TS” and “TSU” Gyratory Crusher requires a gyrating motion to

provide the forces necessary to crush rock. The Crusher opening of the
“TS” and “TSU” Gyratory Crusher is large enough for a person to fall into.
Because of this, the areas above the Crusher must be guarded against
the possibility for someone to fall into the crushing chamber.
Drive power to the Crusher is normally transmitted from an electric motor

through a countershaft extension, coupled to a countershaft. This entire
area of power transmission must be guarded to protect workers from
accidentally falling into or placing a limb into pinch points of the drive
arrangement or against high speed rotating elements. FLSmidth Minerals
has available a drive guard assembly to enclose these elements for
worker and machinery protection. Occasionally the electric motor is
7.500758 S-2
Rev. 0
GYRATORY CRUSHER
Date, Initial
Section 6.3.6 (con’t) MECHANICAL PREVENTATIVE MAINTENANCE (ANNUAL)
Hydraulic Daily, Weekly, and Monthly PM
Adjustment System Tasks
Skid Complete the daily, weekly, and
Checksheets:
Filters and Housings
Check filter elements and housings
for dirt and sludge. Check filter
housings and fittings for signs of
leakage and damage. Replace
damaged components as required.
Screens
Remove and inspect the reservoir
screens. Record observation of
the material in the screens. Clean
the screens. Inspect for damage
and holes in the screen material
and its seals. Replace the screens
as required.
Reservoir
Drain and clean the reservoir.
Remove all traces of sludge and
sediment from both compartments
of the reservoir and its dividers.
Gaskets and Seals
Closely inspect all gaskets and
seals. Replace aged or leaking
Prepare for Service
Fill with the correct grade and type
of new oil to the mark on the sight
gauge. Close and secure the
openings. Clean the exterior of the
reservoir.
7.500762 M - 42
Rev. 0
GYRATORY CRUSHER
6.3.7 –Electrical Preventative Maintenance (Annual)
EQUIPMENT:
¾ Coolers
ELECTRICAL ANNUAL—CRUSHER SHUTDOWN PREVENTATIVE

SAFETY:

their operation due to electrical inspection and tests.
2) Prior to proceeding with electrical PM tasks, check for the presence
COMMENTS:
systems, and its drive motor. Immediately notify a supervisor of any
problems or potential problems concerning safety or problems that might
cause equipment downtime. Document unusual conditions observed,
measurements made, and any work required.
7.500762 M - 43
Rev. 0
GYRATORY CRUSHER
Date, Initial
Section 6.3.7 - ELECTRICAL PREVENTATIVE MAINTENANCE (ANNUAL)
Main Drive Motor Weekly and Monthly PM Tasks
Complete the weekly and monthly
PM tasks specified in PM
Checksheets:
• ELECTRICAL – WEEKLY
• ELECTRICAL - MONTHLY
Insulation Inspection
Inspect all interior components for
signs of excessive heat
discoloration. Closely inspect all
insulation for signs of blistering,
discoloration, and charring.
Inspect all electrical connections
for frayed and damaged insulation,
cracked varnish, and coil
movement.
Stator Insulation Resistance
Use care when measuring
insulation resistance. Contact
with high-voltage electrical
current may be fatal. Ground
windings before and after
testing to drain off all charging
voltage. The grounding time
must be a minimum of four
times the charging time.
The insulation resistance is
measured at ambient temperature
with either a motor-driven or a
Rectox-type megger. The test
voltage is applied between the
entire winding, with all leads
connected together, and grounded
for approximately one minute.
7.500762 M - 44
Rev. 0
GYRATORY CRUSHER
Date, Initial
Section 6.3.7 (con’t) ELECTRICAL PREVENTATIVE MAINTENANCE (ANNUAL)
Main Drive Motor With 1,000 VDC applied, take
(continued) resistance readings every 15
seconds for the first two minutes,
and then every minute during the
remainder of the test. Record the
results and compare them with
previous measurements.
The DC test voltage should
never exceed the motor
operating voltage.
The recommended minimum

insulation resistance is determined
with the following formula:
RM = kV + 1
RM = Recommended minimum insulation
resistance in megohms at 40°C (104°F) of the
entire winding.
kV = Rated motor terminal-to-

terminal voltage.
Air Gap
Measure the air gap between the
rotor and stator at eight equally
spaced locations around the rotor.
Record the measurements and
compare with previous
measurements.
Fasteners
Inspect all nuts and bolts to ensure
they are tight. This is particularly
important for fasteners on the rotor
and the fasteners that could fall
onto the rotor if loosened during
operation.
7.500762 M - 45
Rev. 0
GYRATORY CRUSHER
Date, Initial
Main Drive Motor Main Lead Terminals
(continued) Check the main lead terminals for
signs of excessive heat and
corona. Remove all loose
connections, clean their contact
surfaces until bright, and reconnect
securely.
Inspect and Clean
Inspect the interior again for loose
dirt and dust. Vacuum-clean again
if required
Prepare for operation
Install the end covers and the main
lead junction box cover/door.
Clean the exterior surfaces.
Local Control Panel Face Panel
Check the face panel for damaged
and missing components. Replace
items as required.
Interior
Open the panel/door to gain
access to the interior of the control
box. Inspect all wiring for exposed
conductors. Inspect terminal strips
for signs of excessive heat.
Inspect PCBs for damaged
components. Repair or replace as
required.
Clean
Vacuum-clean the interior of the
control panel box. Clean the
exterior surfaces.
Prepare for Operation
Replace and secure the junction
box cover. When all maintenance
7.500762 M - 46
Rev. 0
GYRATORY CRUSHER
Date, Initial
Local Control Panel completed, remove the lock and
(continued) tag at the MCC according to
established procedure, and
release the unit for service.
Lubricating Oil Weekly and Monthly PM Tasks
Pump Motors Complete the weekly and monthly
Checksheets:
ELECTRICAL – WEEKLY
ELECTRICAL - MONTHLY
Stator Resistance
Remove the junction box cover,
disconnect the power leads,
megger the stator at 500 VDC, and
record the measurements.
Power Terminals
Inspect power terminals for signs
of excessive heat and arcing.
Replace as required. Clean power
terminal contact surfaces until
bright.
Conduit and Cable
Megger the power cables from the
MCC. Repair or replace cables
with low resistance insulation.
Reconnect power terminals in the
junction box and at the MCC.
Interior
Support the shaft, remove the
outboard end bell, and blow out
the motor interior with compressed
air at 207 kPa (30 psi). Reinstall
the end bell, and clean the outside
surface of the housing.
7.500762 M - 47
Rev. 0
GYRATORY CRUSHER
Date, Initial
Lubricating Oil Fan
Pump Motors Remove the fan cover, inspect the
(continued) fan for cracks, and clean the
blades. Inspect the outboard
bearing housing for leaks and
signs of excessive heat. Replace
the cover.
Bearing Clearances
Check bearing radial and axial
clearances at the coupling hub
with a dial indicator. Record
results, and compare with previous
measurements. Measurements in
excess of 0.076 mm (0.003 inch)
may indicate a requirement for
bearing replacement.
Cooler Pump Weekly and Monthly PM Tasks
Motors Complete the weekly and monthly
Checksheets:
Stator Resistance
Power Terminals
bright.
7.500762 M - 48
Rev. 0
GYRATORY CRUSHER
Date, Initial
Cooler Pump Conduit and Cable
Motors (continued) Inspect the power cables from the
Interior
Fan
Remove the fan cover, inspect the
fan for cracks, and clean the
the cover.
Bearing Clearances
Cooler Fan Motors Weekly and Monthly PM Tasks
Complete the weekly and monthly
Checksheets:
7.500762 M - 49
Rev. 0
GYRATORY CRUSHER
Date, Initial
Cooler Fan Motors Stator Resistance
(continued) Remove the junction box cover,
Power Terminals
bright.
Conduit and Cable
Interior
Fan
Remove the fan cover, inspect the
fan for cracks, and clean the
the cover.
Bearing Clearances
may indicate a need for bearing
replacement.
7.500762 M - 50
Rev. 0
GYRATORY CRUSHER
Date, Initial
Lubrication System Weekly and Monthly PM Tasks
Reservoir Heaters Complete the weekly and monthly
Checksheets:
Heating Elements
When the oil has been drained
from the reservoir, check the
surfaces of the heaters for hot spot
discoloration, physical damage,
and erosion. Check the condition
of mounting gaskets and isolators.
Replace elements as required.
Thermal Switches
Check the physical condition of the
thermal switches and their control
wiring. Repair or replace as
required.
Release for Service
Ensure that preventive
maintenance has been completed
on the control cabinet. Remove
the locks and tags at the MCC
according to established procedure
when all maintenance and repair
work has been completed, and
7.500762 M - 51
Rev. 0
Gyratory Crusher
directly coupled to the Crusher. In this case, the worker must be protected
from high speed rotating elements.
The Hydraulic Adjustment Assembly operates using a hydraulic piston that

raises and lowers with the addition of removal of hydraulic fluid. An alarm
should sound to warn workers whenever the adjustment mechanism is
about to be actuated. Workers must be instructed to stand clear.
Insure that all guards are mounted in their proper position prior to
operation of the Crusher.
Though proper guarding should protect the individual worker, it is still

important that workers do not wear loose fitting clothing, ties, and rings, or
have exposed long hair that can get caught up in machinery. Local safety
procedures will apply in all instances.
2.2 - SLIP, TRIP, AND FALL HAZARDS

Working around a Rock Crusher can present a number of potential slip, trip, and
fall hazards, such as rock spillage and oil leaks. During liner changes and other
maintenance activities, it may be necessary to climb down into the internal area
of the Crusher for maintenance and clean up. The interior of the eccentric
assembly and the gear areas will be wet with lubricating oil, which presents a
serious slipping hazard.
Clean up all oil spills that may drain off on major Crusher components that
have been removed from the Crusher or that may have developed from
system leaks.
Use particular care when entering the oil wetted areas of the Crusher.
Also use care in keeping this area clean.
Insure that any and all grease collected during lubrication and
maintenance procedures is cleaned and disposed of properly.
Rock spillage can occur around a Crusher. Insure that spillage is cleaned
up promptly to eliminate potential slip, trip, and fall hazards.
Wet Crusher feed conditions and excessive dust suppression water

sprays can cause wet fines to accumulate on walkways. Wet fines tend to
be very slippery, so this condition should be guarded against.
7.500758 S-3
Rev. 0
GYRATORY CRUSHER
Date, Initial
Hydraulic Weekly and Monthly PM Tasks
Adjustment Pump Complete the weekly and monthly
Motors PM tasks specified in PM
Checksheets:
Stator Resistance
Power Terminals
bright.
Conduit and Cable
Interior
7.500762 M - 52
Rev. 0
GYRATORY CRUSHER
Date, Initial
Hydraulic Fan
Adjustment Pump Remove the fan cover, inspect the
Motors (continued) fan for cracks, and clean the
the cover.
Bearing Clearances
Hydraulic Weekly and Monthly PM Tasks
Adjustment System Complete the weekly and monthly
Reservoir Heaters PM tasks specified in PM
Checksheets:
Heating Elements
When the oil has been drained
from the reservoir, check the
surfaces of the heaters for hot spot
discoloration, physical damage,
and erosion. Check the condition
of mounting gaskets and isolators.
Replace elements as required.
Thermal Switches
Check the physical condition of the
thermal switches and their control
wiring. Repair or replace as
required.
7.500762 M - 53
Rev. 0
GYRATORY CRUSHER
Date, Initial
Hydraulic Release for Service
Adjustment System Ensure that preventive
Reservoir Heaters maintenance has been completed
(continued) on the control cabinet. Remove
the locks and tags at the MCC
when all maintenance and repair
work has been completed, and
7.500762 M - 54
Rev. 0
GYRATORY CRUSHER
6.3.8 – Mechanical Preventative Maintenance (Major)
EQUIPMENT:
¾ Crusher Assembly
MECHANICAL MAJOR—CRUSHER SHUTDOWN PREVENTATIVE

SAFETY:

their operation due to mechanical inspection and tests.
2) Prior to proceeding with mechanical PM tasks, check for the
presence of main and control power at appropriate equipment.
Control power may be in the form of media pressure, temperature,
or low- or high-voltage electrical power.
COMMENTS:
Major maintenance tasks are conducted on the crusher when monthly
inspections indicate that a more detailed inspection or substantial repairs
or component replacements are required. Major maintenance may be
required at six-month to two-year intervals depending on the nature of the
ore crushed, and other site-specific operating conditions. The primary
crusher is started, stopped, and operated from the control console located
in the control room. The primary crusher lubrication system, hydraulic
adjustment system, and spider lubrication system can also be started from
the control console in the control room. These units also have local
control panels normally used for maintenance purposes. Immediately
notify a supervisor of any problems or potential problems concerning
safety or problems that might cause equipment downtime. Document
unusual conditions observed, measurements made, and any work
required.
7.500762 M - 55
Rev. 0
GYRATORY CRUSHER
Date, Initial
Section 6.3.8 - MECHANICAL PREVENTATIVE MAINTENANCE (MAJOR)
Crusher Assembly Daily, Weekly, and Monthly PM
Tasks
Checksheets:
Partial Disassembly
Disassemble the crusher to the
degree necessary to inspect and
measure components for these
major PM tasks.
Outer Eccentric Bushing
Inspect the outer eccentric bushing
for excessive wear and scoring.
Replace the bushing as required.
Eccentric Wear Ring
Inspect the eccentric wear ring for
excessive wear and scoring.
Replace the wear ring as required.
Inner Eccentric Bushing
Inspect the inner eccentric bushing
for excessive wear and scoring.
Replace the bushing as required.
Eccentric
Inspect the outer and inner
surfaces of the eccentric for
excessive wear and scoring.
Replace the eccentric as required.
Main Shaft
Inspect the main shaft bearing
journals for scoring. Repair or
replace the shaft as required.
7.500762 M - 56
Rev. 0
GYRATORY CRUSHER
Date, Initial
Section 6.3.8 (con’t) MECHANICAL PREVENTATIVE MAINTENANCE (MAJOR)
Bevel Gear and Pinion—Check
Crusher Assembly the condition of the bevel gear and
(continued) its pinion gear. Also check the
condition of the pinion bearings.
Replace excessively worn
Hydraulic Adjustment Piston
and Bushings—Inspect the piston
and its bushings for excessive
wear and scoring. Replace
excessively worn and damaged
Hydraulic Adjustment Piston
Seal
Clean and dry the seal and inspect
it for excessive wear and damage.
Replace the seal as required.
7.500762 M - 57
Rev. 0
GYRATORY CRUSHER
6.3.9 – Instrument Preventative Maintenance (Quarterly)
EQUIPMENT:
¾ Crusher Assembly
¾ Lubrication Oil System
¾ Main Shaft Position Indicating System
INSTRUMENT QUARTERLY—INSTRUMENT SHUTDOWN PM

MAINTENANCE
SAFETY:
their operation due to instrument inspection and tests.
2) Prior to proceeding with instrument PM tasks, check for the
presence of control power at appropriate instruments. Control
power may be in the form of media pressure, temperature, or low-
or high-voltage electrical power.
CRUSHER ASSEMBLY COMMENTS:
1) The crusher assembly may or may not include the following

instruments and their service or location. Determine the instruments
supplied by reviewing the drawings and documents included in
Section 7.1 of this manual. Delete any instruments from this list that
were not supplied.
Crusher:
Counter Shaft Bearing Temperature Sensor (Inboard
Bearing)
Counter Shaft Bearing Temperature Sensor (Outboard
Bearing)
7.500762 M - 58
Rev. 0
GYRATORY CRUSHER
Motor:
Stator Temperature Sensor
Rotor Temperature Sensor
Motor Protection Relay
Lubrication System:
Flow Switch/transmitter – Counter Shaft
Flow Switch/transmitter – Bottom Shell
Flow Switch/transmitter – Hydraulic Bottom (Inner Eccentric)
Hydraulic Adjustment:
Pressure Indicator.
Pressure Transmitter
Immediately notify supervision of any problems or potential

problems concerning safety, and problems that might cause
equipment downtime. Document any work performed, work
required, and measurements taken.
7.500762 M - 59
Rev. 0
GYRATORY CRUSHER
Date, Initial
Section 6.3.9 - INSTRUMENT PREVENTATIVE MAINTENANCE (QUARTERLY)
Junction Box
Counter Shaft
Remove the junction box cover
Bearing
and inspect the seal for signs of
Temperature
dust and moisture entry. Repair or
Sensor (Inboard
Bearing)
Terminals
Inspect the wiring terminals for
Disconnect loose terminals, clean
contact surfaces until bright, and
reconnect the terminals.
Conduit and Wire
Inspect conduit and wire for signs
of excessive heat and physical
damage. Repair or replace as
required.
Counter Shaft
Bearing Junction Box
Temperature
Sensor (Outboard Remove the junction box cover
Bearing) and inspect the seal for signs of
Terminals

Conduit and Wire

required.
7.500762 M - 60
Rev. 0
GYRATORY CRUSHER
Date, Initial
Section 6.3.9 (con’t) INSTRUMENT PREVENTATIVE MAINTENANCE (QUARTERLY)
Main Drive Motor

Stator Temperature Junction Box
Sensor
Terminals

Conduit and Wire

required.
Main Drive Motor

Rotor Temperature Junction Box
Sensor Remove the junction box cover
7.500762 M - 61
Rev. 0
Gyratory Crusher
2.3 - PRESSURIZED HYDRAULICS / LUBRICATION

The “TS” and “TSU” Gyratory Crusher uses an FLSmidth Minerals supplied
Hydraulic Adjustment System, with hydraulic oil pressure up to 1,000 psi (69
bar).
The “TS” and “TSU” Gyratory Crusher operates with a lower pressure, high
volume lubrication system, which incorporates pressure relief valves, a filtration
system, motors and pumps, and cooling and heating components.
Crusher workers must be instructed to be aware of the following potential

dangers:
Oil under high pressure presents a considerable danger, when

accidentally released by maintenance personnel. Workers must be
instructed to electrically isolate and lockout the hydraulic power system
and dump the hydraulic pressure whenever maintenance is to be carried
out on the system.
Hydraulic oil is very flammable. Special care must be taken when doing
hot work about the Crusher. It is imperative that the hydraulic power unit
be electrically isolated, locked out and all hydraulic circuits dumped of
pressure.
Only workers trained in the maintenance and operation of the Gyratory

Crusher hydraulic system should be permitted to work on the system.
Only workers trained in the maintenance of these pressure vessels should

be allowed to work on the charged accumulators.
The lubrication system must be shut down, electrically isolated and locked
out whenever maintenance work involves maintenance of crusher
lubrication/hydraulic components or working on the lubrication system by
itself. This is particularly important when the lubricating oil is to be
changed out.
Workers must be fully trained in the operation and maintenance of the

