Assembly and Operating Instructions

Gyratory crusher
KB 63 - 89
Copper ore
CODELCO
Mina Ministro Hales Project
Chile

2-492-20908

Year of manufacture 2011

02/2012 Rev 0

2-492-20908 (Pos 01)

 Revision status

Revision Date Changes Made by

status

0 02.11.2011 Preparation of original (German) Ritterbecks

21.03.2012 Translation from the original Ritterbecks / Habrock

ThyssenKrupp Fördertechnik GmbH

P.O. Box 1463 – D - 59306 Ennigerloh
Schleebergstraße 12 – D - 59320 Ennigerloh
02/2012 Rev 0

Telephone: +49 2524 30 0

Fax: +49 2524 2252
www.tk-processing.com

All parts protected by copyright. All rights reserved including those of translation into other languages. This
document may not be processed, reproduced or distributed by any means, including electronic systems, in
whole or in part without our express permission in writing.

2-492-20908 (Pos 01)

 Table of contents
1 User's guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 1

1.1 Target group - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 1

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

1.3 Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3

1.4 General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 3

1.5 Liability and warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4

1.6 Copyright - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 4

1.7 Technical modifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 4

1.8 Stocking of spare parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 - 5

2 Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 1

2.1 Crusher type, dimensions, capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 1

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

2.3 Over-pressure ventilation for dust sealing 3112-SOP-001 - - - - - - - - - - - - - - - - - - - - 2 - 2

2.4 Grease lubrication for spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 2

2.5 Drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 2

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

3.1 Principles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 1

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

3.3 Personnel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 2

3.4 Noise hazard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 3

3.5 Information regarding residual risks during daily operation - - - - - - - - - - - - - - - - - -3 - 4

3.6 Fire protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 4

02/2012 Rev 0

3.7 Disposal of consumables and process materials - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 5

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

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

4.2 Main components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 2

2-492-20908 (Pos 01) TOC - 1

 4.3 Operating principle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 4

4.4 Assembly groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 6

4.4.1 Crusher shells, concaves and wear parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 6
4.4.2 Main shaft with core and mantle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 10
4.4.3 Spider bearing with grease lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 12
4.4.4 Dust sealing with side-channel compressor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 16
4.4.5 Eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 20
4.4.6 Base plate (with axial bearing ring) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 22
4.4.7 Lower main shaft bearing (axial step bearing) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 24
4.4.8 Hydraulic cylinder and balance unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 26
4.4.9 Crusher main drive and pinion shaft assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 28
4.4.10 Measuring and monitoring equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 30
4.4.11 Oil circulating lubrication and hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 32

5 Transport, Storage and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1

5.1 Transport instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1

5.2 Hoisting devices and slinging equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 4

5.2.1 Lifting gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 4
5.2.2 Lifting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 5
5.2.3 Lifting ropes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 7
5.2.4 Wire rope clamps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 10
5.2.5 Lifting chains - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 12
5.2.6 Hook - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 13
5.2.7 Screw-type lifting eyes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 14
5.2.8 Shackles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 16
5.2.9 Slinging equipment and load protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 18
5.2.10 Substructures for loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 19

5.3 Storage requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 20

5.3.1 General requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 20
5.3.2 Storage facilities & other details - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 21
5.3.3 Special requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 25

5.4 Handling oil hydraulic systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 28

5.4.1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 28
02/2012 Rev 0

5.4.2 Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 28
5.4.3 Pipes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29
5.4.4 Hydraulic hoses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29
5.4.5 Commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 30

TOC - 2 2-492-20908 (Pos 01)

 5.4.6 Hydraulic fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 30
5.4.7 Filling pumps and motors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 30
5.4.8 Pressure settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31
5.4.9 Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31
5.4.10 Cylinders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31
5.4.11 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31
5.4.12 Fluid level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.4.13 Filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.4.14 Oil temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.4.15 Oil change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.4.16 Accumulators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.4.17 Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.4.18 Pipework - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32
5.4.19 Coolers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33
5.4.20 Storage of hydraulic components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33
5.4.21 Period of storage and use duration of hydraulic hoses - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.5 Installation planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 34

5.6 Preparation for installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 35

5.7 General notes on assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 36

5.8 Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 38
5.8.1 Pre-assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 38
5.8.2 Bottom shell - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40
5.8.3 Base plate and eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 42
5.8.4 Pinion shaft assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 44
5.8.5 Hydraulic cylinder and lower components of the main shaft bearing - - - - - - - - - - - - - - 5 - 46
5.8.6 Sealing housing of the dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 48
5.8.7 Mounting the concaves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 50

5.9 Mounting the liner plates - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 52

5.9.1 Spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 54
5.9.2 Main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 56
5.9.3 Sealing ring of the dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 58
5.9.4 Lower main shaft bearing section - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 59
02/2012 Rev 0

5.10 Assembling the assembly groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 60

5.10.1 Bottom shell of the crusher, shell, main shaft, spider - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 60
5.10.2 Direct drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 66
5.10.3 Blower (side-channel compressor) for over-pressure ventilation of the dust sealing - - - 5 - 68
5.10.4 Main shaft hydraulics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 70

2-492-20908 (Pos 01) TOC - 3

 5.10.5 Oil circulating lubrication and hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 71
5.10.6 Grease lubrication for spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 72

5.11 Tightening torques for all relevant bolts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 73

5.12 Assembly, commissioning and servicing of oil lubrication units and hydraulic units 5 -
74

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

6.1 General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1

6.2 Safety notes for operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 1

6.3 Initial start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 2

6.4 Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 3

6.4.1 Prerequisites - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 3
6.4.2 Checks during operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 3

6.5 Malfunctions, troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 5

6.5.1 Fault list / troubleshooting guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 5
6.5.2 Restart of the crusher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 8

6.6 Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 9

6.6.1 Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 9
6.6.2 Emergency stop device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 10

6.7 Handling oil hydraulic systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11

6.7.1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11
6.7.2 Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11
6.7.3 Pipes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11
6.7.4 Hydraulic hoses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 12
6.7.5 Commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 13
6.7.6 Hydraulic fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 13
6.7.7 Filling pumps and motors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 14
6.7.8 Pressure settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 14
6.7.9 Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 14
6.7.10 Cylinders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 15
6.7.11 maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 15
02/2012 Rev 0

6.7.12 Fluid level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 15

6.7.13 Filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 15
6.7.14 Oil temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 15
6.7.15 Oil change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 16
6.7.16 Accumulators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 16

TOC - 4 2-492-20908 (Pos 01)

 6.7.17 Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 16
6.7.18 Pipework - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 16
6.7.19 Coolers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 16
6.7.20 Storage of hydraulic components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 17
6.7.21 Period of storage and use duration of hydraulic hoses - - - - - - - - - - - - - - - - - - - - - - - - 6 - 17

7 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 1

7.1 Important maintenance instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 1

7.1.1 Instructions for cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 4
7.1.2 Instructions for maintenance and servicing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 5
7.1.3 Instructions for repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 7

7.2 Maintenance intervals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7 - 8

7.3 Special maintenance tasks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 12

7.3.1 Crusher shells and concaves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 12
7.3.2 Secure attachment of connecting bolts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 14
7.3.3 Main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 16
7.3.4 Spider bearing with grease lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 18
7.3.5 Dust sealing with side-channel compressor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 22
7.3.6 Eccentric bushing and axial step bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 26
7.3.7 Check the oil level and change the oil at the oil circulating lubrication unit - - - - - 7 - 28
7.3.8 Check the hydraulic oil level and change the hydraulic oil - - - - - - - - - - - - - - - - - - 7 - 29
7.3.9 Direct drive and pinion assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 30

7.4 Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 36
7.4.1 Replacing the concaves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 38
7.4.2 Disassembly of the spider - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 38
7.4.3 Disassembly of the main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 38
7.4.4 Checks to be made with the spider, main shaft and dust sealing housing dismantled - - 7 - 40
7.4.5 Concaves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 42
7.4.6 Liner plates and wearing caps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 44
7.4.7 Main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 46
7.4.8 Spider bearing with grease lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 50
7.4.9 Dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 52
7.4.10 Main shaft axial step bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 54
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7.4.11 Eccentric bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 56

7.4.12 Crusher main drive and pinion shaft assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 64

7.5 Screwed and bolted connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 70

7.5.1 Machine structures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 70

2-492-20908 (Pos 01) TOC - 5

 7.5.2 High-tensile bolted joints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 72

8 Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 1

8.1 Introduction and technical instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 1

8.2 Storage of lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 2

8.3 General information on lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 3

8.3.1 Oil groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 3
8.3.2 Open toothed gears - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 5
8.3.3 Lubricant lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 5

8.4 Table of lubricants (Index 7) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 6

8.4.1 Standard lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 6
8.4.2 Special lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 9

8.5 Lubricating instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 - 12

9 ANNEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 - 1

9.1 Drawings

9.2 Clutches

9.3 Clearance of teeth and bearings

9.4 Processing synthetic casting compound

9.5 Compressor 3112-COM-001

9.6 Monitoring equipment

9.7 Central lubrication

9.8 Oil circulating lubrication and hydraulic units

9.9 Hydraulic cylinder

9.10 Tools

9.11 Gyramatic Version 2.3

9.12 SUPERBOLT® Mechanical clamping elements

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 1 User's guide

The technical documentation (Assembly and Operating Instructions) is designed to

familiarise the user with the machine / plant and its designated use.

The Assembly and Operating Instructions must always be available at the service location
of the machine / plant.

1.1 Target group

All mechanical work may only be carried out by trained specialists. Specialist as defined
by these Operating Instructions are those persons who are familiar with the assembly,
mechanical installation, troubleshooting and the maintenance of the product and who also
have the following qualifications:
– Training in the mechanical field (e.g., as a mechanic or mechatronics technician) with
successful completion of final examination.
– Knowledge of these Operating Instructions.

All electronics work may only be carried out by trained electrical technicians. Electrical
technicians as defined by these Operating Instructions are those persons who are familiar
with electrical installation, commissioning, troubleshooting and the maintenance of the
product and who also have the following qualifications:
– Training in the electronics field (e.g., as a electronics or mechatronics technician) with
successful completion of final examination.
– Knowledge of these Operating Instructions.

All work in the other areas of transport, storage, operation and disposal may only be
carried out by persons who have been properly instructed.
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1.2 Structure of the safety notes

The safety notes in the Assembly and Operating Instructions are highlighted as follows:

SIGNAL WORD
Type and source of danger

Possible consequence(s) of non-observance.

• Measure(s) for prevention of the danger.

The following table shows the classification and significance of the signal words for safety
notes.

Pictograms SIGNAL WORD Significance Consequences of non-

observance
DANGER Imminent danger Death or severe bodily injuries
!

WARNING Possible danger Death or severe bodily injuries

!
General danger

CAUTION Possible danger Minor bodily injuries

!

NOTICE Possible property damage Damage to the machine / plant or

Special danger, e.g.
its environment
electrocution

INFORMATION Useful information or tip:

Simplifies the handling
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 1.3 Definitions

right = on the right-hand side looking in the conveying direction

left = on the left-hand side looking in the conveying direction
• = Instructions for action (in the stated order)
– = Listing in the text
/ = or

1.4 General information

Dear Customer,

These Assembly and Operating Instructions are prepared by ThyssenKrupp
Fördertechnik and have to be observed in every detail by those responsible for the
transport, installation, commissioning, operation, maintenance as well as the disposal of
all consumables and process materials. Only if the responsible individuals follow the
instructions in these Assembly and Operating Instructions will errors in operating and
servicing the machine/plant be avoided and trouble-free operation ensured.

The Assembly and Operating Instructions contain important information on how to operate
the machine / plant safely, properly and efficiently. Observing this information helps to
avoid danger, to reduce repair costs and downtimes and to increase both the reliability and
the life of the machine/plant.

The Assembly and Operating Instructions include numerous instructions referring to

possible hazards. The user is responsible for training the operating staff at the machine/
plant or on site and ensuring that the safety regulations are observed.

The Assembly and Operating Instructions do not include instructions and guidelines for
major repair work.

ThyssenKrupp Fördertechnik can provide trained and qualified personnel to carry out
inspections and repairs.
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1.5 Liability and warranty

ThyssenKrupp Fördertechnik explicitly excludes all liability and warranty claims for
damage or malfunctions arising from:

• Non-compliance with instructions in the Assembly and Operating Instructions

• Incorrect operation
• Any use of the machine other than the specified use
• Faulty maintenance
• Use of consumables (in particular lubricants) not explicitly permitted by the
manufacturer
• Use of spare parts not approved by the manufacturer
• Conversions and modifications not approved by the manufacturer.

The conditions for liability and warranty as specified in the General Conditions of Supply
of ThyssenKrupp Fördertechnik also apply.

1.6 Copyright

We reserve all rights in connection with this documentation, including those relating to
patent registration or provisional patent registration. This documentation may not be
disclosed to third parties or reproduced or used in any other way without our previous
consent in writing.

1.7 Technical modifications

ThyssenKrupp Fördertechnik reserves the right to change designs in the course of

technical developments. Recent modifications may not yet have been included in the
drawings and texts of these Assembly and Operating Instructions. 02/2012 Rev 0

1-4 2-492-20908 (Pos 01)

 1.8 Stocking of spare parts

NOTICE
The use of non-original spare parts

Damage to the machine/plant or its environment is possible

• Only use original spare parts that are approved by ThyssenKrupp Fördertechnik.

Damage caused by using products other than the original spare parts and
accessories is excluded from the liability and warranty.
We expressly point out that we cannot assume any liability for spare parts and
accessories which have not been supplied by us. In some cases the installation of
such products may alter and negatively affect the structural characteristics of the
machine/plant and therefore impair safety.

Continuous operation and operational readiness of the machine/ plant can only be
ensured if important spare and wear parts are held in stock.

Please order spare parts using the information contained in the spare parts list. The spare
parts drawings listed in the spare parts list furnish additional information.

Our warranty only covers genuine spare parts supplied by us.

Please note that parts manufactured by us and non-company products are often subject
to special production and delivery specifications.
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 Blank page

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 2 Technical data

2.1 Crusher type, dimensions, capacity

Crusher type: Gyratory crusher KB 63-89

Piece size of raw material conveyed F100: max. 1200 mm

Piece size of raw material conveyed F80: approx. 328 mm

Dampness of raw material conveyed: max. 3 %

Bulk weight: 1,6 – 1.8 t/m³

Work index: 15,7 kWh/t

Pressure resistance: max. 150 MPa

Crushing gap OSS (design): approx. 180 mm

Crushing gap CSS (design): approx. 135 mm

Product grain size P80: < 150 mm

Crusher mouth opening: approx. 1600 mm

Mantle diameter: 2300 mm

Shaft lifting: approx. 280 mm

Number of teeth bevel gear eccentric bushing: z = 75

Number of teeth pinion shaft assembly: z = 20

Backlash: 3.5 - 4.5 mm

Speed of eccentric bushing: approx. 130 min-1

Speed of pinion: approx. 487 min-1

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2.2 Oil circulating lubrication and hydraulic unit

See ANNEX 9.8

Oil tank: Separate tank

Lubricating oil tank contents: approx. 2500 litres

Hydraulic oil tank contents: approx. 630 litres

2.3 Over-pressure ventilation for dust sealing 3112-SOP-001

See ANNEX 9.5

Blower: Gas ring compressor, one-stage

G 200 2 BH 1500 7A16 with
Intake filter 2BX2 102

Over-pressure: approx. 0.15 bar

Air flow rate: approx. 100 m³/h

Electric motor Voltage: 220/380 V, 50 Hz

Capacity P: 1.3 kW
Speed n: 2950 min-1

2.4 Grease lubrication for spider bearing

See ANNEX 9.7

Pneumatic barrel pump: 200 litres

2.5 Drive

See ANNEX 9.2 and Chapter 4.4.9

Motor: 1000 kW, 6000 V, 50 Hz, 487 min-1

02/2012 Rev 0

Safety coupling: BWL 140 Spezi.

Multiple-disc steel clutch: MTF 514

2-2 2-492-20908 (Pos 01)

 3 General safety notes

3.1 Principles

• The machine/plant has been manufactured in accordance with the recognised safety
regulations. However, this does not preclude danger to life and limb for the user or
others, nor does it prevent harm to the machine/plant and/or other property.

• These safety instructions must be observed by all persons responsible for the
transport, installation, commissioning, operation, maintenance as well as the
dismantling and disposal of consumables and process materials. We recommend that
the owner obtains a signed confirmation that the safety instructions have been read
and understood by his personnel.

• The machine/plant must only be used in technically perfect condition in accordance

with its designated use and the instructions set out in the manual, and only by safety-
conscious persons who are fully aware of the risks involved in operating the machine/
plant. Any malfunctions, especially those affecting the safety of the machine/plant,
should therefore be rectified immediately.

• In addition to the manual, observe and instruct the user in all other generally applicable
legal and other mandatory regulations relevant to accident prevention and
environmental protection.

• These compulsory regulations may also deal with the handling of hazardous
substances, issuing and/or wearing personal protective equipment (safety helmet,
safety boots, safety goggles, hearing protection, respiratory protection).

• Observe all safety instructions and warnings attached to the machine/ plant!

• Ensure that safety instructions and warnings attached to the machine/plant are always
complete and perfectly legible!

• In the event of safety-relevant modifications or changes in the behaviour of the

machine/ plant during operation, stop the machine/ plant immediately and report the
malfunction to the responsible department!

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

• Comply with the prescribed intervals or those specified in the operating manual for
routine checks and inspections!

• For the execution of maintenance work, tools and workshop equipment adapted to the
task on hand are absolutely indispensable.

• The personnel must be familiar with the location and operation of fire extinguishers!

• Observe all fire-warning and fire-fighting procedures!

3.2 Modifications and spare parts

• For safety reasons, conversions and modifications are prohibited unless previously
approved by ThyssenKrupp Fördertechnik.

• Use of accessories and spare parts not approved by ThyssenKrupp Fördertechnik can
lead to unforeseeable dangers.

3.3 Personnel

• Personnel entrusted with work on the machine/plant must have read the manual and
in particular the chapter on safety before beginning work. Reading the Instructions after
work has begun is too late. This applies especially to persons working only
occasionally on the machine/plant, e.g. during setting up or maintenance.

• For reasons of security, long hair must be tied back or otherwise secured, garments
must be close-fitting and no jewellery - such as rings - may be worn. Injury may result
from being caught up in the machinery or from rings catching on moving parts.

• Use protective equipment wherever required by the circumstances or by law!

• Any work on and with the machine/plant may only be carried out by reliable personnel.
Statutory minimum age limits must be observed!
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 • Employ only trained or instructed staff and set out clearly the individual responsibilities
of the personnel for operation, set-up, maintenance and repair!

• Define the machine operator's responsibilities - also with regard to observing traffic
regulations - giving the operator the authority to refuse to carry out instructions by third
parties which compromise safety!

• Work on the electrical system and equipment of the machine/plant may only be carried
out by a skilled electrician or by instructed persons under the supervision and guidance
of a skilled electrician and in accordance with electrical engineering rules and
regulations.

• Work on the hydraulic system must be carried out only by personnel with special
knowledge and experience of hydraulic equipment!

3.4 Noise hazard

Information on the emissions level which is specific to the work station

No permanent work station has been assigned to the plant/machine.

Depending on the material to be processed, noise emissions will occur: these may only
be measured during operation. The user has to ensure the measurement of the sound
power level of all operation positions (e.g. for maintenance and checking, control station)
immediately after commissioning.

INFORMATION
Directive 2003/10/EC of the European Parliament and of the Council dated 6
February 2003 (17th individual directive in terms of Article 16 Paragraph 1 of the
Directive 89/391/EEC).

If other measures fail to prevent from risks due to noise hazards, a suitable and
properly adapted personal ear protection must be made available to and used by
the employee.

Personal ear protection must be worn by the personnel if the noise hazard
reaches the threshold value of 85 dB (A).
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3.5 Information regarding residual risks during daily
operation

The safety requirements specified in the EC Machines Directive have been taken into
account in the machine/plant.

Residual risks can nevertheless still occur during operation.

Residual risks, which remain even after careful shutting off and with platforms
corresponding to the applicable safety requirements, are pointed out below.

Mechanical hazard/material
– Overcharging of the crushing area/ crusher discharge
Overcharging and discharge of crushing material on account of upstream conveying
equipment and/or congestion of material in the feed hopper.
– Dusty operating conditions
on account of the type of feeding material, material feeding, the crushing procedure,
the material discharge.

3.6 Fire protection

• The legal requirements regarding fire protection and fire prevention have to be
complied with and supplemented with in-company regulations. The fire-fighting experts
of the insurance companies should also be consulted in this process.

• Appoint supervisors who are in charge of all the matters related to fire prevention and
fire fighting and provide them with the knowledge required for this task.
The management staff and the engineers have to support them in their task by
providing consultation to them.

• The supervisor must check the fire extinguishing equipment at regular intervals, in
order to ensure that the equipment is always ready for use. 
Rooms which are easily flammable require particular attention in this context!

• The persons commissioned with supervision and fire fighting must have attended a first
aid course. First aid stations must be provided.

• The fire protection regulations must be posted at different locations in the plant.

• The personnel must be informed about the fire protection measures. Any case of fire
must be reported immediately.
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3-4 2-492-20908 (Pos 01)

 • The units and the assembly groups which heat up more strongly during operation on
account of the electrical and/or mechanical stress to which they are exposed must be
monitored by the responsible personnel. This applies e.g. to compressors, gear units,
bearings, motors, oil/hydraulic units.

• The fire extinguishers must be easily accessible and may not be obstructed by objects.
– The personnel must be familiarised with the use of the fire extinguishers to such a
degree that they are capable of fighting fire outbreaks with the appropriate fire
extinguishers.

Fire-fighting rules
• Use fire-fighting water for burning wood, waste, fabric, jute, paper, belts, etc.

• In case of burning liquids (mineral oil, petrol, oil, petroleum, paints, tar, etc.), always
use CO2extinguishers and powder type fire extinguishers.

• In case of burning cables, motors, electric plants, etc. only use powder type fire
extinguishers or CO2fire extinguishers.

3.7 Disposal of consumables and process materials

• The safe and environment-friendly disposal of all consumables and process materials
should be ensured. You should also make sure that all respective national regulations
for the protection of the environment are complied with.
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 Blank page

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 4 Design and operating principle

4.1 Scope of application and designated use

DANGER
Risk of injury through operating the machine/plant with unauthorised
modifications, conversions or spare parts.

Imminent danger of death or severe bodily injuries

• ThyssenKrupp Fördertechnik explicitly excludes all liability and warranty claims

if modifications/conversions are made without the express permission in writing
of the manufacturer.
• Only operate the machine/plant in its original condition. Any deviations from the
original condition must be reported by the operator to the responsible
department.

NOTICE
System damage through use of the machine/plant contrary to its designated
use

Damage to the machine/plant or its environment is possible

The intended use of the machine/plant is regulated by contract. Any other use
contrary to its designated use is prohibited. ThyssenKrupp Fördertechnik cannot
be held liable for damage resulting from such misuse. The risk of such misuse lies
entirely with the user.

• The gyratory crusher must be constantly fed with material in such a way that the
crushing chamber is always filled to at least 80 %.

• The machine/plant must be used exclusively for the intended purpose agreed
upon with the manufacturer.

• Observe the Assembly and Operating Instructions.

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 The constant feeding process guarantees that there is always an even load on the main
shaft bearings ("smooth running under load").
At the same time, wear on all the bearing components affected is kept very low by a stable
lubricating film.
In addition, this operation has a positive effect on the wear pattern of the crushing tools.
Frequent idle-running phases lead to uncontrolled movements of the main shaft in the
spider head bearing and in the lower bearing bushing. At the same time, continual refilling
of the crusher chamber leads to large fluctuations of load and thus to irregular running
under load.
This impact-type method of operation destabilises the lubricating film between the bearing
components which can cause undesirable abrasion on the bearing positions.
This negative operation leads to an irregular wear pattern on the crushing tools / wear
parts.

Prior to the use of the machine/ plant beyond this scope of application, consult the after-
sales service. Otherwise the warranty will lapse.

4.2 Main components

See Illustration 1

The gyratory crusher basically consists of the following assembly groups:

1 Crusher shells (1)
2 Concaves (2)
3 Wear parts (3)
4 Base plate (4)
5 Main shaft with mantle (5)
6 Dust sealing (6)
7 Eccentric bushing with bevel gear (7)
8 Connection of main shaft hydraulics (8)
9 Spider bearing (9)
10 Lower main shaft bearing (axial step bearing) (10)
11 Pinion assembly with pinion (11)
12 Crusher main drive motor (12)
13 Speed monitor (13)
14 Connection of the oil circulating lubrication (14)
15 Connection of the hydraulic unit (15)
16 Connection of grease lubrication (16)
17 Grease filling level sensor (17)
02/2012 Rev 0

18 Distance sensor (position of main shaft/ gap width) (18)

19 Main shaft hydraulics (19)

4-2 2-492-20908 (Pos 01)

 Side-channel compressor 
(blower for over-pressure ventilation) mounted on the steel structure
Grease lubrication pump with control system on substructure
Balance unit for hydraulic main shaft support mounted on the steel structure

Illustration 1
02/2012 Rev 0

2-492-20908 (Pos 01) 4-3

4.3 Operating principle

See Illustration 1
The material fed into the crusher is crushed between the fixed concaves of the crusher
shells and the wobbling mantle of the main shaft.
The driven eccentric bushing causes the main shaft to wobble. This causes the gap
between the concaves and the mantle at the circumference to vary continuously. The
material is broken up by crushing and impact effects until it can leave the crusher through
the crushing gap.
A hydraulic unit (to vertically adjust the main shaft/set the crusher gap and protect against
overload) is combined with the oil circulating lubrication unit of the eccentric bushing and
the axial step bearing (= internal lubrication circuit) as well as the eccentric bushing
(= external lubrication circuit). The units are combined for reasons of accessibility and
maintenance but form separate circuits.

02/2012 Rev 0

4-4 2-492-20908 (Pos 01)

 Illustration 1
02/2012 Rev 0

2-492-20908 (Pos 01) 4-5

4.4 Assembly groups

4.4.1 Crusher shells, concaves and wear parts

See Illustration 2 and Illustration 3

The crusher shells (a cast structure) consist of the following:

– the conical upper and lower shell (1, 2)
– the spider mounted on this (3)
– the three-arm bottom shell, which is located under the lower shell (4).

Illustration 2

The inside of the shells are lined with concaves (5).

The top of the upper shell is also lined with rim liners (6).
The arms of the spider are protected from wear by arm liners (26).
The main shaft (7) is supported and centred in the spider by the spider bearing (8). The
spider bearing is protected by the spider cap (9).
The shells (1, 2) and the bottom shell (4) are positioned via conical seats and bolted to the
external flanges.
02/2012 Rev 0

4-6 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 3

2-492-20908 (Pos 01) 4-7

 The bottom shell is lined with liner plates (10). It is connected to the internal hub via three
arms (11). One of the arms is designed for the installation of the pinion shaft assembly
(12) (pinion shaft assembly tunnel). The compressed air piping (13) for the dust sealing
(14) and the lubrication oil piping (15) are installed in one arm and passed to the outer
eccentric bushing of the external lubrication circuit (16). The arms are protected against
damage from impacting material by liner plates (17).

The hub in the centre accommodates the outer eccentric bushing (16). The eccentric
bushing (18) is arranged in the outer eccentric bushing. The dust sealing (14) is mounted
on top of the hub.

The base plate (19) (including axial step bearing ring) is bolted to the bottom shell, which
supports the eccentric bushing in the axial direction. The hydraulic cylinder (20) supports
the axial step bearing (21) and is arranged under the base plate. The hydraulic cylinder is
also bolted to the bottom shell.

Two inspection opening covers (22) are provided on the bottom shell. An inspection
opening with a cover (23) is arranged on the bottom part of the hub for checking the bevel
gear (24) and the pinion (25).

The bottom flange of the bottom shell is used to mount the bottom shell on the
substructure / foundation.

