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Assembly and Operating Instructions

Gyratory crusherKB 63 - 75Iron ore

Shougang Hierro II

Shougang Hierro S.A.A.San Juan de Marcona, Peru

2-492-20980

Year of manufacture 2013

ThyssenKrupp Frdertechnik GmbHPostfach 1463 D - 59306 Ennigerloh

Schleebergstrae 12 D - 59320 EnnigerlohTelephone: +49 2524 30 0

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

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

2-492-20980 (POS 01)

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Revision status

Date Changes Made by

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Original created (German)Translation from original

Ritterbecks Ritterbecks

25/03/2014 Chapter 2.2 Over-pressure ventilation of the dust sealing - Voltage: Capacity P: Speed n:

Ritterbecks

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Table of Contents

1 User's guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1 - 1

1.1 User groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -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 Oil circulating lubrication and hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 2

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

2.3 Grease lubrication for spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 2

2.4 Drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2 - 3

3 General safety instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3 - 1

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

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

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

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

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

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

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

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

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

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

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

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

4.4.1 Crusher shells, concaves and wear parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 6

4.4.2 Main shaft with mantle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 10

4.4.3 Spider bearing with grease lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 12

4.4.4 Over-pressure ventilation of the dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 16

4.4.5 Eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 18

4.4.6 Base plate (with axial bearing ring) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 20

4.4.7 Lower main shaft bearing (axial step bearing) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 21

4.4.8 Hydraulic cylinder and balance unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 22

4.4.9 Crusher main drive motor and pinion assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 24

4.4.10 Measuring and monitoring equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 26

4.4.11 Oil circulating lubrication and hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 28

5 Transport, storage and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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 - 13

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 of oil hydraulic systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29

5.4.1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29

5.4.2 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29

5.4.3 Pipes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 29

5.4.4 Hydraulic hose lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 30

5.4.5 Commission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31

5.4.6 Hydraulic fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31

5.4.7 Filling pumps and motors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31

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5.4.8 Pressure settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 31

5.4.9 Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32

5.4.10 Cylinders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32

5.4.11 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32

5.4.12 Fluid level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 32

5.4.13 Filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.14 Oil temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.15 Oil change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.16 Accumulators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.17 Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.18 Pipework - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.19 Cooler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 33

5.4.20 Storage of hydraulic components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 34

5.4.21 Duration of storage and use of hydraulic hose lines - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 34

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

5.6 Preparation for installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 36

5.7 General information on assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 38

5.8 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40

5.8.1 Pre-assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40

5.8.2 Weights: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 40

5.8.3 Bottom shell - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 42

5.8.4 Base plate and eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 44

5.8.5 Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 46

5.8.6 Hydraulic cylinder and lower components of the main shaft bearing - - - - - - - - - - - - - - 5 - 50

5.8.7 Sealing housing of the dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 52

5.8.8 Mounting the concaves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 54

5.8.9 Installation of the liner plates in the upper shell - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 59

5.8.10 Spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 60

5.8.11 Main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 62

5.8.12 Sealing ring of the dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 64

5.8.13 Lower main shaft bearing section - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 65

5.9 Assembling the sub-assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 66

5.9.1 Bottom shell of the crusher, shells, main shaft, spider - - - - - - - - - - - - - - - - - - - - - - - - 5 - 66

5.9.2 Arm liners on spider - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 72

5.9.3 Direct drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 74

5.9.4 Compressor for over-pressure ventilation of dust sealing - - - - - - - - - - - - - - - - - - - - - - 5 - 76

5.9.5 Main shaft hydraulics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 77

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5.9.6 Oil circulating lubrication and hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 78

5.9.7 Grease lubrication for spider bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 79

5.10 Prescribed tightening torques for all relevant bolts - - - - - - - - - - - - - - - - - - - - - - - 5 - 80

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

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

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

6.3 Power supply and control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 3

6.4 Initial commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 5

6.5 Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6

6.5.1 Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6

6.5.2 Checks during operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 6

6.6 Malfunctions, troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 7

6.6.1 Fault list / troubleshooting guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 8

6.6.2 Restart of the crusher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11

6.7 Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11

6.7.1 Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 11

6.7.2 Emergency-stop system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 12

6.8 Handling of oil hydraulic systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 12

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

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

7.1.1 Information about cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 4

7.1.2 Information on maintenance and inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 5

7.1.3 Notes relating to 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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

