GYRATORY

CRUSHER
®
FULLER
Copyright © 2019 FLSmidth. ALL RIGHTS RESERVED.
FLSmidth and FULLER are (registered) trademarks of FLSmidth.
This brochure makes no offers, representations or warranties
(express or implied), and information and data contained in this
brochure are for general reference only and may change at any time.
G5477HD | G6089HD | G60113HD
 FULLER HD ®

PRODUCTIVITY
GYRATORY
CRUSHERS

-BOOSTING
CRUSHING
A ROBUST,

SOLUTION
RELIABLE, DURABLE AND
CONSISTENT PERFORMANCE Designed to decrease downtime
With a proven design, using FEA, significant eccentric
throw and crushing action, you experience higher
crushing capabilities and crushing performance and less
maintenance work from our gyratory crushers. Downtime
is minimised due to design features which allow you
to perform maintenance efficiently and safely during
shutdowns. This means you benefit from increased
operational availability and reduced downtime.

High-level, consistent crushing performance, Design features

■ Consistent, accurate and quality
results over a long-life span.
■ Improved operational availability
and throughput.
reduced maintenance time, increased
availability and throughput and easier
modification – is your gyratory crusher
delivering on all fronts?
Finding that reliable, heavy-duty gyratory crusher is the
holy grail for mine sites across all regions and mineral
processing conditions. FULLER-Traylor gyratory crushers
have been delivering at the highest level in some of the
world’s harshest environments, ensuring optimised and
consistent throughput, with maximised uptime, to the
mineral processing industry for over 50 years.
The long operating life of the FULLER® HD gyratory
crushers can be attributed to the robust, hard-wearing
design that is still in use today; in fact, the basic concept
behind the current, third generation, gyratory crusher
remains the same as it did during its inception. But, of
course, it has been continually optimised over time to
meet the productivity demands of today’s mining operation
Key benefits schedules, as well as advancing technology and safety
requirements.
■ Increased safety during shutdowns ■ Hard-wearing and durable –
and maintenance. withstands arduous tasks. These are just some of the key reasons the FULLER brand
■ Serviced by renowned crusher continues to lead the gyratory crusher market and build on
experts. its heritage of providing reliable global mineral processing
equipment technology around the world.
■ Heavy cast-steel shell sections
■ Forged main- and countershaft
■ Long-life bronze components
■ Generous lubrication
■ Versatile material applications
■ Service expertise
This FULLER gyratory crusher originates from the
original FULLER-Traylor Type NT designs. The gyratory
crusher incorporates all the Heavy-Duty design features
(heavy cast-steel shell sections, forged mainshaft and
countershaft, robust gearing, generous lubrication, long-
life bronze components) and focuses on coupling these
historical characteristics with updated maintenance-friendly
features.
Professional support and service
To ensure your FULLER gyratory crusher is operating at
maximum efficiency and that maintenance is carried out
optimally, you have access to professional engineering
and maintenance services, conducted by highly trained
experts, field engineers and technicians. These experts can
optimise your maintenance and shutdown management
programs, help plan your preventive maintenance
programs, manage scheduled repairs and implement these
programs for you.
500 BHN BOTTOM SHELL
LINER ARRANGEMENT
FULLER® HD custom designs bottom shell liners to
suit ore type or other special conditions with the
flexibility to combine abrasion resistant steel plate
with cast shields.
■ Simple liner shapes are easier to handle. High
hardness materials and smaller shapes translate
into less material waste over time (i.e. replace
liners only where needed, not a single large
liner with only localized wear. Bottom shell liners
are not replaced in sets as with concaves).
■ Greater flexibility in spare part sourcing due to
widespread availability of AR plate and simple
inner shapes.
Simple layout of the Type HD bottom shell
■
allows customisation of liner materials
to optimise wear and performance. Cast
shields are available in a variety of materials:
manganese steel, alloy steel or white iron.
■ Bottom shell housing includes 2 inspection ports
for the eccentric gear and countershaft pinion.
MAINSHAFT
ASSEMBLY
The mainshaft assembly is designed with a
threaded sleeve to remove stress risers from
Three inspection ports Maximized AR plate liners the forged shaft and self tightening head
located strategically to view make replacement easier nut to ensure integrity of the mainshaft.
lower mantle and concaves. than cast liners.
Self-lubricating contact dust seal prevents
contaminants from entering oil.
Split ring contact oil seal – prevents
oil loss over dust bonnet.
ECCENTRIC
ASSEMBLY
Three arm design for less
restriction, increased The risk of burned bushings is minimal during demanding
throughput. crushing operations because of large capacity reservoirs
and high oil flow rates to eccentric and shaft bushings.
All bushings are designed keyless and manufactured
from leaded bronze for long life.
Large face width spiral bevel gear set – increases
SPIDER
strength and durability by providing greater contact
area. Less risk of tooth failure due to shock.
ASSEMBLY
COUNTERSHAFT
Bar Type Spider: Requires smaller lay down areas and less
maintenance time than conventional ring spiders (1-2 hours).
Phosphorous bronze spider bushing provides longer life when
compared to “cast iron” bushings. ASSEMBLY
Automatic grease lubrication is standard. Preloaded self-adjusting tapered roller bearings
automatically adjust to temperature fluctuations
Tapered spider bushing - can be removed and installed without and wear, eliminating need for manual endplay.
removing the spider bar.
RTD’s to sense bearing temperatures continuously.
“Supernut” style spider bolts standard – allows rapid removal
an installation of the mainshaft. Triple oil seal positive barrier to oil
loss and dust contamination.
Rotatable countershaft assembly allows
for fine tuning of gear backlash.
G5477HD | G6089HD | G60113HD G5477HD, G6089HD & G60113HD CAPACITIES IN MTPH