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4-8 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 3

2-492-20908 (Pos 01) 4-9

4.4.2 Main shaft with core and mantle

See Illustration 4

The main shaft (1) is made of forged steel. The upper (2) and the lower core (3) are
mounted on the shaft cone. The upper core (2) is fastened by the inner ring nut (4) and
fixed with a cylindrical pin (5).
The upper (6) and lower mantle (7) are mounted on the cores. The lower mantle (7) is
shrink-mounted on the lower core (3). The mantles are clamped by the outer ring nut (8)
and an intermediate ring (9) and held on the cores.
The intermediate ring (9) is welded/tack-welded to the outer ring nut (8) and the upper
mantle (6). The outer ring nut (8) is protected against wear by a cap (10) and hard facing.
The eye bolt (11) is used to assemble/disassemble the main shaft.
The cores and the mantles are back-filled with a special sealing compound (12). (See
ANNEX 9.4)
The sealing ring of the dust sealing (13) is bolted to the underside of the lower core (3).
The upper shaft of the main shaft is protected by the main shaft sleeve (14).
The step bearing upper part (15) of the axial step bearing is mounted on the bottom front
face of the main shaft.

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4 - 10 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 4

2-492-20908 (Pos 01) 4 - 11

4.4.3 Spider bearing with grease lubrication

See Illustration 5 and Illustration 6

The spider bearing is designed as a slide bearing. The top shaft of the main shaft is
surrounded by the main shaft sleeve and guided in the spider bush (1).
The top main shaft bearing is lubricated with grease by a separately arranged lubrication
unit.
The spider bushing is sealed against the crushing chamber by a sealing ring (2) with shaft
sealing rings (4) and the leather packing (5).
A pneumatically operated grease lubrication pump (7) supplies the spider bearing
with grease via the lubricant connection (3).
A filling level sensor (6) is installed in the head of the spider. It is used to monitor the
grease level of the spider bearing and automatically activates the grease lubrication pump
if necessary.
The grease reservoir is provided with a filling level sensor with low level indication.

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4 - 12 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 5

2-492-20908 (Pos 01) 4 - 13

 A flow meter (8) is installed in the grease lubrication line.
The following components are installed on the control plate (9) to control the grease
lubrication pump (7):
– Pressure relief valve to regulate the operating pressure of the grease lubrication pump
– Pressure gauge to indicate the operating pressure of the grease lubrication pump
– 3/2 way valve to activate the grease lubrication pump
– Grease filter
– Check valve

In the event of a failure, the crusher main drive motor can be switched off depending on
the interlocking system.

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4 - 14 2-492-20908 (Pos 01)

 Illustration 6
02/2012 Rev 0

2-492-20908 (Pos 01) 4 - 15

4.4.4 Dust sealing with side-channel compressor

See Illustration 7

The dust sealing protects the section of the oil circulating lubrication inside the gyratory
crusher against the ingress of dust from the crushing chamber (A).
The internal space (B) is sealed by means of a plastic ring (1) which is mounted between
the top and bottom sealing rings (2) and (3) with a clearance. A low radial clearance is
provided between the plastic ring (1) and the sealing housing (4). The plastic ring (1)
follows the wobbling motion of the main shaft. 
A separately arranged blower also generates a slight over-pressure on the inside (B) of
the gyratory crusher.
As a result, there is a continuous air flow from the interior of the crusher (B) to the crushing
chamber (A). This prevents the ingress of dust and other pollutants.
The sealing effect is also maintained if the pressure inside the crusher drops due to the
operating conditions. This is the case e.g. when the main shaft is lifted or the lubrication
oil flows backwards when the crusher is switched off.
The oil seal (5) prevents splash oil from leaking into the space above the plastic ring (1).
The lubricating oil is passed via a duct (6) in the sealing housing and bottom part and is
returned to the tank.

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4 - 16 2-492-20908 (Pos 01)

 Illustration 7
02/2012 Rev 0

2-492-20908 (Pos 01) 4 - 17

 See Illustration 8

Starting from the blower (1), the compressed air is passed to the hollow space of the dust
sealing via a hose/pipe system (2), the pressure transducer (3) (set at 70 mbar) and the
air ducts (4) in the hub of the bottom shell and in the dust sealing housing.
The blower is provided with an intake filter (5) and a pressure relief valve (6) and mounted
on a bracket on the steel structure.
In the event of a failure, the crusher main drive motor can be switched off depending on
the interlocking system.
After the crusher has been switched off, the blower decelerates with a time delay.

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4 - 18 2-492-20908 (Pos 01)

 Illustration 8
02/2012 Rev 0

2-492-20908 (Pos 01) 4 - 19

4.4.5 Eccentric bushing

See Illustration 9

The eccentric bushing is driven by the pinion assembly. It guides the main shaft in the
inner eccentric bushing (4) and generates its wobbling (rotary/oscillating) motion.
The eccentric bushing consists of the eccentric bushing body (1) on which the bevel gear
(2) is mounted by means of a feather key (3) and bolts (7).
The inner eccentric bushing (4) is made of bearing metal and is secured against rotation
by a feather key (5).
The eccentric bushing is lubricated by the oil circulating lubrication internally (between the
inner eccentric bushing and the main shaft), externally (between the eccentric bushing
and the outer eccentric bushing) and on the underside (between the eccentric bushing and
the axial step bearing ring).
The circulating lubrication also supplies the teeth of the bevel gear.
The top device for compensating unbalance (6) fixes the inner eccentric bushing in a
vertical (axial) direction.

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4 - 20 2-492-20908 (Pos 01)

 Illustration 9
02/2012 Rev 0

2-492-20908 (Pos 01) 4 - 21

4.4.6 Base plate (with axial bearing ring)

See Illustration 10

The base plate is arranged between the bottom shell of the crusher (3) and the hydraulic
cylinder (2).
The hydraulic cylinder (2) is bolted to the bottom shell (3) via through holes in the base
plate (1).
The back lash between the bevel gear eccentric bushing and the pinion of the pinion
assembly 
can be preset by means of the slotted spacer plates (4 - 10) which are arranged between
the base plate and the bottom shell.
The axial bearing ring (5) is provided with lubrication grooves and is located on the base
plate. The eccentric bushing slides on the axial bearing ring. The cylindrical pin (6)
secures the axial bearing ring against tuning.
The sealing cord (7) prevents oil losses (lubrication space – external bearing) and the
ingress of pollutants into the interior of the crusher.

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4 - 22 2-492-20908 (Pos 01)

 Illustration 10
02/2012 Rev 0

2-492-20908 (Pos 01) 4 - 23

4.4.7 Lower main shaft bearing (axial step bearing)

See Illustration 11

The lower main shaft bearing (axial step bearing) axially supports the main shaft on the
piston of the hydraulic cylinder and takes up its wobbling motion.
The hydraulic cylinder for adjustment of the crushing gap (main shaft adjustment) and
protection against overload is located below the axial step bearing.
The axial step bearing is designed as a slide bearing. The step bearing upper part (1) is
bolted to the main shaft; the slide bearing plate (2) is arranged on the hydraulic cylinder
and secured against sliding/torsion by the cylindrical pin (3). The step bearing lower part
(4) is moves between them. Lubrication grooves are incorporated in the step bearing
upper part and the slide bearing plate.
The boundaries of the bearing components are supplied with lubrication oil by the internal
lubrication oil circuit.

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4 - 24 2-492-20908 (Pos 01)

 Illustration 11
02/2012 Rev 0

2-492-20908 (Pos 01) 4 - 25

4.4.8 Hydraulic cylinder and balance unit

See Illustration 12

The main shaft hydraulic unit consists of the hydraulic cylinder (1) and the balance unit (2).
It is used to adjust the crushing gap, especially if the crushing tools are worn, and to
protect against overload. 
The separately arranged balance unit is used for vertical guidance of the piston, especially
if the main shaft is suddenly relieved of load during operation of the crusher. Lifting of the
main shaft off the main shaft bearing is thereby prevented.

The balance unit consists of a compressed air tank (3) and a compensation cylinder (4)
with an integrated check valve and an adjustable throttle valve. The cylinder of the balance
unit is connected to the hydraulic cylinder (1) of the main shaft adjustment system via pipe
systems.

The compressed air tank (3) of the balance unit is only filled with enough compressed air
to prevent the pressure from lifting the piston and thus the main shaft via the
compensation cylinder (4) when the crushing chamber is empty.

As soon as the main shaft is lifted, the oil pressure in the balance cylinder drops because
the main shaft no longer is loading the pistons. The pressure in the compressed air tank
presses the oil from the compensation cylinder into the cylinder (5) and causes the piston
with the axial bearing (6) to follow the main shaft.

As soon as the main shaft lowers again, the oil pressure in the cylinder (5) rises and the
oil is pressed back into the compensation cylinder.
A check valve with an adjustable throttle upstream of the compensation cylinder prevents
the oil from rushing into the balance unit (1) when the main shaft is lowered.

The position of the piston and/or the main shaft (i.e. the size of the crushing gap) is
determined by the distance sensor (7).

The three adjustable pressure relief valves (8) are used to limit the working pressure and
thus serve as an overload protection.

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4 - 26 2-492-20908 (Pos 01)

 Illustration 12
02/2012 Rev 0

2-492-20908 (Pos 01) 4 - 27

4.4.9 Crusher main drive and pinion shaft assembly

See Illustration 13

The connection between the electric motor and the pinion shaft assembly is designated
as the drive.

It comprises:
– the multiple-disc clutches (1) between the pinion shaft assembly and the E-motor
– with spacer/distance tube (2)
– the safety coupling (3) between multiple-disc clutch and spacer tube
– speed sensor (14)
– protective box (15) and
– motor console (16).

The multiple-disc steel clutch is used to compensate for minor alignment faults between
the motor shaft journal and the pinion assembly shaft(4).
The spacer tube allows the pinion shaft assembly to be removed without shifting the drive
motor.
The safety coupling is provided with a torque limiter with hydraulic torque setting. The
necessary releasing torque is set by varying the hydraulic pressure. See Chapterl 5.8.4
“Pinion shaft assembly” and ANNEX 9.2 "Kupplungen".

pinion assembly
The pinion shaft assembly is arranged in the pinion shaft assembly tunnel of the bottom
shell of the crusher.
The shaft of the pinion assembly (4) with a pinion (5) to drive the bevel gear of the
eccentric bushing is supported in the pinion assembly housing (6) by roller bearings (7)
and (8).
The bearings are lubricated by the oil filling in the pinion shaft assembly housing (splash
lubrication).
The contact pattern of the teeth of the bevel gear set and the backlash can be adjusted by
changing the thickness of the disks (see Chapterl 7.3.9 “Direct drive and pinion
assembly”).
Resistance thermometers (10) and (11) are installed to monitor the temperature.
The fluid switch (12) monitors the oil level of the pinion shaft assembly housing.
Accelerometers (13) (including evaluation unit) monitor the condition of the roller bearings
of the pinion shaft assembly.
02/2012 Rev 0

4 - 28 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 13 (Illustration similar)

2-492-20908 (Pos 01) 4 - 29

4.4.10 Measuring and monitoring equipment

Monitoring of the oil circulating lubrication and hydraulic unit:

• Levels of lubricating oil tank and hydraulic oil tank
• Temperatures of lubricating oil tank and hydraulic tank
• Operating pressures in lubrication circuits and the hydraulic system
• Filter clogging
• Lubricating oil temperature (return flow)
• Lubricating oil temperature in cooling circuit
• Monitoring of lubricating oil flow rate (flowmeters for supply and return flow)
• Shaft position via distance sensor, see Chapter 4.2 “Main components”.
See also Chapterl 9.8 “Ölumlaufschmierung und Hydraulikaggregate”

Grease lubrication unit for spider bearing

• Filling level of reservoir, see Chapter 4.4.3 “Spider bearing with grease lubrication”
• Grease lubrication level of the spider bearing, see Chapter 4.4.3.
• Flow function through an impulse counter in the grease lubrication line of the spider
bearing, see Chapter 4.4.3
• Pressure of compressor/ blower of dust sealing, see Chapter 4.4.4 “Dust sealing with
side-channel compressor”.
See also Chapterl “9.5 Compressor 3112-COM-001” and Chapterl “9.7 Central
lubrication”

pinion assembly
See also Chapter 4.4.9 “Crusher main drive and pinion shaft assembly”
• Level monitoring of the oil filling of the pinion shaft.
• Temperature of the pinion assembly bearing.
• Speed control
• Accelerometer

See Illustration 14

The speed monitor (1) is arranged on a console (2) bolted to the flange of the pinion
shaft assembly. Two opposite facing sheet metal strips (3) and (4), which function as
cam switches, are mounted on the flange of the multiple-disc clutch.
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4 - 30 2-492-20908 (Pos 01)

 Illustration 14
02/2012 Rev 0

2-492-20908 (Pos 01) 4 - 31

4.4.11 Oil circulating lubrication and hydraulic unit

See Illustration 15 and ANNEX 9

The oil circulation lubrication unit for the lower main shaft bearing (axial step bearing and
eccentric bearing) and the hydraulic unit for setting the crushing gap/main shaft
adjustment and overload protection are combined in one unit.

Function of the oil circulating lubrication

The lubricating oil is drawn from the tank and supplied to the lower main shaft bearing via
two separate oil lines (internal and external lubrication circuits).
The oil for the internal circuit (1) (axial step bearing and inner eccentric bushing) is
conducted to the bearing points through the hydraulic cylinder (2). 
The oil for the external circuit (3) (outer bushing) is conducted to the bearing point via a
separate line.
After the bevel gear and pinion have been lubricated, the two oil flows return to the tank
via a common return line (4).

Function of the hydraulic system

The hydraulic cylinder (2) is a plunger cylinder with an internal duct for conveying the
lubricating oil from the internal circuit and the hydraulic oil connection (5).
During operation of the crusher, the main shaft is axially supported on the piston (7) of the
hydraulic cylinder via the axial step bearing (6).
The main shaft can be lifted/lowered by regulating the oil flow, thereby adjusting the
crushing gap.
The position of the piston, and thus the position of the main shaft, is measured by the
integrated distance sensor (8).
The cylinder is protected against overload caused by feeding material which cannot be
crushed by two pressure relief valves (9) in the cylinder bottom.
The separately arranged balance unit (10) is connected to the hydraulic cylinder (2) via
pipes. It consists of a compressed air tank and a compensation cylinder and prevents the
main shaft from lifting off the axial step bearing under particular conditions of operation.
See also Chapter 4.4.8.

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02/2012 Rev 0

Illustration 15

2-492-20908 (Pos 01) 4 - 33

 Blank page

02/2012 Rev 0

4 - 34 2-492-20908 (Pos 01)

 5 Transport, Storage and Assembly

5.1 Transport instructions

The machine/plant is transported in component parts or as assembly groups. Make sure

that suitable lifting tackle is used to unload the parts from the transport vehicles and move
them to the storage location.
The machine/plant must be transported with adequate care in order to prevent damage
and not endanger staff. In addition to the following information, the general and local
safety and accident prevention regulations must be observed. Overhead gantries and
mobile cranes or lifting tackle with a sufficient load bearing capacity must be available to
carry out the unloading, transport/loading safely and correctly.
The transport and storage symbols on the machine packaging must be heeded.

Keep away from heat Keep dry Caution! Glass! This way up

Sling here Centre of gravity Do not use hand No hand truck

hooks here

Stacking limitation Clamp here Permissible Do not use fork lift

temperature range truck here

Electrostatic sensitive Do not destroy Tear off here Do not roll

02/2012 Rev 0

device barrier

2-492-20908 (Pos 01) 5-1

 When transporting the machine by crane, only use suitable loading devices.
When packing the machine, loading devices may only be attached at the marked points.

DANGER
Risk of injury due to the improper transport of the machine/plant

Imminent danger of death or severe bodily injuries

• Only transport the machine/plant on the designated slinging devices (lugs) and
slinging points.
• The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
• Make sure to use proper transportation equipment.
• Do not walk under suspended loads.
• Secure moveable components.

NOTICE
System damage from improper transport of the machine/plant

Damage to the machine/plant or its environment is possible

• Do not attach any additional slinging points to the machine through welding,
torching or drilling (notching effects and the corresponding risk of crack
formation).
• Do not push together the side walls or the attachment parts of the machine by
pulling lifting gear at an angle!
• If transport securing devices have been furnished do not remove them until
installation has been completed.
02/2012 Rev 0

5-2 2-492-20908 (Pos 01)

 NOTICE
System damage from improper storage/assembly of the machine/plant

Damage to the machine/plant or its environment is possible

• If the machine/plant is to be stored, it has to be left in the delivery condition. The

manufacturer is not liable for damage caused by improper repeated assembly of
the machine/plant.

Check all components for transport damage after delivery to the site.
02/2012 Rev 0

2-492-20908 (Pos 01) 5-3

5.2 Hoisting devices and slinging equipment

WARNING
Risk of injury through components that are improperly secured during
installation

Death or severe bodily injuries are possible

• Make sure that moveable components are properly secured during installation

5.2.1 Lifting gear

Usually, cranes and lifting gear is used for transporting heavy assembly groups and
components. Slinging equipment such as ropes and hooks are critical elements between
the load and lifting equipment.

Safe lifting requires adequately dimensioned and suitably designed lifting gear and
slinging equipment to be used, as well as correct attachment and fixing to the load.

The weight of assembly groups and components is specified in the spare parts catalogue
/ in the Operating Instructions, so that equipment such as e. g. hoisting devices, winches,
cranes, lifting chains can be selected accordingly.

Check hydraulic winches for proper function before use. Only use winches with
adjustment ring. This allows loads to be supported mechanically and prevents their
lowering.

INFORMATION
Before lifting heavy loads, attach a load cell to check the load. 02/2012 Rev 0

5-4 2-492-20908 (Pos 01)

 5.2.2 Lifting

• Before lifting, determine the weight of the load.

• Determine the size and shape of the load; two criteria which determine the following:

– the type of load securing, e. g. with slings, baskets or slings with special fixtures,
– the slinging equipment / load securing fixtures, e. g. lifting rope, lifting chain, screw
eyes, yokes (see following sections),
– the load angle of the slinging equipment.

• Determine the thickness of the slinging equipment to be used. Do not exceed the
permissible load bearing capacity of the slinging equipment.
• If any of the following points are unclear, consult the assembly supervisor responsible:

– correct attachment method,

– selected thickness of slinging equipment,
– type of slinging equipment.

• Check the slinging equipment for damage / faults. Make sure that any faulty slinging
equipment is discarded immediately.
• Do not overload slinging equipment and protect it against sharp corners and edges of
the load e. g. through edge/corner protection made of sacking or metal, boards etc.
• Protect high-gloss/finished surfaces of the load against damage caused by the slinging
equipment. Protective material that is intended to prevent the load/lifting means
slipping must be attached in such a way that it cannot slip if the slinging equipment
becomes loose.
• When attaching slinging equipment at great heights:

– Use the climbing aids provided. If no climbing aids have been provided or these are
not available, use an approved ladder.
– Secure the ladder to prevent it slipping or falling over.
– Use both hands for climbing. Have the slinging equipment to be attached brought
up by lifting tackle (e. g. crane).

• After attaching the slinging equipment, tighten it as far as possible by hand. If the
slinging equipment has to be tightened by crane, make sure that no body parts get
between the load and the slinging equipment, and keep hands and fingers safe.
02/2012 Rev 0

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 • Give the crane driver fixed/agreed clear signals for moving the load.

Before lifting the load:

• Remove any material lying loosely on the load.
• Secure unused rope/chain ends, e. g. by hooking them to the main ring/collecting them
in the shackle.
• Instruct staff to leave the hazard area.
• Check that the load is secured symmetrically at all points.
• Make sure that the slinging equipment cannot damage the load (and vice versa).

After the weight of the load has been picked up completely by the lifting tackle and
the load has been lifted a little:
• Check the load brake.
• Check again whether the load is secured at all points.
• Transport the load over free areas as far as possible.
• Warning signals must be given if there is anyone in the hazard zone.

Setting the load down:

• Set the load down slowly on a respectively sturdy base. Align the base again before
the load is set down.
• Remove slinging equipment from the load and check both for damage.

02/2012 Rev 0

5-6 2-492-20908 (Pos 01)

 5.2.3 Lifting ropes

The number of sling points is equal to the number of rope strands connecting the crane
hook with the load. A load angle i. e. an angle between the horizontal surface of the load
and the lifting ropes is formed by several strands. The smaller the load angle, the smaller
the permissible load bearing capacity of the lifting ropes and thus the effectiveness.

Effectiveness of the load angle

Effectiveness

Load bearing
capacity max. permissible load per strand in
Load angle
relation to 1000 kg
%

30° 50,0 (500 kg)

45° 70,7 (707 kg)

60° 86,6 (866 kg)

90° 100,0 (1000 kg)

02/2012 Rev 0

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 The load bearing capacity/wire rope strength is reduced by:
– Splitting rope loops in the lifting ropes and splitting lifting ropes into continual
strands
– Bending round corners
– Using lifting ropes for clamping
– Acceleration and slowing during lifting and lowering operation
– General wear
– High and low temperatures
– Vibration
– corrosion;

Use:

Although the weight of lifting ropes is lower than that of lifting chains of the same load
bearing capacity, they have a few disadvantages. They can become damaged more easily
and are more difficult to handle since their bending radius is smaller.

Lifting ropes are suitable for vertical lifting operation or for lifting operation where ropes
must be routed in a large radius around corners.

The thickness of a wire rope is given in relation to its outer diameter.

• Protect lifting ropes from the influences of the weather, solvents, high temperatures
and chemicals.
• Avoid knots forming in wire ropes. In the event of a knot, do not use the rope again.
• Protect ropes against sharp-edged corners by enlarging the corner radius. This can be
by means of metallic corner protection devices or blocks. Sacking and wooden boards
can also be used.
• The correct procedure for securing lifting ropes to the hook is as follows:

– Secure each individual strand on the hook to prevent hitching at the hook.
– Never use one single slinging rope strand since this could lead to the load rotating.
The wire rope could be untwisted and thus the splice pulled out. 02/2012 Rev 0

5-8 2-492-20908 (Pos 01)

 • Never wind the wire rope completely around the crane hook (i. e. by 360 degrees). The
low bending radius would damage the rope.
• Check the lifting ropes for:
– broken or cut strands,
– rust and corrosion,
– knots and kinked spots,
– damaged eyes

• Do not bend the eyes of lifting ropes over corners.

• When securing loads by winding the lifting ropes around the load, use shackles (1).
02/2012 Rev 0

2-492-20908 (Pos 01) 5-9

5.2.4 Wire rope clamps

Attach wire rope clips in such a way that the lower part of the clip (6) is pushed against the
long end (5) of the rope, and the yoke of the clip (2) against the dead end (4) of the rope.
Always attach a rope thimble (1). The correct number of clips and distance (3) between
them is given in the following table.
Tighten clamping nuts using the given torques.

Once the rope has been put into operation and is tensioned, tighten the clamping nuts
again. Check the clamping nuts regularly and tighten if necessary. This compensates rope
expansion and the related reduction of rope radius.

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5 - 10 2-492-20908 (Pos 01)

 Diameter of the clamping Required minimum
Rope diameter Distance between clips
yoke number of clips

Inches mm Inches mm Inches mm

3/16 4,76 11/32 8,73 3 76 2

1/4 6,35 7/16 11,11 3-1/4 83 2

5/16 7,94 1/2 12,70 3-1/4 83 2

3/8 9,53 9/16 14,29 4 102 2

7/16 11,11 5/8 15,88 4-1/2 114 2

1/2 12,70 11/16 17,46 5 127 3

5/8 15,88 3/4 19,05 5-3/4 146 3

3/4 19,05 7/8 22,23 6-3/4 172 4

7/8 22,23 1 25,40 8 203 4

1 25,40 1-1/8 28,58 8-3/4 222 4

1-1/8 28,58 1-1/4 31,75 9-3/4 248 5

1-1/4 31,75 1-5/16 36,51 10-3/4 273 5

1-3/8 34,93 1-1/2 38,10 11-1/2 292 6

1-1/2 38,10 1-23/32 43,66 12-1/2 318 6

1-5/8 41,28 1-3/4 44,45 13-1/4 337 6

1-3/4 44,45 1-15/16 49,21 14-1/2 368 7

2 50,80 2-1/8 53,98 16-1/2 419 8

2-1/4 57,15 2-5/8 66,68 16-1/2 419 8

2-1/2 63,50 2-7/8 69,85 17-3/4 451 8

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5.2.5 Lifting chains

Use:

Lifting chains are made of alloyed steel and are sturdier and more flexible than lifting
ropes, but they are not as resistant to impact loads as ropes are. The thickness of a chain
is determined in relation to the diameter (1) of a chain link.

• Avoid knots forming in lifting chains. They weaken the chain strand and can lead to
deformation or other damage to the chain links.
• Shorten lifting chains by hooking them back into the chain or into the main line with the
aid of a gripper hook. Never shorten a chain by twisting, knotting or bolting.

• Protect lifting chains against sharp corners and edges that could deform the chain
links. Use suitable flexible boards or metallic corner protection devices.
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 • If the chain for lifting operation is to be wound around the load to be lifted, always turn
the hook opening away from the direction in which the slings are to be pulled. This
prevents the hook slipping out when the slings are tightened.

• Check lifting chains for:

– notches, cracks, exact dimensions and wear
– deformed chain links, welding burr, bent or open hooks, elongation
– rust and corrosion

• If all the strands of a lifting chain can be hooked back into the main line, the permissible
load bearing capacity of the whole sling can be increased by 50 %.

5.2.6 Hook

The load bearing capacity is usually stamped into the hook.

• If possible, use a hook with spring-loaded snap-in locking devices. If such hooks are
not available, the hook has to be secured temporarily as shown in the diagram.
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5.2.7 Screw-type lifting eyes

The size of screw-type lifting eyes is determined in relation to the diameter of the shank of
the threaded section. A distinction is made between simple screw-type eyes and screw-
type eyes with shoulder.
• For vertical lifting operation, use simple screw-type eyes (without shoulder).
• Screw-type eyes with shoulder are used when loads are to be lifted at certain angles
(e. g. lifting operation with several lifting ropes).

The permissible load bearing capacity that has already been reduced by the load angle,
is reduced even further by the use of screw-type eyes.
A screw-type eye with shoulder that is used e. g. at an angle of 45°, can only used for up
to a load of about 10 % of the permissible load for vertical lifting operation.

Permissible loads for screw-type lifting eyes with shoulder

Shank diameter Vertical lifting Tension at 60° to Tension at 45° to Tension at 90° or
operation the shoulder level the shoulder level loose side pull

per screw-type eye per screw-type eye per screw-type eye per screw-type eye

Inches mm Pounds kg Pounds kg Pounds kg Pounds kg

1/4 6,4 300 136 50 23 30 14 40 18

1/2 12,7 1300 590 200 91 140 64 150 68

3/4 19,3 3000 1361 400 181 250 113 300 136

1 25,4 6000 2722 800 363 500 227 600 272

1-1/4 31,8 9000 4082 1300 590 80 363 900 408

1-1/2 38,1 13000 5897 1800 816 1200 544 1300 590

2 50,8 23000 10433 3300 1497 2100 953 2300 1043

2-1/2 63,5 37000 16783 6000 2722 3500 1724 4300 1950
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 Eyes must be screwed fully in, this ensures the shaft cannot be bent.

• Use screw-type eyes of a suitable size.

• Check the condition of the thread to make sure the screw-type eye fits tightly and that
there is flush and complete contact between the shoulder and the load. Never use
screw-type eyes with cracked or flawed threads.

• Only use screw-type eyes the load bearing capacity of which is suitable for the load,
i. e. shanks with threads that fit exactly in standard boring holes.

• Check shanks of the screw-type eyes for deformation or crack formation.

• Use hardened washers to make sure the edges of the screw-type eye are a tight fit.
The washers must not be thicker than two threads.
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5.2.8 Shackles

Shackles are closed safety devices that cannot be hooked out. Their size is determined in
relation to the diameter of the main part (1) and not in relation to the diameter of the bolt.
A distinction is made between anchor load shackles (on the left of the diagram) and chain
load shackles (on the right).

• Do not expose the main part of the shackle to side tensile loads.
• Ensure the shackle bolt is a perfect fit.
• The permissible load for anchor load and chain load shackles as well as for screw-type
or socket pin is always the same.

DANGER
Danger caused through the use of improper slinging equipment

Imminent danger of death or severe bodily injuries

• Never replace shackle bolts by conventional bolts. Danger of breaking!