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7.3.9 Drive and pinion assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 30

7.3.10 Check of the torsional back lash - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 34

7.4 Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 38

7.4.1 Preparation for replacing the crushing jaws - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 40

7.4.2 Disassembly of the spider - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 40

7.4.3 Disassembly of the main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 42

7.4.4 Checks to be made with the spider, main shaft and dust sealing housing dismantled - - 7 - 44

7.4.5 Exchanging the concaves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 46

7.4.6 Wear parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 48

7.4.7 Main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 50

7.4.8 Spider bearing with grease lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 54

7.4.9 Dust sealing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 58

7.4.10 Axial step bearing of the main shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 60

7.4.11 Exchanging the inner eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 62

7.4.12 Replacement of eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 64

7.4.13 Exchanging the outer eccentric bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 76

7.4.14 Crusher main drive motor and pinion assembly - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 78

7.5 Screw connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 86

7.5.1 Machine structures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 86

7.5.2 High-tensile bolted joints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 - 88

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 - 4

8.3.3 Lubricant lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 - 5

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

8.4.1 Standard lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 - 6

8.4.2 Special lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8 - 9

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

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

9.1 Drawings

9.2 Couplings

9.3 Clearance of teeth and bearings

9.4 Processing synthetic sealing compound

9.5 Compressor (over-pressure ventilation)

9.6 Monitoring devices

9.7 Distance sensor of main shaft setting unit

9.8 Central lubrication

9.9 Oil circulating lubrication and hydraulic unit

9.10 Shaft hydraulics (balance unit, hydraulic cylinder)

9.11 Tools

9.12 SUPERBOLT Mechanical clamping elements

9.13 Gyramatic Version 2.4 - user manual / fault list

9.14 Fluid starter

9.15 Maintenance car with scissor-type elevating platform

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1 User's guide

The technical documentation (Assembly and Operating Instructions) is designed to fami-liarise the user with the machine / plant and its designated use.

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

1.1 User groups

Necessary or expected user skills (competence):

Use personnel qualified for the machine / system with special knowledge of the machine/plant and the processes.

Qualified personnel are persons who, on account of their training, experience and instruc-tion as well their knowledge of the relevant standards, provisions, accident prevention regulations and service conditions, are authorised to carry out the necessary tasks and can recognise and avoid any potential hazards.

The operating personnel receive special instruction from the owner/operator of the machine / plant. Operators must be conscious of the fact that they are in a hazardous area during some manual tasks.Two people always work temporarily on the machine/plant in accordance with the rules of proper use. All operating, monitoring and servicing work is always carried out by at least two people working together.

Those working on the machine / plant must be made familiar with the safety instructions and layout of the emergency-stop systems as well as the related emergency-stop circuits.

To exclude danger to other people, access to the machine / plant is prohibited for unau-thorised people. These people are not familiar with the process workflow and cannot recognise potential hazards.

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1.2 Structure of the safety notes

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

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

SIGNAL WORD

Type and source of danger

Possible consequence(s) of non-observance.

Measure(s) for prevention of the danger.

Pictogram Signal word Significance Consequences of non-obser-vance

General danger

Special danger, e.g. electrocution

DANGER Imminent danger Death or severe bodily injuries

WARNING Possible danger Death or severe bodily injuries

CAUTION Possible danger Minor bodily injuries

CAUTION Possible property damage Damage to the machine / plant or its environment

INFORMATION Useful information or tip:Simplifies the handling

!

!

!

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1.3 Definitions

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

left = on the left-hand side looking in 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 Resource Technologies and have to be observed in every detail by those responsible for the trans-port, installation, commissioning, operation, maintenance as well as the disposal of all consumables and process materials. Only if the responsible individuals follow the instruc-tions 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 pos-sible hazards. The user is responsible for training the operating staff at the machine / plant or on site and ensuring that the safety regulations are observed.

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

ThyssenKrupp Resource Technologies can provide skilled and qualified personnel to car-ry out inspections and repairs if required.