GYRATORY CRUSHER
Feed size mm [in] Open Side Setting of Discharge Opening mm [in]

127 [5”] 152 [6”] 178 [7”] 203 [8”] 229 [9“] 254 [10“]

G5477HD 1371 [54”] 1875 2370 2760 3160

G6089HD 1524 [60”] 3020 3700 4617 5485

G60113HD 1524 [60”] 3715 4435 5195 5725

Capacities are based on the following assumed feed distributions: Please note that the above capacities are typical, but crushing
A Maximum feed to the crusher (F100) equals 80% of the feed applications may vary widely with material, feed characteristics,
opening size and 80% of the gradation (F80) is equal to or less moisture, and work index. For each installation of FULLER® HD
than 50% of the feed top size and (F30) is equal to or less than gyratory crusher a verification of the throughout and capacities
A Cap 10% of the feed top size. Bulk Density is assumed to be 1.6 metric are recommended. Specific throughput needs can be met through
B tons per cubic meter. Capacities are calculated at the maximum engineering analysis and modification of crusher geometry.
B Shield eccentric throw for each machine size.
D
C Spider
D Bushing C mm [in] A B C D E F H J K
E
G5477HD 840 [33.1”] 1580 [62”] 3658 [144”] 6466 [255”] 152 [6”] 6103 [240”] 4248 [167”] 1680 [66”] 2535 [100”]
E Mainshaft sleeve G F
G6089HD 1020 [40.2”] 1912.5 [75.3”] 4425 [174”] 6815 [268”] 152 [6”] 6860 [270”] 4625 [182”] 2485 [98”] 2945 [116”]
F Head nut
G60113HD 1150 [45.3”] 2390 [94.1”] 5380 [211.8”] 7226 [284.5”] 152 [6”] 7321 [288.2”] 5123 [201.7"] 2056 [81”] 3440 [135.4”]
G Rim liner plate
L M R S T U W X Max Lift*
H Top shell H G5477HD 4000 [157”] 5182 [204”] 270 [11”] 3373 [133”] 1195 [47”] 4636 [183”] 1327 [52”] 2124 [84”] 61,600kg

I Middle shell L K
G6089HD 4590 [180”] 5890 [232”] 178 [7”] 3925 [155”] 1460 [57.5”] 5590 [220”] 1500 [59”] 2020 [80”] 66,000kg

J Bottom shell G60113HD 5540[218”] 6210[244.5”] 350[13.8”] 4760 [187.4”] 1530 [60”] 5620 [221”] 1499 [59”] 1976 [78”] 105,725kg

K Concave
L Mantle
M Mainshaft I M
M U
N Bottom shell liner
O Eccentric
P Gear W

Q Pinion
R Countershaft N
S Housing J
F T
T Hydraulic bottom O
Q
U Cap plate P R D H
V Wearing ring
V

S R
T
A

S X
U Discharge
diameter
E J
B B
FULLER® HD gyratory crusher applications K
C
L
Clearence to remove
mainshaft assembly Clearence to
■ Iron Ore ■ Nickel Ore ■ Molybdenum ■ Limestone ■ Silver Ore
remove countershaft
■ Gypsum ■ Alumina/Bauxite ■ Aggregate ■ Basalt Clearence to assembly
■ Gold Ore ■ Dolomite ■ Copper Ore ■ Granite remove eccentric