• If shackles are used at load angles other than 90°, the permissible load bearing
capacity is reduced; see table:
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 Diameter Single shackle Two shackles 60° Two shackles 45° Two shackles 30°
vertical

Inches mm Americ. tonnes Americ. tonnes Americ. tonnes Americ. tonnes

tonnes tonnes tonnes tonnes

1/4 6,4 1/3 0,3 3/4 0,7 1/2 0,5 1/3 0,3

5/16 7,9 1/2 0,5 1 0,9 ¾ 0,7 1/2 0,5

3/8 9,5 3/4 0,7 1-1/4 1,1 1 0,9 3/4 0,7

7/16 11,1 1 0,9 1-3/4 1,6 1-1/2 1,4 1 0,9

1/2 12,7 1-1/2 1,4 2-1/2 2,3 2 1,8 1-1/2 1,4

5/8 15,9 2 1,8 3-3/4 3,4 3 2,7 2 1,8

3/4 19,3 3 2,7 5-1/2 5 4-1/2 4,1 3 2,7

7/8 22,2 4 3 6 7 6 3 5-1/2 5

1 25,4 5-1/2 5 10 9 8 7,2 6 5,4

1-1/8 28,6 6-1/2 5,9 11-1/2 10,5 9-1/2 8,5 6-1/2 5,9

1-1/4 31,8 8 7,2 14 12,7 12 10,8 8 7,2

1-3/8 24,9 10 9 17 15,4 14 12,7 10 9

1-1/2 38,1 12 10,8 20 18,1 17 15,4 12 10,8

1-3/4 44,5 16 14,5 28 25,4 23 20,9 16 14,5

2 50,8 21 19 36 32,6 30 27,1 21 19

2-1/4 57,2 27 24,5 46 41.7 38 34,5 27 24,5

2-1/2 63,5 34 31 58 52,6 48 44 34 31

2-3/4 70,1 40 36,2 69 62,9 57 51,9 40 36,2

3 76,2 80 45,3 87 78,8 71 64.4 50 45,3

4 101,6 100 90,7 173 156,9 142 128,7 100 90,7

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5.2.9 Slinging equipment and load protection

• Protect lifting ropes against sharp edges/corners. Use materials to enlarge the radius,
e. g. metallic corner protection devices (left and right), belts, wooden blocks, sacking,
steel bushings/sleeves. This protects finished load surfaces from the wire rope too.

• Protect lifting chains against sharp edges/corners. Use materials to enlarge the radius,
e. g. metallic corner protection devices (left and right), belts, wooden blocks, sacking,
steel bushings/sleeves. This protects finished load surfaces from the chain too.

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 5.2.10 Substructures for loads

• Make sure that the base has a sturdy and level surface and can bear the whole weight
of the load. Only use hard wood with (approx.) square cross-section as a base.
• Protect finished surfaces by cushioning the base, e. g. with sacking, pressboard, belts.
• Use wedges to prevent the load rolling away or moving (e. g. handles, round forged
parts and rings). When using wedges be careful with your hands and make sure they
do not get crushed if the load moves.

• When using several supports as substructures, only use supports of the same height.
Place the supports under the loads in such a way that these are sturdy and aligned
level. Do not use supports that have rounded edges, are fragile or damaged.

• Compensate unevenness under the supports.

• Use the supports to create a cavity under the load, enabling the slinging equipment to
be attached and removed easily.
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5.3 Storage requirements

5.3.1 General requirements

NOTICE
System damage from improper storage of the machine/plant

Damage to the machine/plant or its environment is possible

• All the delivered machine and plant components must be stored on suitable
underlays to keep them dry. The storage place must be free from vibration.

• The stored machine and plant components must be protected from water, sea
water, aggressive vapour or gas and increased ozone concentration.

If the storage time is exceeded by a lengthy period (i.e. more than 2 months), all the
bearings of the machine and plant components must be completely filled with suitable
grease. The shafts in the bearings must be turned several times once a month. They must
be subsequently topped up with grease. The bearings and housings are thereby protected
from condensation water and rust. After storage, i.e. before the plant component is
commissioned, the grease must be removed and the bearings cleaned and regreased
(approx. 1/3 of the volume of bearing and housing).

All machines and plant components shall have a storage temperature of + 5 °C minimum
and + 45 °C maximum. Electrical equipment is to be stored dry and frost-free,
temperatures between minimum + 5 °C and maximum + 45 °C.

All unpainted surfaces must be provided with suitable protection against corrosion.

The storage location must be dry. If equipment is stored in a shipping container, a

"desiccant material" must be placed in the container prior to storage. The equipment must
be covered and good ventilation provided in the storage place.

The packing climate must be protected from environmental influences, in order to maintain
rust prevention and the effectiveness of siccatives.
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 The storage area must be clean and free from dust and other contaminants.

Equipment must be stored in the original crates or on the original transport skids provided
by TKF. Equipment on transport skids must be loosely covered with tarpaulins, in order to
keep it clean and to allow the air to circulate.

Stored equipment may not be exposed to direct sunlight.

Plant components made of plastic or rubber may not be exposed to direct sunlight. The
storage temperature must be + 5 °C minimum and + 45 °C maximum. It must be protected
from contamination by grease or oil. Rubber parts, such as the belts of troughed belt
conveyors and the filter belts of vacuum belt filters, are normally delivered on coils. The
coils must be stored vertically and not horizontally. Furthermore, the coils may not be
stored directly on the floor. They must be stored vertically on a firm base surface. Pallets
or similar must be used for moisture protection. The coils may not be stacked.

The stored equipment must be secured against damage and loss. Secured storage areas
may only be accessed by authorised personnel.

Insurance with sufficient coverage for damage caused by third parties, transport and
weather damage (lightning, flooding, and storms) and theft must be concluded for the
entire handling/storage period until the machine/plant has been accepted.

5.3.2 Storage facilities & other details

5.3.2.1 "Open-air" storage

Please note that storage under cover (Chapter 5.3.2.2 “"Roofed" storage”) is preferred.
However, large-volume plant components with a paint finish and a low proportion of
machined surfaces as well as wear parts, whose functional capability is not adversely
impaired by surface corrosion, can be stored outdoors (assuming there is no indication to
the contrary on the packaging, e.g. "Keep away from heat", "Keep dry" or similar) See
Chapter 5.1 “Transport instructions”.
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 Examples: "Large-volume plant components"
– Mills (mechanically machined parts such as bearings, retaining flanges on the gear rim
must be provided with protection against corrosion and mechanical damage e.g. by
anti-corrosive grease, plastic foil and wooden banding)
– Gear rim cover
– Mill outlet case
– Chutes
– Ducts for material transport and dedusting
– Crusher frame
– Apron conveyor supporting frame/chain conveyor supporting frame (without drive
units)
– Supporting frame for troughed belt conveyor
– Bed plates
– Structural steelwork elements

Examples: "Wear parts whose surface has no effect on the functional capability"
– Grinding media, rods and balls
– Mill and shell lining
– Slotted plates and rear panel plates for intermediate and discharge diaphragms
– Crusher rolls for RollSizer

Systematic organisation of the material warehouse is strongly recommended, i.e. storage

should correspond to the assembly planning (Example: bed plates and base plates should
be placed at the outer edge of the storage area, etc…). Route plans must be provided in
the store. The store must also be accessible to heavy trucks, mobile cranes and forklifts.
Drainage systems for discharge of surface water must be present.

Items must always be stored on a support such as timber planks, pallets, or similar,
preferably on a level, drained and gravelled base surface. Contact with surface water and
the ground must be avoided. All parts must be stored in such a way that no water can
accumulate.

The effectiveness of the protection of machined surfaces (protection against corrosion

and mechanical damage) must be checked and repaired or renewed if necessary.

Markings on plant components must be readable without the part having to be moved. If
water accumulates on a plant component through visible markings, the component must
be provided with new visible markings at suitable points.
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 5.3.2.2 "Roofed" storage
Plant components which have to be protected from direct sunlight as well as those which
have to be protected from rain as a result of mechanically machined surfaces, rubber or
plastic seals, ventilation holes, or similar.

Examples:
– Rubber belts for troughed belt conveyors. Please note that the belts are delivered on
coils and must be stored in a vertical position.
– Rubber and plastic seals (e.g. for gear rim protection cover, mill outlet casing, material
guide bar of troughed belt conveyors, etc.).
– Components with a high proportion of mechanically machined surfaces, e.g. gear rims,
pinions with bearings, gear units, gear motors, motors, fans, parts of filter plant
housings, rotary gate valves, control and shut-off valves, large-volume couplings,
bearing housings and bearing segments for the slide shoe bearings.
– Idlers for troughed belt conveyors, drive stations and pulleys, mechanical parts of belt
weighers.
– Plant components with ventilation holes e.g. gear units, gear motors and bearings
equipped with openings for air pressure compensation.
– All compact hydraulic units and compressors which have to be protected against dirt
by plastic foil. The covering on the bottom must remain open, in order to prevent the
accumulation of condensation water.
– Operating fluids such as lubricants, grease and oil as well as sealants such as silicone,
paints, thinners and cleansers.

Items must always be stored on a support such as timber planks, pallets, or similar,
preferably on a level, drained and gravelled base surface. Contact with surface water and
the ground must be avoided.

5.3.2.3 Storage "in closed, partially air-conditioned rooms"

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

5.3.2.4 Storage in “closed lockable rooms”

High-quality, sensitive and valuable components.

Examples:
– Measuring instruments
– Sensors
– PCs
– Screens
– Laboratory equipment e.g. test screens, scales, etc....

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 5.3.3 Special requirements

5.3.3.1 Electric motors

Motors must be stored in the original crates if they are not mounted on the equipment.

The storage area must be free of vibration.

Bearings:
– Balls and rollers (regreasable roller bearings). Bearings going into extended storage
must be completely greased beforehand. Motor shafts must be manually rotated once
a month and bearing grease must be topped up. Rotate the shaft by hand before
putting it into service.
– Balls (roller bearings, regreasing not possible). No other provisions are necessary for
the bearings.

All drain openings must be operable and the drain plugs removed during storage. The
motors must be stored so that the drain opening is at the lowest point. All breathers and
automatic drains must be operable via T-safety screws, so that breathing can take place
at a different location from the bearing seats.

Windings must be measured when they are put into storage. When they are removed from
storage, the resistance reading may not be more than 50 % below the original value. Any
values below this value necessitate electrical or mechanical drying. Where a large quantity
of motors is stored, an inspection or sampling should be made by removing the end
brackets and visually inspecting for the presence of water in the grease or rust on the
bearing. If present, replace the bearings and relubricate.

All external parts and motors subjected to corrosion to be protected by corrosive resistant
coating.

Where motors are not stored in the original containers, but are removed and mounted on
other pieces of machinery, the mounting must be such that the drains and breathers are
fully operable. In this respect, the drains must be located at the lowest point of the motor
and the drain plugs removed, so that condensation water can drain out by itself. All other
storage conditions apply, including rotation of the motor shafts. If such conditions cannot
be complied with, the equipment must be treated as if it were mounted in its normal
position and all protective devices such as heaters, breathers and drains were fully
operable.
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5.3.3.2 Gear unit
Oil and grease lubrication:

The oil recommended by the manufacturer must be used for the oil change.

All gear openings such as flanges for oil lubrication, openings for holding thermometers
and pressure and flow sensors must be checked for proper sealing. Replace the seals if
necessary. Breathing or venting: Pressure compensation between the pressure inside the
gear unit and the atmosphere must be provided. The inside of the gear must be protected
against humidity and/or nesting insects or birds.

5.3.3.3 Gear motors

If gear motors, e.g. SEW, are placed in storage, a volatile corrosion inhibitor (VCI) is
added to the lubricant of these gear units.
Some of the gear units are delivered with a higher oil level for long-time storage.

The storage period is a maximum of 3 years in compliance with the documentation

supplied by the manufacturer.

NOTICE
Gear damage from improper storage of the machine/plant

Damage to the machine/plant or its environment is possible

• Gear units must be kept sealed until commissioning, in order to prevent

volatilisation of the VCI corrosion inhibitor.

• Before these gear motors are commissioned, the operating oil level must be
restored using dipstick/oil-inspection glass/oil-level plug.

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 5.3.3.4 Electrical control systems
Control centres (MCC):
– Cover the motor control centre with heavy duty plastic or similar material to prevent the
ingress of foreign matter.
– Motor control centres which are not installed and used immediately must be stored in
a clean dry area. The storage temperature should be constant and between + 5 °C and
+ 45 °C. If the storage temperature fluctuates or if humidity exceeds 60 %, space
heaters must be used to prevent condensation. Control centres must be stored in an
air-conditioned building with adequate air circulation and be protected from dirt and
water.
– Control centres which are designed for indoor applications do not have packaging
which is suitable for outdoor storage. They should therefore be provided with additional
packaging for protection from outside elements and a temporary electric heater to
prevent condensation. A space heater rated at 200 watts per section is adequate for
the average control centre. All loose packaging or flammable material must be
removed before switching on space heaters.
Control centres which are for outdoor use and are not being used must be kept dry
internally by installing temporary heaters or by means of self-contained space heaters.

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

Process control equipment:

Process control equipment should be stored indoors in a heated/air-conditioned room.

Control valves:
The normal storage conditions are valid for all products. “Normal” is defined as conditions
free from heat or cold (+ 5 °C to + 45 °C storage temperature), and where the products
are kept dry and protected from dust. Other products may not be stacked on them.
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5.3.3.5 Miscellaneous mechanical components
Belts and seals
These components must be protected from moisture and stored in a dry environment. The
environment must be ozone free and the belts and seals kept out of direct sunlight, in order
not to adversely affect the performance characteristics.

Bright metal components (e.g. pistons, bushes or the sealing surfaces of valves) must be
conserved by smearing them with a VCI corrosion inhibitor such as rust-inhibiting oil or
wrapped in oiled paper (these additives are referred to internally as VCI = volatile
corrosion inhibitors). Volatile corrosion inhibitors permanently emit small amounts of
protective additives. Rust-inhibiting oil or oiled paper therefore protect surfaces with or
without metal contact and are particularly suitable for irregular shapes such as hollow
parts, tapped holes, pipes and machines.

VCI additives can be used for steel, iron, chrome, cast iron and aluminium. There are also
special VCI additives for copper and copper alloys and for both materials. The VCI method
is not applicable for the conservation of zinc, tin, cadmium, magnesium, lead and alloys of
these metals.

5.4 Handling oil hydraulic systems

5.4.1 General

The reliable functioning of oil hydraulic systems is primarily dependent on careful

maintenance. The service life of the hydraulic elements is usually longer than that of the
mechanical elements (e.g. ball bearings).

The following general instructions may be replaced by special instructions if required.

5.4.2 Assembly

At assembly particular attention is to be paid to utmost cleanliness.

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 5.4.3 Pipes

The pipes are to be cut square. Cutting by means of cutting rollers is not permissible.
Particular instructions shall apply to the welding of pipes.
During all welding operations, it must be ensured that the welding current does not flow
through any hydraulic devices, otherwise internal components may be welded together.
The pipes must be cleaned of dirt before mounting.
The pipes must be laid in such a way that they are unstressed.
Sealants such as hemp and putty are not permitted.
Pump suction lines are to be carefully sealed against the ingress of air. Leak oil lines must
be laid in such a way that the pumps and motor housings always remain filled with oil.
They must not have any connection to pressure lines and drain lines.

5.4.4 Hydraulic hoses

WARNING
Risk of injury through leak or break in the hoses and pressurised medium
escaping

Death or severe bodily injuries are possible

• Stop the machine / plant by pressing the emergency-stop switch.

• Shield the machine / plant in such a way that the pressurised medium cannot
injure anyone or cause a fire.

NOTICE
System damage due to hoses fluttering about during pressure build-up

Damage to the machine/plant or its environment is possible

• Fix the hose in place

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 Hydraulic hoses must be installed in such a way that
• the necessary length is available to avoid kinking and hose tension during operation;
• the minimum radius reaches the prescribed minimum;
• twisting of the hose due to poor installation or during operation (caused by a rotary
connection blocking, for example, or unfavourable movements of the connection
points) is reduced to a minimum;
• they are arranged or protected in such a way that abrasion of the outer hose layer is
minimised;
• they are fixed in a suitable way if the weight of the hose could lead to impermissible
load.

5.4.5 Commissioning

Before filling up with hydraulic fluid, check the tank and pipes once again for cleanliness.
The check must be carried out directly before filling.
Faulty piping or incorrect wiring are generally not noticed before the system is being
commissioned and the required functions fail to be achieved.
Any modification at this stage normally proves to be extremely difficult.
Careful checking of the piping and the wiring on basis of the circuit diagram is therefore
urgently recommended before filling the pressure fluid into the tank.
Solenoid-operated valves and pressure switches must be checked for the type of current
and voltage.
Pumps and their associated electric motors are to be aligned to each other. Any
misalignment between the motor and the pump may cause premature destruction of the
pump. Pumps and their motors must not be distorted by any incorrect pipe connection.
Where not already delivered ready for operation, accumulators are to be expertly provided
with the specified nitrogen charge prior to their incorporation into the system. It is
advisable to mark the gas precharge pressure on the accumulator (e.g. with a sticker) and
also in the circuit diagram, so that an easy comparative check can subsequently be made
if required.

5.4.6 Hydraulic fluid

HLP or HVLP oils selected to meet the respective climatic conditions and room
temperatures must be used.
The hydraulic oil must always be filtered when being filled.

5.4.7 Filling pumps and motors

Prior to their initial start-up, the pumps and motors are to be filled through the leak oil
connection.
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 5.4.8 Pressure settings

At start-up the pressure setting of the limit valves is to be kept low at first. An exception
are type-tested pressure relief valves for hydraulic systems, which do not allow for any
variation because of their fixed-value adjustment.

5.4.9 Start-up

DANGER
Risk of injury caused by control or operating faults

Imminent danger of death or severe bodily injuries

• Make sure no unauthorised persons are in the danger zone

Wherever practical, variable-delivery pumps and motors should be set to a small

swivelling angle, in order to facilitate the initial priming.

The electric motors can now be switched on for a short time (approx. 5 to 10 sec.). Check
the direction of rotation in the process. At the same time it need be checked whether
couplings or other connection parts have become loose.

Before the operating pressure setting can be gradually increased, check that the pump
delivery is quiet and stead. Any leaks must be remedied immediately. The plant must be
vented when it is operated at a low-pressure setting. The fluid level in the tank must be
monitored and fluid (of the same type) must be added if necessary.

After the operating pressure has been reached and the functional test has been
successfully passed, pressure switches, level switches, thermostats, etc. must be
adjusted.

5.4.10 Cylinders

Cylinders must be mounted in such a way that they are unstressed and above all free of
transverse forces, otherwise malfunctions and premature wear may occur.

5.4.11 Maintenance

The frequency of maintenance cannot be specified. It is a purely a matter of experience.

02/2012 Rev 0

Only the regularity with which it is performed is important. The following points must be
regularly checked at intervals recommended by the manufacturer or gained from
experience.

2-492-20908 (Pos 01) 5 - 31

5.4.12 Fluid level

The fluid level must be checked constantly during the commissioning period; after
commissioning it must be initially checked daily and then weekly.

5.4.13 Filters

During the commissioning period, the filters must be checked at intervals of 2 to 3 hours
and must be exchanged if necessary. In the initial 150 - 250 operating hours, the filters
must be serviced considerably more frequently than afterwards. If visual or electrical
clogging indicators are provided, the filter elements must be exchanged according to
these indicators. Actuation of the clogging indicators at cold start is insignificant and is
terminated after a short time if the filter elements are clean.

Breathers must be regularly checked and the filter element exchanged if necessary.

5.4.14 Oil temperature

The operating temperature must not only be measured in the oil tank but also at the
bearing points of the pumps, amongst other places. A temperature rise indicates wear.
(Growing friction and leakage by converting hydraulic energy into heat).

5.4.15 Oil change

The frequency of the system fluid change depends on several operating factors and is
governed by the degree of ageing and pollution.
Regular laboratory tests of the hydraulic oil must be carried out, especially in case of large
oil quantities of oil.

5.4.16 Accumulators

If necessary, the precharge pressure of the nitrogen side of accumulators must be

checked at regular intervals. When doing so, the oil side of the accumulator must be
absolutely unpressurized.

5.4.17 Alignment

At adequate intervals we recommend to check the correct alignment of the energy

converters (pumps, motors, cylinders etc.) at operating temperature and, as far as
possible, under operating pressure. This includes erection bolts, screws, connections,
pipes, couplings, etc.
02/2012 Rev 0

5.4.18 Pipework

The hydraulic pipe system must be checked for leaks at regular intervals. Bolted joints
must be re-tightened when the plant is depressurized.

5 - 32 2-492-20908 (Pos 01)

 5.4.19 Coolers

The fins of oil/air coolers must be cleaned at regular intervals depending on the
environmental conditions.
Oil/water coolers must be decalcified from time to time.
The frequency depends on the hardness of the cooling water used.

5.4.20 Storage of hydraulic components

Store pumps, valves, cylinders, etc. in a dry place in the absence of air humidity.

The storage rooms must be free of corrosives and fumes. Filling with an anti-corrosion oil
is recommended in any case. This oil must be compatible with the subsequent oil grade.
The oil film remaining after draining the anti-corrosion oil may not have an adverse effect
on subsequent use.

5.4.21 Period of storage and use duration of hydraulic hoses

The term period of use describes the total period of application and storage period of a
hose line from its date of production (date of assembly).

As far as storage is concerned, a distinction must be made between the storage of bulk
stock and the storage of hose lines (pre-assembled hoses), since different storage periods
apply.

Hoses and hose lines are subject to a natural ageing process even when stored properly.
This limits the period of use of hydraulic hose lines.

When a hose line is produced (assembled), the hose (bulk stock) should not be older than
four years.
This means that the bulk hose stock should not have been stored for more than four years
when the hose is produced (date of assembly).

The period of use of a hose should not exceed six years - including the storage period of
the hose line - whereby the storage period of the hose line (the assembled hose) should
not be longer than two years.

Summing up, this means:

Maximum storage period for bulk hose stock: 4 years

Maximum storage period for hose line 

(assembled hoses): 2 years

Maximum period of use for hose line 

(inc. storage period for the hose line): 6 years
02/2012 Rev 0

2-492-20908 (Pos 01) 5 - 33

5.5 Installation planning

When planning the installation, please note the following:

– Please refer to the relevant foundation and installation drawings for the main
dimensions of the machine/plant and the associated secondary units.
See ANNEX 9.1 "Drawings".
– Provide additional ladders, walkways, platforms and safety railings for maintenance
work and indicate the permissible traffic loads.
– Provide sufficient space to accommodate the periphery equipment as well as to
arrange the feeding units and conveyors to unload the material to be crushed.
– Provide suitable lifting gear for the installation and for the exchange of spare and wear
parts. It should be possible to position the lifting tackle/load hook vertically on top of the
machine/plant.
– Comply with the specified loading values for the design of foundations and the
calculation of the girder/platform structures.
– The movement of the machine/plant generates horizontal and vertical forces which
must be absorbed by suitable shear braces.
– Ensure that the machine is accessible for cleaning.
– Initiate measures against dangerous environmental influences, e.g. dangerous dusts,
uncontrolled oil leaks, noise.
– Integrate the machine/plant in the existing/planned control system, including
interlocking system, protective and monitoring devices, e.g. emergency stop switches,
local switches, speed monitors, filling level monitors. Integrate optical and acoustic
starting alarms in the control system.

If the conditions at the place of installation require deviations from the installation
drawings, please consult Thyssen-Krupp Fördertechnik.

INFORMATION
The construction contractor is responsible for the correct dimensioning of
foundations, steel platforms, load-bearing ceilings and their supports as well as
for the execution of the construction work and compliance with the official
regulations, even if an erecting engineer of ThyssenKrupp Fördertechnik erects
the machine/plant.

The machine/plant must be aligned using a spirit level.

For installation on a concrete foundation, grout the foundation bolts and the base
frame by concrete mortar 1:2 (1 portion cement; 2 portions sand) after alignment.
Prior to this, carefully clean the surface of the foundation and saturate it with
water.
02/2012 Rev 0

5 - 34 2-492-20908 (Pos 01)

 5.6 Preparation for installation

WARNING
The use of untrained personnel or equipment that does not comply with
safety standards poses additional danger.

Death or severe bodily injuries are possible

• The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.

• When carrying out overhead assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms. Never use machine
parts as a climbing aid! Wear fall protection when carrying out maintenance work
at a higher level.

WARNING
Risk of injury through components that are improperly secured during
installation

Death or severe bodily injuries are possible

• Make sure that moveable components are properly secured during installation

WARNING
Danger from working on electrical systems without proper technical
knowledge

Death or severe bodily injuries are possible

• Work on the electrical systems or equipment may only be carried out by a skilled
electrician or by specially trained personnel under the supervision of an
02/2012 Rev 0

electrician and in compliance with the applicable regulations required for

electricians.

2-492-20908 (Pos 01) 5 - 35

 INFORMATION
The manufacturer accepts no liability for damage resulting from incorrect
installation of the machine!

A careful selection of the tools and appliances used and the assembly personnel
employed is important for the correct execution of the assembly work.

It is recommendable to have the assembly work supervised from start to finish by

assembly specialists from ThyssenKrupp Fördertechnik.

Our warranty is based on the assumption that an assembly specialist from

ThyssenKrupp Fördertechnik will carry out the final assembly and assembly
inspection.

5.7 General notes on assembly

WARNING
Risk of injury through improper assembly and transport

Death or severe bodily injuries are possible

• Make sure that moveable components are secured, also during installation
• Use proper transportation equipment
• Do not walk under suspended loads
• Fasten and lift components properly
• Only transport the machine/plant on the designated slinging devices (lugs) and
slinging points.

WARNING
Risk of injury through assembly work at a higher level

Death or severe bodily injuries are possible

02/2012 Rev 0

• When carrying out overhead assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms.

• Never use machine parts as a climbing aid!

• Wear fall protection when carrying out maintenance work at a higher level.

5 - 36 2-492-20908 (Pos 01)

 WARNING
Risk of injury through work on electrical systems

Death or severe bodily injuries are possible

Work on electrical systems or equipment may only be carried out by a skilled

electrician or by specially instructed personnel under the control and supervision of
a skilled electrician and in accordance with the applicable electrical engineering
rules.

NOTICE
System damage through improperly executed welding work

Damage to the machine/plant or its environment is possible

• Always take note of the pre-heating temperature of all components to be welded

and tack-welded. The pre-heating temperatures specified for welding work to be
performed on the individual materials can be found in the respective assembly
drawings in ANNEX 9.1.
• Never conduct welding current through slide or roller bearings or other moveable
connections or measuring equipment.
• Carry out welding work on individual machine components prior to their
installation.

INFORMATION
The manufacturer accepts no liability for damage resulting from incorrect
installation of the machine!

Careful selection of the tools and appliances used and the installation personnel
is important for correct execution of the assembly work.

We recommend that an assembly specialist from ThyssenKrupp Fördertechnik
supervises the work from start to finish.

Our warranty is based on the assumption that an assembly specialist from
02/2012 Rev 0

ThyssenKrupp Fördertechnik will carry out the assembly and assembly

inspection.

Initial assembly must be carried out by trained personnel.

The respective layout plan and assembly drawings must be carefully studied, see
ANNEX 9.1 "Drawings". All guidelines and notes must be observed.

2-492-20908 (Pos 01) 5 - 37

5.8 Assembly

See ANNEX 9.1 "Drawings"

5.8.1 Pre-assembly

The gyratory crusher is delivered in sub-assemblies and component parts.

The assembly groups and individual components can be assembled and adapted to the
relevant crane capacities at the place of installation.
Suspension points and drawings, see drawings in ANNEX 9.1.

Weights:

Bottom shell with pinion shaft assembly, eccentric bushing, 

base and wearing parts (without hydraulic cylinder): approx. 88500 kg

Lower shell approx. 37500 kg

Upper shell: approx. 50000 kg

Spider with liner plates, arm liner and spider cap: approx. 60000 kg

Main shaft with dust sealing, mantle and step bearing upper 
part of the spider bearing: approx. 68000 kg

Hydraulic cylinder: 14000 kg

Base plate, complete: 3000 kg

Dust sealing, complete: 2200 kg

Spider bearing: 1600 kg

Lower main shaft bearing (axial step bearing): 800 kg

Pinion shaft assembly, complete: 3000 kg

Drive unit: 716 kg without motor

Upper mantle: 5490 kg

Lower mantle: 6740 kg

Outer ring nut: 355 kg

Inner ring nut: 359 kg

Main shaft sleeve: 810 kg

Eccentric bush, complete (with bevel gear): 10059 kg

Spider cap: 7344 kg

02/2012 Rev 0

Outer bushing (bottom shell): 1042 kg

Wear parts (bottom shell): 4828 kg

Wear parts for upper shell: approx. 8000 kg

Wearing parts for spider (arm liner): approx. 15300 kg

5 - 38 2-492-20908 (Pos 01)

 Upper concave: each 461 kg, 20 units

Middle concave: each 422 kg, 20 units

Lower concave: each 496 kg, 20 units

Tightening torques for all relevant bolts, see Chapter 5.11.