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1.5 Liability and warranty

ThyssenKrupp Resource Technologies explicitly exclude all liability and warranty claims for damage or operational malfunctions originating from:

Non-compliance with instructions in the Assembly and Operating Instructions

Incorrect operation

Any use of the machine other than the specified use

Faulty maintenance

Use of consumables (in particular lubricants) not explicitly permitted by the manufac-turer

Use of spare parts not approved by the manufacturer

Conversions and modifications not approved by the manufacturer.

In addition, the conditions for liability and warranty as specified in the General Conditions of Supply of ThyssenKrupp Resource Technologies are applicable.

1.6 Copyright

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

1.7 Technical modifications

ThyssenKrupp Resource Technologies reserves the right to change designs in the course of technical developments. Recent modifications may not yet have been included in the drawings and texts of these Assembly and Operating Instructions.

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1.8 Stocking of spare parts

Continuous operation and operational readiness of the machine / plant can only be ensu-red 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.

CAUTION

The use of non-original spare parts

Damage to the machine/plant or its environment is possible

Only use original spare parts that are approved by ThyssenKrupp ResourceT-echnologies.

Damage caused by using products other than the original spare parts and acces-sories 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.

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2 Technical data

Figure 0

Crusher type: Gyratory crusher KB 63 - 75

Max. particle size feed: 1200 mm ROM80% < 450 mm

Crushing: 0 - 250 (X) mmP80 175 mm

Moisture content: max. 2%

Hardness: fmean = 150 MPafmax = 250 MPa

Bulk density: 2.3 t/m

Crusher work index: 10 kWh/t

Crushing gap OSS (design): approx. 175 mm

Crusher mouth opening: approx. 1600 mm

Mantle diameter: 2030 mm

Stroke of the hydraulic cylinder: max. 280 mm

Circumferential back lash between bevel gear/bevel pinion:

suggested value +/- 15%

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2.1 Oil circulating lubrication and hydraulic unit

See ANNEX 9.8 "Oil circulating lubrication and hydraulic unit"

Oil tank: separate tank

Tank capacity lubricating oil: approx. 1500 litres

Tank capacity hydraulic oil: approx. 250 litres

2.2 Over-pressure ventilation of the dust sealing

See ANNEX 9.5 "Compressor (over-pressure ventilation)"

Blower: Gasring-compressor, single-stage G 200 2BH1500-7AC19G with intake filter 2BX2102

Excess pressure: approx. 0.15 bar

Air flow rate: approx. 100 m/h

Electric motor Voltage:Capacity P:Speed n:

460 V, 60 Hz2.2 kW1800 min-1

Weight: approx. 36 kg

2.3 Grease lubrication for spider bearing

See ANNEX 9.7 "Central lubrication" and ANNEX 9.6.2 "Grease filling level sensor of the top axle mounting"

Electric barrel pump: 200 litres

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2.4 Drive

See ANNEX 9.2 "Couplings" and Chapter 4.4.9 "Crusher main drive motor and pinion as-sembly"

Motor: 750 kW, 60 Hz, 507 min-1

Safety coupling: BWL 125 Spec.

Multiple-disc steel clutch: MTF 514

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3 General safety instructions

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 trans-port, 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 under-stood by his personnel.

The machine/ plant may only be used in a technically perfect condition in accordance with its designated use and the instructions set out in the manual, and only by 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 environ-mental protection!

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

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

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

In the event of safety-relevant modifications or changes in the behaviour of the machine/ plant during operation, stop the machine/ plant immediately and report the malfunction to the responsible department!

Never make any modifications, additions or conversions to the machine/ plant which might affect safety without the supplier's approval! This also applies to the mounting and adjustment of safety devices and safety valves as well as to welding work on load-bearing elements.

Replace hydraulic hoses within at appropriate intervals even if no safety-relevant defects have been detected!

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

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!

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3.2 Modifications and spare parts

For safety reasons, conversions and modifications are prohibited unless previously approved by ThyssenKrupp Resource Technologies.

Use of accessories and spare parts not approved by ThyssenKrupp Resource Tech-nologies 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!

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 know-ledge and experience of hydraulic equipment!

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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.

3.5 Information regarding residual risks during daily opera-tion

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

Residual risks can nevertheless still occur during operation.