“TSU” Gyratory Crusher lubrication/hydraulic system.
7.500758 S-4
Rev. 0
GYRATORY CRUSHER
Date, Initial
Main Drive Motor Terminals
Rotor Temperature Inspect the wiring terminals for
Sensor (continued) signs of excessive heat.
Conduit and Wire
required.
Motor Protection Housing
Relay(s) Inspect the instrument for physical
damage.
Display
Clean and check the condition of
the display.
Terminals
Inspect wiring terminals for signs
of excessive heat and tightness.
Remove loose terminals, clean
until bright, and reconnect.
Conduit and Wire
required.
Cards
Inspect card rack for damage or
burned components.
Housing
Lubrication System Inspect the instrument for physical
Flow damage and signs of leakage.
Switch/transmitter – Replace as required.
Counter Shaft
7.500762 M - 62
Rev. 0
GYRATORY CRUSHER
Date, Initial
Lubrication System Display
Flow Switch/ Clean the display glass and the
transmitter – exterior of the enclosure.
Counter Shaft Junction Box
(continued)
and check the seal for signs of
replace the seal as required.
Terminals
of excessive heat. Disconnect
loose terminals, clean contact
the terminals.
Conduit and Wire
required
For the flow switch: With the oil
at the operating temperature,
observe the flow meter. Adjust the
switch setting as required; using
the globe valve after the switch
reduce the flow while observing
the flow rate indicator and the flow
when the switch actuates.
For the flow transmitter: With the
oil at the operating temperature
and with an independent DC
power supply, check the span (4 to
20 mA) and zero settings.
Compare with no-flow condition.
Set zero as required.
Flow Switch/trans – Housing: Inspect the instrument
Hydraulic Bottom for physical damage and signs of
(inner bushing) leakage. Replace as required.
Display: Clean the display glass
and the exterior of the enclosure
7.500762 M - 63
Rev. 0
GYRATORY CRUSHER
Date, Initial
Flow Switch/ Junction Box
Transmitter – Remove the junction box cover
Hydraulic Bottom and check the seal for signs of
(inner eccentric dust and moisture entry. Repair or
bushing) replace the seal as required.
(continued) Terminals
the terminals.
Conduit and Wire
required.
Setting
Flow Switch/ Housing
transmitter – Inspect the instrument for physical
Bottom Shell (outer damage and signs of leakage.
eccentric bushing) Replace as required
7.500762 M - 64
Rev. 0
GYRATORY CRUSHER
Date, Initial
Flow Junction Box
Switch/transmitter – Remove the junction box cover
Bottom Shell (outer and check the seal for signs of
eccentric bushing) dust and moisture entry. Repair or
(continued) replace the seal as required.
Terminals
the terminals.
Conduit and Wire
required.
Setting
Housing
Pressure Inspect the instrument for physical
Indicating damage and signs of leakage.
Transmitter Replace as required.
7.500762 M - 65
Rev. 0
GYRATORY CRUSHER
Date, Initial
Display
Pressure Clean the display glass and the
Indicating exterior of the enclosure.
Transmitter
(continued) Junction Box
Remove the junction box cover and
check the seal for signs of dust and
moisture entry. Repair or replace the
seal as required.
Terminals
Inspect wiring terminals for signs of
excessive heat. Disconnect loose
terminals, clean contact surfaces
until bright, and reconnect the
terminals.
Conduit and Wire
Inspect conduit and wire for signs of
excessive heat and physical
required.
Setting
With calibration tester, check span
(4 to 20 mA) and zero settings.
Compare with pressure at the
sensor. Set Zero as required.
Gauge
Pressure Indicator Inspect the gauge for signs of
(Gauge) leakage and damage. Repair or
Display
Clean the glass and enclosure.
Calibration
Check last calibration date. Calibrate
if required.
Hydraulic System Housing: Inspect the valve body for
Pressure Relief physical damage and signs of
Valve leakage. Replace as required.
7.500762 M - 66
Rev. 0
GYRATORY CRUSHER
LUBRICATION SKID COMMENTS:

1) The skid and the cooler system may or may not include the
following instruments and their service or location. Determine the
instruments supplied by reviewing the drawings and documents
included in Section 7 of this manual. Delete any instruments from
this list that were not supplied.
Lube Skid:
Temperature indicator(s).
Temperature sensor/transmitter(s).
Level gauge(s).
Level indicating transmitter(s).
Pressure relief valve(s).
Pressure indicator(s).
Pressure differential indicating transmitter(s).
Lube Oil Coolers:
Temperature sensor/transmitter.
Position switch(s): open, closed

Date, Initial

Temperature Gauge
indicator(s). Inspect the gauge for signs of
Display
Calibration
Check last calibration date.
Calibrate if required.
Temperature Sensor/ Transmitter
Sensor(s)/ Inspect the instrument for physical
transmitter(s) damage and signs of leakage.
7.500762 M - 67
Rev. 0
GYRATORY CRUSHER
Date, Initial
Temperature Junction Box
Sensor(s)/ Remove the junction box cover
transmitter(s) and inspect the seal for signs of
(continued) dust and moisture entry. Repair or
Terminals
Conduit and Wire
required.
Setting
With a temperature calibrator
check span (4-20 ma) and zero
settings. Compare with
temperature at the sensing
element. Set zero as required.
Calibration Check last calibration
date. Calibrate if required
Level Gauge Gauge
Inspect the instrument for signs of
leakage and heat damage. Repair
Display
Setting
Check and reconcile with visual
observation of reservoir level.
Level Indicating Sensor/ Transmitter
Transmitter Inspect the instrument for physical
damage and signs of leakage.
7.500762 M - 68
Rev. 0
GYRATORY CRUSHER

Date, Initial
Level Indicating Display
Transmitter Clean the display glass and the
(continued) exterior of the enclosure.
Junction Box
Terminals
Conduit and Wire
required.
Setting
With an independent DC power
supply, check span (4-20 ma) and
zero settings. Compare with
sensing element. Set zero as
required.
Calibration
Pressure Relief Set Point
Valve(s) Check set points as listed on
drawings, Bills of Material and
Erection and Maintenance Data
sheet in Section 7.2 of this
instruction manual.
Valve
Check valve body and bonnet for
damage and leaks. Repair or
7.500762 M - 69
Rev. 0
GYRATORY CRUSHER
Date, Initial
Pressure Relief Mounting
Valve(s) (continued) Ensure valve mounting is secure.
Calibration
Pressure Gauge
Indicator(s) (Gauge) Inspect the gauge for signs of
leakage and damage. Repair or
Display
Calibration
Pressure Housing
Differential Inspect the instrument housing for
Indicating signs of physical damage and
Transmitter excessive heat. Replace unit as
required.
Display
Junction Box
Terminals
Conduit and Wire
required.
7.500762 M - 70
Rev. 0
GYRATORY CRUSHER
Date, Initial
Pressure Setting
Differential With a pressure calibrator , check
Indicating span (4-20 ma) and zero settings.
Transmitter Compare with ambient pressure
(continued) differential at the sensing
locations. Set zero as required.
Calibration
Lube Oil Coolers Housing
Ambient Air Inspect the housing for physical
Temperature damage and signs of leakage.
Sensor(s)/ Replace as required.
transmitter(s)
Junction Box
Terminals
Conduit and Wire
required.
Calibration
Lube Oil Coolers Gauge
Temperature Inspect the gauge for signs of
indicator(s). leakage and damage. Repair or
(Gauge) replace as required.
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Gyratory Crusher
2.4 - LIFTING AND MOVING HEAVY COMPONENTS

The “TS” and “TSU” Gyratory Crusher has a number of very heavy components
and assemblies that must be removed and installed during the change out of
wear liners and other maintenance routines. Crusher workers must be instructed
about the following heavy lifting concerns:
The weights of major Crusher assemblies are listed in the Instruction

Manual as well as in the Parts List supplied with the Crusher. The weights
of individual parts that make up a Crusher assembly are only found in the
Parts List.
FLSmidth Minerals supplies a collection of tools specifically designed for

the installation and maintenance of the “TSU” Gyratory Crusher. Often,
there is only one Tool Collection per group of Crushers supplied. This
collection of Tools has all of the lifting fixtures and specifically sized ring
bolts necessary to install and maintain the “TSU” Gyratory Crusher.
Workers must be made aware of the importance of keeping the tools in an
environmentally protective and secure storage area.
Trained riggers and crane operators along with suitably sized lifting
capacity and rigging must be available when major Crusher maintenance
is undertaken.
Most of the major components of the “TSU” Gyratory Crusher are made
up of machined castings. The actual weights shown are nominal weights
determined by engineering methods. As castings, the actual weights can
be considered to vary by as much as plus or minus 10%.
Many pieces that make up the various Crusher assemblies are at or just
over what would be considered safe weight for a worker to lift. Again,
workers must be instructed to check with the Parts List to determine the
actual weight of the piece and to use proper lifting procedures. Weight
lifting restrictions are the responsibility of the customer’s safety program
and governmental agencies and are thus not addressed in this manual.
2.5 - FLYING OR FALLING OBJECTS

Gravity is used to introduce rock into the Crusher cavity. Overflow, worn chutes
or other possibilities for spillage can cause falling rock to present a safety hazard.
Crushing action can cause rock to be ejected from the crushing chamber,
particularly as rock is first being introduced into the chamber.
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Rev. 0
GYRATORY CRUSHER
Date, Initial
Lube Oil Coolers Display
Temperature Clean the glass and enclosure.
indicator(s).
(Gauge) (continued)
Calibration
Housing
Motorized Ball Inspect the housing for signs of
Valve physical damage and excessive
heat. Repair or replace the unit as
required.
Junction Box
Terminals
Conduit and Wire
required.
Actuation
Apply appropriate input voltage
and ensure that switch opens and
closes. Reconcile position of
valve.
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GYRATORY CRUSHER
HYDRAULIC SKID COMMENTS:

1) The skid may or may not include the following instruments and their
service or location. Determine the instruments supplied by
reviewing the drawings and documents included in Section 7.1 of
this manual. Delete any instruments from this list that were not
supplied.
Hydraulic Skid:
Temperature sensor/transmitter(s).
Level gauge(s).
Level indicating transmitter(s).
Pressure relief valve(s).
Pressure differential indicating transmitter(s).

Date, Initial
Hydraulic Gauge
Adjustment Skid Inspect the instrument for signs of
Level Gauge leakage and heat damage. Repair
Display
Setting
Check and reconcile with visual
observation of reservoir level.
Level Indicating Sensor/ Transmitter
Transmitter Inspect the instrument for physical
Display
Clean the display glass and the
exterior of the enclosure.
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Date, Initial
Level Indicating Junction Box
Transmitter Remove the junction box cover
(continued) and check the seal for signs of
Terminals
Conduit and Wire
required.
Setting
With a calibrator check span (4-20
ma) and zero settings. Compare
with sensing element. Set zero as
required.
Calibration
Pressure Gauge
Indicator(s) (Gauge) Inspect the gauge for signs of
leakage and damage. Repair or
Display
Calibration
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Rev. 0
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Date, Initial
Temperature Gauge
indicator(s). Inspect the gauge for signs of
Calibration
Temperature Sensor/ Transmitter
Sensor/transmitter Inspect the instrument for physical
Junction Box
Terminals
Conduit and Wire
required.
Setting
With a temperature calibrator,
check span (4-20 ma) and zero
settings. Compare with
temperature at the sensing
Temperature
Sensor/transmitter Calibration
(continued) Check last calibration date.
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SPIDER BUSHING LUBRICATION SYSTEM COMMENTS:

1) The Spider Bushing Lubrication System may or may not include the
following instruments and their service or location. Determine the
instruments supplied by reviewing the drawings and documents
Spider Lube System:

Pressure indicator
Pressure sensor/transmitter
End of cycle switch
Controller

Date, Initial
Gauge
Spider Bushing Inspect the gauge for signs of
Lubrication leakage and damage. Repair or
System replace as required.
Pressure
Indicator(s)
(Gauge)
Display
Calibration
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GYRATORY CRUSHER

Date, Initial
Housing
Pressure Inspect the instrument for physical
Indicating damage and signs of leakage.
Transmitter Replace as required.
Display
Clean the display glass and the
exterior of the enclosure.
Junction Box
check the seal for signs of dust and
moisture entry. Repair or replace
the seal as required.
Terminals
Inspect wiring terminals for signs of
terminals.
Conduit and Wire
required.
Setting
With calibration tester, check span
(4 to 20 mA) and zero settings.
Compare with pressure at the
sensor. Set Zero as required.
Housing
End of Cycle Inspect the housing for physical
Switch damage and signs of leakage.
Junction Box
inspect the seal for signs of dust
and moisture entry. Repair or
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Date, Initial
Terminals
End of Cycle Inspect the wiring terminals for
Switch (continued) signs of excessive heat.
Conduit and Wire
required.
Actuation
Manually actuate switch and check
for switch actuation
Panel and Controller
Controller Inspect the instrument for physical
Cables and Plugs
Inspect the power and signal cables
and plugs for damage and bare
conductors. Repair or replace as
required.
Junction Box
inspect the seal for signs of dust
and moisture entry. Repair or
Terminals
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Date, Initial
Controller Conduit and Wire
(continued) Inspect conduit and wire for signs of
required.
Display
Clean the display.
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MAINSHAFT POSITION INDICATION SYSTEM COMMENTS:

1) The Main shaft Position Indication System may or may not include
the following instruments and their service or location. Determine
the instruments supplied by reviewing the drawings and documents
MAINSHAFT POSITION INDICATOR:

Transducer
Cable
Electronics cabinet (power supply, processor,
digital bar graph display)

Date, Initial
Main Shaft Transducer
Position Indication Inspect the instrument for physical
System damage. Replace as required.
Cable and Plugs

Inspect the signal cables and plugs
for damage and bare conductors.
Electronics Cabinet
Inspect the cabinet cover seal for
signs of dust and moisture entry.
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6.4 – COMPONENT AND SUBASSEMBLY

REMOVAL/REPLACEMENT
Introduction:
The following procedures cover the removal and replacement of major
components of the Type “TS” or “TSU” Gyratory Crusher. The purpose of these
procedures is to provide management, supervision, and craftsmen with sufficient
information to safely and effectively plan and accomplish crusher component
removal and replacement. These procedures provide a general, overall
sequence for component removal and replacement with details of each step in
the sequence. Existing conditions may require that the sequence must be
altered slightly to accommodate the prevailing conditions. The details of the
steps in the sequence should require little modification. Normal component
removal and replacement include the correction of minor misfits by moderate
amounts of straightening, shimming, chipping, cutting, grinding, or polishing for
proper fit and location of components. Misfits that cannot be corrected by the
these means, or which require major changes in equipment configuration, must
be reported immediately to FLSmidth USA, Inc. for correction of the misfit, or to
approve the most efficient and economic method of correction to be
implemented. When performing removal and replacement of major components,
such as shell sections or the main shaft assembly, the Erection Record Book
should be used as a reference. The Erection Record Book is a compilation of the
original installation progress, problems encountered and their solutions, and
measurements made. This information is valuable for comparing current and
original conditions and for identifying causes and lasting solutions of potential
problems. Prior to starting component removal and replacement, the appropriate
equipment must be locked and tagged out and the required work permits
obtained in accordance with established procedures.
6.4.1 – REMOVAL PROCEDURES

1) Spider Assembly – Removal
2) Spider Bushing – Removal
3) Main Shaft Assembly – Removal
4) Main Shaft Wearing Ring – Removal
5) Main Shaft Sleeve – Removal
6) Mantle – Removal
7) Core – Removal
8) Dust Bonnet – Removal
9) Contact Seal Ring – Removal
10) Eccentric Assembly – Removal
11) Inner Eccentric Bushing – Removal
12) Gear – Removal
7.500762 M - 81
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Gyratory Crusher
Spillage can accumulate on a lower deck and present slip and trip hazards
for workers. Good housekeeping is absolutely essential for safe Crusher
operations.
As crushing systems often involve a gravity flow design with pre and post
screening applications, it is not uncommon to have one or more decks
above and below the Crusher. Workers must be aware of anytime people
are working above them and likewise, anytime people are working below
them. Work should be coordinated to eliminate the potential for dropped
tools and parts, areas under workers cordoned off, or adequate overhead
protection should be provided.
2.6 - CONFINED SPACES

The discharge area under the Crusher is normally considered a confined space
and should be treated as such. As routine maintenance procedures require the
visual inspection of the underside of the Crusher, the Crusher lubrication lines
and the discharge cavity; the following concerns must be addressed:
Confined space work permits and procedures must be utilized whenever

maintenance work is to be carried out under the Crusher or in the
discharge cavity.
Electrically isolate and lockout the Feed Conveyor to the Crusher, the
Crusher and the Discharge Conveyor.
The discharge area must be designed in such a way as to provide safe

and easy access to the area under the Crusher. The discharge area must
be designed to eliminate spillage and allow for adequate dust control.
2.7 - RESPIRATORY CONCERNS

The crushing of rock produces rock dust. Rock dust is often fine enough to be
carried into the lungs during normal breathing. All rock dust presents some health
hazards, with some rock presenting especially serious health hazards. It is the
responsibility of the customer to provide a system to control the escape of
breathable rock dust or to provide personal protective equipment to protect the
workers.
Working on or about the Crusher also requires welding, thermal cutting and the
use of chemical reagents, all of which can present respiratory issues. Following
are concerns that must be addressed:
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Rev. 0
GYRATORY CRUSHER
13) Outer Eccentric Bushing – Removal

14) Hydraulic Piston Assembly – Removal
15) Center Wearing Ring – Removal
16) Piston Wearing Ring – Removal
17) Hydraulic Piston Bushings – Removal
18) Hydraulic Cylinder – Removal
19) Hydraulic Cylinder Seals – Removal
20) Countershaft Assembly – Removal
21) Pinion – Removal
22) Countershaft Bearings – Removal
23) Concaves – Removal
1) SPIDER ASSEMBLY – REMOVAL (SEE FIGURE 6.4.1.1)

Lockout the primary crusher and the rock breaker according to lock
out procedures.
Lockout all the ancillary systems of the crusher according to lock-
out procedures to create a safe environment.
Remove the spider cap.
Disconnect the lubrication line to the spider bushing at the outside
of the top shell and cap or plug the disconnected ends.
Remove the spider bolt nuts.
Place two hydraulic jacks of sufficient size (200-Ton) on the jacking

pads.
Loosen the spider by jacking through the holes provided in the top
shell. Be sure to jack the spider evenly.
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If hydraulic jacks are not available, drive wedges into the wedge
slots located in the upper shell flange. It is important to drive the
wedges evenly. It may be necessary to use a crane in conjunction
with the wedges to break the spider free. It is essential, however,
to avoid cocking the spider to avoid damage to the machined
surfaces of the spider and to the surfaces in the top shell spider
pockets.
When the spider is free, lift it off the crusher and set it on blocks.
Cover the spider bushing to keep it protected.
2) SPIDER BUSHING – REMOVAL (SEE FIGURE 6.4.1.2)

Remove the spider seal retaining plate and seal.
Remove the spider bushing bolts.
Remove the tapered bushing. A
tapered bushing can be removed
from the spider bore with the spider
and main shaft in place in the
crusher.
9 If the spider and main shaft are
in place in the crusher, place
blocking material between the
head nut and the concaves at a
minimum of three places to
stabilize the main shaft
assembly.
Remove the spider bushing bolts
and place these bolts in the tapped
holes in the spider bushing flange.
Tighten these bolts in a star pattern
to jack the bushing out of the tapered spider bore.
If the main shaft and the spider have been removed from the
crusher, pull the tapered bushing using steps above.
The bushing can also be lifted out with an overhead crane or
pressed out with a hydraulic jack after the spider has been removed
from the crusher.
Clean the bore of the spider before installing a new bushing.
3) MAIN SHAFT ASSEMBLY – REMOVAL

Lift the main shaft assembly out of the crusher and stand it
vertically in the main shaft repair pit or maintenance stand with the
use of a crane.
Protect machined surfaces. Unless the eccentric will be removed
immediately, cover the dust bonnet inside the crusher to exclude
dirt.
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GYRATORY CRUSHER
4) MAIN SHAFT WEARING RING – REMOVAL

Place eyebolts in one or more of the tapped holes provided in the
outer diameter of the main shaft wearing ring.
Remove the cotter pin and nut.
With a bar, pry the ring loose from the recess. Be aware that a
single dowel to keep the ring from rotating is placed between the
ring and main shaft.
Remove the ring when it is free.
Clean the recess in the main shaft. Check the tightness of the stud,
which is installed with LOCTITE.
If the stud is loose, remove the stud, and clean and reinstall it with
LOCTITE. The stud can be tightened down with pliers or a pipe
wrench; use care not to damage the threads.
5) MAINSHAFT SLEEVE – REMOVAL