02/2012 Rev 0

2-492-20908 (Pos 01) 5 - 39

5.8.2 Bottom shell

See Illustration 16, drawing 4350852 and drawing 4350768 in ANNEX 9.1

• Clean and slightly oil all contact surfaces.

• Install, align, tack-weld and weld liner plates (4) on to the bottom shell. The instructions
provided in drawing no. 4350852 in the ANNEX 9.1 must be followed.
• Align, tack-weld and weld the liner plates (5) on to the conical part of the hub. The
instructions provided in drawing no. 4350852 in the ANNEX 9.1 must be followed.
• Place wearing caps (6) on the arms of the bottom shell and tack-weld.
• Align the protective cap (7) with the through bore for mounting the base plate and weld
oil-tight.
• Insert the disk (8) in the hole (pressured-air system) on the inside of the hub and weld
oil-tight.
• Screw the retaining ring (9) at bottom part of hub.

NOTICE
Plant damage caused by improper bolting

Damage to the machine/plant or its environment is possible

• Take the clearance of bolts in the though holes into account!

• Mark the position of the retaining ring in relation to the hub for subsequent assembly
and disassembly work.
• Lower the outer eccentric bushing (10) into the hub and turn it until the bottom recesses
of the outer eccentric bushing rest on the retaining ring (9).
• Jack up the bottom shell (1) in such a way that the eccentric bushing (2), the base plate
(3) and the hydraulic cylinder (3) can be mounted from below. 02/2012 Rev 0

5 - 40 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 16

2-492-20908 (Pos 01) 5 - 41

5.8.3 Base plate and eccentric bushing

See Illustration 17, drawing 4350768 and drawing 4350843 in ANNEX 9.1

• Prepare the base plate (1) and place on jacks.

• Place spacer plates (2) (3 mm - for setting the backlash of the toothed gears of the
bevel pinion and the bevel gear) onto the base plate.
• Insert cylindrical pin (3) and position the axial bearing ring (4).
• Prepare the eccentric bushing (5) for assembly.
• Thoroughly oil all the running surfaces of the axial step bearing ring (4), the outer
eccentric bushing in the bottom shell and the eccentric bushing.
• Place the complete eccentric bushing on the axial bearing ring (4) of the base plate (1).
• Fix the bottom shell and carefully allow the outer bushing to slide on to the eccentric
bushing, then continue lowering to the base plate.
• Ensure that the sealing cord (6) is not damaged when lowering into the bottom seat.
• Bolt the base plate to the bottom shell.

02/2012 Rev 0

5 - 42 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 17

2-492-20908 (Pos 01) 5 - 43

5.8.4 Pinion shaft assembly

See Illustration 18 and drawing 4350788 sheets 1 + 2 in ANNEX 9.1

• Clean and slightly oil the contact surfaces of the pinion shaft assembly tunnel/pinion
shaft assembly.
• Insert the complete pinion assembly (1) with sealing cord (2) in the pinion assembly
tunnel (3) of the bottom shell (4).
• Arrange disks (5) (5 mm thickness; for correct backlash) between the pinion assembly
flange and tunnel and screw the pinion assembly to the bottom shell.
• Check backlash, to do this:
– Check backlash (3.5 - 4.5 mm) (see ANNEX 9.3)
– If necessary, change the thickness of the disks (5) and the thickness of the filler
plates (6) between the base plate and the bottom shell.

INFORMATION
The final check of the tooth backlash can be made after the hydraulic cylinder has
been installed and the main shaft inserted.

02/2012 Rev 0

Illustration 18

5 - 44 2-492-20908 (Pos 01)

 See Illustration 19

• Install resistance thermometers (7) and (8).

Illustration 19

• Install an oil level indicator (9) with fluid switch (10).

• Install accelerometers (11) and (12).
02/2012 Rev 0

2-492-20908 (Pos 01) 5 - 45

5.8.5 Hydraulic cylinder and lower components of the main shaft
bearing

See Illustration 20 and ANNEX 9.10 "Tools"

• Clean and slightly oil all contact surfaces.

• Position the hydraulic cylinder on the scissor lift table of the maintenance car and fix in
place.
• Insert sealing cord (1) in the cylinder flange of hydraulic cylinder (2).
• Place oil ring (3) on the piston of the hydraulic cylinder and bolt on.
• Insert cylindrical pin (4) in the piston surface to prevent rotation.
• Place the sliding ring (5) and the step bearing lower part (6) of the spider bearing on
the piston.
• Position the hydraulic cylinder below the hub of the bottom shell using maintenance
car. 
See separate documentation for details of the maintenance car function and drawing
4523430.

WARNING
Risk of crushing when the maintenance car is moving

Death or severe bodily injuries are possible

• Make sure no unauthorised persons are near the maintenance car.

• Avoid the danger zone.

• Use the scissor lift table to lift the hydraulic cylinder with the maintenance car at a
standstill.
Pay attention to the correct position of the oil connections. Do not damage the sealing
cord (1).
Mount the hydraulic cylinder on the bottom shell.

INFORMATION
The final check of the tooth backlash can be made after the hydraulic cylinder has
been installed and the main shaft inserted.
02/2012 Rev 0

5 - 46 2-492-20908 (Pos 01)

 Illustration 20
02/2012 Rev 0

2-492-20908 (Pos 01) 5 - 47

5.8.6 Sealing housing of the dust sealing

See Illustration 21, drawing 4350021 sheets 1 + 2 and drawing 4350716 im ANNEX 9.1

• Insert O-ring (1) in the bottom shell to seal the air duct.

INFORMATION
Use additional sealing agent to enhance the flange sealing effect, e.g. Hylomar©.

• Insert sealing cord (2), glue the ends together.

• Attach the seal housing (3) to lifting gear, lower to the bottom shell and align the oil and
air ducts with each other.
• Place the seal housing on the hub of the bottom shell and bolt on.
• Insert disk (oil seal) (4) in the seal housing.
• Mount the inspection cover (5) on the bottom shell.
• Mount the air (6) and oil lines (7) in the bottom shell, so that they are oil- and air-tight.
During the further assembly process, seal the lines with caps to prevent dust from
entering. Further important assembly instructions provided in drawing 4350021 sheets
1 + 2in the ANNEX 9.1 must be followed.
• Cover the opening of the seal housing.
• Pay attention to the clearance between the housing (1) and the bearing bush (8), follow
the instructions in drawing 4350716 in the ANNEX 9.1.

02/2012 Rev 0

5 - 48 2-492-20908 (Pos 01)

 Illustration 21
02/2012 Rev 0

2-492-20908 (Pos 01) 5 - 49

5.8.7 Mounting the concaves

See Illustration 22 and Illustration 23

For mounting the concaves, see drawing 4521259 in ANNEX 9.1.

• Attach and connect the lower shell to the prepared bottom shell.
See Chapter 5.10.
• Place the upper shell on the lower shell and connect them.
• Longitudinally align the receiving pockets for the spider in the direction of loading (pay
attention to the position of the grease lubrication connection for the spider bearing). 
Tightening torques of bolts, see Chapter 5.11.
• Clean and remove the grease from the contact surfaces of the shells and concaves.
When back-filling synthetic resin casting compound and cement-bonded Betec casting
compound, do not apply separating agent to the concaves and the internal surfaces of
the crusher shells.

For preparation and processing of the casting compound see ANNEX 9.4.

• Insert and align the shims (1) in the lower shell.

• Weld round steel bars (2; spacer bars for horizontal joint) to the lower concaves (3).
• Insert the lower row of concaves (3) and distribute equally over the circumference.
Comply with the vertical distances.
Check that all bearing points of each concave are close-fitting. If necessary, insert
shims.
• Use assembly rings for securing and as assembly aids where necessary.
• Drive in wooden wedges (5) between the concaves and the auxiliary assembly ring (4).
(See Illustration 23)
• Insert and drive in the conical holding pins (6).
If the holding pins protrude above the top edge of the concaves, shorten them to the
exact height of the concaves.

NOTICE
Plant damage caused by improper bolting

Damage to the machine/plant or its environment is possible

• Drive the conical holding pins in diametrically opposite in a clockwise direction

in several steps.
02/2012 Rev 0

• Seal all horizontal and vertical joints of the concaves (3, 8, 9) with hemp ropes (10).

5 - 50 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 22

2-492-20908 (Pos 01) 5 - 51

 • Backfill the row of concaves (3) by inserting synthetic resin casting compound (7) in the
openings provided for each concave. Ensure that all the concaves are backfilled
completely. See ANNEX 9.4.

• Position the next rows of concaves (8, 9) offset to the centre and align them. Pay
attention to the vertical joints. 
Weld the round steel bars (2) to the upper sides of the concave (8) beforehand.
• Possibility: Insert the next auxiliary assembly rings (11) and secure the concaves with
wooden wedges (12).
• Backfill each row of concaves (8, 9) with synthetic resin sealing compound (7).
• After hardening, remove the stopper plates, sealants, wooden wedges and auxiliary
assembly rings.

5.9 Mounting the liner plates

For mounting the liner plates, see drawing 4350852 in ANNEX 9.1.

• Insert liner plates (13) in the upper shell, align and bolt into place. Tightening torques
of bolts see Chapter 5.11.

02/2012 Rev 0

5 - 52 2-492-20908 (Pos 01)

 Illustration 23
02/2012 Rev 0

2-492-20908 (Pos 01) 5 - 53

5.9.1 Spider bearing

See Illustration 24 and drawing 4350718 in ANNEX 9.1

• Clean all the contact surfaces, prepare the conical spider bushing (1) for installation.
Further important assembly instructions provided in drawing no. 4350718 in the
ANNEX 9.1 must be followed.

INFORMATION
The spider bushing must slide into the seat of the spider without force.
Do not press in or cool the bushing under any circumstances: rework the spider
bushing if necessary.

• Pre-mount the sealing ring (2) and radial seals for the shaft (3) and mount them to the
spider bushing (1) using bolts (5).
• Lay the leather packing in a warm oil bath before inserting it.
Pre-mount the leather packing (4).
• Screw the ring bolts into the threaded bore holes (13) of the spider bushing (1) for
mounting.
• Lower the spider bushing (1) into the spider a little way in order to align it to the
lubrication system connection (10).
Follow the assembly instructions to calculate the required dick thickness (6) on drawing
no. 4350718 in ANNEX 9.1 "Drawings".

• Place washers (6) corresponding to the calculated washer thickness.

• Insert the spider bushing (1) into the spider.
• Provide the bolts (8) with washers (9), fit and tighten up.
• Screw the ring bolts into the threaded bore holes (13) of the spider bushing (1).
• Install filling level sensor (11) with bracket and route the cables through the cable duct,
so that they are oil-tight.

Function of the two holes (12) in the spider:

The two holes (12) must be securely sealed with sealing screws (screw plugs and seals).
These screw plugs must be removed immediately before disassembling the spider
bushing (1). Two oil pumps (provided by the customer) must then be attached to both R
1/4" threaded connections. Applying an oil film between the surfaces of the spider bushing
and the spider with suitable overpressure will facilitate the subsequent disassembly of the
spider bushing. After the spider bushing (1) has been disassembled, the cleaned R 1/4"
threaded connections in the spider must be resealed by the cleaned screw plugs with the
appropriate seals.

Screw plug DIN 910 - G 1/4 A x 8 - A1 2 pieces

02/2012 Rev 0

Metallic gasket CU DIN 7603 A 14 x 18 2 pieces

5 - 54 2-492-20908 (Pos 01)

 Illustration 24
02/2012 Rev 0

2-492-20908 (Pos 01) 5 - 55

5.9.2 Main shaft

See Illustration 25 and drawing 4350711 in ANNEX 9.1

• Use suitable equipment to jack up the main shaft (1) over a pit.
• Use the eye bolt (2) for transport.
• Clean the main shaft (1), upper core (3) and lower core (4).
• Slightly grease the cone of the main shaft.

Assembly of the cores

• Place the lower core (4) on the main shaft cone and measure the protrusion of the shaft
cone from the lower core (4).
• Heat up the lower core (4) to approx. 70°C above ambient temperature and shrink it on
approx. 7.2 mm deeper than the protrusion length. Use a stop collar.
• Put on the upper core (3) and fix it axially with an inner ring nut (5) before the lower
core (4) has cooled down. Screw down the ring nut slightly.
• Allow the lower core (4) to cool down and then release the inner ring nut (5).
• Backfill the lower core (4) and upper core (3) with sealing compound (6). 
See ANNEX 9.4.
• Put on the inner ring nut (5), tighten it up and fix it with a cylindrical pin (11).

Assembly of the mantles

• Clean and degrease the lower mantle (7) and upper mantle (8).
• Clean and lightly grease the cores (3 and 4).
• Place the lower mantle (7) on the cone of the core and measure the protrusion of the
mantle from the core.
• Heat the lower mantle (7) to approx. 70°C above ambient temperature and shrink it on
approx. 7 mm deeper than the protrusion length. Use a stop collar.
• Put on the upper mantle (8) and fix it axially with a ring nut (9) before the lower mantle
(7) has cooled down. Screw down the ring nut slightly.
• Allow the lower mantle (7) to cool down and unscrew the ring nut (9).
• Backfill the bottom mantle (7) and top mantle (8) with sealing compound (6). See
ANNEX 9.4.
• Screw on the intermediate ring (10) and the ring nut (9) and tighten up. Tack-weld the
intermediate ring to the ring nut (9) and the mantle (8). Follow the instructions in the
drawing.
• Clean the main shaft sleeve (12) and the top shaft (13) of the main shaft.
• Screw eye bolts into the main shaft sleeve, pre-heat the main shaft sleeve to approx.
80°C above ambient temperature.
• Quickly place the main shaft sleeve on the main shaft.
02/2012 Rev 0

• Place the protective cap (14) on the ring nut (9) and screw up.

5 - 56 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 25

2-492-20908 (Pos 01) 5 - 57

5.9.3 Sealing ring of the dust sealing

See Illustration 26 and drawing 4350716 in ANNEX 9.1.

Fit a plastic sealing ring (1) in the dust sealing. For this purpose:
• Screw the top and bottom sealing rings (2) and (3) together and measure the distance
between them.
• Measure the thickness of the plastic sealing ring (1).
The clearance of the plastic sealing ring between the top and bottom sealing ring must
be 0.2 to 0.3 mm.
• To ensure this clearance, determine the required thickness of the shims (4).
• Separate the top and bottom sealing rings. Screw the top sealing ring into the main
shaft.
• Arrange the plastic sealing ring on the bottom sealing ring, position the shims and
screw the top and bottom sealing rings in place.

Illustration 26
02/2012 Rev 0

5 - 58 2-492-20908 (Pos 01)

 5.9.4 Lower main shaft bearing section

See Illustration 27

Further important assembly instructions provided in drawing 4350796in the ANNEX 9.1
must be followed.

Screw the step bearing upper part (1) to the main shaft.
For this purpose:
• Insert the upper positioning cylindrical pin (2) in the step bearing upper part.
• Screw the step bearing upper part (1) of the axial step bearing to the main shaft.
• Secure the bolts with binding wire (3).
02/2012 Rev 0

Illustration 27

2-492-20908 (Pos 01) 5 - 59

5.10 Assembling the assembly groups

See Illustration 28 and drawing 4350021 sheets 1 + 2, 4601387 sheets 1 - 5, 4350852 and
4523233 in ANNEX 9.1.

5.10.1 Bottom shell of the crusher, shell, main shaft, spider

• Place the filler plates for the necessary sealing compound on the steel structure /
foundation.
• Place the bottom shell of the crusher (1) on the steel structure / foundation and align the
pinion assembly tunnel with the motor.
• Horizontally align the bottom shell and screw it firmly to the sub-structure (steel
structure / foundation) using anchor bolts/stone bolts. See drawing no. 4601387 sheets
1 - 5.
• Cover the crusher feet with Betec casting compound, allow to harden and re-tighten
the nuts. (See ANNEX 9.4)
• Clean the flange faces and conical seats of the bottom shell and the shells (2 and 3).
• Place the lower shell (2) on the bottom shell and align it horizontally so that an even
flange joint is obtained.

Before the torque is applied the flange surfaces must be on top of one another with a
parallel gap of 2 - 4 mm.
• Insert the bolts (17) from below and tighten as follows:
– Tightening torque 14500 Nm,
– pre-tighten the bolts gradually:
1st step: 30% of Ma / Fa
2nd step: 60% of Ma / Fa
3rd step: 100% of Ma / Fa
– Tighten the bolts (17) evenly crosswise at each stage until the flanges are smoothly
flush.
• Screw on lock nuts and tighten up.
02/2012 Rev 0

5 - 60 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 28

2-492-20908 (Pos 01) 5 - 61

 • Attach the upper shell (3) and align it horizontally so that a uniform flange joint is
obtained.

INFORMATION
Longitudinally align the receiving pockets of the upper shell for the spider (4) in
the direction of loading. 
Pay attention to the installation position of the grease lubrication line.

Before the torque is applied the flange surfaces must be on top of one another with a
parallel gap of 2 - 4 mm.
• Insert the bolts (16) from below and tighten as follows:
– Tightening torque 14500 Nm,
– pre-tighten the bolts gradually:
1st step: 30% of Ma / Fa
2nd step: 60% of Ma / Fa
3rd step: 100% of Ma / Fa
– Tighten the bolts (17) evenly crosswise at each stage until the flanges are smoothly
flush.
• Screw on lock nuts and tighten up.

• Install the concaves and the liner plates before the assembly of the main shaft and
spider.
See section 5.4.6.
• Clean and grease the bottom shaft of the main shaft (5), the eccentric bushing (6) and
the components of the axial step bearing (7).

NOTICE
System damage through improper assembly

Damage to the machine/plant or its environment is possible

• When inserting the main shaft, do not damage the oil seal (8), the axial step
bearing (7), the dust sealing (9) or the eccentric bushing (6).
• When positioning the spider (4), do not damage the shaft sealing (10) and the
spider bushing (11).
To facilitate fitting, slightly turn the main shaft by means of the eccentric bushing
(6).
02/2012 Rev 0

5 - 62 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 28

2-492-20908 (Pos 01) 5 - 63

 • Attach a hoist to the eye bolt of main shaft, lift the main shaft and allow it to slide into
the eccentric bushing.
• Check the correct position of the oil seal (8), the step bearing lower part of the axial
step bearing (7) and the dust sealing (9) for installing the main shaft.
• Pre-assemble the grease lubrication and sensor line on the spider (4).
See section 5.8.

INFORMATION
When positioning and aligning the spider (4), pay attention to the routing of the
grease lubrication line for the spider bearing. Insert eye bolts into the 4 bores of
the spider (4) for transport. After the spider has been set down, remove the eye
bolts and seal the bores with the screw plugs.

• Attach the spider (4) and align it horizontally so that a uniform flange joint is obtained.
• Do not forget to grease the contact surfaces to the sealing compound beforehand.
• Screw on the spider.
Tighten the bolts with Superbolt clamping nuts (12) (see also ANNEX 9.12):
– Tightening torque 500 Nm,
– pre-tighten the bolts gradually:
Tighten 4 opposite pressure screws by hand and align the nuts;
tighten these 4 screws crosswise using 50% of the tightening torque;
then tighten these 4 screws crosswise using 100% of the tightening torque;
now change to crosswise tightening of the bolts and tighten all bolts with the torque.
Repeat the process until all screws and bolts have been tightened evenly.

INFORMATION
To loosen the connection just loosen the bolts, do not remove them.

• Backfill the gap (15) between the spider and the upper shell (3) with sealing compound.
See instructions ANNEX 9.4.
• Fill the spider bearing with grease as per the table of lubricants.
• Mount the spider cap (13).
• Mount the arm liners (14). See drawing 4350852 in the ANNEX 9.1
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5 - 64 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 28

2-492-20908 (Pos 01) 5 - 65

5.10.2 Direct drive

See Illustration 29

Further important assembly instructions provided in drawing 4521231 and 4523431 in the
ANNEX 9.1 must be followed.

• Slide the distance ring (1) and the feather keys (2) and (3) on to the shaft butt ends of
the pinion assembly and motor.
• The crusher, pinion assembly and crusher main drive motor must be precisely aligned.
Align the components accordingly and secure them. If possible, backfill up with suitable
sealing compound.
• Mount multiple-disc clutches (4), distance tube (5) and safety coupling (6).
See ANNEX 9.2

NOTICE
Plant damage caused by improper assembly of the couplings

Damage to the machine/plant or its environment is possible

• Mount the multiple-disc steel clutch (4) so that it is unstressed. if necessary,

the motor must be axially displaced during assembly, in order not to exceed the
permissible load.
Comply with the tightening torques!
• To protect the safety coupling (6) from damage/destruction, the following oil
procedure must be heeded during assembly:

First fill the lubricating chambers with oil. This takes about 45 minutes.

The pressure chambers can only be filled with oil once the lubricating chambers
have been filled. See also ANNEX 9.2

• Mount the bracket (7) for the speed monitor (8) on the pinion assembly flange.
• Screw the 4 cam switches (9) on the flange of the multiple-disc clutch.
• Mount, align and connect the speed monitor.
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 Illustration 29
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2-492-20908 (Pos 01) 5 - 67

5.10.3 Blower (side-channel compressor) for over-pressure ventilation
of the dust sealing

See Illustration 30

Further important assembly instructions provided in drawing 4350373in the ANNEX 9.1
must be followed.

• Screw on the bracket (1) to accommodate the side-channel compressor (2).

• Mount the side-channel compressor.
• Connect the hose/pipe system (3) between the side-channel compressor (2) and air
pipe (4) in the bottom shell.
• Connect the electric motor and check the direction of rotation.
• Install and electrically connect the pressure transducer (5).

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 Install and electrically connect the pressure transducer (5).

Illustration 30
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5.10.4 Main shaft hydraulics

See Illustration 31 and drawing 4524030, 4524049 and 4412679 in the ANNEX 9.1.

• Mount the compensation cylinder (1), pressure gauge (2) and compressed air tank (3)
on the bracket (4).
• Mount the high-pressure hoses (5) and pipelines (6) as per drawing no. 4412679.

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Illustration 31

5 - 70 2-492-20908 (Pos 01)

 5.10.5 Oil circulating lubrication and hydraulic unit

See Illustration 32 and drawing no. 4524045, 4524041 and 4524040 in the ANNEX 9.1.

• Clean / blow compressed air through the lubricating oil and hydraulic lines before
mounting.
• Set up the oil tank with the oil circulating lubrication unit and the hydraulic unit in an
easily accessible place near the crusher which is as dust-free and protected from the
elements as possible.
If the crusher is installed in enclosed inside areas, provide good ventilation to prevent
heat accumulation.
• Install the return pipe systems with a downward gradient of at least 10 %.
• Connect the pressure lines of the lubrication pump unit to the lubrication oil supply on
the hydraulic cylinder (internal lubrication) and the oil supply of the crusher (external
lubrication).
• Install and connect the hose/pipe systems to the oil cooler.
Install the oil/air cooler in such a way that it is not exposed to direct sunlight.
Assemble the connections to the main shaft hydraulics (Section 4.5.4) and the
hydraulic cylinder.
• Fill with filtered lubricants as per the table of lubricants.
• Connect the electric motors of lubrication pumps of the hydraulic unit and the oil cooler
and check the directions of rotation.
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Illustration 32

2-492-20908 (Pos 01) 5 - 71

5.10.6 Grease lubrication for spider bearing

See Illustration 33 and drawing 4350926 sheets 1 + 2 and drawing 4350790 in the
ANNEX 9.1.

• Mount a flow meter (1) on the upper shell.

• Mount the filling level sensor (2) in the head of the spider and pass the cables through
the cable duct in the spider.
• Mount the grease lubrication pump (3) on the filled grease reservoir (4). Mount the
lubricant line of the grease lubrication pump for the spider bearing.
• Attach the grease control unit (5) to the support.
• Clean all grease and air pipes by air prior to the final connection.
• Rinse the lubricating grease lines by hand with grease until clean grease flows. Then
assemble the connection to the grease lubrication unit of the spider bearing.
• Pump grease into the cap until the filling level sensor actuates. If necessary, adjust the
height of the filling level sensor.

Illustration 33
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5 - 72 2-492-20908 (Pos 01)

 5.11 Tightening torques for all relevant bolts

See Illustration 34
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Illustration 34

2-492-20908 (Pos 01) 5 - 73

5.12 Assembly, commissioning and servicing of oil
lubrication units and hydraulic units

General
The reliable function of oil lubrication units and hydraulic units mainly depends on careful
maintenance. Contrary to common opinion, the service life of hydraulic components is
generally longer than that of mechanical components (e.g. ball bearings).
The following general instructions may occasionally be replaced by special instructions.

Assembly
Particular attention must be paid to extreme cleanliness during the assembly.

Pipes
The pipes must be sawn off square. Cutting the pipes with cutting rollers is not
permissible. Special instructions apply to the welding of pipes.
During all welding operations, it must be ensured that the welding current does not flow
through any hydraulic devices, otherwise internal components may be welded together.
The pipes must be cleaned of dirt before mounting.
The pipes must be laid in such a way that they are unstressed.
Sealants such as hemp and putty are not permitted.
Pump suction lines must be carefully sealed against the ingress of air. Oil lines must be
laid in such a way that the pumps and motor housings always remain filled with oil. They
may not have any connection to leak oil lines and drain lines.

Initial start-up
Before filling with hydraulic fluid, check the tank and pipes once again for cleanliness. It is
important that this check is made directly before filling takes place.
Faulty pipework or incorrect wiring is generally not noticed until the plant is being
commissioned and the required functions are not available. 
Any modification at this stage normally proves to be extremely difficult. 
Careful checking of the pipes and the wiring on basis of the circuit diagram is therefore
strongly recommended before filling the tank with hydraulic fluid.
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 Solenoid-operated valves and pressure switches must be checked for the type of current
and voltage.
Pumps and the associated electric motors must be aligned with each other. Any
misalignment between the motor and the pump may cause premature destruction of the
pump. Pumps and oil motors may not be stressed by an incorrect pipe connection.
Unless they have been delivered ready for operation, accumulators must be properly
provided with the specified nitrogen charge before they are installed in the plant. It is
advisable to mark the gas precharge pressure on the accumulator (e.g. with a sticker) and
also in the circuit diagram, so that an easy comparative check can subsequently be made
if required.

Hydraulic fluid
CLP, HLP or HVLP oils selected to meet the respective climatic conditions and room
temperatures must be used.
The hydraulic oil must always be filtered when being filled.

Filling pumps and motors

Pumps and motors must be filled through the leak oil connection before their initial start-
up.

Pressure settings
The pressure setting of the limit valves must initially be kept low at start-up. Type-tested
pressure relief valves for hydraulic accumulator systems which do not permit any variation
because of their fixed-value adjustment are an exception.

Start-up
Due to the existing safety regulations, it is both desirable and recommendable that
persons not required for direct operation are leaving the site or retire to a safe distance at
commissioning.
Wherever practical, variable-delivery pumps and motors should be set to a small
swivelling angle, in order to facilitate the initial priming.
The electric motors can now be switched on for a short time (approx. 5 to 10 sec.). Check
the direction of rotation in the process.
Before the operating pressure setting can be gradually increased, check that the pump
delivery is quiet and stead. Any leaks must be remedied immediately. The plant must be
vented when it is operated at a low-pressure setting. The fluid level in the tank must be
monitored and fluid (of the same type) must be added if necessary.
After the operating pressure has been reached and the functional test has been
successfully passed, pressure switches, level switches, thermostats, etc. must be
adjusted.
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 Cylinders
Cylinders must be mounted in such a way that they are unstressed and above all free of
transverse forces, otherwise malfunctions and premature wear may occur.

Maintenance
The frequency of maintenance cannot be specified. It is a purely a 
matter of experience. Only the regularity with which it is performed is important. The
following points must be regularly checked at intervals recommended by the manufacturer
or gained from experience.