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

Mechanical hazard/material

Overcharging of the crushing area/ crusher dischargeOvercharging and discharge of crushing material on account of upstream conveying equipment and/or congestion of material in the feed hopper.

Dusty operating conditionson account of the type of feeding material, material feeding, the crushing procedure, the material discharge.

INFORMATION

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

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

Personal ear protection must be worn by the personnel if the noise hazard reaches the threshold value (85 dB (A)).

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3.6 Fire protection

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

Appoint supervisors who are in charge of all the matters related to fire prevention and fire fighting and provide them with the knowledge required for this task.The management staff and the engineers must support them in their task in an advisory capacity.

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

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

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

The personnel must be informed about the fire protection measures. Any case of fire must be reported immediately.

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

The fire extinguishers must be easily accessible and may not be obstructed by objects.

The personnel must be familiarised with the use of the fire extinguishers to such a degree that they are capable of fighting fire outbreaks with the appropriate fire extin-guishers.

Fire-fighting rules

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

In case of burning liquids (mineral oil, petrol, oil, petroleum, paints, tar, etc.), always use CO2 extinguishers and powder type fire extinguishers.

In case of burning cables, motors, electric plants, etc. only use powder type fire extin-guishers or CO2 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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4 Design and operating principle

4.1 Scope of application and designated use

The constant feeding ensures that the main shaft bearing is always uniformly loaded ("quiet load running").At the same time a stable film of lubrication keeps wear to a minimum on all of the affected bearing components.This method also has a positive effect on the wear pattern of the crushing tools.

DANGER

Risk of injury through operating the machine/plant with unauthorised modi-fications, conversions or spare parts

Imminent danger of death or severe bodily injuries

ThyssenKrupp Resource Technologies explicitly excludes all liability and war-ranty claims if modifications/conversions are made without the express permis-sion 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 depart-ment.

CAUTION

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

Damage to the machine/plant or its environment is possible

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

The gyratory crusher must be constantly fed with material to ensure that the crushing chamber is always at least 80 % full.

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

Observe the Assembly and Operating Instructions.

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Frequent idle-running phases lead to uncontrolled movements of the main shaft in the spi-der head bearing and in the lower bearing bushing. At the same time, continuous re-filling of the crushing chamber causes fluctuating loads and consequently uneven running under load.This impact-type method of operation destabilises the lubricating film between the bearing components which can cause undesirable abrasion on the bearing positions.This negative operating mode leads to an uneven wear patter with respect to the crushing tools / wear parts.

4.2 Main components

See Illustration 2

The gyratory crusher basically consists of the following assembly groups:

1Crusher shells (1)

2Concaves (2)

3Wear parts (3)

4Base plate (4)

5Main shaft with mantle (5)

6Dust sealing (6)

7Eccentric bushing with bevel gear (7)

8Connection of main shaft hydraulics (8)

9Spider bearing (9)

10Lower main shaft bearing (axial step bearing) (10)

11Pinion assembly with pinion (11)

12Crusher main drive motor (12)

13Speed monitor (13)

14Connection for the oil circulating lubrication (14)

15Connection for the hydraulic unit (15)

16Connection for grease lubrication (16)

17Grease filling level sensor (17)

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

19Main shaft hydraulics (19)

INFORMATION

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

Overpressure-ventilation attached to the steel structure

Grease lubrication pump with control on the sub-structure

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Figure 1

Balance unit for main shaft hydraulics attached to the steel structure

Oil circulating lubrication and hydraulic unit (main shaft adju-stment)

attached to the steel structure

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4.3 Operating principle

See Illustration 2

The material fed into the crusher is crushed between the fixed concaves (2) of the crusher shells (1) and the wobbling mantle of the main shaft (5) .

The tumbling movement of the mains shaft (5) is driven by the eccentric bushing (7) . This causes the gap between the concaves and the mantle to vary continuously at the circum-ference. The material is broken up by crushing and impact effects until it can leave the crusher through the crushing gap.

The main shaft (5) is radially guided in the upper spider bearing (9) in the spider bushing and in the lower eccentric bushing (7). Axial support of the main shaft (5) is provided by a hydraulic cylinder (19) which can be used to adjust the crushing gap by moving the piston and thus the main shaft (5).