Chip grooves lengthwise along the outside of the sleeve until it
opens and can be pulled off the main shaft.
6) MANTLE – REMOVAL
Place the main shaft assembly in a vertical position in its repair pit
or stand. Be sure to support the weight of the assembly on the
bottom of the shaft, not on the core. Supporting the weight of the
assembly on bottom of the core could loosen the fit on the shaft.
Place blocking and wedges between the eccentric journal of the
main shaft and the repair pit walls to support it vertically.
Remove the head nut by first removing the dowel pins between the
head nut and the mantle. The nut is most easily loosened by
welding ears onto it or using the tapped “slugging” holes provided,
then striking the ears with a ram suspended from a crane. If the nut
does not come loose, cut the burn-out (filler) ring located between
the nut and the mantle. This will relieve the pressure on the head
nut threads so the nut can be removed. A new burn-out (filler) ring
can be welded to the nut so that it can be reused. Refer to Main
Shaft Assembly drawing in Section 7 of this manual for the
procedure.
With the head nut removed, loosen the mantle by striking it on the
bottom with the ram used on the head nut. Heat the lower portion
of the lower mantle if necessary.
Weld lugs to the mantle and lift it off the core.
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GYRATORY CRUSHER
7) CORE – REMOVAL
Place the main shaft and core assembly in a vertical position in its
repair pit or stand. Support the weight of the assembly on the
bottom of the main shaft, not on the core.
Place blocking and wedges between the eccentric journal of the

main shaft and the repair pit walls or stand members to support it
vertically.
Remove the threaded shaft sleeve and the Teflon split seal rings
from the main shaft.
Weld lugs to the core and lift it from the main shaft. Inspect the fit
at the inside bottom of the core.
If the core is not loose on the main shaft it is necessary to apply
heat to the core as follows:
9 Raise the core and the main shaft until the bottom of the
main shaft, or main shaft wearing ring, is 3/8” to 1 / 2” (10 to
12 mm) from the bottom of the pit or stand.
9 Place blocking and wedges between the eccentric journal of
the main shaft and the pit walls or stand to support it
vertically but not prevent the main shaft from moving
vertically.
9 Support the weight of the main shaft and the core from the
bottom of the core.
9 Heat the outside of the core in the area where the core fits
onto the main shaft until the core expands sufficiently and
the main shaft “drops out” of the core.
8) DUST BONNET ASSEMBLY – REMOVAL (SEE FIGURE 6.4.1.3)

Remove the bolts that attach the Dust Bonnet Assembly to the
Bottom Shell taking care not to remove the clamp plate bolts.
Attach shackles to the lifting holes provided on the inside of the
dust bonnet.
Slowly lift the assembly out of the crusher. Do not allow the
assembly to swing during lift.
Place the Dust Bonnet Assembly on blocks and protect it from the
elements.
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GYRATORY CRUSHER
9) MAINSHAFT SPLIT (CONTACT) SEAL RING – REMOVAL

Remove dust bonnet bolts from the gear cover and lift the dust
bonnet off the assembly.
The contact seal sits free in the cavity between the gear cover and
the dust bonnet.
10) ECCENTRIC ASSEMBLY– REMOVAL

Record the gear set backlash prior to removing the eccentric
assembly.
Install Eccentric Assembly Lifting Shackles.
Lift the Eccentric Assembly slowly. Do not allow the assembly to
swing during lift.
Place Eccentric Assembly on blocks and protect Gear and bearing
surfaces from the elements.
11) INNER ECCENTRIC BUSHING – REMOVAL

Remove the bolts, oil deflector, counterweight (if provided) and seal
(if provided).
Chip grooves along the bore of the bushing until it collapses, and
can be pulled out.
Clean the bore of the eccentric before inserting a new bushing.
The bushing can be lifted out without chipping grooves along the
bore of the bushing. Use a lifting bar or plate bearing against the
bottom of the bushing. Use care in pulling the inner eccentric
bushing with the eccentric assembly in the crusher to prevent
damage to either the pinion or the gear.
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12) GEAR – REMOVAL (SEE FIGURE 6.4.1.4 [LATER])

Place wood blocking around the eccentric to
within a few millimeters of the gear teeth.
Remove the lower counterweight.
Incrementally remove the gear bolts to lower
the gear onto the blocking.
Lift the eccentric out of the gear and set on
separate blocking.
13) OUTER ECCENTRIC BUSHING – REMOVAL

Remove the bolts and chip grooves along the
bore of the bushing until it collapses, and can
be pulled out.
Clean the bore before inserting the new
bushing.
The bushing can be lifted out without
chipping grooves along the bore of the
bushing. Use a lifting bar or plate bearing
against the bottom of the bushing.
14) HYDRAULIC PISTON ASSEMBLY – REMOVAL

(SEE FIGURE 6.4.1.5)
Thread piston removal tool into through
center wearing ring into the top of the piston
until fully engaged.
Ensure that all hydraulic lines have been
drained as suction could inhibit removal.
Use piston removal tool to slowly lift the
piston out of the crusher.
Do not allow the assembly to swing during
lift.
Place piston assembly on blocking and
protect entire assembly from the elements.
15) CENTER WEARING RING – REMOVAL (SEE

FIGURE 6.4.1.5)
The center wearing ring removal is accomplished by
simply lifting out the ring by using eye bolts in
threaded holes, as it does not have any fasteners and rests on the
piston wearing ring in a spigot fit.
The wearing ring can be removed from the crusher with the piston
assembly as one unit.
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GYRATORY CRUSHER
16) PISTON WEARING RING – REMOVAL (SEE FIGURE 6.4.1.5)

The piston wearing ring removal is accomplished by simply
removing the retaining bolts and lifting out the ring. Installation is
accomplished by simply placing the cleaned and oiled ring onto the
piston and centering it.
The wearing ring can be removed from the crusher with the piston
assembly as one unit.
17) HYDRAULIC PISTON BUSHINGS – REMOVAL (SEE FIGURE 6.4.1.5)

Remove the bolts holding the seal retainer to the piston.
Chip grooves along the O.D. of the bushing until it springs open
and can be pulled off.
The bushing can be lifted off without chipping grooves along the
bore of the bushing. Use a lifting bar against the bottom of the
bushing.
With the bottom bushing removed, invert the piston.
Remove the Piston Wear Ring bolts and the Wear Ring.
Chip grooves along the O.D. of the bushing until it springs open
and can be pulled off.
The bushing can be lifted off without chipping grooves along the
bore of the bushing. Use a lifting bar against the bottom of the
bushing.
18) HYDRAULIC CYLINDER ASSEMBLY –

REMOVAL (SEE FIGURE 6.4.1.6)
Open lines at appropriate places
to drain the lubricating and
hydraulic oils from the bottom of
the crusher.
Remove the protection around
the lube and hydraulic lines.
Remove all piping and wiring
connected to the underside of
the crusher.
Cap or plug all disconnected hydraulic
and lubrication lines.
Remove socket head cap screw.
Lift and remove assembly.
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19) HYDRAULIC CYLINDER AND SEALS – REMOVAL

Remove the wiper ring retainer and the wiper ring from the top of
the hydraulic cylinder.
Invert the piston assembly.
Remove the seal retainer. The “U” seal should stay on the retainer.
Remove the “U” seal from the retainer by prying it from the retainer.
20) COUNTERSHAFT ASSEMBLY– REMOVAL (SEE FIGURE 6.4.1.7)

Record the gear set backlash prior to removing the countershaft
assembly. Record the number and thickness of gaskets between
the counter shaft housing and the bottom shell.
Remove the countershaft extension & safety coupling.
Remove RTD wiring & lube lines. Cover and protect these lines
after removal.
Match mark Countershaft position on the housing and the bottom
shell.
Remove the bolts retaining the countershaft assembly to the bottom
shell.
Rotate assembly so the arrow is facing right when viewed from
motor. (maximum backlash condition)
Turn in the jacking
bolts to start moving
the countershaft
assembly out of the
bottom shell. Lift
the assembly
slightly with a lifting
device and slide the
assembly out to
remove it. Use care
in lifting the counter
shaft assembly
during removal to
prevent damage to
either the pinion or
the gear.
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21) PINION – REMOVAL (SEE FIGURE 6.4.1.8)

Place the counter shaft assembly in a horizontal position and
remove the retaining ring from the pinion end of the counter shaft.
Using a gear puller, pull the pinion from the counter shaft. A
hydraulic assisted gear puller is recommended.
Due to the geometry of the pinion and the counter shaft housing,
the jaws of the puller may not fit between the pinion and the counter
shaft housing. In this case, first remove the counter shaft with the
pinion mounted from the counter shaft housing following the
instructions in the following Section 6.7.1.22 (counter shaft
bearings) and pull the pinion from the counter shaft with a gear
puller as described above.
22) COUNTERSHAFT BEARINGS – REMOVAL (SEE FIGURE 6.4.1.8)

Remove the coupling hub on the outboard end of the assembly by
simultaneously applying heat and pulling it off with a puller. The hub
is heated with rosebud torch tips to the range of 300° to 500°F
(149° to 260°C).
Loosen the clamping Allen head screws on the nut, and unscrew
the nut.
Remove the pinion acording to the pinion removal proceedure.
Remove the spring retainer, trough, and the spring from the pinion
end of the countershaft.
Remove the locknut and shaft bushing from the drive end.
Remover the Inner seal retianer and the spacer along with any
attached seals and retainers not previously removed from the drive
end of the countershaft.
Pull the outer races from both ends of the assembly.
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GYRATORY CRUSHER
If the rollers will not slide through the housing cut the roller cage
free and remove the rollers from one end of the countershaft.
Slide the shaft out of the housing.
Pull the inner races from the shaft.
Clean and inspect the shaft for defects.
23) CONCAVES – REMOVAL

Place a cover over the bonnet to prevent dirt from falling into the
interior of the crusher.
Starting with the top row of concaves, weld lifting eyes to each
concave.
Use a carbon electrode to split one concave with a 2 inch (50-mm)-
wide, full-depth, and full-height cut (or cut locking pins).
Use wedges to remove the free concave.
The others in the row can then be removed by driving wedges
between the shell and the remaining concaves.
The successive rows of concaves are removed with the same
method.
Clean the backing material from the concaves that are to be
reused.
Clean the backing material and any other foreign material from the
insides of the shell sections.
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Gyratory Crusher
When the Crusher is installed, areas about the Crusher mounting flange
and about the Crusher countershaft must be sealed up to prevent the
escape of fugitive rock dust. The area about and between the feed chute
and the feed hopper of the Crusher should also be sealed. FLSmidth
Minerals Service Technicians will be present during the installation of the
Crusher to assist the customer or the customer’s agent in how to best seal
up these areas.
Often the true seriousness of a dust control problem cannot be determined

until after the Crusher has been in operation for a short period of time.
Therefore, it is often necessary to over design for dust control system to
insure proper control at the onset of crushing.
Working in or near the discharge area of the Crusher may agitate (kick-up)
breathable dust.
The epoxy based backing compound used with the “TSU” Gyratory
Crusher has a caustic agent that is both caustic by skin contact and by
breathable fumes. Adequate personal protective equipment and
ventilation is necessary when working with these chemicals.
2.8 - HIGH NOISE LEVELS

The very nature of crushing rock generates high decibel level of noise. The
actual noise generated is determined by the type of rock being crushed, the
amount of energy being put into the rock and the type of structure that the
Crusher is mounted on. Typically, the decibel readings will be found to be in the
85 to 105 dB range. As it is very difficult to abate this noise from the area around
the Crusher, it is often necessary to require the use of noise protection devices
for workers. Following are some concerns:
The actual noise generated by a “TSU” Gyratory Crusher will have to be

determined by measurement during normal crushing operations. The
customer will then have to determine what personal hearing protection is
required for the worker as well as what time exposure limits may have to
be put in place.
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GYRATORY CRUSHER
6.4.2 – REPLACEMENT PROCEDURES

1) Mantle – Replacement
2) Core– Replacement
3) Main Shaft Sleeve – Replacement
4) Main Shaft Split (Contact) Seal Ring– Replacement
5) Inner Eccentric Bushing – Replacement
6) Outer Eccentric Bushing – Replacement
7) Hydraulic Piston Bushing– Replacement
8) Hydraulic Piston Seals– Replacement
9) Concaves – Replacement
10) Spider Pocket Lining – Replacement
11) Gear – Replacement
12) Pinion – Replacement
13) Countershaft Bearing – Replacement
1) MANTLE – REPLACEMENT (SEE

FIGURE 6.4.2.1)
Place the main shaft and core
assembly in a vertical position
in its repair pit or stand and
place blocking and wedges
between the eccentric journal of
the main shaft and the repair pit
walls or stand members to
support it vertically.
Lightly coat the surface of the
core with lubricating oil or a
release agent before placing
the lower mantle on the core.
Place the lower mantle on the
core. Center the mantle on the
core by equalizing the distance
from the core to the outside
surface of the mantle at the
upper end of the mantle.
Seal the bottom of the mantle to
prevent leakage of the backing
material (epoxy) that is poured
between the core and mantles.
(Clay and Plaster of Paris have
been used successfully as a sealant).
The minimum allowable temperature is
45°F (7°C) for epoxy pouring.
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Prepare and pour backing material between the mantle and the
core in accordance with the information provided by the backing
material manufacturer.
Lightly coat the core with lubricating oil or a release agent and
place the middle mantle on the core. Place 0.5-inch (12.7-mm)-
thick metal blocks on the top of the lower mantle and place the
middle mantle on these blocks, creating a gap between the middle
and lower mantles.
Center the middle mantle by equalizing the distance from the core
to the outside surface at the top and bottom of the mantle.
Seal the gap at the joint between the middle and lower mantles,
filling the gap back to the core.
Prepare and pour backing material between the mantle and the
core in accordance with the information provided by the backing
material manufacturer.
Allow the epoxy to harden for 18 to 24

hours before proceeding.
Lightly coat the core with lubricating oil or a release agent and
place the upper mantle on the core. Place 0.5-inch (12.7-mm)-thick
metal blocks on the top of the middle mantle and place the upper
mantle on these blocks, creating a gap between the upper and
middle mantles.
Center the upper mantle by equalizing the distance between the
core and the outer surface of the bottom of the upper mantle. Also
make certain that the top surface of the upper mantle is at a 90-
degree angle with the main shaft and it will mate squarely with the
head nut.
Put the head nut on and insert four equally spaced 3-inch (75-mm)
metal blocks to hold it off of the upper mantle top. This will keep
the upper mantle from floating, and keep it centered and square
with the main shaft.
Seal the gap at the joint between the middle and upper mantles,
filling the gap back to the core.
Place troughs near the top of the upper mantle to direct backing
material between the upper mantle and the core.
Prepare and pour backing material between the upper mantle and
the core in accordance with the information provided by the backing
material manufacturer. Do not pour backing material above the top
of the core.
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Tighten the head nut with a slugging (striking) wrench and sledge
hammer.

When the backing material has cured, loosen the head nut and
remove the metal blocks and other mantle positioning devices.
Tighten the head nut assembly again by striking the ears previously
attached to the head nut with a ram suspended from a crane.
Pin the head nut assembly in two places with provided dowel pins
and weld the pins to the head nut.
After two days of operation with the new mantle, remove the pins
and re-tighten the nut. Reinsert the pins and weld them to the head
nut.
2) CORE – REPLACEMENT
2.1) CORE CONTACT CHECK

Contact testing shall be carried out with the Mainshaft and Core
positioned vertically.
Both components should be at ambient temperature when being
presented for contact test.
Apply four(4) 50mm(2") wide axial stripes of Prussian Blue to the
tapered bore of the Core, approximately 90 degrees apart.
Bluing shall be applied lightly and uniformly. Film thickness of
Bluing should not exceed 0.025mm (.001").
Slowly lower the Core over the Mainshaft. When the Core is
approximately 1" above its natural resting place (the point at which
gravity will cause the mating tapers to make intimate contact), the
top end of the Core is to be centered over the Mainshaft. Utilizing
four wooden wedges, approximately 90 degrees apart, equalize the
clearance between the inside diameter of the Core, and the outside
diameter of the Mainshaft. Once the Core has been centered on
the Mainshaft, drive the wooden wedges in an additional distance
of 30mm(1.25"). This will maintain centrality of the Core when it is
being lowered to its natural resting position.
Slowly lower the Core onto the Mainshaft until the Core reaches its
natural resting place and its entire weight is suspended by the
tapered fit.
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Slowly lift the Core off the Mainshaft. Ensure the core does not
contact the shaft while it is being lifted. Any unwanted contact
between the Core and Mainshaft may result in a non-uniform bluing
transfer to the Mainshaft taper. Verify the length and uniformity of
bluing transferred onto the Mainshaft taper at all four locations.
Full length tape transfers shall be taken from the Mainshaft taper at
all four locations. Photographs may be taken, for additional
information, or as an expedient means of transmitting results from
remote locations.
If the measured contact is less than 80%, report the results
immediately to FLS Minerals for disposition.
2.2) CORE ASSEMBLY (AFTER CONTACT CHECK)

Place the Mainshaft in a vertical position in its repair pit or stand.
Place blocking and/or wedges between the eccentric journal of the
Mainshaft and the stand members to support it vertically.
Care should be taken to ensure that the

shaft is not marred during this procedure.
Slide the core over the Mainshaft and center it. Tack weld blocks to
the top of the core to maintain equal spacing around the shaft.
Allow room for the core to drop a limited distance.
Place stands beneath the core to permit the core to drop (slide
downward) when it is set. The drop distance range is 0.220inch
(5.5 mm) minimum, and 0.25inch (6.0 mm) maximum.
Heat the outside area of the core corresponding to the taper fit with
four large torches (to rapidly heat the core).
The core will begin to drop to the stands as it expands. When the
core has retained enough heat and is resting on the stands, stop
heating.
Allow the core to cool to 65°F (18°C) or ambient temperature.
Prepare and pour backing material to fill the space between the
Mainshaft and the core in accordance with the information provided
by the backing material manufacturer.
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Allow the Core to cool prior to installing

mantles
3) MAIN SHAFT SLEEVE – REPLACEMENT

Place the main shaft in a vertical position.
Remove all upsets and gouges on the shaft sleeve area of the main
shaft. Grind all gouges with a pencil grinder to remove any fissures
and to blend the periphery of the gouge into the main shaft
diameter.
Clean the shaft sleeve area of the main shaft.
Heat the shaft sleeve uniformly throughout the full diameter and
length to 230°F [110°C] above the ambient temperature. Use
temperature indicating sticks (TEMP STIKS) and do not exceed
500° F [260° C].
Special care must be taken not to distort or

damage the threads during heating and
handling.
Once the sleeve is heated to the correct temperature, begin placing

the sleeve onto the main shaft. If the sleeve begins to jam or tilt on
the main shaft, raise it slightly and realign it. Once the sleeve
begins to lower onto the main shaft, do not stop! Continue with
installation until the sleeve is fully seated.
Secure the Main Shaft Sleeve to the main shaft as shown on the
main shaft assembly drawing in Section 7 of this manual.
4) MAIN SHAFT CONTACT SEAL RING – REPLACEMENT

Refer to the installation section (section 3) of this manual for
removal and replacement.
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5) INNER ECCENTRIC BUSHING – REPLACEMENT (SEE FIGURE 6.4.2.2)

Place the eccentric with the eccentric bore vertical.
Carefully clean the bore of the eccentric.
Coat the bore of the eccentric with oil, not grease - grease will
contaminate the lubrication oil filter(s).
Examine the arrangement of drilled and tapped holes in the inner
eccentric bushing flange and the eccentric. One hole is spaced
unevenly to orient the bushing in the eccentric. Identify and mark
this hole in each piece before proceeding.
Insert a threaded guide rod in two holes of the eccentric to assure
alignment of the
bushing during
installation. The guide
rods must be of
sufficient length to
permit the rods to
guide the bushing its
entire length during
installation.
Carefully clean the
inner eccentric
bushing, and remove
any upsets on the
surfaces. To facilitate
the installation of the
bushing, cool the
bushing with either dry
ice or liquid nitrogen.
Refer to “Installing Interference Fit Components”

in Section 3 for further instructions and
precautions.
Cool the bushing to 176°F [80°C] below ambient temperature. Rig,

and with a crane, lower the bushing onto the guide rods, taking
care of the bushing alignment with respect to the drilled and
tapped.
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Begin insertion of the bushing into the cylinder. If the bushing

begins to jam or tilt in the cylinder, raise it slightly and realign it.
Once the bushing begins to lower into the cylinder, do not stop!
Continue with installation until the bushing is fully seated.
6) OUTTER ECCENTRIC BUSHING – REPLACEMENT