Fluid level
The fluid level must be checked constantly during the commissioning period; after
commissioning it must be initially checked daily and then weekly.

Filters
During the commissioning period, the filters must be checked at intervals of 2 to 3 hours
and must be exchanged if necessary. In the initial 150 - 250 operating hours the filters
must be serviced considerably more frequently than afterwards. If visual or electrical
clogging indicators are provided, the filter elements must be exchanged according to
these indicators. Actuation of the clogging indicators at cold start is insignificant and is
terminated after a short time if the filter elements are clean.
Breathers must be regularly checked and the filter element exchanged if necessary.

Oil temperature
The operating temperature must not only be measured in the oil tank but also at the
bearing points of the pumps, amongst other places. A temperature rise indicates wear.
(Growing friction and leakage by converting hydraulic energy into heat).

Oil change
The frequency of the system fluid change depends on several operating factors and is
governed by the degree of ageing and pollution.
Regular laboratory tests of the hydraulic oil must be carried out, especially in case of large
oil quantities of oil.

Accumulators
If necessary, the precharge pressure of the nitrogen side of accumulators must be
checked at regular intervals. When doing so, the oil side of the accumulator must be
absolutely unpressurized.
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 Alignment
We recommend that the correct alignment of the energy converters (pumps, motors,
cylinders, etc.) is checked at appropriate intervals, both at operating temperature and
under operating pressure if possible. This includes erection bolts, screws, connections,
pipes, couplings, etc.

Pipework
The hydraulic pipe system must be checked for leaks at regular intervals. Bolted joints
must be re-tightened when the plant is depressurized.

Coolers
The fins of oil/air coolers must be cleaned at regular intervals depending on the
environmental conditions. Oil/water coolers must be decalcified from time to time. The
frequency depends on the hardness of the cooling water used.

Storage of hydraulic components

Store pumps, valves, cylinders, etc. in a dry place in the absence of air humidity.
The storage rooms must be free of corrosives and fumes. Filling with an anti-corrosion oil
is recommended in any case. This oil must be compatible with the subsequent oil grade.
The oil film remaining after draining the anti-corrosion oil may not have an adverse effect
on subsequent use.
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 Blank page

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 6 Commissioning and operation

6.1 General information

Not just for reasons of warranty it is highly recommended to call for the assistance of
ThyssenKrupp Fördertechnik staff for the commissioning process, This is not only for
reasons relating to the warranty, but also for the purpose of:
• having the machine/plant checked
• determining the optimum capacity
• training the operating personnel
• passing on additional advice on operation, maintenance and upkeep.

For the initial commissioning routine note the instructions relating to the components
included in the ANNEX 9.

6.2 Safety notes for operation

• Operate the machine/plant only if all protective and safety-oriented devices, such as
removable safety devices and emergency shut-off equipment, sound-proofing
elements and exhausters, are in place and fully functional.
• Check the machine/ plant at least once every shift for obvious damage and defects!
Report any changes (including changes in the operating performance) to the
responsible department immediately! If necessary, stop the machine/ plant
immediately and lock it!
• In the event of malfunctions, stop the machine/ plant immediately and lock it!
Have any defects remedied immediately!
• Follow the start-up and shut-down procedures and control displays as set out in the
manual!
• Before starting up/actuating the machine/ plant, make sure that nobody is at risk!
• If abnormal vibrations suddenly occur in the equipment supporting structure the
operation of which is corresponding with vibrations and unbalances, these abnormal
vibrations must be eliminated prior to feeding the machine with material.
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2-492-20908 (Pos 01) 6-1

6.3 Initial start-up

• Check that
– the oil circulating lubrication for the eccentric and axial step bearing,
– the hydraulic system with the balance unit,
– the grease lubrication for the spider bearing and
– the stand oil lubrication unit of the pinion assembly shaft
– the safety clutch
is sufficiently filled with the lubricant or hydraulic oil specified in the table of lubricants
(Chapter 8.4).

• Switch-on the recirculating oil lubrication.

• Check that the monitoring, heating and cooling systems of the oil circulating lubrication
have been set correctly and electrically connected/interlocked, so that the crusher
cannot be started without lubrication.
• Switch on the hydraulic unit. Place the balance unit in a state of readiness for
operation.
• Set the crushing gap!
Measure the crushing gap by means of a folding rule and set it in accordance with the
required product grain size (see Chapter 2 “Technical data”).
Do not exceed the max. permissible main shaft adjustment of 280 mm.
• Pump up the safety clutch between the electric motor and the crusher to 90 MPa (900
bar). (See ANNEX 9.3).

NOTICE
Plant damage caused by wrong oil pressure

Damage to the machine/plant or its environment is possible

• Check oil pressure in the safety clutch pressure chamber again after the run-in
period.

• Switch on the lubrication pump for the spider bearing.

• Switch on the side-channel compressor for the dust sealing.
• Switch on the crusher main drive motor.
• Allow the gyratory crusher to test run for approx. 2 hours without material. Check that
the control equipment, e.g. flow meters, thermostats, level indicators of lubrication
units and the hydraulic unit of the crusher, is functioning correctly. Remedy any faults/
02/2012 Rev 0

failures immediately or have them remedied.

• Increase the feed rate of the material over a period of approx. 8 hours thereby steadily
increasing the load on the gyratory crusher (no maximum size of feed material to start
with).

6-2 2-492-20908 (Pos 01)

 6.4 Normal operation

6.4.1 Prerequisites

– Sufficient lubricant and/or hydraulic oil levels (see previous section).

– The associated ball valves upstream/downstream of the pump provided for operation
(one of the two pumps) must be opened.
The ball valves of the second pump (standby pump) must be closed.
– The oil pump must be switched on.
– The oil circulation rate of the external bearing (radial) must be approx. 215 l/min and
that of the internal bearing (axial) approx. 215 l/min.
– The return flow temperature may not exceed approx. 55 °C.
– The tank heating system and the air/oil cooler must be operative. The lubricating oil
must have a temperature of approx. 35 °C on start-up of the crusher.
Activation of the heating system at 34 °C.
Switch off of the heating system at 38 °C.
– The oil filters must be operative, i.e. excessively clogged filters must be cleaned and/
or replaced.
– The ball valve between the tank and the pump and between the pump and the oil/air
cooler must be open on the pump for the oil cooling circuit.

6.4.2 Checks during operation

• Monitor the position indicators of main shaft/check the crushing gap. The position of
the piston in the hydraulic cylinder and thus the position of the main shaft is measured
by the distance sensor starting from the bottom position and indicated in the control
station/control cabin.
• Monitor the position indicators of main shaft/check the overload protection for
actuation.
In case of overload, the operating pressure is exceeded.
Open two pressure relief valves for a short period of time. A negligible amount of oil
leaks from the hydraulic cylinder: The main shaft is lowered and the crushing gap is
increased to empty the crushing chamber.
The lowering of the main shaft on overload can be seen on the display of the main shaft
adjustment in the control station/control cabin.
• Check the temperature of the lubricating oil.
If the temperature of the lubricating oil is too high, an alarm signal is actuated by
thermostats. The crusher main drive motor is switched off if the max./ max. oil
temperature is exceeded.
02/2012 Rev 0

2-492-20908 (Pos 01) 6-3

 • Check the flow rate of the lubricating oil.
Monitoring is via flowmeter. If the oil circulating quantity is too low, an acoustic and
visual warning is output and the crusher main drive motor is switched off.
• Check the electric filter clogging indicator.
The lubricating oil is cleaned by a switchable pressure filter in the supply line. As soon
as one of the filters is clogged, the second (bypass) filter is switched over to and the
filter element of the first filter can be replaced.
• Check that the heating system switches on and off.
The heating system in the lubricating oil tank is monitored by a temperature controller.
• Check that the oil cooling system switches on and off.
The air/oil cooler and the pump of the cooling circuit of the oil circulating lubrication are
controlled via a temperature controller in the return line.
If the oil temperature is above 45 °C, the cooler and the pump motor switch on.
If the oil temperature is below 40 °C, the cooler and the pump motor switch off.
• Check the lubricating oil and hydraulic oil levels.
Monitoring is by a magnet level switch. An alarm is output as soon as the level
decreases to the minimum oil level.
The crusher motor is switched off at min.min. after an idling time of 5 minutes.
• Check the supply line of the oil circulating lubrication. Monitoring is via pressure
controller. An acoustic and visual warning is output and the crusher main drive motor
is switched off as soon as the pressure is lower than the min. pressure.
• Check the hydraulic pressure of the safety coupling (90 MPa/ 900 bar).
• Monitor the feeding of the material to be crushed in the feed opening.
• Monitor the pilot lamps/displays and arrange for the necessary maintenance work after
warning messages.
• After a failure has been displayed/signaled, acknowledge the failure and arrange for
the cause of failure to be remedied.
• Monitor the ammeters (power input) and operating displays.
• Monitor the crushing gap/shaft position display.
• Switch off the gyratory crusher by pressing the emergency-stop button in the case of
danger.
• Set the crushing gap.
Due to progressive wear of the crushing tools, the product grain size no longer
corresponds to the originally set crushing gap after a certain period of operation.
Reduce the crushing gap according to the condition of wear.
• Check new crushing gap
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6-4 2-492-20908 (Pos 01)

 6.5 Malfunctions, troubleshooting

Failures/faults are displayed in the control station/control cabin.

The crusher is switched off automatically depending on the failure/fault.
The cause of failures/faults which are not displayed must be found and remedied.

6.5.1 Fault list / troubleshooting guide

Fault Cause Remedy

Gyratory crusher comes Overload, accumulation of material in • Lower the main shaft and allow excessive
to a standstill the crushing chamber, the safety material to drop out.
coupling has actuated. • Check and change the crushing gap if
necessary.
• Check material to be crushed for excessive
oversize and undersize.
• Check that the material is uniformly fed in
and distributed in the crushing chamber.

Lubrication oil flow rate too low
• Exchange the filter inserts of the supply
filters.
• Check the function of the flowmeters.
• Check the delivery rate of the lubrication oil
pumps.

Lubricating oil temperature too high
• Check the function of the oil coolers,
temperature controllers and cooling circuit
pump.
• Check the flow rate and the operating
pressure of the oil circulating lubrication.

Metallic foreign bodies in the crushing • Correct the setting of the pressure relief
chamber, and the overload protection is valves in the cylinder bottom/replace the
not functioning pressure relief valves.

min./ min oil level in lubricating oil tank • Eliminate leaks, top up lubricating oil.

Pressure of dust sealing has fallen • Check the blower, hose lines, pressure
below min. transducers, sealing ring of the dust
sealing.

Grease level in the spider bearing has • Check the grease lubrication pump, grease
fallen below min. lines, flowmeter; grease tank empty.

Grease drum filling level has fallen • Grease tank empty.

below min.
02/2012 Rev 0

Product grain size too Crushing gap too large • Reset the crushing gap by adjusting the
large main shaft.

Crushing tools worn • Replace crushing tools.

Main shaft has been Overload through foreign bodies • Reset the crushing gap by raising the main
lowered shaft.

2-492-20908 (Pos 01) 6-5

 Fault Cause Remedy

Hydraulic oil level too low • Top up hydraulic oil.

• Eliminate leakage/retighten bolted
connections.

Message - Operating Lubrication oil pump defective Check lubrication oil pump. Replace if
pressure of oil damaged/worn.
circulating lubrication
too low

Supply filter clogged Clean/replace filter insert.

Leaky oil lines/bolted connections • Eliminate leaks

• Retighten bolted connections.

Message - Oil level in Hoses and/or bolted connections leaky • Replace hoses and retighten bolted
lubricating oil tank too connections.
low

Oil cooler leaky • Repair oil cooler.

Oil level in oil circulating Seal in the piston of hydraulic cylinder • Replace seals in the piston
lubrication rising and worn
hydraulic oil level falling

Message - Increased Damage to axial step bearing/eccentric • Check axial step bearing and eccentric
return temperature of bushing bushing.
lubricating oil • Replace if damaged/worn.
• Check return line filter.

Insufficient lubrication • Check the flow rate and the operating

pressure of the oil circulating lubrication.

Insufficient cooling of lubricating oil • Check oil cooler, cooling circuit pump and
temperature controller for oil cooler.

Temperature controller for heating rods • Replace temperature controller.

defective

Message - Supply filter Filter inserts clogged • Replace filter inserts

of oil circulating
lubrication clogged

Increased current Gyratory crusher overloaded • Check the feed quantity and feed material
consumption of the size.
crusher motor • Check the main shaft position.

Speed of pinion Gyratory crusher overloaded • Check the feed quantity and feed material
assembly shaft too low size.
• Check the main shaft position.

Return line filter (screen Axial clearance between the sealing ring • Replace sealing ring of the dust sealing.
basket) of oil circulating and sealing housing too large;
02/2012 Rev 0

lubrication clogged:
– by dust particles

Side-channel compressor defective (no • Repair side-channel compressor

over-pressure)/intake filter of side- • Clean/replace intake filter of side-channel
channel compressor clogged. compressor.

6-6 2-492-20908 (Pos 01)

 Fault Cause Remedy

– by silver to grey- Damage to axial step bearing (step • Check lower part of the axial step bearing/
coloured metal bearing lower part)/bevel gear or pinion bevel gear or pinion assembly shaft.
deposits of the pinion shaft assembly

lower shaft of the main shaft • Check lower shaft of main shaft.
• Replace if damaged/worn.

– by bronze-coloured Damage to inner eccentric bushing/ • Check inner eccentric bushing.

metal deposits

Axial step bearing (step bearing upper • Check step bearing upper part and slide
part and slide bearing plate) bearing plate of the axial step bearing.

Outer bushing of the eccentric bushing • Check outer bushing of the eccentric
in the bottom shell bushing.

Axial step bearing ring between the • Check axial step bearing between the base
base plate and the hub of the bottom plate and the hub.
shell • Replace if damaged/worn.

Frequent readjustment Crushing tools worn • Replace crushing tools.

of the crushing gap • Remedy hydraulic leaks/retighten bolted
required connections.

Main shaft cannot be Hydraulic pump output too low/ • Repair/replace hydraulic pump/
lifted. defective/piston slide valve of the way Clean the piston slide valve.
valve 
jammed

Incorrect setting of the pressure relief • Correct the setting.

valve

Leakage oil losses at seals in the • Remedy leakage; replace seals.

hydraulic cylinder/ in valves

Main shaft cannot be Material accumulated in the bottom shell • Remove the accumulated material.
lowered fully. of the crusher, e.g. because the
extractor device failed

The balance unit is defective • Repair the balance unit.

Abnormal noises in the Roller bearings defective/teeth worn, • Localise the noise by means of a
pinion shaft assembly damaged stethoscope. Have the damage assessed
by a gear unit specialist. If required, replace
the defective roller bearing/pinion.

Continuous topping up Radial sealing rings worn/O-ring on • Radial sealing rings/ replace O-ring.
of oil in the pinion bearing housing defective
assembly required

Grease consumption of Hoses defective • Replace hoses.

spider bearing too high

bolted connections loose • Retighten bolted connections.

02/2012 Rev 0

Spider bushing/main shaft sleeve worn • Replace spider bearing and main shaft
sleeve.

Streaks of grease on Shaft seal worn • Replace shaft sealing below the spider
the main shaft sleeve of bushing.
the main shaft

2-492-20908 (Pos 01) 6-7

 Fault Cause Remedy

Spider bushing/main shaft sleeve worn • Replace spider bearing and main shaft
sleeve.

Vibration on the drive Drive unit or a component of the drive • Check and retighten fastening bolts.
unit unit is loose.

Alignment inaccurate • Re-align crusher main drive motor.

Roller bearing defective • Replace roller bearing.

Pressure relief valve Incorrect setting of the pressure relief • Correct setting/ replace valve.
does not maintain the valve/valve seat damaged or jammed
required pressure.

Pump does not reach Internal leakage of pump due to wear • Replace pump.
the required delivery
rate.

Jerky movement of the Fluctuations in hydraulic pressure or • Bleed the hydraulic cylinder.
hydraulic cylinder delivery flow/ air inclusions in the
hydraulic cylinder

Foam formation in the Water in the hydraulic oil/lubricating oil • Drain condensate from the tank/ change
hydraulic oil/lubricating hydraulic oil/ lubricant oil.
oil • Use foam inhibitors.

6.5.2 Restart of the crusher

After a standstill of the crusher with a full feed opening, e.g. due to power failure or fault
message from a monitoring device:
• Lower the main shaft, several times if necessary, in order to clear it.
• Switch-on the crusher main drive motor in the lower shaft position while lowering 
(3 tries/hr possible).

If the crusher does not run up:

• Clear the crusher by hand.
02/2012 Rev 0

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 6.6 Shutting down

6.6.1 Normal operation

The material feed must always be interrupted before the crushing plant is stopped. The
crushing plant can then run "empty".

When shutting the plant down care must be taken that a buffer layer remains in the feed
hopper to protect the belt cover.

NOTICE
System damage caused by wrong material feeding after the feeding
conveyer has been emptied

Damage to the machine/plant or its environment is possible

• If the feed hopper is emptied, smaller sized material must be fed first again when
material feeding restarts. This protects the belt cover of the feed hopper against
damage caused by the subsequent larger pieces.
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6.6.2 Emergency stop device

NOTICE
System damage from material overfilling when using emergency-stop
switch

Damage to the machine/plant or its environment is possible

When emergency stop has been pressed, there is a danger of material overfilling
at the transfer points, as all upstream and downstream parts of the plant are
switched off with no specific shutdown sequence.

• The emergency-stop-switches must not be used for normal shutdown.

• Acknowledge the fault.
• Switch the main electrical supply back on.

Several emergency-stop switches must be installed on the machine/plant.

The emergency-stop switches are identified by red impact surfaces on yellow background.

The switches engage on actuation.

• The whole electrical system is switched off by the emergency stop.

• Ascertain the danger or damage, and provide first aid if necessary.
• Have any defects rectified.
• In order to restart the plant after having rectified the emergency case, the actuated
switch is to be unlocked by turning the impact surface to the right-hand side.
• Acknowledge the fault.
• Switch the main electrical supply back on.

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 6.7 Handling oil hydraulic systems

6.7.1 General

The reliable functioning of oil hydraulic systems is primarily dependent on careful

maintenance. The service life of the hydraulic elements is usually longer than that of the
mechanical elements (e.g. ball bearings).
The following general instructions may be replaced by special instructions if required.

6.7.2 Assembly

At assembly particular attention is to be paid to utmost cleanliness.

6.7.3 Pipes

The pipes must be sawn off square. Cutting the pipes with cutting rollers is not
permissible. Special instructions apply to the welding of pipes.
During all welding operations, it must be ensured that the welding current does not flow
through any hydraulic devices, otherwise internal components may be welded together.
The pipes must be cleaned of dirt before mounting.
The pipes must be laid in such a way that they are unstressed.
Sealants such as hemp and putty are not permitted.
Pump suction lines must be carefully sealed against the ingress of air. Leak oil lines must
be laid in such a way that the pumps and motor housings always remain filled with oil.
They must not have any connection to pressure lines and drain lines.
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6.7.4 Hydraulic hoses

WARNING
Risk of injury through leak or break in the hoses and pressurised medium
escaping

Death or severe bodily injuries are possible

• Stop the machine / plant by pressing the emergency-stop switch.

• Shield the machine / plant in such a way that the pressurised medium cannot
injure anyone or cause a fire.

NOTICE
System damage due to hoses fluttering about during pressure build-up

Damage to the machine/plant or its environment is possible

• Fix the hose in place

Hydraulic hoses must be installed in such a way that

• the necessary length is available to avoid kinking and hose tension during operation;
• the minimum radius reaches the prescribed minimum;
• twisting of the hose due to poor installation or during operation (caused by a rotary
connection blocking, for example, or unfavourable movements of the connection
points) is reduced to a minimum;
• they are arranged or protected in such a way that abrasion of the outer hose layer is
minimised;
• they are fixed in a suitable way if the weight of the hose could lead to impermissible
load.
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 6.7.5 Commissioning

Before filling with hydraulic fluid, check the tank and pipes once again for cleanliness. The
check must be carried out directly before filling.

Faulty pipework or incorrect wiring is generally not noticed until the plant is being
commissioned and the required functions are not available.
Any modification at this stage normally proves to be extremely difficult.
Careful checking of the pipes and the wiring on basis of the circuit diagram is therefore
strongly recommended before filling the tank with hydraulic fluid.

Solenoid-operated valves and pressure switches must be checked for the type of current
and voltage.

Pumps and the associated electric motors must be aligned with each other. Any
misalignment between the motor and the pump may cause premature destruction of the
pump. Pumps and their motors must not be distorted by any incorrect pipe connection.

Unless they have been delivered ready for operation, accumulators must be properly
provided with the specified nitrogen charge before they are installed in the plant. It is
advisable to mark the gas precharge pressure on the accumulator (e.g. with a sticker) and
also in the circuit diagram, so that an easy comparative check can subsequently be made
if required.

6.7.6 Hydraulic fluid

HLP or HVLP oils selected to meet the respective climatic conditions and room
temperatures must be used.

The hydraulic oil must always be filtered when being filled.

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6.7.7 Filling pumps and motors

Prior to their initial start-up, the pumps and motors are to be filled through the leak oil
connection.

6.7.8 Pressure settings

At start-up the pressure setting of the limit valves is to be kept low at first. An exception
are type-tested pressure relief valves for hydraulic systems, which do not allow for any
variation because of their fixed-value adjustment.

6.7.9 Start-up

DANGER
Risk of injury caused by control or operating faults

Imminent danger of death or severe bodily injuries

• Make sure no unauthorised persons are in the danger zone

Wherever practical, variable-delivery pumps and motors should be set to a small

swivelling angle, in order to facilitate the initial priming.

The electric motors can now be switched on for a short time (approx. 5 to 10 sec.). Check
the direction of rotation in the process. At the same time it need be checked whether
couplings or other connection parts have become loose.

Before the operating pressure setting can be gradually increased, check that the pump
delivery is quiet and stead. Any leaks must be remedied immediately. The plant must be
vented when it is operated at a low-pressure setting. The fluid level in the tank must be
monitored and fluid (of the same type) must be added if necessary.

After the operating pressure has been reached and the functional test has been
successfully passed, pressure switches, level switches, thermostats, etc. must be
adjusted.
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 6.7.10 Cylinders

Cylinders must be mounted in such a way that they are unstressed and above all free of
transverse forces, otherwise malfunctions and premature wear may occur.

6.7.11 maintenance

The frequency of maintenance cannot be specified. It is a purely a matter of experience.

Only the regularity with which it is performed is important. The following points must be
regularly checked at intervals recommended by the manufacturer or gained from
experience.

6.7.12 Fluid level

The fluid level must be checked constantly during the commissioning period; after
commissioning it must be initially checked daily and then weekly.

6.7.13 Filters

During the commissioning period, the filters must be checked at intervals of 2 to 3 hours
and must be exchanged if necessary. In the initial 150 - 250 operating hours, the filters
must be serviced considerably more frequently than afterwards. If visual or electrical
clogging indicators are provided, the filter elements must be exchanged according to
these indicators. Actuation of the clogging indicators at cold start is insignificant and is
terminated after a short time if the filter elements are clean.

Breathers must be regularly checked and the filter element exchanged if necessary.

6.7.14 Oil temperature

The operating temperature must not only be measured in the oil tank but also at the
bearing points of the pumps, amongst other places. A temperature rise indicates wear.
(Growing friction and leakage by converting hydraulic energy into heat).
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6.7.15 Oil change

The frequency of the system fluid change depends on several operating factors and is
governed by the degree of ageing and pollution.
Regular laboratory tests of the hydraulic oil must be carried out, especially in case of large
oil quantities of oil.

6.7.16 Accumulators

If necessary, the precharge pressure of the nitrogen side of accumulators must be

checked at regular intervals. When doing so, the oil side of the accumulator must be
absolutely unpressurized.

6.7.17 Alignment

At adequate intervals we recommend to check the correct alignment of the energy

converters (pumps, motors, cylinders etc.) at operating temperature and, as far as
possible, under operating pressure. This includes erection bolts, screws, connections,
pipes, couplings, etc.

6.7.18 Pipework

The hydraulic pipe system must be checked for leaks at regular intervals. Bolted joints
must be re-tightened when the plant is depressurized.

6.7.19 Coolers

The fins of oil/air coolers must be cleaned at regular intervals depending on the
environmental conditions.
Oil/water coolers must be decalcified from time to time.
The frequency depends on the hardness of the cooling water used.
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 6.7.20 Storage of hydraulic components

Store pumps, valves, cylinders, etc. in a dry place in the absence of air humidity.

The storage rooms must be free of corrosives and fumes. Filling with an anti-corrosion oil
is recommended in any case. This oil must be compatible with the subsequent oil grade.
The oil film remaining after draining the anti-corrosion oil may not have an adverse effect
on subsequent use.

6.7.21 Period of storage and use duration of hydraulic hoses

The term period of use describes the total period of application and storage period of a
hose line from its date of production (date of assembly).

As far as storage is concerned, a distinction must be made between the storage of bulk
stock and the storage of hose lines (pre-assembled hoses), since different storage periods
apply.

Hoses and hose lines are subject to a natural ageing process even when stored properly.
This limits the period of use of hydraulic hose lines.

When a hose line is produced (assembled), the hose (bulk stock) should not be older than
four years.
This means that the bulk hose stock should not have been stored for more than four years
when the hose is produced (date of assembly).

The period of use of a hose should not exceed six years - including the storage period of
the hose line - whereby the storage period of the hose line (the assembled hose) should
not be longer than two years.

Summing up, this means:

Maximum storage period for bulk hose stock: 4 years
Maximum storage period for hose line 
(assembled hoses): 2 years
Maximum period of use for hose line
(inc. storage period for the hose line): 6 years
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 Leerseite

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 7 Maintenance

7.1 Important maintenance instructions

WARNING
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation

Death or severe bodily injuries are possible

• Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off and secured against restarting.

• Note the information in the Operating Instructions on adjusting, maintenance and

inspection work and observe the intervals set out, including information on the
replacement of parts and equipment! The work may only be carried out by qualified
personnel.

• Inform the operating personnel before starting service and maintenance work! Appoint
a person to supervise the work!

• When carrying out any work concerning the operation, conversion or adjustment of the
machine/ plant and its safety-oriented devices or any work related to maintenance,
inspection and repair, always follow the start-up and shutdown procedures described
in the Operating Instructions and the information on maintenance work!

• As a general principle, all work on the machine/ plant should only be carried out when
the machine/ plant is at a standstill.

• If the machine/ plant has been completely shut down for maintenance and repair work,
it must be secured against inadvertent restart by:
– Locking the main control elements and removing the key and/or
– attaching a warning sign to the main switch.
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 • Before restarting the machine/plant after repair work, check that all safety devices have
been attached.

• After electrical installation or repair work, test the protection systems (e.g. earth
resistance).

• To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting gear and secured. Only
use suitable and technically perfect lifting gear and suspension systems with an
adequate carrying capacity! Never work or stand under suspended loads!

• The fastening of loads and the instruction of crane operators should only be entrusted
to experienced persons! The marshaller must be within eyesight of the operator or
have verbal communication with him.

• When carrying out overhead assembly work, always use specially designed or other
suitable and safe climbing aids and working platforms. Never use machine parts as a
climbing aid! Wear fall protection when carrying out maintenance work at a higher
level.

• Keep all handles, steps, handrails, platforms, landings and ladders free of dirt, snow
and ice!

• Always tighten up any bolted connections which have been loosened during
maintenance and repair work!

• Any safety devices removed for setting up, maintenance or repair purposes must be
refitted and checked immediately upon completion of the maintenance and repair work.

• Ensure that all consumables and process materials and replaced parts are disposed
off safely and in an environmentally friendly manner!

• Only use original fuses with the specified current rating! Shut down the machine/ plant
immediately if faults occur in the electrical power supply!

• Work on the electrical system or equipment may only be carried out by a skilled
electrician or by specially instructed personnel under the control and supervision of a
skilled electrician and in accordance with the applicable electrical engineering rules.

• If prescribed, the power supply to parts of machines and plants on which inspection,
maintenance and repair work is to be carried out must be disconnected. Check that the
isolated parts have been disconnected from the supply, then earth and short-circuit
them and insulate any adjacent live parts!
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 • The electrical equipment of the machine/plant must be inspected at regular intervals.
Any defects such as loose connections or scorched cables must be rectified
immediately.