Refer to the Installation section (Section 3) of this manual for
information.
7) HYDRAULIC PISTON BUSHINGS – REPLACEMENT

Place the hydraulic piston with the cylinder vertical.
Carefully clean the cylinder of the hydraulic piston.
Coat the bore of the hydraulic piston with oil, not grease, as grease
will contaminate the lubrication oil filter(s).
Carefully clean the piston bushing, and remove any upsets on the
surfaces.
Refer to “Installing Interference Fit Components”

in section 3 for further instructions and
precautions.
Heat the bushing to 158°F [70°C] above ambient temperature. Rig,

and with a crane, lower the bushing onto the guide rods, taking
care of the bushing alignment with respect to the drilled and
tapped.
Begin insertion of the bushing into the hydraulic cylinder. If the
bushing begins to jam or tilt in the cylinder, raise it slightly and
realign it. Once the bushing begins to lower into the hydraulic
cylinder, do not stop! Continue with installation until the
bushing is fully seated.
8) HYDRAULIC PISTON SEALS – REPLACEMENT

See the Installation Section (Section 3) of this manual for further
information
9) CONCAVES – REPLACEMENT
information
10) SPIDER POCKET LINING – REPLACEMENT

information
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11) GEAR – REPLACEMENT

Place gear on blocking at a height sufficient to align with the
eccentric assembly mounting surface. (THREADED ROD
METHOD)
Lower the eccentric assembly into the center of the gear and align
the pilot of the gear carrier with the gear.
Install bolts and torque to required value.
Install outer counterweight and torque to required value.
Eccentric assembly should rest on its own blocking and not on the
gear blocking.
The contact surface of the gear must be in 360°

contact with the corresponding horizontal
surface of the gear carrier.
12) PINION – REPLACEMENT

Heat the pinion to 350° F [176° C] using the heating methods
described in the Installing Interference Fit Components Section
(Section 3) of this manual.
Allow the pinion to soak at the 350° F [176° C] for an hour. Use a
“pin” gauge to confirm the inside diameter of the pinion has
increased by at least 0.010” [0.25 mm].
Place a cloth lifting strap around the pinion in a choker hitch and lift
and level the pinion.
Place the key in position on the counter shaft.
The back surface of the pinion must be in 360°

contact with the corresponding surface of the
spacer or pinion bearing.
Lift the pinion and begin placing the pinion on the counter shaft. If
the pinion begins to jam on the counter shaft , remove the pinion
slightly and realign it. Once the pinion begins to go on the counter
shaft, do not stop! Continue with installation until the pinion is
fully in contact with the inboard counter shaft bearing inner
race.
Install the key retainer ring in the groove of the counter shaft.
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SECTION 7:
DOCUMENTATION
DOCUMENT NAME DOCUMENT NUMBER
Parts List
General Arrangement
Foundation/Clearance Requirements
Mainshaft Assembly
Gear/Pinion Assemby
Hydraulic Adjustment Assembly
Spider Assembly
Bottom Shell Liner & Shield Assembly
Middle Shell Assembly
Bottom Shell Assembly
Top Shell Assembly
Eccentric Assembly
Concave Assembly
Mantle Position Indicator Assembly
Spider Lube System
Countershaft Extension Assembly
Top Shell Seal Assembly
Lube/Hydraulic System Schematic
Doc. No.: 59001428

Rev. A
GYRATORY CRUSHER
SECTION 7:
DOCUMENTATION (CON’T)
DOCUMENT NAME DOCUMENT NUMBER
Lube/Hydraulic Unit – Bill Of Material

Lube/Hydraulic Unit – General Arrangement
Lube/Hydraulic Unit – Schematic
Lube/Hydraulic Unit – Wiring Diagram
Dust Seal Blower Assembly
Weight, C.G., & Handling – Bottom Shell
Weight, C.G., & Handling – Middle Shell
Weight, C.G., & Handling – Top Shell
Weight, C.G., & Handling – Spider
Weight, C.G., & Handling – Mainshaft
Dust Bonnet Assembly
Relief Valve And Accumulator Assembly
Drive Guard Assembly Drawing
Electrical – Control
& Instrument Diagrams (Sheet 2.01-2.09)
Electrical – Load List (Sheet 11.01)
Electrical – Instrument List (Sheet 21.01)
Electrical – Functional Specification (Sheet 3.01)
Doc. No.: 59001428

Rev. A
Gyratory Crusher
2.9 - CRUSHER CONTROL SYSTEM

OPERATING AND SAFETY INTERLOCKS
The “TSU” Gyratory Crusher may come with a PLC System that monitors the
vital signs of the Crusher as well as assists in operating the Crusher within the
design limitations. Altering or isolating (jumper out) the interlocks of this system
not only affects the mechanical well being of the Crusher, it can seriously effect
the safety of the workers about the Crusher.
Never make changes to the Control System without prior approval of

FLSmidth Minerals.
If it becomes necessary to make temporary changes to the Control

System and FLSmidth Minerals cannot be contacted in a timely manner,
insure that approval has been provided by local mine operational and
safety management and that any changes are well documented.
2.10 - GENERAL SAFETY CONCERNS

Tools used to maintain the “TSU” Gyratory Crusher: Many components that
make up assemblies of the “TSU” Gyratory Crusher are assembled with
interference fits. Therefore maintenance workers will be required to use open
flame and/or cryogenic agents in the installation and removal of various parts.
Following is a list of safety concerns:
Open flames present obvious safety concerns for the workers. Because
some parts have to be heated rapidly and thoroughly, it is important that
more than one heating torch is used at the same time (two torches, two
workers). It is imperative that workers be trained in the safe use of open
flame heating devices.
Liquid nitrogen and dry ice are commonly used to chill components for
assembly. Working with cryogenics presents unique safety hazards and
workers must be trained in the safe use of these agents and appropriate
personal protective equipment.
Air impact tools are frequently used for assembly and disassembly work.
Because of the size of the fasteners, these tools are frequently large and
cumbersome. Workers need to be trained in the proper use of these
compressed air tools. Workers are to be trained in the standard safety
practices with respect to the use of compressed air and compressed air
tools.
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SECTION 8:
VENDOR DOCUMENTATION
Countershaft Bearings 8.1

Countershaft RTDs 8.2
Lube & Hydraulic Unit 8.3
Air Oil Cooler 8.4
Relief Valve 8.5
Pressure Gauges 8.6
Needle Valves 8.7
Temperature Gauge 8.8
Ball Valve 8.9
Flow Transmitters 8.10
Globe Valves 8.11
RTD and Thermowell Assembly 8.12
Relief Valve & Accumulator Assembly 8.13
Spider Lube System 8.14
Mantle Position Indicator System 8.15
Safety Coupling 8.16
Hydraulic Jacking System 8.17
Takstik-Low Speed Switch 8.18
Dust Seal Air Blower 8.19
Hoses 8.20
Doc. No.: 59001428

Rev. A
Gyratory Crusher
The air impact tool is frequently used to turn jacking bolts that remove
interference fit parts. In this case, it is important the part be removed as
rapidly as possible, before heat can soak into the mating part. It is
advisable that more than one person be assigned to a tool, so that the tool
can be utilized without excessive fatigue to an individual worker.
Some fasteners used in the “TSU” Gyratory Crusher require high torque
values to establish proper pre-load. These high torque values can require
the use of torque multipliers. Workers need to be trained in the safe
utilization of these tools.
Please refer to the Maintenance Section of this Instruction Manual for

specific cautions with respect to welding to manganese and high chrome
white iron wear materials.
Under no circumstances should any welding be done on the actual cast

components of the Crusher. Though such welding does not present any
particular safety hazard, the high carbon steel alloy of these castings can
be seriously compromised by improper welding techniques. It is imperative
that FLSmidth Minerals be contacted before any such welding is
undertaken.
Though housekeeping concerns have been mentioned with respect to Slip and
Trip Hazards above, it is still important to reiterate this concern:
Always correct the causes of spillage as they occur and clean up spillage
as soon as possible.
Clean up all oil spills or other types of spills that would result in slip
hazards.
Pick up and put away tools, cable rigging, wash down water hoses, air
pressure hoses and acetylene torch equipment as immediately after they
are used.
As working with the “TS” and “TSU” Gyratory Crusher presents many unique
safety issues as described above, it is very important that workers receive proper
hazard awareness training relating to these issues. Following are topics of job
specific training:
All workers should become familiar with the general operation and
maintenance of the Crusher.
7.500758 S-9
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Gyratory Crusher
Workers must be made aware of the specific safety hazards related to

working about the Crusher.
Workers need to be trained in the safe use of tools and materials used in
the maintenance and operation of the Crusher.
As mentioned at the onset, this Section on Safety is only to be utilized as a guide

to assist the customer in developing there own safety program with respect to
working on and about the Type “TS” and “TSU” Gyratory Crusher. All general
site safety instructions apply to a Gyratory Crusher. Any conflicts within the
instructions are to be discussed with the site manager. Any questions and
concerns related to the safe operation and maintenance of the Crusher should be
directed to the Engineering and Sales Department of FLSmidth.
7.500758 S - 10
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GYRATORY CRUSHER
SECTION 3:
INSTALLATION
Introduction 3.1
Receipt of Material 3.2
Indoor Storage 3.3
Outdoor Storage 3.4
Foundation 3.5
Installation Considerations 3.6
Hydraulic Support Ring Installation 3.7
Hydraulic Cylinder Housing Installation 3.8
Hydraulic Cylinder Piston Installation 3.9
Bottom Shell Installation 3.10
Bottom Shell Grouting 3.11
Bottom Shell Liners Installation 3.12
Outer Eccentric Bushing Installation 3.13
Eccentric Assembly Installation 3.14
Countershaft Assembly Installation 3.15
Dust Bonnet/Gear Guard Installation 3.16
Middle Shell Installation 3.17
Top Shell Installation 3.18
Concave Ring Segment Installation 3.19
Concaves Installation 3.20
7.500759 I-1
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GYRATORY CRUSHER
Spider Pockets, Backing Material Installation 3.21
Main Shaft Assembly Installation 3.22
Spider Lubrication Hose and Spider Bushing Installation 3.23
Spider Shields Installation 3.24
Spider and Spider Seal Installation 3.25
Spider Cap Installation 3.26
Top Shell Wear and Seal Plates Installation 3.27
Mantle position Indicator Installation 3.28
Lubrication and Hydraulic System Installation

and Connection 3.29
Lubrication and Hydraulic System Filling and Flushing 3.30
Spider Bushing Lubrication System Installation 3.31
Drive Motor, Couplings, and Countershaft Extension

Assembly Installation 3.32
Torque Limiting Coupler Installation 3.33
Drive Guard Installation 3.34
Countershaft Tak-Stik Installation 3.35
Dust Seal Blower Connection 3.36
Post Installation Inspection 3.37
7.500759 I-2
Rev. 1
GYRATORY CRUSHER
3.1 - INTRODUCTION
This Section provides information for the proper assembly and installation of the
various components that make up a “TS” or “TSU” Gyratory Crusher. Due to the size
and weight of these components, several pieces will arrive as pre-assembled
components (sub-assemblies); such as, Countershaft, Eccentric, and Hydraulic
Bottom. FLSmidth highly recommends that this manual, as well as the Parts List, be
read before completing the assembly of the Crusher or carrying out any maintenance
on the Crusher.
The following information is provided in a separate package labeled “Drawings and

Data”:
Weights
Clearances and Crusher template
Unbalanced forces
Crusher mounting and clearance drawing
Lube/Hydraulic Unit general arrangement drawing
Power unit hydraulic schematic drawing
Air blower mounting and clearance drawing
Index for field connections
P & ID drawings
Crusher oil piping
Air cooler and piping general arrangement
3.2 - RECIEPT OF MATERIAL

A complete inspection is recommended as soon as possible following delivery of the
Crusher. Look for any damage that might have occurred during transit. Also verify that
all “shipped loose” items listed on the Bill of Lading, Freight Bill or Manifest are
accounted for. Immediately notify the carrier and FLSmidth of any damage or
shortages.
3.3 - INDOOR STORAGE

When necessary, indoor storage of components must be done with the utmost of care
to ensure that no damage is done to any components during the storage period.
While in storage, the equipment must be inspected every two weeks. At this time, rust
must be removed and paint or rust preventive coatings replaced as required.
All protective materials such as waterproof paper, wood, and rust preventive coatings
must be repaired or replaced if these items have been damaged during shipment.
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GYRATORY CRUSHER
The following items are to be stored indoors at a temperature not less than 40°F (5°
C) unless noted otherwise. Items not listed below will follow outdoor storage
procedures.
Countershaft Extension Assembly
Eccentric Assembly
Electric Motors
Bronze Components
Main Shaft Contact Seal
Main Shaft Head Nut
Lubrication/Hydraulic Assembly
Spider Lubrication System Assembly
Air/Oil Coolers
Control Panels/Instruments
Gears
Couplings
Dust Bonnet
Gaskets & Seals
Epoxy
All Bolts, Nuts, Washers, Dowel Pins, Shims, Pipe Valves, and Miscellaneous
Hardware.
3.4 - OUTDOOR STORAGE

The remaining crusher components consist of major fabricated and machined parts.
These items are painted and the machined surfaces are coated with a rust
preventative.
All parts are to be inspected upon arrival at the site. Surfaces damaged during
shipment are to be repaired by removing rust and repainting or recoating with rust
preventive as required. Thereafter, the parts should be inspected at frequent intervals
to remove rust and repair protective coatings as required.
Special attention should be given to machined surfaces, such as:

Main shaft bearing surfaces.
Main shaft threads.
Shell flanges, tapered fits, and bolt holes.
Spider bore and spider pocket fit surfaces.
Mantle bore.
Core bore and outside diameter.
7.500759 I-4
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GYRATORY CRUSHER
Soleplates.
Bottom shell bores and flanges.
Bottom plate surfaces.
Rust formation on these surfaces may cause irreparable damage.
These components may be stored outside; however, they must be protected from the
elements. All items stored outside must be placed on appropriate pads and blocking
to prevent these components from sinking into the mud. These pads and blocking
should be inspected at frequent intervals and necessary corrective action must be
undertaken to prevent damage to stored components.
3.5 - FOUNDATION
The crusher is to be erected upon a foundation that must be designed to support the
weight of the equipment and to withstand the loads occurring during operation.
The foundation should include personnel access to the underside of the crusher for
installation and maintenance.
Leave the top of the foundation rough to provide anchorage for grout.
The foundation bolts should be set in sleeves and should be checked against
certified drawings for location.
Make certain that allowance is made for shims, grout, the crusher base, and
mounting hardware when setting the bolts.
Provisions must also be made for supporting items such as drive units, the
lubrication/hydraulic pumping unit, oil coolers, grease lubrication system, and
the dust seal blower if supplied.
3.6 - INSTALLATION CONSIDERATIONS

Normal installation operations include the correction of misfits by straightening,
shimming, chipping, cutting, or grinding for proper fit of elements. Misfits which cannot
be corrected by the foregoing means or which require major changes in equipment
configuration are to be reported immediately to FLSmidth for correction of misfits or to
approve the most efficient and economic method of correction to be implemented.
The installation of the crusher is to be made in accordance with the parts list and
drawings provided in Section 7 of this instruction manual. They define the physical
arrangements, pertinent dimensions, interconnections, loads, and other
characteristics, data, and information needed for the erection and installation of all
components supplied.
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GYRATORY CRUSHER
While there is a general, overall sequence of installation which will be followed, there
are many details for which the sequence will be determined by conditions existing at
the site.
An Erection Record Book should be made available to compile all progress made,
problems encountered, and measurements obtained during the different installation
phases of each crusher. The installation checklist of this instruction manual is to be
completed and transmitted to the FLSmidth project manager. This information is
valuable for comparing conditions during the installation and later during production,
and for helping identify causes of potential problems for easier and lasting solutions.
The crusher is shipped in major subassemblies whose final assembly must be

completed on site. The installation of these subassemblies, and those assembled on
site, must be installed in accordance with the drawings provided in this manual, and
the installation data referenced in this section of the manual. These documents
contain information specific to this crusher. They define the physical arrangements,
pertinent dimensions, loads, and other characteristics, data, and information needed in
the erection and installation of all components supplied. Carefully observe match
marking of mating components during installation.
It is very important to know that any field modification to components can and will
nullify the warranty, unless authorized by FLSmidth.
3.7 - HYDRAULIC SUPPORT RING INSTALLATION

Install studs in the bottom shell in the locations shown in the bottom shell assembly
drawing and as indicated on the parts list. Quantity and arrangement of the studs and
pins may vary.
It is critical that the correct torque level is

achieved for these fasteners as they support
all the vertical loads from the mainshaft
7.500759 I-6
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GYRATORY CRUSHER
FIGURE 3.7.1
3.8 – HYDRAULIC CYLINDER HOUSING INSTALLATION

The crusher is provided with a separate hydraulic cylinder which can be installed prior
to bottom shell installation. To do this make sure the bottom shell is supported in a
manner that allowes adequate room underneth for clearance of the complete
assembly.
1. Thoroughly clean the mounting surface of the hydraulic support ring.
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GYRATORY CRUSHER
2. Place the Large O-ring on the outside diameter of the housing. Carefully
move it up to the juncture of the OD and the flange.
Care must be taken not to nick or rip the O-

ring. To facilitate installation a light coating
of oil is recommended on the housing while
sliding it in place.
3. Place a thin bead of RTV silicone on the mounting surface close to the ID if
the opening in the cylinder.
4. Use a guide rod or other means to ensure the cylinder is lowered in place so
the guide pin is located in the hole on the cylinder housing. Using lifting
eyes and an overhead crane lower the hydraulic cylinder housing
5. Once the Cylinder housing is in place tighten the bolts using a star pattern
to the torque listed on the assembly drawing.
3.9 – HYDRAULIC CYLINDER PISTON INSTALLATION

The crusher is designed so the piston can be installed from above using a special
installation. This can be done prior to bottom shell installation if desired for easy
access.
1. Thoroughly clean the inner surface of the hydraulic cylinder housing.
2. Carefully lubricate the surfaces to aid in installation.
3. Inspect the piston center for obstructions. This is the oil port for the crusher
bottom lubrication.
4. Place the cleaned and oiled center wearing ring on the piston wear ring
5. Thread the special tool supplied into the piston through the lubrication port
in the center. This will capture the center wear for safe handling.
6. Carefully lower the piston into the housing from above. Care must be taken
to properly align it so it does not cock and seize at installation.
3.10 BOTTOM SHELL INSTALLATION

The crusher is provided in one, two, or three sections as determined by the crusher
size and transportation restrictions.
1. Thoroughly clean the top surface of the foundation and the bottom surface
of the bottom shell to remove all dirt, grease, oil, and paint.
2. Place steel shims typically 2 inches x 2 inches x 2 inches (50 mm x 50 mm x
50 mm) in size on the foundation at both sides of each foundation bolt.
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GYRATORY CRUSHER
3. Check that the shim stacks are nearly level. Add shims as required. The
shim stacks must be high enough to provide room for level adjustment and
grout.
4. Lower the bottom shell onto the shims.
5. Tighten the nuts on the foundation bolts evenly in a cross pattern.
6. Verify the level of the bottom shell.
3.11 - BOTTOM SHELL GROUTING

Use a non-shrink epoxy grout suitable for use on heavy operating equipment. The
loads indicated on the foundation drawing are used to select the correct grout. It is the
responsibility of the client to select the grout but FLSmidth has recommended
suppliers to assist in this selection.
Apply the grout according to the grout manufacturer’s directions.
Care must be taken to ensure full contact

between the grout and the underside of the
bottom shell.
3.12 - BOTTOM SHELL LINERS INSTALLATION

After the grout has become sufficiently strong, according to the grout manufacturer’s
recommendations, install the:
1. Rib Liners
2. Outer Bottom Shell Liners
3. Countershaft Liners
4. Rib Shields
Liners and the components they mount on are

composed of castings. As such they have as
cast surfaces that may differ from the design
dimension due to casting tolerance. Thus it is
normal for some field fit-up, trimming, and
shimming
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GYRATORY CRUSHER
FIGURE 3.12.1
3.13 – OUTER ECCENTRIC BUSHING INSTALLATION

1. Carefully clean the top, the bore, and the lower portion of the bottom shell
hub including the countershaft chamber.
2. Coat these areas with oil, not grease, as grease will contaminate the
lubrication filter.
3. Inspect the bore holes in the hub for the outer eccentric bushing lubrication
feed, the dust bonnet air feed, and optional eccentric wearing surface oil
feed, making sure that they are clear of foreign material.
4. Examine the arrangement of drilled and tapped holes in the outer eccentric
bushing flange and the crusher shell.
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GYRATORY CRUSHER
The pattern is not equally spaced. Make

sure the holes are properly aligned.
5. Insert a threaded guide rod in two holes of the bottom shell hub to assure
alignment of the bushing during installation. The guide rods must be of
sufficient length to permit the rod to guide the bushing its entire length
during installation. See Figure 3.13.1 below.
FIGURE 3.13.1
6. Carefully clean the outer eccentric bushing, and remove any upsets on the
surfaces. To facilitate the installation of the bushing, cool the bushing with
dry ice to 80 degrees Celsius below ambient or to bottom shell temp
(whichever is lower).
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GYRATORY CRUSHER
7. Pack the interior (bore) completely with dry ice and cover the bushing with
an insulating blanket or a tarpaulin.
8. When the temperature is 80 degrees Celsius below ambient, or crusher
shell temp (whichever is lower), use a crane and lower the bushing onto the
guide rods, taking care of the bushing alignment with respect to the drilled
and tapped holes.
9. Begin insertion of the bushing into the bottom shell. If the bushing begins to
jam or tilt in the bottom shell, raise it slightly and realign it. Immediately
continue the insertion.
Once the bushing begins to lower into the

bottom shell, DO NOT STOP! Continue
with the installation of the bushing until it
is fully seated.
10. Immediately bolt in place and torque to the values on the eccentric
assembly drawing.
3.14 – ECCENTRIC ASSEMBLY INSTALLATION

1. Clean the chamber for the bevel gear, and the mating surface for the gear
cover on the bottom shell.
2. Clean and oil the eccentric support bushing. Lower it into place using the
three tapped holes and provided lifting eyes. See figure 3.14.1 below.
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GYRATORY CRUSHER
FIGURE 3.14.1
3.15 – COUNTERSHAFT ASSEMBLY INSTALLATION

1. The countershaft assembly is shipped completely assembled. Clean and oil
it, and remove any upsets on machined surfaces.
2. Place the initial assembly gaskets and the gear set adjustment gaskets onto
the counter shaft assembly housing. Refer to Countershaft Assembly
drawing and the Countershaft Assembly Bill of Material in Section 7 of this
instruction manual for the number and description of the gaskets required.
3. The countershaft housing is designed with an offset between the bore and
the OD of the housing. To insert the curved tooth gear, rotate the
countershaft assembly housing 90 degrees (clockwise) from operating
condition (arrow pointing up) so that the pinion is lowered relative to the
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GYRATORY CRUSHER
gear. Insert the countershaft assembly. Once the countershaft assembly is

fully inserted carefully rotate it 90 degrees (counterclockwise) till it is in
operating position (Refer to Countershaft Assembly Drawing for
Countershaft Directional Arrow). A turning lug is provided to aid the rotation
of the assembly. Refer to the Countershaft Assembly drawing and parts list
in section 7 of this instruction manual.
4. Bolt the assembly to the bottom shell and torque the bolts to the values
specified on the Countershaft Assembly Drawing, which can be found in
Section 7 of this manual.
5. Backlash is measured using the Gear Instruction drawing. Refer to the
Gear Instruction Drawing found in Section 7 of this manual for the pinion
pitch radius and the recommended backlash.
6. Use a copy of the Gear Set Backlash Data to record measurements and
calculate the actual backlash. Send a copy of this completed Data Sheet to
FLSmidth.
7. Place a dial indicator on the flag attached to the coupling bolt.
8. Measure the distance “R” (See Figure 3.15.1 below) from the centerline of
the pinion shaft to the point where the dial indicator plunger touches the
flag. Record this measurement in Column B on the datasheet.
9. Rotate the countershaft counterclockwise until the pinion contacts the gear.
(STEP 1)
10. Set the dial indicator to “0”. (STEP 2)
11. Rotate the countershaft clockwise until the pinion again contacts the gear.
Record the dial indicator reading in “Column C” on the datasheet. (STEP 3)
12. Rotate the eccentric 90 ° and repeat the three previous steps.
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GYRATORY CRUSHER
FIGURE 3.15.1
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FIGURE 3.15.2 - GEARSET BACKLASH DATA
A B C D
Pinion “R” Dial Backlash Angular
Comments Date Initials
Pitch (inches Indicator Calculation Position
Radius ) Reading (A/B)*C
(inches) (inches) (inches)
Thickness of Gaskets Number of Gaskets at

Counter Shaft Vertical Position of Gear
0.031” [0.79 mm}
At Counterweight.
0.062” [1.57 mm] 180° from Counterweight.
NOTES:
1. All measurements are in inches.
2. The measurement “R” in Column B is the distance between the countershaft
centerline and the point where the dial indicator plunger touches the bar in the
countershaft nut.
3. If initial installation of the gearset, record the measurements and calculations in the
Erection Record Book, and send a copy to FLSmidth Minerals USA, Inc.
13. Rotate the eccentric 90° again (the pinion is now in contact with the gear
180 ° from the first measurement) and repeat steps 1, 2, and 3.
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GYRATORY CRUSHER
14. Rotate the eccentric 90° again (the pinion is now in contact with the gear
270 ° from the first measurement) and repeat steps 1, 2, and 3.
15. Rotate the eccentric 90° again (the gear has now made one complete
revolution) and repeat steps 1, 2, and 3.
16. Using Figure 3.15.2 (GEARSET BACKLASH DATA), Calculate the
backlash:
17. Divide the pinion pitch radius (Column A) by the distance between the
countershaft centerline and the dial indicator (Column B).
18. Multiply the result of the division by the dial indicator reading (Column C).
19. Record the result of this multiplication in Column D. This is the backlash of
the gear set.
20. Compare the backlash calculated in Column D with the required backlash
from the “Erection and Maintenance Data” drawing in Section 7 of this
manual.
21. Adjust the backlash as required by rotating the countershaft in the bore of
the Bottom Shell. Use the values given in the gear erection drawing in
Section 7 of this manual for required backlash.
22. When the correct backlash has been set, complete the datasheet (Figure
3.15.2) by recording comments, the date, the initials of the personnel who
made the measurements, calculations, and backlash adjustments, the
angular position of the countershaft assembly, and the number of gaskets at
the countershaft.
23. Match and mark angular position. Make sure to mark position of the
Countershaft rotation before removal of the Countershaft.
24. Lightly coat the driving flanks of the pinion teeth with a gear marking
compound.
25. Install the counter shaft assembly into the bottom shell using the thickness
and number of gaskets and match it to the marks determined in the previous
information of Section 3.15 above.
26. Rotate the pinion through 270°
27. Remove the counter shaft assembly from the bottom shell and observe the
contact pattern on the pinion.
28. Select the contact pattern from Figure 3.15.3 that represents the contact
pattern observed and report it to FLSmidth.
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GYRATORY CRUSHER
FIGURE 3.15.3 – GEARSET CONTACT PATTERNS
3.16 – DUST BONNET/GEAR GUARD INSTALLATION

1. Clean the bonnet and remove any upsets.
2. Clean the gear cover and remove any upsets.
3. Place the gear cover upside down and install the eccentric stabilizer. Be
careful to torque to proper levels and secure the bolts indicated on the
drawing
4. Place the gear cover right side up and clean the mating surface with the
dust bonnet
5. Place the two seal rings in the annular groove that is formed between the
gear cover and the bonnet when they are assembled.
6. Place the dust bonnet on the gear cover being careful to align the dowel pin
and the guide hole.
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GYRATORY CRUSHER
7. Clean the mounting surface on the bottom shell taking special care that the
oil and air ports are clear.
8. Use care to align the dowel pin and the guide hole as this will ensure the
ports are properly aligned.
9. Place a thin bead of RTV silicone on the mounting surface of the bottom
shell. This bead should be on the inside of the tapped holes to provide an
oil seal.
10. Measure the outside diameter of the bonnet and fabricate a cover for it.
Make it sturdy as it will be used as a work platform during later assembly,
and to prevent dirt and debris from falling into the eccentric.
3.17 – MIDDLE SHELL INSTALLATION

1. Clean the mating flanges of the bottom shell and middle shell and remove
any upsets on the flange contact surfaces.
2. Coat the mating surfaces of the bottom shell upper flange and the middle
shell lower flange with oil.
3. Check the Middle Shell Weight, C.G., and Handling Drawing in Section 7 of
this manual to determine if special orientation of the shell is required.
4. Lower the shell into position, carefully aligning the holes of the bolts with the
bottom shell. The fit between the shells is a taper fit. Lower the middle
shell evenly to prevent cocking the shell in the fit. As the middle shell
approaches contact on the taper fit, level the shell.
5. Install the shell bolts and nuts and tighten the nuts evenly to prevent cocking
the middle shell. Tighten the nuts until the flanges are in contact for 360 °.
6. After the flanges are in contact, torque the nuts to the value given in the
Middle Shell Assembly Drawing in Section 7 of this manual.
3.18 – TOP SHELL INSTALLATION

1. Note: For Split Top Shells, assemble the halves per the Top Shell Assembly
drawing listed in Section 7 first, and then follow the instructions as shown
below.
2. Clean the mating flanges of the middle shell and top shell and remove any
upsets on the flange contact surfaces.
3. Coat the mating surfaces of the middle shell upper flange and the top shell
flange with oil.
4. Lower the shell into position, carefully aligning the holes of the bolts with the
middle shell. The fit between the shells is a taper fit. Lower the top shell
evenly to prevent cocking the shell in the fit. As the top shell approaches
contact on the taper fit, level the shell.
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GYRATORY CRUSHER
5. Install the shell bolts and nuts and tighten the nuts evenly to prevent cocking
the top shell. Tighten the nuts until the flanges are in contact for 360 °.
6. After the flanges are in contact, torque the nuts to the value given in the Top
Shell Assembly drawing in Section 7 of this manual.
3.19 – CONCAVE RING SEGMENT INSTALLATION

1. The concave ring segments support the lower row of the concave assembly
during installation. The segments consisting of four arcs are placed into a
recess of the shell and are welded to form a continuous ring. Note that the
ends of each segment are chamfered for welding per the Middle Shell
Assembly drawing found in Section 7.
2. Grind the welds so the welding beads do not protrude above the surface of
the ring. The rings are made from mild steel.
3.20 – CONCAVE INSTALLATION
As a result of crushing, the face of manganese concaves can

cold work and grow (peen). Space must be provided between
adjacent concaves in all rows and between adjacent rows of
concaves for this growth. When positioning the concaves,
distribute the vertical space between adjacent concaves as
evenly as practical.
Note: Alloy concaves do not cold work and consequently the
crushing surface does not grow (peen).
1. To determine the horizontal space to be left between each row of concaves,

stack one concave from each row up the side of the shell as shown in
Figure 3.20.1. Notice that the concaves for the upper row have lugs that
must fit into the machined groove in the top shell. Measure the space
between the top of the lug and the top of the groove in the top shell. This
space must be distributed as evenly as practical between the rows of
concaves. The top of the lug in the upper concave must contact the top of
the groove in the shell.
2. Power brush the surfaces of the concaves and the mating portion of the
shell bore to remove dirt, grease, oil, and protective coatings. Also, remove
any upsets on these surfaces.
3. After a row of concaves has been installed, an epoxy backing material is
poured between the row of concaves and the crusher shell.
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GYRATORY CRUSHER
4. The epoxy is intended to function as a material to fill the space between the
outside surface of the concaves and the inside surface of the shell. This
distributes the crushing forces evenly from the inside of the concaves
through the backing material and to the shell and prevents flexing of the
concaves.
5. Each concave has half of a tapered slot at the top of each vertical side.
When the concaves are installed in the crusher, the tapered slots in two
adjacent concaves form one complete slot.
6. Position the concaves in each row to equalize the vertical joints and shim
the concave pads if required.
7. Place the tapered pin in the tapered slot between adjacent concaves.
Lightly tap these pins in place to lock the concave in position. The top of the
tapered pins may sit above or below the top of the concaves due to
manufacturing practices and tolerances. Use caution when driving the
tapered pins between the adjacent concaves to maintain the equalized
spacing of the vertical joints.
8. Cut off the portion of the tapered pins extending above the top of the
concaves.
9. Seal the joints as shown in Figure 3.20.1. Be careful not to completely fill
the space between concaves.
10. The vertical space between adjacent concaves and the horizontal space
between rows of concaves must be partially filled with backing material. The
backing material in the vertical spaces between adjacent concaves makes
each row of concaves a complete ring. The backing material in the
horizontal spaces between rows of concaves makes the concaves complete
from the top shell lug groove to the concave ring segment. With this
arrangement the concaves are locked in position and the movement of
individual concaves is prevented.
11. Pour backing material between the shell and the concaves in accordance
with the information provided by the backing material manufacturer.
12. Most backing material is poured in the field, using the following basic
procedures that must be supplemented on site to include additional detail
and to adjust for local conditions.
13. Gaps and joints must be sealed to prevent leakage during pouring.
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GYRATORY CRUSHER
FIGURE 3.20.1
14. Complete mixing of the two-part compound is very necessary. Be sure to

mix thoroughly to the bottom of the container. The mixture can set very fast
in the container. As soon as the two parts are mixed, it must be used.
15. Repeat the procedure for each row of concaves, also filling the horizontal
spaces between rows with backing material. Stagger all vertical spaces as
shown in Figure 3.20.1.
16. The Upper Concaves must be installed so that the top of the lug in the
upper concave must contact the top of the groove in the top shell as shown
in Figure 3.20.1. Additionally the horizontal engagement ( overlap ) of the
concave lug into the shell groove must be at least 10mm as illustrated in
Figure 3.20.1. If engagement is less than 10mm, grind material off back of
concave support pads to increase engagement accordingly.
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GYRATORY CRUSHER
3.21 – SPIDER POCKETS, BACKING MATERIAL INSTALLATION

1. Clean the spider pockets and the mating ends of the spider arms. Place
shims on the machined ledge at the open side of each pocket to keep the
spider elevated slightly, so that subsequently there will be room to draw the
spider down and set it firmly in its taper fit. Refer to Figure 3.21.1. Use the
shim thickness as specified in Table 3.21.1.
TABLE 3.21.1 - SPIDER POCKET SHIM THICKNESS

CRUSHER NOMINAL OPENING SIZE SHIM THICKNESS
1400mm [ 55” ] or Less 20mm [3/4 inch]
Greater than 1400mm [ 55“ ] 25mm [1 inch]
7.500759 I - 23
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GYRATORY CRUSHER
FIGURE 3.21.1
2. Block the spider bolt holes in the spider and the top shell spider pocket with
wooden plugs or a board and fill the bottom of the pocket with clay, plaster
of Paris, or other sealing mixture until it is flush with the top of the shims.
3. Center the spider in the top shell. Use a feeler gauge between the machined
ledge on the top shell and the lip under the spider at two or more points on
each side to determine when the spider is centered.
4. Cover any gap through which backing material could escape.
5. Prepare and pour epoxy backing material in accordance with instructions
provided for the concaves and the manufacturer of the backing material.
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GYRATORY CRUSHER
6. Mark an end of the spider and its corresponding pocket of the top shell.
This will ensure the proper mating of the spider ends to the correct top shell
spider pocket in the future.
7. After the backing material hardens, remove the spider, shims, plugs, and
sealing material.
3.22 – MAIN SHAFT ASSEMBLY INSTALLATION

1. Clean and oil the main shaft assembly eccentric journal.
2. Remove the cover over the bonnet.
3. Lift the main shaft assembly and carefully lower the eccentric journal of the
main shaft into the bonnet until it enters the eccentric. Always lift the main
shaft assembly by the device provided on top of the main shaft only.
4. Carefully align the contact seal to enter the bonnet and lower the main shaft
assembly further until the seal ring is just above the bonnet.
5. Carefully align the dust seal ring so that it will clear the bonnet on the
outside.
6. Continue to lower the main shaft assembly until it has made contact with the
center wearing ring.
3.23 – SPIDER LUBRICATION HOSE AND SPIDER BUSHING

INSTALLATION
1. Clean the bushing bore and machined bore for the spider hose clamp.
Remove any upsets.
2. Install the spider hose, clamp, and gasket into the spider. Make sure that
the bolts are tight.
3. Clean the bushing and remove any upsets in it.
4. Draw the bushing into the spider bore with the bushing retaining bolts until
the bushing flange is firmly seated on the spider. Check the hole register
while drawing the bushing into place. Use a star-tightening pattern on the
bolts while drawing the bushing into place.
5. If the bushing is difficult to draw into place with the bolts, it may be cooled
with dry ice or liquid nitrogen. Refer to the Installing Interference Fit
Components section of this manual.
6. After the bushing is firmly in place, Install and tighten all fasteners for the
bushing in a star pattern to the torque value listed on the Spider Assembly
Drawing located in Section 7 of this manual.
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GYRATORY CRUSHER
3.24 – SPIDER SHIELDS INSTALLATION

1. Fit shields onto the Spider.
2. Install the bolts, nuts, and washers into the shields and spider arms and
tighten the nuts securely. To ensure that the nuts do not loosen, they can
be tack-welded onto the bolts.
3. Seal the gaps between the edge of the shields and bolt holes in the spider
arms.
4. Prepare and pour epoxy backing material between the shields and spider
arms in accordance with instructions provided for the concaves and the
manufacturer of the backing material.
3.25 – SPIDER AND SPIDER SEAL INSTALLATION

1. Grease the machined surfaces at the ends of the spider and the interior of
the bushing.
2. Place the spider seal onto the bottom of the spider journal of the main shaft.
3. Lift the spider and place it over the main shaft and into the top shell spider
pockets. Leveling the spider during lifting minimizes the chance of binding
in the spider pockets. The spider is lowered into position using care as the
journal of the main shaft enters the bushing and the ends enter the pockets.
Do not let it bind in the pockets. Make sure that the spider grease hose
enters in the correct hole in the top shell.
4. Install the spider bolts and the torque nuts. The procedure to tighten the
torque nuts is as follows:
4.1. Place the washers and nuts on the bolts. Thread the nuts onto the
bolts by hand until firmly in place against the washers and then back
the nut off two turns.
4.2. Tighten the torsion bolts on each of the nuts with a torque wrench to
the torque listed on the Spider Assembly Drawing in Section 7 of this
manual. Tighten the bolts in a star pattern and alternate between
spider ends to prevent cocking the spider in the spider pockets.
Check and retighten the torsion bolts after 2 days of crusher
operation.
3.26 – SPIDER CAP INSTALLATION