• If work on live parts is necessary, it may only be carried out in the presence of a second
person who can disconnect the power supply in an emergency by actuating the
emergency stop button or main power switch. Cordon off the working area with a red-
and-white safety chain and a warning sign. Only use insulated tools!

• Before starting work on high-voltage assemblies and after disconnecting the power
supply, the supply cable must be earthed and components such as capacitors short-
circuited with an earthing rod!

• Carry out welding, flame-cutting and grinding work on the machine/ plant only if this has
been expressly authorised, as there may be a risk of explosion and fire!

• Before carrying out welding, flame-cutting and grinding work, clean dust and other
inflammable substances from the machine/ plant and its surroundings and provide
adequate ventilation (risk of explosion)!

• Check all lines, hoses and bolted connections regularly for leaks and obvious damage!
Repair any damage immediately! Splashing oil may cause injury and fires.

• Depressurise all system sections and pressure pipes which are to be opened in
accordance with the instructions for the assembly group concerned before carrying out
any repair work!

• Hydraulic lines must be laid and connected in line with good professional practice!
Do not mix up any exchange connections! The fittings, lengths and quality of the hoses
must comply with the technical requirements.

• Follow the applicable safety regulations when handling oil, grease and other chemical
substances!

• Be careful when handling hot consumables and process materials (risk of burning or
scalding)!
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7.1.1 Instructions for cleaning

CAUTION
Risk of injury when working without personal safety equipment

Physical injury is possible

• Always wear a face protector when carrying out cleaning work with high-
pressure or steam jet cleaners.

• Check the degree of soiling of the machine/plant every day. Do not allow material to
accumulate or cake. The mechanical interaction of the plant components may be
interfered with and malfunctions and increased wear occur.

• Always clean the assembly group in question before commencing maintenance work.

• Before cleaning the machine/ plant with water or steam jet (high-pressure cleaners) or
other cleaning agents close/ tape up all openings into which water, steam and
detergents should not be allowed to penetrate for safety or operational reasons.
Electric motors and switch cabinets are at particular risk.

• Do not use corrosive detergents.

• Do not direct the spray jet at electrical devices, relay boxes and switch cabinets, intake
and breather filters or greased surfaces.

• Always hold the spray jet a sufficiently large distance away from the surface being
cleaned and do not direct the spray jet at these surfaces at right angles.

• Clean places which are difficult to reach with suitable equipment e.g. special brooms.

• The covers and tapes need be removed completely after cleaning.

• After cleaning, check all lubricant and hydraulic oil lines for leaks, loose connections,
friction areas and damage! Eliminate any defect immediately!
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 7.1.2 Instructions for maintenance and servicing

WARNING
Risk of injury by neglecting proper maintenance intervals

Death or severe bodily injuries are possible

• All pending maintenance work must be completed according to schedule The

manufacturer does not accept liability for damage resulting from maintenance
work which has not been carried out or has not been carried out according to
schedule.

NOTICE
System damage through improper maintenance

Damage to the machine/plant or its environment is possible.

• Check the machine / plant at least once per shift for obvious damage and
defects! Report any changes (including changes in the operating performance)
to the responsible department immediately!
• In the event of malfunctions, stop the machine/ plant immediately and lock it! 
Have any defects remedied immediately!
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 Failures arising from inadequate or improper maintenance may cause high repair costs
and long downtimes. Regular maintenance is therefore indispensable.

Functional safety, trouble-free operation and the service life of the machine/ plant depend
on proper cleaning, inspection and maintenance.
• Check the machine/ plant at the specified intervals (inspection intervals, maintenance
periods) for proper operation, lubrication condition and wear.
• Replace or repair all damaged/ worn parts.
• Check the paintwork for corrosion at regular intervals but no later than every 6 months.
Touch up all damaged areas in line with good professional practice.
• Have the function of all instrumentation and control devices/ electrical interlocks
checked by qualified personnel at regular intervals.

INFORMATION
Downtimes for repairs can also be used for scheduled maintenance work.

The required frequency of checks for wear, inspection, maintenance and repair cannot be
specified beforehand owing to the variety of service conditions. An appropriate routine
inspection schedule must be prepared making allowance for the operating conditions.

The maintenance table (Chapter 7.2) is a guideline for inspection and maintenance work.

For maintenance and repair work strictly follow the general safety notes included in
(Chapter 3).

INFORMATION
For lubricating the machine/ plant see Chapter 8.
For maintenance and servicing of the components, see ANNEX 9.

As recommended for commissioning, you are advised to have repairs carried out by
ThyssenKrupp Fördertechnik staff the first time. Your maintenance staff will have the
opportunity to take part in an intensive training course.
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 7.1.3 Instructions for repairs

WARNING
Risk of injury caused by improper fastening

Death or severe bodily injuries are possible

• To avoid the risk of accidents, individual parts and large assemblies being
moved for replacement purposes should be carefully attached to lifting gear and
secured. Only use suitable and technically perfect lifting gear and suspension
systems with an adequate carrying capacity! Never work or stand under
suspended loads!
• The fastening of loads and the instruction of crane operators should only be
entrusted to experienced persons! The marshaller must be within eyesight of the
operator or have verbal communication with him.
• When carrying out overhead assembly work, always use specially designed or
other suitable and safe climbing aids and working platforms. Never use machine
parts as a climbing aid! Wear fall protection when carrying out maintenance work
at a higher level.

• Immediately replace worn components with new components.

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

Maintenance intervals are:

– defined periods of time (maintenance periods) or
– a certain number of operating hours (approx. 8000 operating hours/a and the
maintenance intervals derived from this).

The following table provides an overview of the maintenance intervals with the
abbreviations D (= daily), W (= weekly), and M (= monthly) used in the maintenance
tables.

Maintenance interval Maintenance period Number of operating

hours (Bh)
T daily/prior to each start-up approx. 22
W weekly approx. 150
M1 monthly approx. 650
M3 quarterly approx. 2000
M6 half-yearly approx. 4000
M12 yearly approx. 8000

Carry out the relevant inspection/maintenance work as soon as the first of the two possible
maintenance intervals is reached.
The maintenance intervals (maintenance periods and operating hours) for carrying out
maintenance work are suggestions and recommendations of ThyssenKrupp
Fördertechnik. 
However, the frequency of maintenance work depends on the specific local operating
conditions, such as
– Operating time
– Operating condition and
– Wear.

The operating conditions must therefore be monitored and taken into account. It
may be necessary to change or adapt the maintenance intervals over the course of
time.

Observe the instructions for components in the ANNEX 9.

The maintenance tables include the following:

– The inspection/maintenance work to be carried out in shortened form. 
The section numbers in brackets refer to the detailed description of the inspection/
maintenance work;
02/2012 Rev 0

– The maintenance intervals marked by a dot (starting with T to M12), at which the
relevant maintenance work has to be carried out.

7-8 2-492-20908 (Pos 01)

 See the Chapter 8 “Lubrication” for:
– The quantities of lubricant (grease/lubricating oil);
– The designation of the lubricants whose level has to be checked and which have to be
topped up or changed.

Maintenance interval

Inspection/maintenance work Note T W M1 M3 M6 M12

• Check the setting of the crushing gap (in


the operator's cabin)

• Check the crusher for abnormal noises


and obvious damage.

• Visually check the oil circulating


lubrication and hydraulic unit for leaks

• Check the oil quantity and pressure of the

oil circulating lubrication and hydraulic 
pressure.

• Check the oil temperature of the oil with the machine running 
circulating lubrication.

• Check the optical clogging indicators of

the filters of the oil circulating lubrication

and hydraulic system, replace the filters if
necessary (Chapter 7.3.7).

• Check the function and the degree of


soiling of the oil/air cooler.

• Check the precharge pressure in the

compressed air tank of the balance unit.  

• Check the crusher for soiling and material


deposits; clean if necessary.

• Check the crusher inlet/outlet for free


passage.

• Check the oil level of the pinion shaft


assembly (Chapter 7.3.8).

• Check the oil level in the tank of the oil


circulating lubrication (Chapter 7.3.7).

• Check the oil level in the hydraulic oil tank


(Chapter 7.3.8).

• Check the screen basket in the lubricating


oil tank for dirt accumulation.
02/2012 Rev 0

• Manually check/measure the width of the


crushing gap (Chapter 7.3.3).

• Check the wear parts in the spider and


bottom shell for wear (Chapter 7.3.3).

2-492-20908 (Pos 01) 7-9

 Maintenance interval

Inspection/maintenance work Note T W M1 M3 M6 M12

• Check the concaves for completeness


and damage (Chapter 7.3.3).

• Check the mantle and the main shaft


sleeve (Chapter 7.3.3).

• Check the spider bearing for leaks. 

• Check all fastening bolts for

completeness and secure attachment 
(Chapter 5.10 and Chapter 7.3.2).

• Check the filling level in the reservoir of

the lubrication unit of the spider bearing 
(Chapter 7.3.4).

• Check the over-pressure system


(Chapter 7.3.5)

• Check the connection cable of the


position encoder for damage.

• Check the compressed air for free


passage (Chapter 7.3.5).

• Check the hydraulic pressure of the safety


coupling (90 MPa = 900 bar).

• Check the breather filter of the pinion

shaft assembly; clean/replace if 
necessary.

• Check the breather filter of the oil and

hydraulic tank; clean/replace if 
necessary.

• Check the spider bushing of the spider

bearing for wear and clearance to the 
main shaft sleeve (Chapter 7.3.4).

• Analyse the lubricating oil of the oil

circulating lubrication unit, change the oil 
if necessary (Chapter 7.3.7).
Oil change every 2000
• Analyse the lubricating oil of the pinion
operating hours, but no later
shaft assembly, change the oil if 
than every 6 months
necessary (Chapter 7.3.9).

• Analyse the hydraulic oil, change the oil if


necessary (Chapter 7.3.8).

• Check the sealing housing for wear and

clearance of the sealing ring 
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(Chapter 7.3.5).

• Change hydraulic oil of safety clutch after every 15 actuations of

(ANNEX 9) the safety coupling or after 12 
months

7 - 10 2-492-20908 (Pos 01)

 Maintenance interval

Inspection/maintenance work Note T W M1 M3 M6 M12

• Check the components of the dust sealing


for wear.

• Change the grease of the spider bearing 

when checking the crushing
• Check the running surfaces of the main tools
shaft, axial step bearing, eccentric

bushing, outer bushing in the bottom
shell, axial bearing ring for wear.

• Check the tooth backlash between the


bevel gear and the bevel pinion.

• Annual inspection 

For maintenance and repair of the components see ANNEX 9.

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7.3 Special maintenance tasks

The following parts of the machine must be serviced at regular intervals:

– Crusher shells and concaves
– Secure attachment of connecting bolts
– Main shaft
– Spider bearing with grease lubrication
– Dust sealing with side-channel compressor
– Eccentric bushing and axial step bearing
– Check the oil level and change the oil at the oil circulating lubrication unit
– Check the hydraulic oil level and change the hydraulic oil
– Direct drive and pinion assembly

7.3.1 Crusher shells and concaves

See Illustration 35, drawing 4350021 sheets 1 + 2 and 4350852 in the ANNEX 9.1

– Check the concaves (1) for damage

• Check the positions of the concaves from above through the loading opening for
completeness and obvious damage with the crusher empty and at standstill.

INFORMATION
The continuous wear from operation can be detected because the main shaft
height must be increased. For replacing the concaves, refer to Section 7.4.2.

Check interval: weekly

– Check the spider cap, spider, upper shell, lower shell and bottom shell

• Check the spider cap (2) for damage with the crusher empty and at standstill.
The wear of the wall thickness of the spider cap can only be checked with the spider
cap removed (see Section 7.4.5).
• Check the thickness and condition of the arm liners (3). Replace worn arm liners.
• Check the thickness and condition of the liner plates (4, 5). Check the attachment of
the liner plates. Replace worn plates.
• Check the attachment of the liner plates (6) on the conical part of hub (crusher outlet)
- weld seams - re-weld liner plates if necessary; replace worn plates.
• Check the position and condition of the wearing caps (7) on the arms (bottom shell of
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the hub), realign/replace if necessary.

Check interval: weekly

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02/2012 Rev 0

Illustration 35

2-492-20908 (Pos 01) 7 - 13

7.3.2 Secure attachment of connecting bolts

See Illustration 36

• Check all bolts.

• Re-tighten loose bolts to the tightening torque specified in Chapter 5.11 or if not
indicated, in accordance with the table in 7.3.2.

• Check the secure attachment of the ring nut (1) for securing the mantle on the main
shaft.

• Re-tighten a loose ring nut. To do so, weld a knocking cam on the ring nut.

Check interval: weekly

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02/2012 Rev 0

Illustration 36

2-492-20908 (Pos 01) 7 - 15

7.3.3 Main shaft

See Illustration 37

– Check the crushing gap

The height of the main shaft (1) can be vertically adjusted to change the crushing gap
locally/centrally.

The crushing gap increases and must be re-adjusted due to increasing wear of the
crushing tools (concaves and main shaft).

Check the actual size/width of the crushing gap with the crusher empty and at standstill.
For this purpose:
• Open the inspection hole cover (2) in the bottom shell.
• Measure and average the crushing gap (4) at three points. Re-adjust the crushing gap
if necessary.

Check interval: depends on material to be crushed. We recommend starting with a weekly

check.

– Check the mantle for damage, check the main shaft sleeve

• Check the mantle (3) from above through the feed opening for obvious damage with
the crusher empty and at standstill.
The continuous wear from operation can be detected because the main shaft height
must be increased. 
For replacing the concaves, see Chapter 7.4.7 “Main shaft”.
• Check the secure attachment of the mantle. Re-knock the outer ring nut (5) if
necessary.
• Check the main shaft sleeve (6) of the main shaft for wear / damage, e.g. wear marks,
longitudinal grooves. Replace the main shaft sleeve if excessively worn/visibly
damaged (see Chapter 7.4.7 “Main shaft”).

Check interval: weekly

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7 - 16 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 37

2-492-20908 (Pos 01) 7 - 17

7.3.4 Spider bearing with grease lubrication

See Illustration 38

INFORMATION
The following checks must be carried out with the main shaft fully lowered (before
switching off the crusher). Always check all components of the spider bearing with
the spider and main shaft dismantled (e.g. replacement of the concaves and
mantle).

Check the spider bushing for wear:

• Clean the top part of the spider, dismantle the spider cap (1) and remove the lubricating
grease.

• Check the clearance (2) between the spider bushing (3) and the main shaft sleeve (4).
Press the main shaft on the spider bushing by means of a hydraulic device.
Measure the clearance between the spider bushing of the upper bearing and the main
shaft sleeve by means of a feeler gauge. The clearance may be a max. of 3.5 mm. If
this is exceeded, the spider bushing must be replaced (see Section 7.4.5).

If the clearance exceeds the permissible value to a large extent, the inclination of the main
shaft will change in a way causing abrasion to the inner eccentric bushing due to a wrong
inclination angle.
The main shaft will elevate when the spider bushing and the main shaft sleeve are being
exchanged. This results in an edge pressure in the inner eccentric bushing. The main
shaft may seize during crushing through the action of the operating pressure.
Check the inner eccentric bushing for run-in marks and cracks caused by edge pressure.

NOTICE
System damage caused by worn eccentric bushing

Damage to the machine/plant or its environment is possible

• When replacing a worn spider bushing, also replace the inner eccentric bushing
(see Section 7.4.8).

• Check the condition of the leather packing (5), shaft sealing rings (6) and toroidal
sealing ring (7).
• Use a grease pump to fill the space above the spider bearing with grease (see
lubrication instruction, Section 8).
02/2012 Rev 0

• Re-mount the spider cap. Ensure that no dirt to gets into the spider bearing.

Check interval: every 3 months

7 - 18 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 38

2-492-20908 (Pos 01) 7 - 19

 Maintenance of the grease lubrication unit:
The grease level above the spider bearing is monitored by a filling level sensor (8). Grease
is pumped into the chamber until the upper filling level is reached. The grease pump is
then switched off. Please refer to the function specifications for further information.

• Check the function of the lubrication pump.

• Top up the grease according to the lubrication instructions (Section 8) if necessary.
• Check for leaks, re-tighten loose bolted connections.

Check interval: weekly

NOTICE
System damage caused by insufficient lubricant

Damage to the machine/plant or its environment is possible

• Check the grease level one month after commissioning. To do this, remove the
spider cap.

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7 - 20 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 38

2-492-20908 (Pos 01) 7 - 21

7.3.5 Dust sealing with side-channel compressor

See Illustration 39 and Illustration 40

It is best to check the dust sealing with the main shaft fully lifted.

INFORMATION
Always check all components of the dust sealing for wear with the spider and the
main shaft dismantled.

Check the sealing housing for wear, check the clearance of sealing ring

With the main shaft installed, this check may be carried out either
– through access A, whereby all the dimensions can be checked, or
– through access B (inspection flap), whereby a visual check can be carried out from the
outside.

The following checks must be carried out:

• Check the sealing housing (1) for run-in grooves, which can be caused by the
polyamide sealing ring (2). If the run-in grooves are deep, the sealing housing must be
replaced.
• Check the condition of the polyamide sealing ring (2) and measure the radial clearance
(3) between the polyamide sealing ring (2) and the sealing housing (1). If the radial
clearance is considerably larger than 2 mm, replace the polyamide sealing ring (2).
• Ensure that the polyamide sealing ring (2) can slide between the upper (4) and lower
sealing ring (5). The axial clearance may be 0.2 - 0.3 mm. If necessary, change the
clearance by adding other shim packages (6).

Check interval: weekly

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Illustration 39

7 - 22 2-492-20908 (Pos 01)

 Illustration 40
02/2012 Rev 0

2-492-20908 (Pos 01) 7 - 23

 Check the over-pressure system:

See Illustration 41

• Carry out a visual check for the secure attachment of bolted joints and damage to
hoses. Re-tighten loose bolted joints, replace damaged hoses.
• After the crusher has been switched off, check that the compressor (1) switches off with
a time delay.
• As a preventive measure, check the intake air filter (2) of the compressor for clogging.
Clean/replace if necessary.
• Remove any dust deposits from the compressor housing.

Check interval: weekly

Check the compressed air for free passage:

• Check the connection piping for accumulated oil, e.g. due to splash oil below the dust
sealing. Otherwise the free passage of the compressed air for the dust sealing cannot
be guaranteed.
• Unscrew the hose connection (3) to the air pipe and check whether oil flows out.
• Blow compressed air through the ducts (4).

Check interval: monthly

For maintenance work on the side-channel compressor, refer to ANNEX 9.5.

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7 - 24 2-492-20908 (Pos 01)

 Illustration 41
02/2012 Rev 0

2-492-20908 (Pos 01) 7 - 25

7.3.6 Eccentric bushing and axial step bearing

See Illustration 42

INFORMATION
Direct checks / inspection of the axial step bearing (1) and the eccentric bushing
(2) are not possible without dismantling the spider, the main shaft and dust sealing
beforehand. Therefore always check the axial step bearing and the eccentric
bushing after the spider and the main shaft have been dismantled and replace if
necessary (see Section 7.4; checks in a dismantled condition are also described
there).

When carrying out maintenance on the oil circulating lubrication, indirect conclusions with
regard to possible wear or damage to the axial step bearing or eccentric bushing can be
drawn from signals generated by the control system and the visual inspection of plant
components:

Control messages:
• Increased oil return temperature
• Higher current consumption

Visual check of plant components:

• Bronze-coloured metal deposits in the screen basket indicate possible damage to the
inner eccentric bushing/the step bearing upper part/the slide bearing plate of the axial
bearing or the outer bushing.
• Silver to grey metal deposits indicate possible damage to the axial bearing, the bevel
gear, the bevel pinion, the eccentric bushing or the main shaft.

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7 - 26 2-492-20908 (Pos 01)

 Illustration 42
02/2012 Rev 0

2-492-20908 (Pos 01) 7 - 27

7.3.7 Check the oil level and change the oil at the oil circulating
lubrication unit

See also Chapter 7.2 “Maintenance intervals”

• Carry out a visual check of the oil circulating lubrication system for leaks. Only re-
tighten/replace leaky bolted joints in an unpressurised condition.
• Check the oil level on the oil inspection glass of the tank with the crusher and
lubrication pumps switched off.
• Top up with oil if the oil level is too low.
• Switch off the crusher and the oil circulating lubrication unit for an oil change. Drain
the oil when it is at operating temperature.
• Provide an adequately sized tank (used oil quantity approx. 2,500 l).
• Drain and collect the used oil and dispose of it according to the regulations.
• Open the maintenance cover of the tank and clean the tank. Only use non-linting cloth
for cleaning (no cotton waste).
• Check the tubular steel protective casings of the heating inserts for damage.
• Provide the maintenance cover with a new seal if necessary.
• Fill with new filtered lubricating oil (filter fineness 25 µm). For the oil quantity and
quality, see lubricating instructions (Section 8).

Check the screen basket of the oil circulating lubrication:

• Check the screen insert of the screen basket with the cone crusher at standstill and the
oil circulating lubrication switched off; clean, if clogged.
Check interval: weekly

Checks at the oil /air cooler of the oil circulating lubrication

• Check that the cooling air can flow freely in and out.
• Clean the cooling fins or blow them out by means of compressed air.
Check interval: daily

Depending on the time of year and the oil viscosity, an increase in the oil return
temperature, longer switch-on times and shorter pause intervals of the coolers may be an
indication of
– mismatched temperature settings, e.g. switch-off function of the heating system
– insufficient protection against strong sunlight
– insufficient oil flow through the coolers.
02/2012 Rev 0

7 - 28 2-492-20908 (Pos 01)

 7.3.8 Check the hydraulic oil level and change the hydraulic oil

See also Chapter 7.2 “Maintenance intervals”

• Lower the main shaft completely.

• Check the hydraulic oil level on the inspection glass of the tank. The hydraulic oil level
must be at the max. mark.
• If the oil level is too low, top up with filtered oil (25 µm) until the max. mark is reached.
• Carry out a visual check of the complete system for leaks.
• In this respect, also unscrew the cover on the cylinder bottom of the hydraulic cylinder
and check the connection of the distance sensor.

WARNING
Risk of injury through leaking connections/ bolted joints

Death or severe bodily injuries are possible

• Only tighten/ replace in pressureless state.

NOTICE
System damage caused by mixing hydraulic oil with the lubricant oil of the
circulating lubrication

Damage to the machine/plant or its environment is possible

• Replace the piston seals on the hydraulic cylinder

If hydraulic oil has to be topped up several times a week without there being any
obvious leaks, this may be an indication of wear on the piston seals of the
hydraulic cylinder.

• Dismantle and repair/exchange the hydraulic cylinder (see Section 7.4.8.2).

Check interval: daily

• To change the hydraulic oil, lower the main shaft completely and switch off the
crusher and the hydraulic unit.
• Provide a tank (oil quantity approx. 630 l).
• Drain and collect the used oil and dispose of it according to the regulations.
02/2012 Rev 0

• Open the maintenance cover of the hydraulic oil tank and clean the tank. Only use non-
linting cloth for cleaning (no cotton waste).
• Provide the maintenance cover with a new seal if necessary.
• Fill with new filtered oil (filter mesh 25 µm). The max. filling level has been reached as
soon as the oil level is at the top edge of the inspection glass.
For oil quantity and quality, see the lubricating instructions (Section 8).

2-492-20908 (Pos 01) 7 - 29

 Check of the preload pressure of the balance unit
• Check the preload pressure on the pressure gauge of the air tank. The pressure
should be between 6 and 8 bar. If the pressure is too low, use the compressed air
system to re-fill with air.
Check interval: daily

7.3.9 Direct drive and pinion assembly

See Illustration 43
• For checks of the multiple-disc clutch and safety coupling, see ANNEX 9.

Oil level check and oil change at the pinion assembly

• Read the oil level on the oil inspection glass (1) with the crusher switched off.
• If the oil level is too low, unscrew the breather (2) and top up with filtered oil (filter mesh
25 µm) through the filter opening. Use the oil stated in the lubricating instructions
(Section 8).
• Carry out a visual check for leaks.
If oil has to be topped up every week without there being any obvious leaks, the shaft
sealing rings (3) on the pinion side are leaky.
Check interval: daily

See Chapter 7.2 “Maintenance intervals”

• Switch off the crusher to change the oil.
Drain the oil when it is at operating temperature.
• Place an tank (oil quantity approx. 50 l) under the pinion assembly.
• Unscrew the screw plug (4) on the pinion assembly flange.
• Collect the used oil and dispose of it according to the regulations.
• Screw in the screw plug with a new seal.
• Unscrew the breather and fill with filtered oil (filter mesh 25 µm) via the filter opening.
For the oil quantity and quality, see lubricating instructions (Section 8). Check the oil
level on the inspection glass.
• Clean/replace the breather and screw in.
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7 - 30 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 43

2-492-20908 (Pos 01) 7 - 31

 Resistance thermometer (5) for monitoring the bearing temperature
• Check the function
Check interval: daily

Accelerometer (6) for monitoring the condition of the bearing

• Check the function
Check interval: daily

Fluid switch (7) for monitoring the oil filling

• Check the function
Check interval: daily

Speed monitor of the pinion assembly shaft

• Check the function
Check interval: daily

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7 - 32 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 43

2-492-20908 (Pos 01) 7 - 33

 Check of the torsional back lash
See Illustration 44 and ANNEX 9.3
The backlash, i.e. the distance between the teeth of the bevel pinion (1) and the bevel gear
(2) should be 3.5 - 4.5 mm. The back lash refers to the average pitch circle diameter and
the pitch circle radius.
Incorrect backlash, i.e. excessive torsional backlash due to wear, not only causes
annoying running noises but also accelerates wear and tooth breakage.
The backlash can only be checked / measured outside the crusher. An auxiliary device
consisting of a
– Magnet support with arm and dial gauge (3),
– Bracket (4) and
– Pipe clip with auxiliary measuring rod (5) is required for this.

Proceeding from an average pitch circle radius (rm) of the bevel pinion, the backlash can
be measured as the path of rotation, the distance to the auxiliary measuring rod measured
by the dial gauge. To reduce measuring inaccuracies, the distance of the dial gauge to the
centre line should be an integer multiple higher than the pitch circle radius as far as
possible. 
For example, the desired measuring result would be at 2x(3.5 - 4.5 mm).
• Mount the bracket on the bearing cover of the pinion assembly and set the dial gauge
on the magnet support to the specified distance and align with the centre line of the
pinion assembly shaft.
• Turn the multiple-disk clutch and thus the bevel pinion to the right until the teeth of the
bevel pinion and the bevel gear contact each other.
• Attach the pipe clip and the auxiliary measuring rod to the multiple-disk clutch and align
vertically towards the dial gauge.
• Turn the multiple-disk clutch to the left until the teeth contact each other again. Read
off and record the value on the dial gauge. Swing the dial gauge away.
• Since approx. 4 rotations of the bevel pinion correspond to one rotation of the bevel
gear, turn the multiple-disc clutch by another 4 full rotations. Repeat the measuring
process after each single rotation. This is to account for the possible influence on the
measured values of the changing clearance between the eccentric bushing and the
outer bushing.
• Average the four measurements and convert to the actual back lash. If the calculated
average value is below / above these values, readjust the backlash.
• Readjust the back lash. To do so, change the thickness / number of
– the spacer plates (6) between the base plate and the bottom shell and
– the shims (7) of the pinion assembly flange.
Check interval: every 12 months

Visual check for damage

• Open the inspection opening (8) in the bottom shell with the crusher at standstill.
02/2012 Rev 0

• Carry out a visual check of the bevel pinion (1) and bevel gear (2) for jamming, grooves
and tooth breakage.
Check interval: every 3 months

7 - 34 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 44

2-492-20908 (Pos 01) 7 - 35

7.4 Repairs

WARNING
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation

Death or severe bodily injuries are possible

• Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off and secured against restarting.

INFORMATION
Heed Chapter 7.1.3 “Instructions for repairs”

• Have an annual general plant inspection carried out by responsible qualified personnel
and management staff. If necessary, consult ThyssenKrupp Fördertechnik. Have any
defects and damage remedied immediately!
• Co-ordinate the time and location of repair work with the regular maintenance and
inspection work.
• Spare parts must comply with the technical requirements specified by the
manufacturer. This is always ensured when using original spare parts - see spare parts
lists.
• Provide a complete set of wear parts - see spare parts lists. Replace when necessary
and re-machine worn parts if possible.
• Workshop equipment is required for the repair of assembly groups. Dismantle and
install assembly groups in the workshop.
• The assembly groups and individual components can be assembled and adapted to
the relevant crane capacities at the place of installation.
• Suspension points and drawings, see drawings in ANNEX 9.1.
• For weights of the components see Chapter 5.8.1 “Weights:”.
• Tightening torques for all relevant bolts, see Chapter 7.5.