1. The cap does not have any fasteners and is simply set into place. The hole
in the top of the cap is used to place a rod through and lift.
2. If the spider lubrication pump is in operation at this time, operate the pump
until grease appears between the spider bushing and the main shaft spider
journal.
7.500759 I - 26
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DISTRIBUTION and REVISION RECORD SHEET
FOR
Gyratory Crusher - Type “TS”
Customer: SIERRA GORDA
FLS Contract No.: 11-20472-720
Main Parts List No.: LATER
Revision
REV.
Manual REMARKS BY TRANSMITTAL
Volume No. DATE
ALL ELECTRONIC COPY - PRELIMINARY PRE-A DAT 25Aug11
ONLY FOR INFORMATION
Distribution
Hardcopy Electronic
Customer 1
FLS Engineering
Doc. No.: 59001428

Rev. A
GYRATORY CRUSHER
3.27 – TOP SHELL WEAR AND SEAL PLATES INSTALLATION

1. Place the top shell wearing and seal plates in position on the top shell and
bolt them into place according to the assembly drawing in Section 7 of this
manual.
3.28 – MANTLE POSITION INDICATOR INSTALLATION

1. Install the Mantle Position indicator (MPI) as it is shown on the assembly
drawing found in section 7 of this manual. The MPI is mounted to the
bottom of the Hydraulic Cylinder Assembly.
3.29 – LUBRICATION AND HYDRAULIC SYSTEM INSTALLATION

AND CONNECTION
1. Locate the Lubrication & Hydraulic Skid, Oil Cooler(s), and Relief
Valve\Accumulator Assembly per the Lubrication and Hydraulic System
Schematic.
2. Support, level, and anchor the Lubrication & Hydraulic Skid, Oil Cooler(s),
and Relief Valve\Accumulator Assembly per the vendor drawings in Section
8. The Relief Valve\
3. Accumulator Assembly should be mounted as close as possible to the
crusher and oriented vertically as per the vendor drawing; also install the
lubrication system cooler(s) as per the vendors instructions located in
Section 8 of this manual.
4. Install the interconnection piping and components per the Lubrication and
Hydraulic Schematic and corresponding Parts List Section which are found
in Section 7 of this manual. The use of pickled and oiled steel pipe is
recommended. Piping should be pickled before installing into the system,
so as to avoid damage to components.
During installation, be particularly careful in keeping pipes,

fittings, and hoses free of all forms of dirt, grease, and foreign
matter that could enter the system. Inspect each piece carefully,
clean it as necessary and blow and flush it clear at the time of
connection.
5. Charge the accumulator to 300 psi [21 kg/cm2] with dry nitrogen. Follow the
accumulator manufacturer’s instructions included in Volume 2 of this
instruction manual. If supplied, use the optional charging hose and pressure
gauge. The accumulator relief valve set point should be verified to the
Lube and Hydraulic System Schematic Drawing in Section 7.
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GYRATORY CRUSHER
6. Verify the Oil Cooler relief valve set points, as well as all other components
to the Lubrication and Hydraulic Schematic, Field Instrument List, and
corresponding drawings located in Section 7 of this manual.
7. Test the Lubrication and Hydraulic Systems and check for leaks.
8. Make appropriate electrical connections to the components of the system.
9. Make provisions for heating all lines that will be exposed to temperatures
lower than those specified on the hydraulic system schematic.
DO NOT activate the sump tank heater or pump until the system
has been filled with oil.
3.30 – LUBRICATION AND HYDRAULIC SYSTEM FILLING AND

FLUSHING
1. Flush the lubrication system, the hydraulic adjustment system, and the
lubrication system cooling circuit for at least 16 hours with a flushing oil with
a viscosity of 100 SSU @ 100° F [38° C]. Flushing should be continued until
no visible contamination remains in the system.
2. Bypass the crusher and the cooler(s) by connecting the crusher supply line
to the crusher return line immediately adjacent to the crusher and by
connecting the cooler(s) inlet line to the cooler(s) outlet line immediately
adjacent to the cooler(s).
3. Bypass the hydraulic system relief valve and the hydraulic system
directional control valve(s) by connecting the inlet line to the outlet line of
these components immediately adjacent to these components.
4. Place screens at the reservoir lube oil return and at the reservoir hydraulic
system relief valve return.
5. Fill the reservoirs with flushing oil through a 25 micron filter.
6. Raise the flushing oil temperature to approximately 140° F [60° C] with the
reservoir heaters.
7. Check the screens at the reservoirs frequently and clean them as required.
8. Continue flushing until the screens indicate acceptable cleanliness levels.
9. After flushing the system, drain all flushing Oil and verify that all drain plugs
are installed and all drains are closed.
10. Pour in the amount of oil required to fill the reservoirs. Close the covers
immediately after filling has been completed to prevent contaminants from
entering the systems. The same oil is used in both the lubrication system
and the hydraulic adjustment system. This eliminates possible damage to
7.500759 I - 28
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GYRATORY CRUSHER
the crusher anti-friction and plane bearings in the event the hydraulic oil
leaks past the hydraulic piston packing into the lubrication oil.
Do not activate the heater or pump(s) until the

reservoir has been filled with oil. Be sure appropriate
valves are fully open before starting the pump.
3.31 – SPIDER BUSHING LUBRICATION SYSTEM INSTALLATION

1. Lubrication to the spider for the spider bushing is delivered from a barrel
pump that can be located (for convenience) near the bottom shell of the
crusher. Refer to the manufacturer’s instructions in Section 8 of this manual
for more details of installation for this system.
2. Interconnections and additional instructions for the spider bushing
lubrication system are shown on the Spider Bushing Lubrication Schematic
drawing located in Section 7 of this manual.
3. Make provisions to heat the lubrication container used with the pump and
the interconnecting line between the pump and the spider if they will be
subjected to ambient temperatures lower than specified on the Spider
Bushing Lubrication System Schematic drawing located in Section 7 of this
manual.
4. When the pump is operational, remove the spider cap and operate the
pump until lubricant appears.
5. Lubricant will be only be pumped to the spider when the crusher is in
operation and normal provisions are provided for running the spider
lubrication equipment independently of the crusher for special functions
such as filling the lines.
6. The controller controls the interval at which lubricant is pumped to the
bushing and monitors the system performance. The controller can be set to
deliver a constant stream of lubricant when the bushing area is being filled
initially or after the bushing area has been cleaned out. Set the controller to
deliver the grease flow rate indicated on the Spider lube schematic drawing
in Section 7 of this manual. Refer to the manufacturer’s literature for
programming details in Section 8.
7.500759 I - 29
Rev. 1
GYRATORY CRUSHER
3.32 – DRIVE MOTOR, COUPLINGS, AND COUNTERSHAFT

EXTENSION ASSEMBLY INSTALLATION
NEVER run the crusher in the reverse direction. The main shaft
and head nut threads have been designed for rotation in the
specified direction only.
1. Prepare to install the drive motor by reviewing the “Foundation Clearance

Requirements” drawing located in Section 7 of this manual and the motor
manufacturer’s installation instructions and drawings located in Section 7
and 8 of this manual.
2. Install the motor on its foundation using the motor manufacturers
instructions located in Section 8 of this manual.
3. Locate and inspect the countershaft extension and safety coupling. Clean
this assembly and remove any upsets present.
4. Align the motor output shaft with the crusher countershaft. Maintain the
gaps between the coupling hubs specified on the counter shaft extension
drawing and maintain the coupling manufacturers radial and angular
alignment requirements as listed in Section 7.
5. Set the motor output shaft at its magnetic center. This is very important for
maintaining the coupling hub gaps during operation.
6. Jog the motor to verify rotation. If it is not rotating in the direction specified
on the foundation requirement drawing, reconnect it.
3.33 – TORQUE LIMITING COUPLER INSTALLATION

1. Install the coupling using the manufacturers instructions located in Section 8
of this manual.
2. Adjust the coupling using the manufacturer’s instructions and per the torque
release set point specified in the Counter Shaft Extension Drawing located
in Section 8 of this instruction manual.
3.34 –DRIVE GUARD INSTALLATION

1. Install the drive guard using the assembly drawing located in Section 7 of this
manual.
2. The support legs are cut to length on-site, to ensure proper height.
7.500759 I - 30
Rev. 1
GYRATORY CRUSHER
3.35 – COUNTERSHAFT “TAK-STIK” INSTALLATION

1. Install the low speed switch (also known as “Tak-Stik”) using the
manufacturers instructions located in Section 8 of this manual.
2. Adjust the Tak-Stik using the manufacturers instructions located in Section 8
of this manual, and the Functional Spec Located in Section
3.36 – DUST SEAL BLOWER CONNECTION

1. Connect the Dust Seal Blower to the crusher using the assembly drawing
found in Section 7 of this manual. If the Dust Seal Blower was not supplied,
then disregard this step.
3.37 – POST INSTALLATION INSPECTION

1. Before the crusher is started, check the entire installation thoroughly.
Include the following points:
1.1. All temporary installation aids, debris, tools, etc. have been removed
from the interior of the crusher and surrounding area.
1.2. The lubrication system and the hydraulic adjustment system have been
prepared for operation; their pumps rotate in the specified
direction.
1.3. The spider bushing lubrication equipment has been flushed, the spider
bushing lubricated, the controller programmed, and the spider cap
installed.
1.4. All components that require lubrication have been properly lubricated.
1.5. The drive assembly has been properly aligned.
1.6. The mantle position indicator has been calibrated in accordance with its
manufacturer’s instructions
**NOTE: ANY ADDITIONAL INFORMATION REQUIRED FOR INSTALLATION CAN

BE FOUND IN SECTION 7 LABELED “DOCUMENTATION” OF THIS MANUAL.
7.500759 I - 31
Rev. 1
GYRATORY CRUSHER
SECTION 4:
COMMISSIONING
Introduction 4.1
Commissioning Sequence Flowchart 4.2
Crusher Assembly Pre-Commissioning Procedures 4.3
Bearing Lubrication Pre-Commissioning

Procedures 4.4
Hydraulic Adjustment System

Pre-Commissioning Procedures 4.5
Mantle Position Indicating System

Pre-Commissioning Procedures 4.6
No-Load Commissioning Procedure 4.7
Full Load Commissioning Procedure 4.8
Mechanical Pre-Commissioning Checklist 4.9
Electrical Pre-Commissioning Checklist 4.10
Instrumentation Pre-Commissioning Checklist 4.11
7.500760 C-1
Rev. 0
GYRATORY CRUSHER
4.1 - INTRODUCTION
The purpose of commissioning is to ensure that all the crusher systems and
associated equipment have been constructed according to their design.
Commissioning includes preoperational testing and initial run-in and operation of
the crusher without feed. Commissioning begins in accordance with the overall
project schedule and commences during the construction phase.
Preoperational testing activities include:
9 Cleaning and flushing of equipment.
9 Testing of controls and instrumentation.
9 Preliminary system run-in performance tests and inspections.
9 Installation of temporary facilities required to perform the tests and run-in.
9 Scheduling and coordination of participating vendors and their associated
activities.
Prior to starting the crusher for repositioning the main shaft, inspection, or
testing, a thorough inspection must be made of the immediate area. This is done
to make sure that there is no potential for personal injury or equipment damage
as a result of moving the crusher main shaft and mantle.
The areas that must be visually inspected include the exterior of the crusher
shell, the drive system, and the interior of the crusher. The MCC, hydraulic
adjustment skid, the lube skid and spider lube system should also be observed to
make sure they are operable and present no hazards to personnel or equipment
in the area.
7.500760 C-2
Rev. 0
GYRATORY CRUSHER
4.2 - COMMISSIONING SEQUENCE FLOW CHART

RESPONSIBILITY ACTIVITY FORMS/REPORTS
EPCM Contractor Final Stages of Schedules with Completion

Construction Milestones for Equipment
Manufacturer Prepare Preoperational and Written Guidelines for Each

Functional Test Guidelines Equipment Type
Manufacturer Identify Test Packages; Content of Each Package:

Prepare Procedures and • Equipment List
Database • Instrument List
• C&IDs (Marked Up)
• Test Description
• Test Datasheets
• Test Certificate
• Procedure
Manufacturer with Owner and Prepare Preliminary Test

EPCM Contractor Schedule Bar Chart of Each Package
EPCM Contractor Prepare Detailed Test Printout of Equipment With

Schedule Milestone Dates
EPCM Contractor, Final Installation and Vendor Vendor End of Service Form
Manufacturer, and Vendors Approvals and Daily Summaries
EPCM Contractor, Conduct Preoperational Test Test Certificates and Data-

Manufacturer, and Owner sheets
Witness
EPCM Contractor and Punchlist Printout of Deficiencies and

Manufacturer Responsibilities
All Equipment in Package

Successfully Tested
7.500760 C-3
Rev. 0
GYRATORY CRUSHER
RESPONSIBILITY ACTIVITY FORMS/REPORTS
EPCM Contractor and Conduct Package Functional Test Certificates and

Manufacturer Test Datasheets
EPCM Contractor and Punchlist Printout of Deficiencies and

Manufacturer Responsibilities
EPCM Contractor, Owner, and Monitor Operation of Crusher

Manufacturer Package No-Load Run
EPCM Contractor, Resolve Performance Issues

Manufacturer, Vendors
Package Successfully Tested as

a System
-Turnover Package -
Turnover Letter
Crusher Package Turnover
Exceptions List
To Owner and Signoff:
Test Datasheets
Hang Green Tags Test Certificates
Vendor data
Other Required Information
EPCM Contractor, Owner, and Monitor Operation of Crusher

Manufacturer Package as Feed is
Introduced
EPCM Contractor, Resolve Performance Issues

Manufacturer, Vendors
7.500760 C-4
Rev. 0
GYRATORY CRUSHER
4.3 - CRUSHER ASSEMBLY PRE-COMMISSIONING

PROCEDURES
The purpose of this procedure is to prepare the crusher assembly, including the
shell and its attachments, for the no-load start-up and initial start-up.
4.3.1 - MECHANICAL / LUBRICATION
4.3.1.1 - Ensure the crusher drive system is locked out and tagged
in accordance with established procedures.
4.3.1.2 - Inspect the interior of the crusher for missing and loose
liners, bolts and nuts. Check the following:
9 Spider arms and cap.
9 Concaves.
9 Mantle.
9 Bottom shell interior and exterior.
9 Countershaft assembly.
4.3.1.3 - Remove all temporary installation aids, debris, and
construction materials from inside the crusher.
4.3.1.4 - Check the exterior of the crusher shell for missing and
loose flange bolts and nuts. Tighten or install as required.
4.3.1.5 - Check that there is grease at the spider bushing. If there
is none, flush the spider lubrication system, reconnect it,
and prepare it for operation.
4.3.1.6 - Check that all components that require lubricants have
been lubricated.
4.3.1.7 - Check that the countershaft extension assembly has been
securely attached to the crusher and it’s motor, and is in
correct alignment.
4.3.1.8 - Ensure that the mantle position indicator is in place, wired,
and has been calibrated according to the manufacturer’s
instructions.
4.3.1.9 - Recheck all piping and wiring under the crusher to make
sure that all are protected from damage.
4.3.1.10 - Bleed the air from the hydraulic adjustment system and
inspect the hydraulic lines for leakage.
4.3.1.11 - Raise the crusher main shaft 2 inches (50 mm) using the
hydraulic adjustment system.
7.500760 C-5
Rev. 0
Preface
This instruction manual is written and illustrated to provide detailed information

for the safe and proper installation, operation, and maintenance of your new “TS”
or “TSU” Gyratory Crusher(s). Both first time, and experienced operation and
maintenance personnel should fully read and understand this manual and keep
this manual available for future reference.
Basic operating methods are covered in this book. The majority of all large
Gyratory Crusher maintenance issues are related to improper operating
conditions. Following the operation guidelines of this manual will assist you in
assuring a long and productive utilization of your Gyratory Crusher(s). As you
develop experience with proper operation of your Gyratory Crusher(s), you will
be able to expand upon the operating and maintenance techniques defined in
this manual.
Improvement and advancement of product design may result in changes to your

machine that may not be included in this printing. Operations and maintenance
bulletins will be issued by FLSmidth to supplement the information contained
within this manual, as necessary. Each subsequent printing of this manual is
reviewed and revised, as required, and will be updated to incorporate the
appropriate changes.
Descriptions and specifications for your “TS” or “TSU” Gyratory Crusher were in
effect at the time this manual was approved for publication. FLSmidth reserves
the right to discontinue models and change design or specifications at any time,
without notice or obligation.
Any questions regarding your Gyratory Crusher(s) or this manual should be

directed directly to FLSmidth or through your local FLSmidth representative.
This instruction manual is to be used as a general guide. Additional technical

information required for the assembly and installation of your “TS” or “TSU”
Gyratory Crusher(s) is to be obtained from the assembly drawings found in the
Parts Manual provided with your Gyratory Crusher(s).
Doc. No.: 59001428

Rev. A
GYRATORY CRUSHER
4.3.1.12 - When the lubricating oil is at operating temperature, start

the oil pump and allow the oil to circulate through the
crusher until a full flow can be seen returning to the
sump tank.
4.3.1.13 - Check the volume of oil flow to the eccentric and
countershaft bearings.
4.3.1.14 - Complete the pre-commissioning checklist provided in
this section.
4.3.2 – ELECTRICAL
4.3.2.1 - Verify that all instruments, sensors, alarms, timers, and
interlocks are at their specified settings
4.3.2.2 - Check the operation of the alarms on the lubrication oil
inlet and outlet lines.
4.3.2.3 - Complete the pre-commissioning checklists
4.4 - BEARING LUBRICATION PRE-COMMISSIONING

PROCEDURES
The purpose of this procedure is to prepare the crusher lubrication system for the
no-load and initial start-up of the crusher. This is accomplished by checking the
mechanical and electrical components and the instruments in the system.
4.4.1.1 - Check the physical and functional condition of the crusher
lubrication system and its mechanical components.
4.4.1.2 - Complete the pre-commissioning checklist
4.4.2 - ELECTRICAL
4.4.2.2 - Check the operation of the alarms on the lubrication oil
inlet and outlet lines.
7.500760 C-6
Rev. 0
GYRATORY CRUSHER
4.5 - HYDRAULIC ADJUSTMENT SYSTEM PRE-

COMMISSIONING PROCEDURES
The purpose of this procedure is to prepare the hydraulic adjustment system for
the no-load and initial start-up of the crusher. This is accomplished by checking
the mechanical and electrical components and the instruments in the system.

4.5.1.1 - Check the physical and functional condition of the
hydraulic adjustment system and its mechanical
components.
4.5.2 - ELECTRICAL
4.5.2.2 - Check the operation of the alarms on the hydraulic
adjustment system.
4.6 - MANTLE POSITION INDICATING SYSTEM PRE-

COMMISSIONING PROCEDURES
The purpose of this procedure is to prepare the mantle position indicating system
for the no-load and initial start-up of the crusher. This is accomplished by
calibrating the signal transmitter, and setting the null, the span, the low set point
and the high set point of the mantle position indicating system and checking the
mechanical and electrical components and the instruments in the system.
4.6.1.1 - Check the physical and functional condition of the mantle
position indicating system and its mechanical
components.
4.6.2 - ELECTRICAL
4.6.2.1 - Check the calibration of the signal transmitter and adjust if
required.
7.500760 C-7
Rev. 0
GYRATORY CRUSHER
4.6.2.2 - With no hydraulic fluid beneath the piston, turn the “0”
potentiometer of the transducer until 0” [0 mm] is read on
the output (bargraph).
4.6.2.3 - Measure the distance between the top of the head nut and
the bottom of the spider. Raise the main shaft either 12”
[300 mm] or the measured distance – whichever is less –
and turn the “E” potentiometer of the transducer until
either 12” [300 mm] or the measured distance is read on
the output (bargraph).
4.6.2.4 - Set the low set point of the indicating/alarm at 2” [50 mm]
and set the high set point at either 11” [280 mm] or the
distance measured in 2.3 minus 1” [25 mm].- whichever is
less.
interlocks are at the specified settings.
4.7 - NO-LOAD COMMISSIONING PROCEDURES

There are several phases in placing a new crusher into operation. There is an
initial running-in period when the crusher is operated under no-load conditions for
an eight-hour period. This is followed by a one-hour operating period with a
partial feed load. Upon satisfactory completion of this operation, the crusher is
prepared for normal, full-load service by operating at 50 percent feed load for six
to eight hours. After satisfactory operation at this feed rate, the load is gradually
increased to 100 percent of design feed load over a period of 40 hours.
When the crusher is first started, it must contain no ore. The purpose of the
running-in test is to allow the crusher to bed-in and run in the bearings and gears
to check their operation closely.
4.7.1 Ensure that these conditions are met as part of No-Load

commission Pre-check:
4.7.1.1 - The crusher main shaft has been raised 2 inches (50 mm)
with the hydraulic adjustment system.
4.7.1.2 - The lubricating oil is at operating temperature, an oil pump
has been started, and oil is circulating through the
crusher. Oil flow has been verified by the observation of a
full flow of oil to the sump tank (reservoir) on the lube skid.
7.500760 C-8
Rev. 0
GYRATORY CRUSHER
4.7.1.3 - The correct volume of oil is flowing to the eccentric, pinion,

and countershaft and has been verified.
4.7.1.4 - The spider lubrication system is operational.
4.7.1.5 - The countershaft extension is secure and its coupling
covers are in place.
4.7.1.6 - The motor lockout locks have been removed at the motor
control center (MCC).
4.7.2 - Ensure all safety interlocks have been tested and are functional
prior to starting the crusher and its auxiliary equipment.
4.7.3 - To prevent the main shaft from rotating too rapidly during the
breaking-in period, insert two grader size tires into the crushing
chamber with steel cables. Place them 180° apart.
4.7.3.1 - The normal motion of the main shaft is gyratory (the
bottom end of the shaft moves in a circle while the top is
stationary). In some cases, due to the viscosity of the oil
between the shaft and the eccentric, there is a tendency
for the idle running main shaft to rotate or spin in addition
to gyrating. The spinning is detrimental during the
running-in period. The grader tires are inserted into the
crusher to provide just enough friction to keep the shaft
from spinning. They will move from their original positions
as the crusher is running.
THE CRUSHER SHOULD NEVER OPERATE MORE THAN

15 MINUTES WITHOUT LOAD OR TIRES.
4.7.4 - Start the crusher from the local control panel or from the distributed
control system (DCS).
4.7.5 - While the crusher in operation, look for oil leakage from the oil inlet
and return pipe lines.
4.7.6 - Check the countershaft bearing temperature. No discomfort should
be felt when a bare hand is placed on the countershaft housing.
Confirm suspected excessive temperatures through the counter
shaft bearing temperature detectors and with a portable thermal
detector.
7.500760 C-9
Rev. 0
GYRATORY CRUSHER
4.7.7 - Ensure that the oil cooling system is operating properly. Check
that the temperature and pressure gauges operating on the
pumping unit are steady and operating correctly.
4.7.8 - Ensure that the spider bushing lubrication system is functioning
properly.
4.7.9 - Test the hydraulic support and adjustment systems.
4.7.10 - At 15-minute intervals record the data as shown on the data sheet
in Section 4.10 of this manual. Continue recording these readings
until the oil temperature remains constant for one hour and then
continue the readings at 1 hour intervals throughout the 8 hour
test period.
4.7.11 - Observe the drive motor winding and bearing temperatures with
the motor monitoring instruments (if purchased).
4.7.12 - At the end of the eight-hour running-in period stop the drive motor
and record the time it takes for the crusher to stop (run down).
Stop the lubrication systems and the hydraulic adjustment
system.
4.7.13 - Remove the return screen from the lube oil skid reservoir. Inspect
its contents and record observations, and clean the screen with
solvent. Install the screen and secure it. It is normal to find a
small amount of foreign material in the screen basket due to the
bedding-in process and dislodged particles not removed by
flushing.
4.7.14 - Remove the tires from the crushing chamber.
4.7.15 - Ensure that the shell bolts, spider bolts, and foundation bolts are
tight.
4.7.16 - Ensure that the crusher drive motor foundation bolts are tight.
4.7.17 - Prepare the crusher for initial start-up with feed.
4.8 - FULL LOAD COMMISSIONING PROCEDURES

The crusher is to be ran for 1 hour with a 50 percent feed load. (It is important to
ensure that the feed material is dry and does not contain fines or lumps larger
than two-thirds of the feed opening.) The feed is stopped and the crusher is
cleared (crushed out) and stopped. The crusher is inspected and, if all is
satisfactory, started again at a feed rate of 50 percent of capacity. The crusher is
run for eight hours at a 50 percent feed rate. If the crusher is within operating and
design specifications, the crusher is run for 40 hours while gradually increasing
feed rate to full design capacity.
7.500760 C - 10
Rev. 0
GYRATORY CRUSHER
4.8.1 - Check and ensure that the following conditions should exist at this
time:
4.8.1.1 - The crusher main shaft has been raised 2 inches (50 mm)
with the hydraulic adjustment system.
4.8.1.2 - The lubricating oil is at operating temperature, an oil pump
has been started, and oil is circulating through the
crusher. Oil flow has been verified by the observation of a
full flow of oil to the sump tank (reservoir) on the lube skid.
4.8.1.3 - The correct volume of oil is flowing to the eccentric and
countershaft and has been verified.
4.8.1.4 - The spider lubrication system is operational.
4.8.1.5 - The countershaft extension is secure and its coupling
covers are in place.
4.8.1.6 - The motor lockout locks have been removed at the motor
control center (MCC).
4.8.2 - Ensure all safety interlocks have been tested and are functional
prior to starting the crusher and its auxiliary equipment.
4.8.3 - Start the crusher from the local control panel or from the
distributed control system (DCS) and establish a 50 percent feed
rate.
4.8.4 - With the crusher in operation, look for oil leakage from the oil inlet
and return pipe lines.
4.8.5 - Check the countershaft bearing temperature. No discomfort should
be felt when a bare hand is placed on the countershaft housing.
Confirm suspected excessive temperatures through the counter
shaft bearing temperature detectors and with a portable thermal
detector.
4.8.6 - Ensure that the oil cooling system is operating properly. Check
that the temperature and pressure gauges operating on the
pumping unit are steady and operating correctly.
4.8.7 - Ensure that the spider bushing lubrication system is functioning
properly.
4.8.8 - Test the hydraulic support and adjustment systems.
4.8.9 - At 15-minute intervals, record the data. Continue recording these
readings until the oil temperature remains constant for one hour
and then continue the readings at 1 hour intervals throughout the
40 hour test period.
7.500760 C - 11
Rev. 0
GYRATORY CRUSHER
4.8.10 - Observe the drive motor winding and bearing temperatures with
the motor monitoring instruments (if purchased).
4.8.11 - At the end of the eight-hour 50 percent load period, stop the feed
and allow the crusher to empty. When the crusher is empty of
ore, stop the drive motor and record the time it takes for the
crusher to stop (run down). The lubrication systems and the
hydraulic adjustment system remain in operation if they were
operating properly.
4.8.12 - Ensure that the shell bolts, spider bolts, and foundation bolts are
tight. Tighten any loose bolts and nuts as required.
4.8.13 - Ensure that the crusher drive motor foundation bolts are tight.
Tighten any loose bolts and nuts as required.
4.8.14 - When all checks, inspections, and adjustments have been
completed, the crusher is started and feed introduced at a 50
percent rate. During the following 40 hours, the feed rate is
gradually increased to 100 percent of design capacity.
4.8.15 - Set the adjustment system relief valve while the crusher is
operating under a normal full crushing load. Adjust the relief
valve until the normal load causes it to open and allows the main
shaft to descend, then set it higher so that it will hold under the
normal load peaks. Several adjustments may be necessary to
attain a satisfactory setting. The required setting of the relief
valve may vary as ore is extracted from different locations in the
mine or pit due to the hardness of the ore. The purpose of the
relief valve is to protect the crusher from uncrushable objects. If
an object gets caught in the crusher, the valve opens and the
main shaft descends to discharge the uncrushable object.
RECORD THE RELIEF VALVE SETTING AT THIS INITIAL
SETTING AND EVERY TIME IT IS CHANGED.
4.8.16 - During the following 40 hours, repeat all checks and inspections
made during the previous eight hours of operation.
7.500760 C - 12
Rev. 0
GYRATORY CRUSHER
4.9 - MECHANICAL
PRE-COMMISSIONING CHECKLIST
Note: This form is to be completed during assembly of the gyratory crusher. The original
of the completed form is to be maintained in the client’s erection site master I, O, and M
manual and a copy of the completed form is to be transmitted to the FLSM project
manager for inclusion in the contract documents.
CUSTOMER ____________________ SERIAL No. _____________________
Item Record Value Date Initials

Value (if
required)
1. Spider Bushing Lubrication X (min.)
a. frequency lube pump is actuated. X
b. number of “counts” or time pump is
actuated
2. Dust Bonnet Air Supply Air Pressure. X (psi)
3. Lube Oil Tank Level. X
4. Hydraulic Tank Oil Level X
5. #1 Lube Pump Relief Valve Setting X (psi)
6. #2 Lube Pump Relief Valve Setting X (psi)
7. Hydraulic Oil Flow to Hydraulic Bottom X (gpm)
8. #1 Hydraulic Pump Relief Valve Setting X (psi)
9. #2 Hydraulic Pump Relief Valve Setting X (psi)
10. #1 Cooling Pump Relief Valve Setting X (psi)
11. #2 Cooling Pump Relief Valve Setting X (psi)
12. Lube Oil Flow to Hydraulic Bottom X (gpm)
13. Lube Oil Flow to Bottom Shell X (gpm)
14. Lube Oil Flow to Counter Shaft Housing X (gpm)
15. Lube Oil Flow to Pinion
16. Counter Shaft Housing for leaks
17. Hydraulic Bottom to Bottom Shell for leaks
18. Lube System Piping for leaks
7.500760 C - 13
Rev. 0
GYRATORY CRUSHER

Value (if required)
19. Hydraulic System Piping for leaks

20. Cooling System Piping for leaks
21. Counter Shaft Seal for leaks
22. Contents of Lube Tank Screen Basket
23. Lube Tank Oil Temperature
24. Hydraulic Tank Oil Temperature
25. Controlled Torque Coupling Pressure
26. Presence of Grease in Counter Shaft
Housing Seal Chamber
27. Head Nut Tightness
28. Free Vertical Movement of Main Shaft
7.500760 C - 14
Rev. 0
GYRATORY CRUSHER
4.10 - ELECTRICAL

Value (if required)
1. Lubrication Skid, Lubrication System
Pump Motors.
a. POWER TERMINALS – With the
pump motors isolated from their
the power connections to the
correct motor terminals and check
for tightness. Disconnect and clean
loose terminals, and reconnect
securely.
b. JUNCTION BOX SEAL – Inspect
the junction box cover seals for
signs of leakage and damage.
Replace as required. Vacuum-clean
the junction box interiors
c. LOCAL CONTROLS– (if purchased)
Inspect local control panels for
d. CONDUIT AND CABLE – Inspect
power cable and conduit for
physical damage. . Repair or
e. STATOR RESISTANCE – At the
MCC, megger the stator and record
the measurements.
f. FAN – Remove the fan cover,
inspect the fan for cracks, and clean
7.500760 C - 15
Rev. 0
TYPE “TS” - GYRATORY CRUSHER
TABLE OF CONTENTS
SECTION 1 GENERAL INFORMATION
SECTION 2 SAFETY
SECTION 3 INSTALLATION
SECTION 4 COMMISSIONING
SECTION 5 OPERATION
SECTION 6 MAINTENANCE
SECTION 7 DOCUMENTATION
SECTION 8 VENDOR INFORMATION
Doc. No.: 59001428

Rev. A
GYRATORY CRUSHER

Value (if required)
Lubrication Skid, Lubrication System
Pump Motors (continued).
the blades. Inspect the outboard
bearing housing for leaks and signs
of excessive heat. Replace the
cover.
g. RELEASE FOR TESTS – Clean
motor housing surfaces to assist
cooling. Remove locks at MCC
when all the preceding checks and
tests have been completed, and
release the unit for running checks.
h. CHECK ROTATION – When all

other checks have been completed,
start and run the system, one motor
and pump set at a time. Check the
rotation of each and record direction
looking from motor to fan.
i. MOTOR CURRENT DRAW – When
the lubricating system is operating
normally, take voltage and current
readings for all three phases at the
MCC. Compare values and check
for an unbalanced condition (more
than 5%).
2. Lubrication Skid, Cooling System

Pump Motors
pump motors isolated from their
the power connections to the
correct motor terminals and check
for tightness. Disconnect and clean
securely.
7.500760 C - 16
Rev. 0
GYRATORY CRUSHER

Value (if required)
Lubrication Skid, Cooling System Pump
Motors (continued)
the junction box interiors.
c. LOCAL CONTROLS–(if Purchased)
the measurements.
cover.
7.500760 C - 17
Rev. 0
GYRATORY CRUSHER

Value (if required)
Lubrication Skid, Cooling System Pump
Motors (continued)
the cooling system is operating
than 5%).
3. Lubrication Skid, Cooling System Fan
Motors
fan motors isolated from their power
and control circuits, check the
power connections to the correct
motor terminals and check for
tightness. Disconnect and clean
securely.
c. LOCAL CONTROLS– (if purchased)
physical damage. Repair or replace
as required.
the measurements.
inspect the fan for cracks, and
clean the blades. Inspect the
outboard bearing housing for leaks
and signs of excessive heat.
7.500760 C - 18
Rev. 0
GYRATORY CRUSHER

Value (if required)
Lubrication Skid, Cooling System Fan
Motors (continued)
than 5%).
4. Lubrication Skid, Cooling System Drain
Valve
a. VALVE - Inspect the valve for signs
of physical damage and excessive
heat. Replace the unit as required.
c. CONDUIT AND CABLE - Inspect
power and control cable and
conduit for physical damage. Repair
7.500760 C - 19
Rev. 0
GYRATORY CRUSHER

Value (if required)
Lubrication Skid, Cooling System Drain
Valve (continued)
d. POWER AND CONTROL
TERMINALS - Check the power
and control wiring for connection to
the correct terminals and check for
securely.
e. VALVE OPERATION - Apply
appropriate input voltage and
ensure that valve opens and closes.
Reconcile switch and signal with
position of valve.
5. Cooling System Drain Valve – located
at coolers
a. VALVE - Inspect the valve for signs
of physical damage and excessive
heat. Replace the unit as required.
c. CONDUIT AND CABLE - Inspect
power and control cable and
conduit for physical damage. Repair
d. POWER AND CONTROL
TERMINALS - Check the power
and control wiring for connection to
the correct terminals and check for
securely.
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Value (if required)
Cooling System Drain Valve – located at
coolers (continued)
e. VALVE OPERATION - Apply
appropriate input voltage and
ensure that valve opens and closes.
Reconcile switch and signal with
position of valve.
6. Lubrication Skid, Heaters.
heaters isolated from their power
heater terminals and check for
securely.
c. CONDUIT AND CABLE – Inspect
as required.
d. CHECK CONTINUITY – Check
each heater for continuity. Replace
the junction box covers.
e. RELEASE FOR TESTS – Remove
locks at MCC according to
established procedure when all the
preceding checks and tests have
been completed, and release the
unit for running checks.
7. Hydraulic Skid, Pump Motors
fan motors isolated from their power
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Value (if required)
Hydraulic Skid, Pump Motors (continued)
motor terminals and check for
securely.

c. LOCAL CONTROLS– (if
purchased) Inspect local control
panels for damaged or missing
buttons, switches, and indicators.
the measurements.
cover.
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Value (if required)
Hydraulic Skid, Pump Motors (continued)
start and and run the system, one
motor and pump set at a time.
Check the rotation of each and
record direction looking from motor
to fan.
than 5%).
10. Hydraulic Skid, Heaters.
heaters isolated from their power
heater terminals and check for
securely.
c. CONDUIT AND CABLE – Inspect
as required.
d. CHECK CONTINUITY – Check
each heater for continuity. Replace
the junction box covers.
e. RELEASE FOR TESTS – Remove
locks at MCC according to
established procedure when all the
preceding checks and tests and
been completed, and release the
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GYRATORY CRUSHER

Value (if required)
Hydraulic Skid, Heaters (continued)

unit for running checks.
9. Hydraulic Skid, Direction Control
Solenoid Valve(s)
a. Check valve(s) for RAISE function
b. Check valve(s) for LOWER function
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4.11 - INSTRUMENTATION

Value (if
required)
1. Lubrication Skid, Temperature
Gauges
a. GAUGES - Inspect for physical
required.
b. CALIBRATION - Check the date on
the calibration sticker if applicable
Switch(s) - Thermostats
a. SWITCH - Inspect for physical
required.
b. JUNCTION BOX SEAL - Inspect the
junction box cover seals for signs of
leakage and damage. Replace as
required. Vacuum-clean the junction
box interiors.
c. TERMINALS – Check for correct
connection to terminals. Check
wiring terminals for signs of
terminals.
d. WIRE AND CONDUIT - Inspect
wire and conduit for physical
damage, abrasion and exposed
required.
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Gyratory Crusher
SECTION 1:
GENERAL INFORMATION
Introduction 1.1
Equipment Description 1.2
Contact Information 1.3
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Value (if
required)
Lubrication Skid, Temperature Switch(s)
(continued)
e. SWITCH OPERATION - Place bulb
(sensor) of switch in a liquid and
heat and/or cool the liquid to the
required switch actuation
temperature(s) and set the switch to
actuate at these temperature(s).
f. Record the actuation temperatures.