The standards and tightening torques for machine bolts are included in Chapter 7.5.1.

INFORMATION
02/2012 Rev 0

Always use these tightening torques unless special tightening torques are stated.

7 - 36 2-492-20908 (Pos 01)

 Specific repair work, e.g. disassembly and assembly of structural units, assembly
groups and components are described in separate sections. These descriptions do not
exclude the use of other possibilities which may be appropriate from time to time.
However, the safety of the repair personnel and the machine / plant may not be adversely
affected.
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2-492-20908 (Pos 01) 7 - 37

7.4.1 Replacing the concaves

See Illustration 45 and drawings in ANNEX 9.1

To replace the concaves (1), disassemble the arm liners (2), spider (3), main shaft (4) and
liner plates (5). Use suitable tools e.g. Hytorc torque wrench, Superbolt torque wrench
(see ANNEX 9.10) to unscrew the nuts, remove the bolts and threaded bolts and to loosen
the spider from the upper shell (5).

• Empty the crusher, switch it off and secure it against accidental restarting.
• Disassemble the spider cap (5) and remove any grease via the spider bushing (7) and
dispose of it in an environmentally-friendly manner.
• Detach the control cable (8) and grease line (9). (They are located on the upper shell).
• Lift off the arm liners (2).

7.4.2 Disassembly of the spider

• Screw eye bolts into the transport holes of the spider (3).
• Attach the spider to the crane. Undo the connecting bolts and carefully lift the spider
together with the control cable and grease line.

INFORMATION
To detach the spider from the casting compound (if necessary), insert hydraulic
cylinders (provided by the customer) in the threaded holes in the upper shell.

• Lift the spider with the crane and place it down on the floor. Check the sealing elements
and spider bushing, replace if necessary (see Chapter 7.4.8).

7.4.3 Disassembly of the main shaft

• Attach crane to the eye bolts (10) of the main shaft (4) and lift the main shaft out of the
inner eccentric bushing (11). Ensure that the oil seal (14) in the sealing housing (13) of
the dust sealing does not catch on the main shaft. Possible safety hazard through
falling off!
• Protect the step bearing upper part (14) of the axial step bearing from damage and
place the main shaft in a supporting device/shaft stand on the floor.
• Cover the sealing housing of the dust sealing, thereby protecting the eccentric bushing
and axial step bearing against the ingress of dust.
• Carry out checks with the spider and main shaft dismantled. See Chapter 7.4.4.
• Check the liner plates (15) and wearing caps (16) in the bottom shell. Replace them if
02/2012 Rev 0

necessary.

7 - 38 2-492-20908 (Pos 01)

 Illustration 45
02/2012 Rev 0

2-492-20908 (Pos 01) 7 - 39

7.4.4 Checks to be made with the spider, main shaft and dust sealing
housing dismantled

See Illustration 46
Certain assembly groups of the crusher must be dismantled, in order to exchange the
concaves, mantle and other wearing parts in the crusher.
After dismantling, the following crusher components which are normally inaccessible
should always be checked for wear.

• Checks for wear with the spider dismantled:

– Wall thickness of the spider cap ( 1)
– Spider bushing of the spider bearing (2). 
For the exchange, see Chapter 7.4.8.
– Seals (toroidal sealing ring, shaft sealing rings, leather packing) of the spider
bushing. 
For the exchange, see Chapter 7.4.8.

• Checks for wear with the spider and main shaft dismantled:
– Main shaft sleeve (3) and lower shaft of the main shaft.
For the exchange, see Chapter 7.4.7.
– Step bearing upper part (4) of the axial step bearing.
For the exchange of the axial step bearing, see Chapter 7.4.10.
– Check the wear and clearance of the polyamide sealing ring (5) between the top
and bottom sealing ring of the dust sealing. For the exchange of the polyamide
sealing ring, 
see Chapter 7.4.9.
• Other checks:
– Free passage of air duct to the sealing housing. 
If necessary, detach the air connection from the bottom shell of the crusher and
blow compressed air through the air duct.
– Check the bottom sealing ring (6) for secure attachment.
– Check the sealing housing for damage through the polyamide sealing ring (5). For
the exchange of the sealing housing, see Chapter 7.4.9.

• Checks for wear with the spider, main shaft and dust sealing housing
dismantled:
– Inner eccentric bushing (7) of the eccentric bushing. For the exchange, see
Chapter 7.4.11.1.
• Other checks:
– Clearance between the outer bushing and the eccentric bushing. To check, turn the
eccentric bushing, so that it contacts one side of the outer bushing.
For the exchange of the outer bushing, see Chapter 7.4.11.4.
02/2012 Rev 0

– Check the step bearing lower part (8) and slide bearing plate (9) of the axial step
bearing for damage. 
For the exchange of the axial step bearing, see Chapter 7.4.10.

7 - 40 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 46

2-492-20908 (Pos 01) 7 - 41

7.4.5 Concaves

See Illustration 47

Dismantling the concaves

• Weld lifting eye to the concaves (1 to 3) and attach the crushing concave to be
dismantled to the crane.
• Remove the concaves in rings from top to bottom. For this purpose:
– Separate /flame cut one concave of the relevant concave ring.
– Loosen and lift out the concaves by means of a hydraulic hammer or pneumatic
hammer.

WARNING
Risk of injury caused by dust load

Death or severe bodily injuries are possible

• Ensure good ventilation.

• Wear a face mask as protection against the dust of the casting compound.

• Remove the old casting compound from the spider and shell and clean them.

Mounting the concaves

• For mounting the concaves, see Chapter 5.8.7 and drawings in ANNEX 9.1.

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7 - 42 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 47

2-492-20908 (Pos 01) 7 - 43

7.4.6 Liner plates and wearing caps

See Illustration 47

• Weld lifting eyes to the liner plates (4,5,7).

• Separate (grind off, flame-cut, gouge) the weld seams which join the liner plates to the
crusher shells, and dismantle the liner plates in rings from top to bottom.

• Clean/re-grind the bearing surfaces.

• Position, press on, tack-weld and weld new liner plates (horizontal weld seams at top,
bottom and plug weld).
Heed the welding instructions on the drawings in ANNEX 9.1!

• Check, exchange and re-position the wearing caps (6) on the arms in the bottom shell.
For mounting the liner plates and wearing caps, see Chapter 5.8.7 and Chapter 5.8.2.

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7 - 44 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 47

2-492-20908 (Pos 01) 7 - 45

7.4.7 Main shaft

See Illustration 48

Exchange of the main shaft sleeve

• Screw eye bolts into the threaded holes of the main shaft sleeve (1), attach to lifting
gear and pull sling ropes tight.
• Cut wearing bushing (1) lengthways and then insert for disassembly.

NOTICE
System damage caused by damaging the axle when cut

Damage to the machine/plant or its environment is possible

• Do not cut through wearing bushing (1) completely.

• Heat the main shaft sleeve to approx. 100 °C above the ambient temperature.
• Quickly withdraw the main shaft sleeve from the main shaft and set it down
immediately. If the main shaft sleeve cools down too rapidly during the pulling process
and re-shrinks on the main shaft, reheat it.
• Allow the main shaft to cool down.
• Clean the seat of the main shaft sleeve and the shaft of the main shaft.
• Attach a new main shaft sleeve to a hoist and heat it up to approx. 100 °C above
ambient temperature.
• Quickly place the main shaft sleeve on the shaft. If necessary, continue to heat the
main shaft sleeve during installation.
• After the installation. clean and grease the main shaft sleeve.

Exchanging the mantles

• In order to avoid damage to the dust sealing when replacing the mantles (2) and (3),
remove the bottom sealing ring (4), the polyamide sealing ring (5) and the top sealing
ring (6) from the main shaft.
• In order to avoid damage, remove the step bearing upper part (7).
• Place the main shaft in the supporting device.
• Detach the protective cap (8) and outer ring nut (9). If this is not possible, the
intermediate ring (10) must be separated by a horizontal flame cut to relieve the
pretension in the thread.
• Lift off the mantles (2) and (3) individually. To do so, weld on 4 lifting eyes (11) (for each
crushing cone) offset by 90° (mantle consists of austenitic manganese steel).
02/2012 Rev 0

• Pre-heat the bottom third of the top mantle (2) to approx. 50 °C above ambient
temperature and loosen it by hitting it around the entire circumference; then lift it off.
• Repeat this process for the lower mantle (3).

7 - 46 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 48

2-492-20908 (Pos 01) 7 - 47

 Mounting the mantles
• Clean the contact surfaces of the mantles.
• For mounting the new mantles, see Chapter 5.9.2.
• Screw up the step bearing upper part (7) of the axial step bearing.

We recommend checking the complete axial step bearing. Also check the dust sealing
before mounting the main shaft.

• Re-mount the dust sealing. Check the bolts on the sealing housing for secure
attachment/re-tighten if necessary.

INFORMATION
The cores (12 and 13) do not need to be replaced after an initial installation in line
with good professional practice.
When exchanging the mantles (2 and 3), check the secure attachment of the
cores. If secure attachment of the cores is not provided, remove them using the
same method as for the mantles (see Chapter 7.4.7) and check them for external
damage.
Reinstall the cores after a functional check (see Chapter 5.9.2).

02/2012 Rev 0

7 - 48 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 48

2-492-20908 (Pos 01) 7 - 49

7.4.8 Spider bearing with grease lubrication

See Illustration 49

If excessive grease leaks from the main shaft sleeve, and the clearance between the main
shaft sleeve and the spider bushing of the spider bearing is considerably below the max.
value of 3.5 mm, replace only the sealing elements of the spider bushing.
If the clearance exceeds 3.5 mm, the spider bushing must be exchanged. In both cases,
remove the spider cap and withdraw the spider bushing from its seat in the spider (see
Chapter 7.3.4) – check the spider bushing for wear.

• Empty the crusher, switch it off and secure it against re-start.

• Set up a working platform in the crusher inlet.
• Clean the spider cap (1) and spider (2). Remove the spider cap.
• Remove the sensor bracket (3).
• Remove the grease filling over the spider bushing (4) and dispose of it in an
environmentally-friendly manner.
• Unscrew the bolts (5) of the spider bushing. Screw 2 jack screws into the threaded
holes (6) and force the spider bushing out of the seat of the spider.
For this purpose use the forcing hydraulics (12).

INFORMATION
For dismantling the outer eccentric bushing (4), see Chapter 5.9.1 “Spider
bearing” and ANNEX 9.1 "Drawings".

• Insert eye bolts into the threaded holes (7) and use a hoist to lift out and set down the
spider bushing with sealing ring (9).
• Remove the leather package (10).
• Replace the leather package (10) and shaft sealing rings (11). Soak the new leather
package in oil beforehand.
• Clean and grease the seat of the spider.
• Insert the spider bushing with sealing ring (9) (replace if worn).

INFORMATION
The spider bushing must slide into the seat of the spider without force. Do not
press in or cool the bushing under any circumstances. Rework the spider bushing
if necessary.

• Mount the sensor bracket (3).

02/2012 Rev 0

• Top up the grease and mount the spider cap.

• Restore the operational condition.

Exchange of the grease lubrication pump

If the delivery rate of the grease pump is too low and no other causes are detected, the
grease lubrication pump is defective and must be replaced (see ANNEX 9).

7 - 50 2-492-20908 (Pos 01)

 Illustration 49
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2-492-20908 (Pos 01) 7 - 51

7.4.9 Dust sealing

See Illustration 50

Dismantle the spider and the main shaft (see Chapter 7.4.2 and Chapter 7.4.3) and
replace the worn components of the dust sealing.
• Unscrew the bottom sealing ring (1) from the top sealing ring (2) on the dismantled
main shaft and remove the plastic sealing ring (3).
• Apply a small amount of grease to the new plastic sealing ring. Re-insert the spacer
disks (4). The plastic sealing ring must slide radially (clearance 0.2 to 0.3 mm) and may
not jam.
• To replace the sealing housing (5), remove the oil seal (6), undo the bolts and remove
the sealing housing.

INFORMATION
Check the clearance (max. 3 mm) between the outer bushing in the bottom shell
of the crusher and the eccentric bushing with the sealing housing dismantled. If
the clearance is excessive, remove the outer bushing and replace it. For
dismantling the outer bushing, see Chapter 7.4.11.4.

• Clean the bearing face of the sealing housing on the bottom shell of the crusher. Insert
a new toroidal sealing ring ring (7) and O-ring (8).
• Place a new sealing housing in the seat of the bottom shell of the crusher and bolt it in
place. Ensure that the holes of the air and oil duct are on top of each another.
• Insert the oil seal (6) and reinstall the main shaft and spider.
• Restore the operational condition.

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 Illustration 50
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2-492-20908 (Pos 01) 7 - 53

7.4.10 Main shaft axial step bearing

See Illustration 51

To check the wear directly and to exchange the axial step bearing, either
– dismantle the hydraulic cylinder (1) (see Removing the hydraulic cylinder and
exchanging the eccentric bushing, Chapter 7.4.11.3) and remove the axial step
bearing (2) and (3) in a downward direction or
– dismantle the spider and the main shaft (see Chapter 7.4.2 and Chapter 7.4.3) and
remove the axial step bearing in an upward direction.

The second possibility is described here, i.e. the spider and main shaft are dismantled.
• To dismantle the axial step bearing, remove the oil seal (4) and dismantle the sealing
housing (5) of the dust sealing. We also recommend removing the inner eccentric
bushing (6) (see Chapter 7.4.11.1).
• Screw eye bolts into the threaded holes of the slide bearing plate (3) and attach the
slide bearing plate to a hoist.
• Lift out the slide bearing plate and the step bearing lower part resting on it (2) through
the eccentric bushing. Tilt the slide bearing plate if it cannot be lifted off the piston of
the hydraulic cylinder.
• Unscrew the step bearing upper part (8) from the main shaft. See Chapter 7.4.7.
• Place the components of the axial bearings on top of each another and measure them,
i.e. determine the wear. The overall height of the new axial step bearing is approx. 200
mm.
The depth of the lubrication grooves in the step bearing upper part and the slide
bearing plate is 8 mm in each case. If the overall height is less than approx. 185 mm
(depth of lubrication grooves only approx. 1 mm ) or if there is other damage, replace
all the components of the axial step bearing.
• Check all the components of the axial step bearing, in particular:
– Sliding surface and lubrication grooves of the step bearing upper part
– Sliding surface of the step bearing lower part and
– Sliding surface and lubrication grooves of the slide bearing plate for damage.
Replace the components if they are damaged.

• The axial step bearing is installed in the reverse order. Ensure that the new slide
bearing plate rests on the rotary locking (9) of the piston.
• Mount the main shaft and spider.
• Restore the operational condition.
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02/2012 Rev 0

Illustration 51

2-492-20908 (Pos 01) 7 - 55

7.4.11 Eccentric bearing

7.4.11.1 Replacing the inner eccentric bushing

See Illustration 52

To exchange the inner eccentric bushing (1), either

– dismantle the spider, the main shaft and the sealing housing of the dust sealing or
– the hydraulic cylinder and the eccentric bushing (see Chapter 7.4.11.2 “Removing the
hyLdraulic cylinder and exchanging the eccentric bushing”).

The first possibility is described here, i.e. the spider, main shaft and sealing housing of
dust sealing are dismantled.

• Check the inner eccentric bushing (and the main shaft) for grooves, cracks, run-in
marks caused by an excessive edge pressure and increased bearing temperatures.
Check the dimensional accuracy.

NOTICE
System damage caused by damage to the eccentric bushing

Damage to the machine/plant or its environment is possible

• Check the spider bushing of the spider bearing and replace if worn (see
Chapter 7.4.8).
• When mounting a new inner eccentric bushing, also replace the spider bushing.

• Unscrew the device for compensating unbalance (2) from the eccentric bushing (3) and
screw eye bolts into the inner eccentric bushing (1).
• Remove the inner eccentric bushing including the feather key (4) from the eccentric
bushing by means of a hoist.
• Insert a new inner eccentric bushing and feather key in the groove of the eccentric
bushing and re-mount the device for compensating unbalance.
• Mount the sealing housing of the dust sealing.
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 Illustration 52
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7.4.11.2 Removing the hyLdraulic cylinder and exchanging the eccentric bushing
See Illustration 53

To remove the eccentric bushing (1), dismantle the hydraulic cylinder (2) and the base
plate (3) beforehand.
• Empty the crusher, change over to local operation, lift the main shaft. Switch off the
crusher.
• Open the inspection hole cover (4) on the bottom shell and place supporting trestles
(5) on the three arms of the bottom shell.
• Lower the main shaft so that the mantle rests securely on the three supporting trestles.
• Lower the piston (5) of the hydraulic cylinder to the full extent.
• Switch off the hydraulic unit and depressurise the hydraulic system.
• Move the maintenance car under the hydraulic cylinder.

WARNING
Risk of crushing when the maintenance car is moving

Death or severe bodily injuries are possible

• Make sure no unauthorised persons are near the maintenance car.

• Avoid the danger zone.

Removing the hydraulic cylinder

• Drain and collect residual oil from the lines, cylinder and the surface of the piston.
• Remove the pipes of the hydraulic system (7) and (8) and the oil circulation lubrication
(9) and protect them from the ingress of dust.
• Disconnect the connection cable (10) of the distance sensor (11).
• Mark the position of the hydraulic cylinder with respect to the bottom shell.
• Position and use the maintenance car to dismantle the hydraulic cylinder and the base
plate as well as the eccentric bushing. See the maintenance car documentation.
• Unscrew the fastening bolts (12) of the secured hydraulic cylinder.
• Lower and remove the hydraulic cylinder by means of a scissor lift table.

INFORMATION
Check the axial step bearing after the hydraulic cylinder has been removed and
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replace it if necessary (see Exchanging the axial step bearing, Chapter 7.4.10).

7 - 58 2-492-20908 (Pos 01)

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Illustration 53

2-492-20908 (Pos 01) 7 - 59

7.4.11.3 Removing the eccentric bushing

See Illustration 54
• The maintenance car with scissor lift table is required to dismantle the eccentric
bushing (1) and the base plate (2).
• Unscrew the fastening bolts (3) of the secured base plate. Remove and keep the
spacer plates in sets for reuse (7 – 10) - important for setting the backlash between the
bevel pinion and the bevel gear.

CAUTION
Risk of injury caused by the eccentric bushing moving on the base plate

Physical injury is possible

• Lower the base plate and eccentric bushing, so that the eccentric bushing is still
guided in the bottom shell.
• Secure the eccentric bushing against lateral sliding from the base plate.

• Remove the base plate and the eccentric bushing.

• Screw eyelet bolts into the eccentric bushing.
• Lift the eccentric bushing from the base plate and the axial bearing ring (4) using a
crane and set it down.
• Check the following for wear and damage:
– Eccentric bushing (1) (including inner eccentric bushing) and bevel gear (5)
– Bevel pinion (6) of the pinion assembly
– Axial bearing ring (4)
– Outer bushing (11) in the bottom shell of the crusher.
• Replace the eccentric bushing body if it is damaged.
• Heat the damaged/worn bevel gear (max. 150 °C) and lift it off the eccentric bushing
(which can be re-used) by means of a hoist.
• Replace the feather key (12) and install a new warm bevel gear.

NOTICE
System damage caused by uneven wear

Damage to the machine/plant or its environment is possible

02/2012 Rev 0

• When replacing the bevel gear, also replace the bevel pinion of the pinion
assembly (see Chapter 7.4.12).

• Replace a damaged / worn axial bearing ring (4).

7 - 60 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 54

2-492-20908 (Pos 01) 7 - 61

7.4.11.4 Exchanging the outer bushing

WARNING
Risk of crushing when the maintenance car is moving

Death or severe bodily injuries are possible

• Make sure no unauthorised persons are near the maintenance car.

• Avoid the danger zone.

• Position the maintenance car with scissor lift table under the crusher (refer also to the
maintenance car documentation).
• Secure the flange ring (2) of the outer eccentric bushing (1).
• Unscrew the bolts and detach the flange ring of the outer eccentric bushing by means
of jack screws.
• Lower the outer eccentric bushing and the flange ring, remove them from the working
area and replace them.
• For mounting, oil the new outer bushing and re-mount in the reverse order.

7.4.11.5 Mounting the eccentric bushing

• Replace all the sealing rings and clean and oil the sliding surfaces before mounting the
eccentric bushing (3). Replace the sealing cord (4) of the base plate.
• Use a suitable device to mount the base plate (5), axial bearing ring (6) and eccentric
bushing (3); secure the components against sliding.
• Use suitable lifting gear to partially slide the eccentric bushing onto the main shaft (13)
and into the outer eccentric bushing (1) of the bottom shell.
• Place and align the spacer plate (7 – 10) on the base plate.
• Lift the base plate and the eccentric bushing up further. Slightly turn the drive coupling /
pinion assembly shaft, so that the teeth of the bevel gear can engage the pinion.
• Press the base plate into the seat of bottom shell; do not damage the sealing cord (4).
Screw on the base plate (5) by means of bolts (11).
• Check the back lash, re-adjust if necessary (see Chapter 7.3.9).
• Replace the O-rings and seals on the flange of the hydraulic cylinder before mounting
the hydraulic cylinder.
• When mounting the hydraulic cylinder, ensure that the bores (residual oil drain) in the
base plate and the cylinder flange are on top of each other.
• Re-connect the lubricating oil lines, hydraulic lines and distance sensor.
02/2012 Rev 0

• Bleed the hydraulic cylinder.

• Lift the main shaft, remove the supporting trestles (12), close the inspection hole cover.
• Restore the operational condition.

7 - 62 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 55

2-492-20908 (Pos 01) 7 - 63

7.4.12 Crusher main drive and pinion shaft assembly

See Illustration 56 and Chapter 5.10.2

7.4.12.1 Exchanging the bevel pinion

If the bevel pinion (1) has to be replaced:

• Remove the protective hood over the crusher main drive motor.
• Remove the bracket of the speed monitor (5).
• Remove the hose connection (6) of the fluid switch (7) and drain and collect the oil from
the pinion assembly and dispose of it.
• Attach the spacer tube (8) to ropes, mark the flanged connections.
• Remove the screws of the distance tube.
• Push back the multiple-disc clutch (3) towards the motor (2) until the centring of spacer
tube are exposed.
• Set down the spacer tube and remove/set down the multiple-disc clutch (3) with safety
coupling (9) from the clutch hub (on the pinion assembly shaft).
• Unscrew the pinion shaft assembly. Remove the shims (10) and keep them in a safe
place - important for setting the backlash between the bevel pinion and the bevel gear.
• Remove the pinion shaft assembly from the pinion assembly tunnel using a cable
winch - keep it horizontal.
• Reattach the cable winch and place the pinion shaft assembly in a stable supporting
unit with the pinion pointing upwards.
• Unscrew the end disk (11), screw in eye bolts and attach the pinion to a hoist.
• Heat the pinion and remove it by means of a hoist.

INFORMATION
The roller bearings of the pinion shaft assembly can be exchanged in this
dismantled state (see the following section).

• Screw in the eye bolts before mounting the new bevel pinion. Preheat the new bevel
pinion to a max. 150 °C in the oil bath and install it.

NOTICE
System damage caused by uneven wear
02/2012 Rev 0

Damage to the machine/plant or its environment is possible

• When replacing the bevel gear, also replace the bevel pinion of the pinion
assembly (see Chapter 7.4.11.3).

7 - 64 2-492-20908 (Pos 01)

02/2012 Rev 0

Illustration 56

2-492-20908 (Pos 01) 7 - 65

 • Screw on the end disk.
• Replace the toroidal sealing ring (12).
• Insert the pinion shaft assembly in the pinion assembly tunnel by means of cable
winches. Slightly turn the pinion assembly shaft, so that the pinion can engage in the
bevel gear.
• Insert shims (10) and screw on the pinion shaft assembly.
• Check torsional backlash and contact pattern.
See Chapter 7.3.9 and ANNEX 9.3.
• Re-mount the distance tube (8), multiple-disc clutch (3) and safety coupling (9).
See Chapter 5.10.2 and ANNEX 9.3.
• Re-mount the bracket of the speed monitor (5).
• Mount the hose connection (6).
• Fill with filtered oil (25 µm) according to the lubrication instructions in Section 8, and
check the oil level on the oil level indicator (13).
• Restore the operational condition.

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02/2012 Rev 0

Illustration 56

2-492-20908 (Pos 01) 7 - 67

7.4.12.2 Exchange of the roller bearings

See Illustration 57

Disassembly
• Unscrew the bolts (1) and remove the bearing cover (2).
• Place the pinion shaft assembly housing (3) (with the pinion side down) vertically in a
stable supporting device. Attach the pinion assembly shaft (4) to a hoist (Ill. 1).
• Detach the locking plate (5) and unscrew the shaft nut (6).
• Remove the ring (7) and V-ring (8).
• Unscrew the bolts (9) and remove the bearing cover (10) with helical compression
springs (11) and shaft sealing ring (12).
• Remove the spacer sleeves (13) and (14).
• Remove the spacer sleeve (15).
• Remove the pinion assembly shaft (4) together with the bearings (16), inner race of the
bearing (17) and spacer sleeve (18) from the pinion shaft assembly housing; place it
horizontally on a support.
• Remove the bearing (16) from the pinion assembly shaft.
• Remove the outer race of the bearing (17) from the housing (3).

Assembly
• Check all the spacer sleeves for grooving, replace if necessary.
• Replace the toroidal sealing rings (19, 20, 21).
• Install new bearings (16) on the shaft.
• Insert a new bearing (17) in the bearing housing (3).
• Lower the pinion assembly shaft (4) into the housing together with the bearings (16)
(Ill. 1).
• Re-insert the spacer sleeves (14) and (13) in the housing.
• Exchange the O-ring (22) and push the spacer sleeve (15) on the shaft.
• Insert the bearing cover (10) with helical compression springs (11) and shaft sealing
ring (12) and tighten the bolts (9).
• Install the V-ring (8) and ring (7) on the shaft.
• Attach the locking plate (5) and tighten and secure the shaft nut (6).
• Push the spacer sleeve (18) on to the shaft.
• Insert the shaft sealing ring (23) and tighten the bearing cover (2) by means of bolts (1).
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02/2012 Rev 0

Illustration 57

2-492-20908 (Pos 01) 7 - 69

7.5 Screwed and bolted connections

Always protect all screwed and bolted connections against corrosion.

7.5.1 Machine structures

For machine structures: Standard Quality

Hexagon bolt (thread up to head) DIN EN ISO 4017 8.8 / 10.9 / 12.9

Hexagon socket head cap bolt DIN EN ISO 4762 8.8 / 10.9 / 12.9

Hexagon socket head cap bolt with short head DIN 7984 8.8 / 10.9 / 12.9

Hexagon nut DIN EN ISO 4032 8 / 10 / 12

Washer DIN 6916 C 45 hardened

Hexagon fitted bolts DIN 609 8.8 / 10.9 / 12.9

• Use only the following bolts and nut qualities together:

Bolt quality: 8.8 10.9 12.9

Nut quality: 8 10 12

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 Tightening torques for machine structures

Calculated with µk = 0.14 (new bolts, without post-treatment) in accordance with VDI 2230

Tightening torque Ma (Nm)

Bolt diameter Class

8.8 10.9 12.9

M6 11 15 18

M8 26 36 43

M10 51 71 86

M12 88 123 148

M16 211 300 358

M20 412 579 697

M24 711 1000 1196

M30 1422 2010 2403

M36 2481 3491 4197

M42 3991 5609 6727

M48 6021 8473 10150

M56 9650 13582 16279

M64 14416 20300 24320

INFORMATION
Only use the tightening torques listed in the table when no special tightening
torques are indicated in the relevant section.
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7.5.2 High-tensile bolted joints

In the case of high-tensile (friction-type bolted connections), the force is transmitted by

friction between the contact faces and depends on the pretensioning force of the bolts.
The contact faces must be bright. They must be cleaned by sandblasting, flame cleaning
or chemical detergents (DIN 18800, DIN V 18800-7 - Annex D.1.6).

• Use bolts, nuts and washers from one manufacturer only. A uniform protection against
corrosion is compelling.
• Only use properly oiled bolts in perfect condition.
• Use a torque wrench to produce the required bolt pretensioning force.