Sensor(s) (if purchased)
a. SENSOR - Inspect for physical
required.
box interiors.
terminals.
d. WIRE AND CONDUIT - Inspect wire
and conduit for physical damage,
abrasion and exposed conductors.
e. SENSOR OPERATION - Place all
related control loops in the manual
mode and with an independent
calibrator check the span (4 – 20
mA) and zero settings. Compare
with conditions at the sensing
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Value (if
required)
Lubrication Skid, Temperature
Sensor(s) (continued)
f. DATE - Check the date on the
calibration sticker.
4. Lubrication Skid, Level Gauge
a. GAUGE - Inspect for signs of
b. CLEAN - Clean the glass and
enclosure.
c. LEVEL - Check and reconcile
with visual observation of the
reservoir level.
5. Lubrication Skid, Low level Switch
a. SWITCH - Check for signs of
b. JUNCTION BOX SEAL - Inspect
Replace as required. Vacuum-
clean the junction box interiors.
c. TERMINALS - Check for correct
excessive heat. Disconnect
surfaces until bright, and
required.
e. SWITCH OPERATION –
Physically move float until switch
actuates. Adjust switch actuation
as required.
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Value (if
required)
6. Lubrication Skid, Pressure Gauges
a. GAUGE - Check the gauge for
b. GAUGE - Clean the glass and
enclosure.
c. STICKER - Check the date on the
d. calibration sticker. Recalibrate if
required.
7. Lubrication Skid, Filter Differential
Switch.
terminals.
required.
e. SWITCH OPERATION –With an
independent calibrator check the
switch actuation point. Adjust if
required. Record switch set point.
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Value (if
required)
8. Lubrication Skid, Cooling System Flow
Switch
box interiors.
terminals.
d. WIRE AND CONDUIT - Inspect wire
and conduit for physical damage,
abrasion and exposed conductors. X
e. SWITCH OPERATION – Operate
the cooling system pump with the oil
at the operating temperature and
check the switch actuation point.
Adjust switch actuation as required.
Record switch set point.
9. Hydraulic Skid, Temperature Gauges
a. GAUGES - Inspect for physical
required.
b. CALIBRATION - Check the date on
the calibration sticker if applicable.
10. Hydraulic Skid, Temperature Switch(s)
– Thermostats
a. SWITCH – Inspect for physical
required.
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Value (if required)
Hydraulic Skid, Temperature Switch(s)
– Thermostats (continued)
d. WIRE AND CONDUIT – Inspect
required.
e. SWITCH OPERATION – Place
bulb (sensor) of switch in a liquid
and
heat and/or cool the liquid to the
required switch actuation
temperature(s) and set the
switch to actuate at these
temperature(s).
f. Record the actuation
temperatures.
11. Hydraulic Skid, Temperature
Sensor(s) (if purchased)
required.
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Value (if required)
Hydraulic Skid, Temperature Sensor(s)
(continued)
required.
e. SENSOR OPERATION - Place
all related control loops in the
manual mode and with an
span (4 – 20 mA) and zero
settings.
f. Compare with conditions at the
required.
12. Hydraulic Skid, Level Gauge
a. GAUGE - Inspect for signs of
b. CLEAN - Clean the glass and
enclosure.
c. LEVEL - Check and reconcile
with visual observation of the
reservoir level.
13. Hydraulic Skid, Low level Switch
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Value (if required)
Hydraulic Skid, Low level Switch
(continued)
required.
Physically move float until
switch actuates. Adjust switch
actuation as required.
14. Hydraulic Skid, Pressure Gauges

a. GAUGE - Check the gauge for
b. GAUGE - Clean the glass and
enclosure.
c. STICKER - Check the date on
the calibration sticker.
Recalibrate if required.
15. Cooling System, Ambient
Temperature Sensor
required.
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Value (if required)
Cooling System, Ambient Temperature
Sensor (continued)
required.
e. SENSOR OPERATION - Place
all related control loops in the
manual mode and with an
span (4 – 20 mA) and zero
settings.
f. Compare with conditions at the
required.
16. Lubrication System, Flow Switches
reconnect the terminals
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Value (if required)
Lubrication System, Flow Switches
(continued)
required.
Operate the cooling system
pump with the oil at the
operating temperature and
check the switch actuation point.
Adjust switch actuation as
required. Record switch set
point.
17. Main Shaft Position Indicating
System
a. JUNCTION BOX SEAL - Inspect
b. TERMINALS - Check for correct
c. WIRE AND CONDUIT - Inspect
required.
d. ALARM SET POINTS – check
both HIGH and LOW alarm
actuation points. Adjust as
required.
e. DATE - Check the date on the
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GYRATORY CRUSHER

Value (if required)
18. Inboard and Outboard Countershaft
Bearing Temperature Sensors
required.
required.
e. SENSOR OPERATION – Check
the operation of the sensor.
Compare the readings with
conditions at the sensing
element. Correct if required.
19. Counter Shaft Speed Sensor
required.
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Gyratory Crusher
1.1 - INTRODUCTION
We at FLSmidth would like to congratulate you on the purchase of your new “TS”
or “TSU” Gyratory Crusher. With the proper maintenance and care, it will serve
your plant for many years. This section of the manual addresses the procedures
and tools you need to efficiently and quickly obtain information, parts pricing and
availability, technical assistance, emergency trouble shooting service, and other
features of FLSmidth extensive background and knowledge.
The ultimate goal of the crushing process is to reduce the size of the ore
received from the mine (known as run-of-mine or ROM ore). The crushing
process is the first step in comminution. Comminution is the process of
progressively reducing ore to finer sizes. Further reduction occurs in the
downstream grinding plant. The crusher breaks down ROM material and delivers
it to a surge pocket located beneath the crusher. The crushing circuit is designed
to be an open-circuit crushing system (without any screening and recycling of
oversize particles). The crushed ore is withdrawn from the surge pocket for
further treatment in the grinding operation. The operator regulates ore dumping
to maintain the proper levels in the crusher bowl and surge pocket beneath the
crusher.
Before proceeding, we would like to stress the importance of fully reading and
understanding this manual to ensure that you get the most out of your Gyratory
Crusher.
1.2 - EQUIPMENT DESCRIPTION

The size of the crusher and the size of the drive motor are listed on the “Erection
and Maintenance Data Sheet” in the Maintenance section of this manual.
The first number in the size designation is the measurement of the crusher feed
opening. The second number in the size designation is the measurement at the
widest diameter at the bottom of the lower mantle. Therefore, a 1400 x 2100
gyratory crushers has a 1400mm [55”] feed opening and a maximum mantle
diameter of 2100mm [83”].
100 percent of the feed to the crusher should be smaller than 90 percent of the
radial opening size. This size distribution reduces the possibility of blocking the
crusher openings.
The crusher body consists of a cast-steel frame that includes, in its lower part,
the driving mechanism. The driving mechanism is made up of the eccentric
(which provides the gyratory movement of the main shaft and mantle), the gear,
and the countershaft assembly (which includes the pinion and its shaft). The
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Value (if required)
Counter Shaft Speed Sensor
(continued)
required.
e. SENSOR OPERATION – Check
the operation of the sensor.
Correct if required.
20. Crusher Drive Motor High Power
Draw Alarm/Shutdown Circuit
a. Confirm circuit is operational.
b. Confirm starting torque limit is
set at 180% of full load torque
and breakdown torque limit is
set at 250%.
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SECTION 5:
OPERATION
Pre-Operational Inspection 5.1
Start-Up From Complete Shutdown 5.2
Start-Up From Standby Shutdown 5.3
Start-Up From Emergency Shutdown 5.4
Start-Up From Power Failure 5.5
Shutdown Procedures 5.6
Complete Shutdown 5.6.1
Standby Shutdown 5.6.2
Emergency Shutdown 5.6.3
Power Failure 5.6.4
Operating Considerations 5.7
Ore Receiving and Crushing:

Routine Observations and Inspections 5.7.1
Adjusting Crusher Open-Side Setting 5.7.2
Clearing the Crusher 5.7.3
Clearing Tramp Material Jam 5.7.4
Proper Rock Breaker Installation 5.8
Proper Rock Breaker Use 5.9
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5.1 - PRE-OPERATIONAL INSPECTION

A preoperational inspection of all major and auxiliary equipment is required
whenever any portion of the primary crusher is started up from a complete
shutdown.
The primary crusher requires the following utilities in order to start up and be
operated:
1) Electrical power.
2) Air supply for dust seal
In addition to the start-up procedures specified on the following pages, portions

of the primary crusher may be started after one or more equipment items have
been down for maintenance. In this case, perform the appropriate preoperational
inspection for each equipment item worked on.
When the preoperational inspection is complete, the primary crusher equipment

can be restarted according to the appropriate start-up procedure, depending on
the nature of the maintenance that was performed.
Any personnel working in the area near the primary crusher equipment being
started must be warned of the impending start-up. The primary crusher
equipment must not be started until the downstream circuits are prepared to
accept feed. Primary crusher service and utility equipment must be running
before starting the process equipment.
The general starting sequence is:

1) Primary crusher lubrication systems
2) Primary crusher hydraulic system
3) Downstream equipment
4) Primary crusher drive motor - (the spider lubrication system should be
interlocked to start and stop as the crusher drive motor starts and stops)
5.2 - START-UP FROM COMPLETE SHUTDOWN

Operators must inspect the primary crushing area visually before start-up from a
complete shutdown. This inspection determines whether activities, such as
maintenance tasks, must be performed before the start-up begins. If the primary
crusher was down for maintenance or any other activities that required the
primary crusher discharge pocket to be completely emptied, fine ore material
must be transported and dumped into the primary crusher.
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Ensure that all electrical disconnects for the primary crusher and all ancillary
equipment are closed (switched on). All lockout devices should be removed
except for equipment undergoing maintenance. Visually inspect the primary
crusher chamber. Ensure there are no loose or missing liners. Check the spider
assembly for worn, damaged, or missing wear plates.
Prior to starting the primary crusher, ensure that the mantle height is correct and
within current operating limits. The mantle height should be at least 2 inches (50
mm) above the fully down position. This allows room to move the mantle both up
and down.
1) Initiate the start of the primary crusher discharge conveyor.
2) Initiate the start of primary crusher.
5.3 - START-UP FROM STANDBY SHUTDOWN

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

The procedures for starting up from an emergency shutdown differ from those
after controlled shutdowns. In an emergency shutdown, the primary crusher
shuts down under load and retains all the ore that was inside when it shut down.
The primary crusher lubrication systems and hydraulic system continue to run
unless all or part of the system was involved in the emergency.
1) If an equipment fault caused the shutdown, visually inspect the equipment
that caused the shutdown and ensure that the cause has been cleared.
2) If a process-upset condition caused the shutdown, proceed with the start-
up when the upset condition is corrected.
3) If necessary, restart the hydraulic and lubrication systems.
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GYRATORY CRUSHER
4) If ore remains in the crusher, it may be necessary to clear the crusher

before starting the crusher. Lowering the mantle reduces the load on the
motor during the subsequent start-up. Failure to do so can result in failure
of the crusher motor.
5) Proceed with the crusher start-up following the procedures in Section 5.3,
“Start-Up From Standby Shutdown”.
5.5 - START-UP FROM POWER FAILURE

This procedure is based on the assumption that the primary crushing system was
operating normally when the power failure occurred, and that the crusher
discharge conveyor was loaded. If the crusher was not loaded when the power
failure occurred, start the primary crushing system as if it were a standby
shutdown (refer to Section 5.3, “Start-Up From Standby Shutdown”). After the
cause of the power failure has been determined and the condition corrected, the
start-up is essentially the same as that from a complete/standby shutdown.
1) Ensure that the cause of the power failure has been corrected and all
power systems have been restored.
2) Ensure that there is no resulting damage to equipment.
3) Ensure that all motor disconnects have been reset. Lowering the mantle
reduces the load on the motor during the subsequent start-up. Failure to
do so can result in failure of the crusher motor.
4) If the crusher was loaded at the time the power failure occurred, the
crusher must be cleared to restart. Once the crusher has been cleared,
start the primary crushing system as if it was a complete shutdown (refer
to Section 5.2, “Start-Up From Complete Shutdown”).
5.6 – SHUTDOWN PROCEDURES

There are two primary objectives of the shutdown procedure: to secure
equipment so damage is prevented and to make start-up efficient and timely.
After a complete shutdown, equipment should be inspected thoroughly and a list
of maintenance and repair items prepared. After an emergency shutdown, a
visual inspection of the equipment is required before start-up.
This section contains procedures for shutting down the crushing equipment.
These procedures have been divided into the following subsections:
5.6.1 - COMPLETE SHUTDOWN
5.6.2 - STANDBY SHUTDOWN
5.6.3 - EMERGENCY SHUTDOWN
5.6.4 - POWER FAILURE
All shutdown functions are controlled from the control console in the crusher
control room.
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5.6.1 – COMPLETE SHUTDOWN

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

A standby shutdown occurs when the crusher is expected to remain shut
down for a short period of time (less than 2 hours is the usual time).
Generally, the lubrication systems and hydraulic system are not shut
down.
1) Notify the mine or haul truck dispatch that the crusher is shutting
2) Allow the crusher to operate until all material in the dump pocket
and crusher has been crushed and passed into the crusher
discharge pocket.
3) If any rocks remain that are bridging the crusher opening, or that
are plugging the crusher chamber, they should be broken with the
rock breaker or removed with the rock hook.
4) Shut down the primary crusher drive motor. Do not shut down the
crusher lubrication systems or hydraulic system unless instructed to
do.
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5.6.3 – EMERGENCY SHUTDOWN

An emergency shutdown can be caused or initiated by a major equipment
malfunction, by a personnel safety situation, or by certain protective
interlock conditions designed to prevent equipment damage. An
emergency shutdown may be initiated by personnel to prevent, for
example, damage to the crusher discharge conveyor.
If the crusher discharge conveyor shuts down due to an emergency
condition, and it will remain down for a prolonged period of time, the
primary crusher should be manually shut down. However, it should not be
shut down before its present load has been crushed.
The following procedure is based on the assumption that when the
emergency occurred, the primary crushing system was operating
normally. After the cause of the emergency shutdown has been
determined and the condition corrected, the primary crushing system may
be started up according to Section 5.4, “Start-Up From Emergency
Shutdown”.
1) Shut down any equipment as required to isolate the emergency.
2) Determine whether any personnel have been injured as a result of
the emergency and notify emergency personnel and emergency
services.
3) Set any dump pocket signals to the No Dumping mode.
4) Notify the mine or haul truck dispatch that the crusher has shut
5) Determine the cause of the emergency shutdown and correct the
condition. Ensure that all personnel are accounted for before
restarting any equipment.
5.6.4 – POWER FAILURE

When a power failure occurs, the primary crusher may be loaded. In the
event of a power failure, all process equipment stops without further action
on the part of the operator. In the event of a power outage, all process
equipment trips and/or shuts down.
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5.7 – OPERATING CONSIDERATIONS

Operators must perform certain tasks related to crusher equipment and
operations. The operator tasks for the primary crusher area are usually as listed
below.
1) ORE RECEIVING AND CRUSHING: ROUTINE OBSERVATIONS
AND INSPECTIONS
2) ADJUSTING CRUSHER OPEN-SIDE SETTING
3) CLEARING THE CRUSHER
4) CLEARING TRAMP MATERIAL JAM
5.7.1 – ORE RECEIVING AND CRUSHING: ROUTINE

OBSERVATIONS AND INSPECTIONS
It is the responsibility of the operator to monitor the operation of the
primary crushing system to ensure that the ore is crushed and
stockpiled in a safe and efficient manner.
The following procedures list the routine inspection requirements of the
operator while the unit is in operation. This observations and
inspections should be carried out several times during the course of
each shift.
1) Ensure that all personnel working in and around the area are
using their personal protective equipment and that they are
obeying all safety rules and regulations.
2) Throughout the primary crushing area, check aisles and
walkways around equipment for debris, maintenance
materials, and other tripping or slipping hazards.
3) When trucks are dumping, observe the loads being dumped
to identify any foreign material or tramp metal that could jam
or damage the crusher.
The primary crusher motor could start without

warning from a remote command. DO NOT
reach behind or remove safety guards during the
inspection.
4) Visually inspect the crusher.

A. When in operation, listen to the crusher motor
operation for unusual sounds and vibrations that
could indicate mechanical problems.
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B. Check for signs of leaking crusher motor seals and

leaking crusher countershaft seals.
C. Ensure that all safety guards are in place and
securely fastened. Ensure that all safety and warning
signs are clearly visible.
D. Check for loose or missing crusher shell bolts. Loose
shell bolts will be more apparent when the crusher is
in operation.
5) Visually inspect the spider lubrication system.
A. Check the spider lubrication system components for
signs of visible damage.
B. Check the grease pump and grease line for signs of
leaks and other damage.
C. Ensure sufficient grease is remaining in the barrel.
Prepare for a change out if necessary.
Components of the lubrication system could start

without warning from a remote command. DO
NOT reach behind or remove safety guards
during the inspection.
6) Visually inspect the primary crusher lubrication

system.
A. Ensure that all safety guards are in place and
B. When in operation, listen to the system operation for
unusual sounds and vibrations that could indicate
mechanical problems.
C. Check the oil reservoir, oil coolers, all supply and
return piping, and all valves for signs of oil leaks.
D. Check the lubrication oil level.
E. Examine the oil coolers. Remove any accumulated
debris from the radiators.
F. Listen to the radiator fans for any abnormal noise.
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7) Visually inspect the primary crusher hydraulic adjustment

system.
Components of the hydraulic adjustment system

could start without warning from a remote
command. DO NOT reach behind or remove
safety guards during the inspection.
A. Ensure that all safety guards are in place and

B. When in operation, listen to the system operation for
unusual sounds and vibrations that could indicate
mechanical problems.
C. Check the oil reservoir, accumulator, raise and lower
valves, and all supply and return piping for signs of oil
leaks.
D. Check the hydraulic adjustment system oil level.
8) Visually inspect the crusher discharged product.

A. Evaluate the size of the material and determine
whether an adjustment of the mantle is necessary.
5.7.2 – ADJUSTING CRUSHER OPEN-SIDE SETTING

1) A lead or foil ball approximately 4 inches (100 mm) in
diameter larger than the expected crusher setting
2) Ruler or tape measure
3) Safety harness and safety line
4) Rope
The operator is responsible for setting and adjusting the primary crusher
open-side setting (OSS) to maintain an opening that produces a crushed
ore product of the required size. The closed-side setting is measured;
however, the emphasis is placed on setting the open-side. This is
because of the near-vertical orientation of the crushing chamber of a
gyratory crusher. This orientation allows some ROM to pass through the
open side of the crusher without being crushed. The open side, therefore,
represents the approximate top size of the crusher product.
7.500761 Op - 9
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A - PROCEED ®

Aw - PROCEED / WITH COMMENTS

FOR INFORMATION ONLY D - REVIEWED FOR INFORMATION

TYPE “TS” AND “TSU”

MANUAL NO.: 59001427

The OSS should be checked weekly, whenever there is reason to suspect

CSS + THROW = OSS

The closed-side setting is measured by passing a soft malleable metal,

THE CRUSHER SHOULD NEVER OPERATE MORE THAN

2) Ensure that the operator performing the CSS measurement

4) Retrieve the ball and measure the smallest dimension. This

A. Approximate how far the mantle must be raised or

5.7.3 – CLEARING THE CRUSHER

SPECIAL EQUIPMENT REQUIRED:

During the course of normal crushing operations, there may be occasion

to reach down into the crushing chamber to clear the

A. If a large rock is uncovered, an attempt should first be

5.7.4 – CLEARING TRAMP MATERIAL JAM

SPECIAL EQUIPMENT REQUIRED:

Clearing tramp metal from a gyratory crusher is a major problem that

Each circumstance must be evaluated to determine the best and safest

The thermal cutting torch is a self-contained tool consisting of a

The torch generates heat to temperatures exceeding 2,475ºC (4,487ºF)

Always work from the top of the crusher and never

6) The torch operator should either stand in a cage, lowered

Do not attempt to dislodge or loosen the tramp

7) Connect the cutting torch to an oxygen supply, and set the

When working with torch cutting equipment, use

9) Open the oxygen-regulating valve completely. The cutting

When doing any torch cutting around a crusher,

Do not touch the tramp iron or put any pressure on

11) During the cutting operation, protect the discharge feeder

Do not use a thermal cutting torch when the pipe

5.8 – PROPER ROCK BREAKER INSTALLATION

5.9 – PROPER ROCK BREAKER USE

Improper use of the rock breaker can damage

Manganese Steel Growth and

Preventative Maint. Checksheets 6.3

Component and Subassembly Removal/Replacement 6.4

1.3 - CONTACT INFORMATION

o FLSmidth Minerals Pty Ltd. (Melbourn, Australia)

o FLSmidth Minerals Pty Ltd. (Perth, Australia)

6.2 – MANGANESE STEEL GROWTH AND TRIMMING OF

The surface of alloy concaves does not work-

6.3 – PREVENTATIVE MAINTENANCE CHECKSHEETS

Mechanical - Daily Section 6.3.1

6.3.1 – Mechanical Preventative Maintenance (Daily)

Item Task Repairs Required,

Item Task Repairs Required,

SPIDER BUSHING Air Filter (if air operated system

6.3.2 – Mechanical Preventative Maintenance (Weekly)

PREVENTATIVE MAINTENANCE DESCRIPTION:

MECHANICAL WEEKLY – SHUTDOWN PREVENTATIVE MAINTENANCE

Item Task Repairs Required,

o FLSmidth Ltda. (Sorocaba, Brasil)

o FLSmidth Minerals Ltd. (Toronto, Canada)

o FLSmidth Minerals Ltd. (Montreal, Canada)

o Technequip Division (Ontario, Canada)

o FLSmidth Minerals S.A. (Santiago, Chile)

The “TS” and “TSU” Gyratory Crusher requires a gyrating motion to

Drive power to the Crusher is normally transmitted from an electric motor

The Hydraulic Adjustment Assembly operates using a hydraulic piston that

Though proper guarding should protect the individual worker, it is still

Wet Crusher feed conditions and excessive dust suppression water

Immediately notify supervision of any problems or potential