Components are marked as Manufacturer

Material data Marked HSFG
follows data

Hexagon bolt HSFG  10.9 yes HSFG

as per DIN 6914

Hexagon nut HSFG  10 yes HSFG

as per DIN 6915

Washer  - yes HSFG

as per DIN 6916

• Use only the following bolts and nut qualities together:

Bolt quality 10.9 12.9

Nut quality 10 12

For steel structures: Standard Quality

Hexagon bolt DIN 6914 10.9 / 12.9

Hexagon nut DIN 6915 10 / 12

Washer DIN 6916 C 45 hardened

• Use the required pretensioning forces indicated in the table below or in the drawing.
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 Pretensioning forces and tightening torques applicable to torque methods for sets corresponding to
tensile strength class 10.9 according to table 5, DIN V 18800-7.

Torque method

Basic pretensioning Required tightening torque to achieve the basic

force Fv in kN pretensioning force
MA in Nm

Hot-galvanised and As manufactured and

Dimensions
lubricated 1) slightly oiled

M 12 50 100 120

M 16 100 250 350

M 20 160 450 600

M 22 190 650 900

M 24 220 800 1100

M 27 290 1250 1650

M 30 350 1650 2200

M 36 510 2800 3800

1) Nuts lubricated with molybdenum disulphide or equivalent lubricants

Check the friction grip connection immediately following installation and at least once a year:

Prestressed bolted connections (DIN V 18800-7 1.2.2.2)

(1216) When using the torque method, at least 5 % of the sets of the connection must be
checked (at least 2 bolted connections for connections with less than 20 bolts). A test
torque which is a maximum of 10% higher than the applied tightening torque is transmitted
to the set on the side on which it was tightened. Proceed as described in Table 7
depending on the angle of rotation that is achieved till the torque wrench is activated. If
necessary, retain the element not to be turned in order to prevent it from turning.

Checking the prestressing force according to the torque method 

(DIN V 18800-7 Table 7)

Angle of additional Measures

rotation

< 30° none, pretensioning is adequate

30° to 60° pretensioning is adequate, check two adjacent bolts of the same connection

> 60° replace the bolt, check two adjacent bolts of the same connection
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 Blank page

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 8 Lubrication

8.1 Introduction and technical instructions

WARNING
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation

Death or severe bodily injuries are possible

• Cleaning, inspection, maintenance and repair work may only be carried out
when the machine/plant is switched-off.

Maintaining the operating reliability and an adequate service life calls for orderly
lubrication with lubricants which are most suitable for the individual application. It is not
possible to determine the complete characteristics of the lubricants by means of the
reference values stated in the table of lubricants. The supplier of the lubricant is solely
responsible for the correct selection of the lubricant with due consideration given to the
local conditions and conditions of application of such industrial systems as well as the
state-of-the art-in the field of lubrication engineering.

The lubricants are provided by the owner on-site.

We will not accept any claim for defects or damage which can be attributed to incorrectly
selected lubricants.

In summary, we recommend the exclusive use of high-quality lubricants which have been
selected by reputable companies in accordance with our guiding values.

INFORMATION
All of the mineral oil companies stated in the table of lubricants offer a lubrication
service, and their technicians are available to our customers to answer any
questions about appropriate lubrication.
02/2012 Rev 0

2-492-20908 (Pos 01) 8-1

 NOTICE
System damage through improper lubrication

Damage to the machine/plant or its environment is possible

• Lubrication and any work in connection with lubrication must be carried out at
operating temperature with the machine/ plant at a standstill.

In particular, the following points must be noted:

– Refer to the table of lubricants for recommended lubricants (Chapter 8.4, Special
lubricants Chapter 8.4.2).

– Carry out lubrication at the lubrication intervals specified in the lubricating instructions
(Chapter 8.5) using the stated lubricants and quantities.

– It goes without saying that this recommendation does not exclude lubricants of another
make with the same properties.

8.2 Storage of lubricants

• Carefully close the container immediately after removing lubricant. Store the
containers in enclosed dry indoor areas. You thereby avoid contamination of the
lubricants. Ensure that lubricants are stored, used and disposed of in an
environmentally friendly manner and comply with the relevant national environmental
regulations when handling lubricants.

• Observe the relevant national occupational safety, health and fire protection
regulations when storing and handling lubricants.

• Mark drums, canisters, oil cans and grease guns with different colours according to
their content. Mixing of lubricants is not allowed.
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 8.3 General information on lubrication

8.3.1 Oil groups

The oil types listed in Chapter 8.4 “Table of lubricants (Index 8)” are broken down into the
following oil groups:

• Mineral oils = CLP

• Polyglycols = CLP PG (synthetic oils)
• Poly-a-olefins = CLP HC (synthetic oils)
• Hydraulic oils = HLP
• Hydraulic oils = HVLP (improved viscosity-temperature relationship)

INFORMATION
Gear unit

To select oils, refer to the viscosity indicated on the ID plate of the gear unit.

Comply with the oil quality required by the manufacturer. If necessary, have the
quality confirmed by your supplier. Every lubricant manufacturer or supplier is
responsible for the quality of its products.

The required quantity depends on the oil level measured on the inspection glass,
the dipstick or the oil overflow opening.

Change the oil in accordance with the intervals stipulated by the gear unit
manufacturer. In addition, check the oil level regularly and top-up, if necessary.

When the oil type is changed, as little old oil as possible may remain in the gear
unit. As a rule, small residues do not cause any problems. Gear oils of different
types and from different manufacturers may not be mixed together. If necessary,
have the compatibility of the new oil with the residues of the old oil confirmed by
the manufacturer.

When changing from polyglycols to other gear oils or vice versa, always
thoroughly purge the gear unit with the new oil. Residues of the old oil must be
completely removed from the gear unit.
02/2012 Rev 0

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 • Carry out regular relubrication at appropriate intervals. Poor lubrication may cause
damage to the machine components.
• When purging, use a low-viscosity oil type of the same basis and from the same
manufacturer; never mix mineral oil with synthetic oil.
• Rinse out and dry the bearing and bearing housing if a grease with different soap
properties is to be used.
• Completely fill the bearings with grease. Only partially fill the free space in the housing
with grease (around 30-50 %). Then mount the bearings.
• Completely fill the labyrinth gaps with grease.
• Relubricate the bearings and labyrinths.

After lubricating:
• Do not wipe grease off lubricating nipples/lubricating heads!

NOTICE
System damage from contamination in the grease

Damage to the machine/plant or its environment is possible

• Work in a clean manner! Even minor contamination in the grease will affect the
service life of the bearing points.

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 8.3.2 Open toothed gears

DANGER
Risk of injury through cleaning, inspection, maintenance, and repair work
during operation

Imminent danger of death or severe bodily injuries. Open toothed rim drives and
toothed racks may draw in and crush parts of the body

• Never lubricate the machine while it is in operation.

Thoroughly clean open toothed rim drive units and toothed racks before lubrication. Apply
lubricant in a thin and even layer.

8.3.3 Lubricant lines

Ensure that the lubricant lines are thoroughly cleaned before commissioning and that they
are filled with the prescribed lubricant.
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8.4 Table of lubricants (Index 8)

8.4.1 Standard lubricants

8.4.1.1 Lubricating oils

Index Fuchs
Used for Class Aral BP ESSO Mobil Shell Texaco Klüber
number Europa

Hydraulic
couplings and ISO VG 32 Vitam Energol Nuto Renolin Rando LAMORA
A1 DTE 24 Tellus 32
hydraulic HLP GF 32 HLP-HM 32 H 32 B 10 HD 32 HLP 32
systems

ISO VG Vitam Energol Nuto Renolin Rando Oil LAMORA

A2 DTE 25 Tellus 46
46 HLP GF 46 HLP-HM 46 H 46 B 15 HD 46 HLP 46
Hydraulic
systems
ISO VG Vitam Energol Nuto Renolion Rando Oil LAMORA
A3 DTE 26 Tellus 68
68 HLP GF 68 HLP-HM 68 H 68 B 20 HD C-68 HLP 68

ISO VG Vitam Bartran Univis Renolin Tellus Rando Oil

B1 DTE 13 M —
32 HVLP HF 32 HV 32 N 32 MR 32 MC T 32 HD AZ 32

Hydraulic ISO VG Vitam Bartran Univis Renolin Tellus

B2 DTE 15 M —
systems 46 HVLP HF 46 HV 46 N 46 MR 46 MC T 46

ISO VG Bartran Univis Renolin Tellus Rando Oil

B3 — DTE 16 M —
68 HVLP HV 68 N 68 MR 68 MC T 68 HD CZ 68

Renolin Klüberoil
ISO VG Degol Energol Spartan Mobilgear Omala Meropa
C1 CLP 150/ GEM
150 CLP BG 150 GR-XP 150 EP 150 600 x P150 150 150
Plus 1-150 N

Renolin Klüberoil
ISO VG Degol Energol Spartan Mobilgear Omala Meropa
C2 CLP 220/ GEM
220 CLP BG 220 GR-XP 220 EP 220 600 x P220 220 220
Plus 1-220 N

Renolin Klüberoil
Gear units and ISO VG Degol Energol Spartan Mobilgear Omala Meropa
C3 CLP 320/ GEM
gear motors 320 CLP BG 320 GR-XP 320 EP 320 600 x P320 320 320
Plus 1-320 N

Renolin Klüberoil
ISO VG Degol Energol Spartan Mobilgear Omala Meropa
C4 CLP 460/ GEM
460 CLP BG 460 GR-XP 460 EP 460 600 x P460 460 460
Plus 1-460 N

Renolin Klüberoil
ISO VG Degol Energol Spartan Mobilgear Omala Meropa
C5 CLP 680/ GEM
680 CLP BG 680 GR-XP 680 EP 680 600 x P680 680 680
Plus 1-680 N

ISO VG Renolin Mobilgear Klübersynth

Degol Omala Pinnacle
D1 150 CLP — — Unisyn SHC XMP GEM
PAS 150 HD 150 EP 150
HC CLP 150 150 4-150 N

Enersyn
ISO VG EP-XF 220 Renolin Mobilgear Klübersynth
Degol Omala Pinnacle
D2 220 CLP (is no — Unisyn SHC XMP GEM
PAS 220 HD 220 EP 220
HC longer CLP 220 220 4-220 N
produced)
Synthetic gear
ISO VG Renolin Mobilgear Klübersynth
oil Degol Enersyn Omala Pinnacle
D3 320 CLP — Unisyn SHC XMP GEM
PAS 320 EP-XF 320 HD 320 EP 320
02/2012 Rev 0

HC CLP 320 320 4-320 N

ISO VG Renolin Mobilgear Klübersynth

Degol Omala Pinnacle
D4 460 CLP — — Unisyn SHC XMP GEM
PAS 460 HD 460 EP 460
HC CLP 460 460 4-460 N

ISO VG Renolin Mobilgear Klübersynth

Omala
D5 680 CLP — — — Unisyn SHC XMP — GEM
HD 680
HC CLP 680 680 4-680 N

8-6 2-492-20908 (Pos 01)

 Index Fuchs
Used for Class Aral BP ESSO Mobil Shell Texaco Klüber
number Europa

ISO VG
Degol Renolin Tivela Synlube Klübersynth
E1 150 CLP — — —
GS 150 PG 150 S 150 CLP 150 GH 6-150
PG

ISO VG
Degol Enersyn Glycolub Renolin Glycoyle Tivela Synlube Klübersynth
E2 220 CLP
GS 220 SG-XP 220 e 220 PG 220 HE 220 S 220 CLP 220 GH 6-220
PG
Synthetic gear
oil ISO VG
Degol Enersyn Renolin Glycoyle Tivela Synlube Klübersynth
E3 Cannot be 320 CLP —
GS 320 SG-XP 320 PG 320 HE 320 S 320 CLP 320 GH 6-320
mixed with PG
mineral oil.
ISO VG
Degol Enersyn Glycolub Renolin Glycoyle Tivela Synlube Klübersynth
E4 460 CLP
GS 460 SG-XP 460 e 460 PG 460 HE 460 S 460 CLP 460 GH 6-460
PG

ISO VG
Degol Enersyn Renolin Glycoyle Tivela Klübersynth
E5 680 CLP — —
GS 680 SG-XP 680 PG 680 HE 680 S 680 GH 6-680
PG

Non-return ISO VG Degol Energol Teresso DTE Oil Tellus Oil Rando
F1 — —
devices 46 CL CL 46 CS 46 46 Medium C 46 Oil 46

ISO VG Degol Energol Renolin Morlina Rando

G1 — — —
100 CL CL 100 CS 100 DTA 100 100 Oil EE

Neck journal ISO VG Degol Energol Renolin Morlina Rando

G2 — — —
bearings and 150 CL CL 150 CS 150 DTA 150 150 Oil F
slide bearings
ISO VG Degol Energol Renolin Morlina Ursa Oil
G3 — — —
220 CL CL 220 CS 220 DTA 220 220 P 45

ISO VG Degol Energol Renolin Morlina Viscoma

G4 — — —
320 CL CL 320 CS 320 DTA 320 320 Oil 144

ESSOLU
- Vanellus-T TITAN Ursa Klüberoil
Motor oil Kowal BE Delvac Rimula
H1 Rollers -Energol Universal Super LA GEM
SAE 30 Motor Oil -XD-3 Super X 30
HDS HD SAE 30 Ursatex 1-100 N
-HDX

API GL 4 TITAN Spirax Multigear Klübersynth

Gear unit Gear Oil Gear Oil Gear oil Mobilube
J1 SAE 90 Gear MP G 80 W SAE GEM
chain links Hyp 90 EP SAE 90 GX-D 90 HD 90-A
EP SAE 90 90 85 W-90 4-220 N

Index
Minimum requirement to DIN Pour point
number

A = Oil to DIN 51524-2 based on mineral oil - 24 °C to - 27 °C

B = Oil to DIN 51524-3 based on mineral oil - 42 °C

C = Oil to DIN 51517-3 based on mineral oil - 9 °C to - 24 °C

D = Oil to DIN 51517-3 based on poly-a-olefins - 30 °C to - 48 °C

E = Oil to DIN 51517-3 based on polyglycols - 27 °C to - 45 °C

F+G = Oil to DIN 51517-2 based on mineral oil —

02/2012 Rev 0

2-492-20908 (Pos 01) 8-7

8.4.1.2 Lubricating greases
Marking to DIN 51502 / 51825
Base oil: Mineral oil
Saponification type: Lithium-12-hydroxystearate
Application temperature range: - 20 °C to 120 °C

Index
Fuchs
num- Used for Class Aral BP ESSO Mobil Shell Texaco Klüber
Europa
ber

Low-
Grease lubrication CENTOP
NLGI Aralub Energrease viscosity Mobilux Simnia
K1 unit for spider — — LEX
000 GFP 000 HT 000 EP grease EP 023 Grease 000
bearing GLP 500
000

Low-
Tooth couplings of MICROL
NLGI Aralub Energrease viscosity Renolit Mobilplex Alvania Marfak
K2 main shaft UBE
00 FDP 00 HT-EP 00 gear SO-D8024 44 GL 00 00
bearings GB 00
grease

Alvania
Tooth couplings MICROL
NLGI 0 Energrease Beacon grease Multifak
K3 and grease — — — UBE
KPO K-20 LS 0 EP 0 EP R- EP 0
lubrication systems GB 0
OEP1

Alvania MICROL
Grease lubrication NLGI 1 Energrease Beacon Renolit Mobilux
K4 — Grease EP — UBE
systems KP1K-20 LS-EP 1 EP 1 FEP 2 EP 1
1 GL 261

Lubrication
Alvania CENTOP
systems and roller NLGI 2 Aralub Energrease Beacon Renolit Mobilux Multifak
K5 Grease EP LEX
bearings (heavy- KP2K-20 H-LP 2 LS-EP 2 EP 2 FEP 2 EP 2 EP 2
(LF) 2 2 EP
duty)

Alvania
Roller bearings NLGI 3 Aralub Energrease Renolit Glissando CENTOP
K6 Beacon 3 Mobilux 3 Grease RL
(normal-duty type) K3K-20 HL 3 LS 3 FWA 220 FT 3 LEX 3
3

8.4.1.3 Heavy-duty lubricating greases

Marking to DIN 51502 

Base oil: Poly-alpha-olefin (PAO), fully synthetic 
Saponification type: Gel thickener 
Application temperature range: - 50 °C to 200 °C
Application range: high-speed bearings (e.g. pinion assembly bearings, …)

Index
num- Used for Class Aral BP ESSO Fuchs Mobil Shell Texaco Klüber
ber

Roller bearings
Mobiltemp
L1 (high temperature NLGI 2 — — — — — — —
SHC 100
load)
02/2012 Rev 0

8-8 2-492-20908 (Pos 01)

 Marking to DIN 51502 
Base oil: fully synthetic 
Saponification type: Lithium complex
Application temperature range: - 40 °C to 160 °C
Application range: Crusher rotor bearings, RollSizer, …

Index
num- Used for Class Aral BP ESSO Fuchs Mobil Shell Texaco
ber

Roller bearings
Mobilith Albida
L2 (high temperature NLGI 2 — — — — —
SHC 220 PPS 2
load)

Marking to DIN 51502 

Base oil: Poly-alpha-olefin (PAO), fully synthetic 
Saponification type: Gel thickener
Application temperature range: - 50 °C to 180 °C
Application range: slow-speed bearings (e.g. feed conveyor, chain scraper, …)

Index
num- Used for Class Aral BP ESSO Fuchs Mobil Shell Texaco
ber

Roller bearings
Mobiltemp
L3 (high temperature NLGI 1,5 — — — — — —
SHC 32
load)

8.4.2 Special lubricants

8.4.2.1 Lubricating oils for tube mills

Application range: Lubrication of toothed rim

Index Klüber
Lubrication of toothed rim Fuchs
num-
(nozzle greasing) black transparent Lubritech
ber

GRAFLOSCON Klüberplex
M1 Priming lubrication by hand Ceplattyn 300
A - G1 ULTRA AG 11-462

GRAFLOSCON Klüberfluid
M2 Inlet process Inlet Ceplattyn - RN
B - SG-00 ULTRA B-F 2 ULTRA

Operating lubrication
(Adhesive lubricant with good EP
characteristics.) GRAFLOSCON Klüberfluid
M3 Ceplattyn KG 10 HMF
FZG special test A/2, 76/50 > 12th degree of C - SG-0 Ultra C-F 8 ULTRA
load,
Abrasive wear < 0.2 mg/kWh

GRAFLOSCON Klüberfluid
M4 Operating lubrication from + 5 °C to 100 °C Ceplattyn KG 10 HMF - 1000
C - SG-1000 Ultra C-F 4 ULTRA
02/2012 Rev 0

GRAFLOSCON Klüberfluid
M5 Operating lubricant from + 15 °C to + 120 °C Ceplattyn KG 10 HMF - 2500
C - SG-2000 Ultra C-F 3 ULTRA

2-492-20908 (Pos 01) 8-9

8.4.2.2 Lubricating oils for gyratory crushers
Oils

Index CASTROL
Used for Class CASTROL
number BIO TOP

ISO VG
N1 Tribol 943 AW 32 Tribol BioTop 1448 / 32
32 HLP
Hydraulic unit
axle adjustment and overload protection. ISO VG
N2 Tribol 943 AW 46 Tribol BioTop 1448 / 46
46 HLP
Pinion assembly of the V-belt drive
ISO VG
N3 Tribol 943 AW 68 Tribol BioTop 1448 / 68
68 HLP

ISO VG
N4 Tribol 1100/100 —
100 CLP

Oil unit ISO VG

N5 Tribol 1100/150 Tribol BioTop 1418 / 150
Oil circulating lubrication 150 CLP

ISO VG
N6 Tribol 1100/220 Tribol BioTop 1418 / 220
220 CLP

Greases

Index CASTROL
Used for Class CASTROL
number BIO TOP

Tribol 3020/1000-000
P1 NLGI 000 —
GP 000K-40
grease lubrication system
for spider bearing
Tribol 3020/1000-00
P2 NLGI 00 —
GP 00K-40

NLGI 2 Molub-Alloy
P3 Roller bearings Tribol 3020/1000-2
KP2K-20 Bio Top 9488-1

02/2012 Rev 0

8 - 10 2-492-20908 (Pos 01)

 8.4.2.3 Hydrodynamic couplings
Application range: Power transmission oils
Pour point: up to - 42 °C

Index
Fuchs
num- Used for Class Aral BP ESSO Mobil Shell Texaco
Europa
ber

Hydraulic couplings ISO VG 32 Degol BG Energol Torque Renolin Mobilfluid Tegula Rando
Q1
(Voith) HLP 32 HLP-HM 32 Fluid N 45 MR 10 125 32 HD 32

Application range: Power transmission oils

Base oil: fully synthetic
Pour point: - 42 °C to - 63 °C

Index
num- Used for Class Castrol Klüber Mobil
ber

Summit
Hydraulic couplings Hyspin
Q2 ISO VG 32 HySyn SHC 524
(Voith) AWH-M 32
FG 32

CASTROL Hyspin AWH-M 32 = Pour point - 42 °C

Klüber Summit HySyn FG 32 = Pour point - 45 °C

Mobil SHC 524 = Pour point - 63 °C

8.4.2.4 Hydraulic oils for low temperature applications

Application temperature range: min. - 40 °C up to max. + 70 °C

Pour point: up to - 60 °C

Index
num- Used for Class Shell
ber

Tellus
R1 Hydraulic systems ISO VG 32
Arctic 32

8.4.2.5 Fire-resistant hydraulic oils

Flash point: 300 °C

Fire point: 360 °C
Pour point down to - 20 °C

Index
Used for Class Fuchs Europa Quintolubric
number
02/2012 Rev 0

PLANTOFLUX AT-S Quintolubric

S1 Hydraulic systems ISO VG 46
VG 46 888-46

PLANTOFLUX AT-S Quintolubric

S2 Hydraulic systems ISO VG 68
VG 68 888-68

2-492-20908 (Pos 01) 8 - 11

8.5 Lubricating instructions

NOTICE
System damage due to incorrect indications of oil quantities and/or oil
classes

Damage to the machine/plant or its environment is possible

• The specifications on the type plates of gears, motors etc. referring to the oil
quantity and oil class to be filled take priority over the specifications in these
lubricating instructions.

Lubricating point Num Lubricant Lubricating intervals in Lubricant quantity

ber acc. to operating hours
Chapter 8.4
index Oil change Re- Oil change Re-
number lubrication lubrication

1 Oil circulation 1 D2 We recommend Always check approx. inspection

Lubrication unit that oil checks the oil level in 2500 litres glass and
Eccentric bearing are carried out the tank and approx. min./ max.
system: every 3 months. before start- 300 litres in signal to
Eccentric bushing Without these up the system control station
and outer bushing, regular oil
eccentric insert analysis, change
and main shaft, the oil every
bevel gear and 2000 hours but
drive pinion, axial no later than
step bearing main every 6 months.
shaft

2 pinion assembly 1 C1 approx. Inspection

50 litres glass

3 Hydraulic system 1 B2 We recommend Always check approx. inspection

Axle adjustment that oil checks the oil level in 630 litres glass and
and overload are carried out the tank min./ max.
protection every 3 months. before start- signal to
Without these up control station
regular oil
analysis, change
the oil every
2000 hours but
no later than
02/2012 Rev 0

every 6 months.

8 - 12 2-492-20908 (Pos 01)

 Lubricating point Num Lubricant Lubricating intervals in Lubricant quantity
ber acc. to operating hours
Chapter 8.4
index Oil change Re- Oil change Re-
number lubrication lubrication

4 Lubrication system 1 K1 Fill up grease Setting of the approx. Visual check
of the spider Recommen level level indicator 200 kg. in the Tank filling
bearing dation P1 grease tank of and min.
spider bushing of the grease signal to
the spider and pump control station
main shaft sleeve and approx. 
of the main shaft 50 - 60 litres
in the system

5 HYGUARD 1 A1 After 15 0,059 litres

Safety coupling Recommen actuations or
type BWL 140 dation N1 after 12 months
spec. at the latest: 
Change oil

Observe the lubricating instructions for components in the ANNEX 9.

02/2012 Rev 0

2-492-20908 (Pos 01) 8 - 13

 Blank page

02/2012 Rev 0

8 - 14 2-492-20908 (Pos 01)

 9 ANNEX

9.1 Drawings

9.2 Clutches

9.3 Clearance of teeth and bearings

9.4 Processing synthetic casting compound

Processing of Betec casting compound

9.5 Compressor

9.6 Monitoring equipment

9.7 Central lubrication

9.8 Oil circulating lubrication and hydraulic units

9.9 Hydraulic cylinder

9.10 Tools

9.11 Gyramatic Version 2.3

02/2012 Rev 0

9.12 SUPERBOLT® Mechanical clamping elements

2-492-20908 (Pos 01) 9-1

 Blank page

02/2012 Rev 0

9-2 2-492-20908 (Pos 01)

 9.1 Drawings

Name Drawing No.

Gyratory crusher, complete 4523233

Installation plan 4601387 sheets 1 - 5

Crusher shells, complete 4350021 sheets 1 + 2

Concaves, complete 4521259

Wear parts, complete 4350852

Base plate, complete 4350768

Shaft, complete 4350711

Dust sealing, complete 4350716

Eccentric bushing, complete 4350843

Main shaft hydraulics, complete 4524030

Spider bearing 4350718

Axial step bearing, complete 4350796

Pinion shaft assembly, complete 4350788 sheets 1 + 2

Drive, complete 4521231

Balance unit 4524049

Piping on site 4412679

Lubrication for spider bearing, complete 4350790

Grease lubrication pump, complete 4350926 sheets 1 + 2

Blower, complete 4350373

Clearance of teeth and bearings 4350802

Cooler pipework 4524041

Cylinder pipework 4524040

Hydraulic diagram 4524045

Change Crusher Cylinder 4523430

Dismantling Crusher Motor 4523431

Semimobile crusher station 4507887 Sheet 4

Changing crusher main shaft
02/2012 Rev 0

2-492-20908 (Pos 01) 9-3

 Blank page

02/2012 Rev 0

9-4 2-492-20908 (Pos 01)

 9.2 Clutches
02/2012 Rev 0

2-492-20908 (Pos 01) 9-5

 Blank page

02/2012 Rev 0

9-6 2-492-20908 (Pos 01)

 9.3 Clearance of teeth and bearings
02/2012 Rev 0

2-492-20908 (Pos 01) 9-7

 Blank page

02/2012 Rev 0

9-8 2-492-20908 (Pos 01)

 9.4 Processing synthetic casting compound
Processing of Betec casting compound
02/2012 Rev 0

2-492-20908 (Pos 01) 9-9

 Blank page

02/2012 Rev 0

9 - 10 2-492-20908 (Pos 01)

 9.5 Compressor
02/2012 Rev 0

2-492-20908 (Pos 01) 9 - 11

 Blank page

02/2012 Rev 0

9 - 12 2-492-20908 (Pos 01)

 9.6 Monitoring equipment
02/2012 Rev 0

2-492-20908 (Pos 01) 9 - 13

 02/2012 Rev 0

9 - 14 2-492-20908 (Pos 01)

 9.7 Central lubrication
02/2012 Rev 0

2-492-20908 (Pos 01) 9 - 15

 Blank page

02/2012 Rev 0

9 - 16 2-492-20908 (Pos 01)

 9.8 Oil circulating lubrication and hydraulic units
02/2012 Rev 0

2-492-20908 (Pos 01) 9 - 17

 Blank page

02/2012 Rev 0

9 - 18 2-492-20908 (Pos 01)

 9.9 Hydraulic cylinder
02/2012 Rev 0

2-492-20908 (Pos 01) 9 - 19

 Blank page

02/2012 Rev 0

9 - 20 2-492-20908 (Pos 01)

 9.10 Tools
02/2012 Rev 0

2-492-20908 (Pos 01) 9 - 21

 Blank page

02/2012 Rev 0

9 - 22 2-492-20908 (Pos 01)

 9.11 Gyramatic Version 2.3
02/2012 Rev 0

2-492-20908 (Pos 01) 9 - 23

 Blank page

02/2012 Rev 0

9 - 24 2-492-20908 (Pos 01)

 9.12 SUPERBOLT® Mechanical clamping elements
02/2012 Rev 0

2-492-20908 (Pos 01) 9 - 25

 Blank page

02/2012 Rev 0

9 - 26 2-492-20908 (Pos 01)