A hydraulic unit (for vertical adjustment of the main shaft/setting the crushing gap and pro-tecting against overload) is integrated the unit for the oil circulating lubrication of the ec-centric bushing and the axial bearing (= internal lubrication circuit) as well as the eccentric bushing (= external lubrication circuit). The units are combined for reasons of accessibility and maintenance but form separate circuits.

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Figure 1

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4.4 Assembly groups

4.4.1 Crusher shells, concaves and wear parts

See Figure 3 and Figure 4

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

the conical upper and lower shell (1, 2)

the spider mounted on these (3)

the three-arm bottom shell, which is located under the lower shell (4),

the spider cap (5).

Figure 2

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Figure 3

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The inside of the shells are lined with concaves (9).

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 crusher axle (7) is supported and centred by the top axle mounting (8) within the spi-der (7). The spider bearing is protected by the spider cap (5).

Bowls (1, 2) and bottom part (4) are positioned via conical seats and screwed to the exter-nal flanges.

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 assembly (12) (pinion 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) and (27).

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.

There is an inspection opening cover (22) provided on the bottom part. An inspection ope-ning with a cover (23) is arranged on the bottom shell 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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Figure 1

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4.4.2 Main shaft with mantle

The main shaft (1) consists of forged steel. A fire protection ring (3) is bolted to the main shaft.

The mantle (2) is attached to the shaft cone. The mantle (2) is clamped by the outer ring nut (6) and an intermediate ring (4) and held on the shaft cone.

The intermediate ring (4) with the outer ring nut (6) and the mantle (2) are secured against twisting by a welded seam (w1, w2). The outer ring nut (6) is protected from wear by a cap (5) and hard facing.

The eye bolt (9) is used to assemble/disassemble the main shaft.

The mantle is back-filled with a special sealing compound (7) (see ANNEX 9.4).

The sealing ring of the dust sealing (8) is screwed to the underside of the main shaft (1).

The upper shaft of the main shaft is protected by the main shaft sleeve (10).

The step bearing upper part (11) of the axial step bearing is mounted on the bottom front face of the main shaft.

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Figure 4

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4.4.3 Spider bearing with grease lubrication

See Figure 6 and Figure 7

The top main shaft bearing is designed as a slide bearing. The top shaft of the main shaft is surrounded by the main shaft sleeve (1a) and guided in the spider bush (1c) with insert (1b).

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 (4) with shaft sealing rings (2) and the leather packing (3).

A pneumatically operated grease lubrication pump (7) supplies the top axle mounting with grease via the lubricant connection (5).

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.

Figure 5

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Figure 6

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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 lubri-cation 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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Figure 2

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4.4.4 Over-pressure ventilation of the dust sealing

See Figure 9 and Figure 10

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 pro-vided 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 inside the gyratory crusher (B).

As a result, there is a continuous air flow from the interior of the crusher (B) to the crushing chamber (B). 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.

Figure 7

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Starting from the compressor (1), the compressed air is passed to the hollow space of the dust sealing via a hose/pipe system (2), the pressure transducer (3) (adjustable from 70 -150 mbar) and the air ducts (4) in the hub of the bottom shell and in the dust sealing

housing.

The compressor is provided with an intake filter (5) and a pressure relief valve (6) and mounted on a bracket on the steel structure.

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

After the crusher has been switched off, the blower decelerates with a time delay.

Figure 8

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4.4.5 Eccentric bushing

The eccentric bushing is driven by the pinion assembly. It guides the main shaft in the inner eccentric bushing (4) and generates its wobbling (rotary/oscillating) motion.

The eccentric bushing consists of the eccentric bushing body (1) on which the bevel gear (2) is mounted by means of a feather key (3) and bolts (7).

The inner eccentric bushing (4) is made of bearing metal and is secured against rotation by a feather key (5).

The eccentric bushing is lubricated by the oil circulating lubrication internally (between the inner eccentric bushing and the main shaft), externally (between the eccentric bushing and the outer eccentric bushing) and on the underside (between the eccentric bushing and the axial step bearing ring).

The circulating lubrication also supplies the teeth of the bevel gear.

The top device for compensating unbalance (6) fixes the inner eccentric bushing in a ver-tical (axial) direction.

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Figure 9

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4.4.6 Base plate (with axial bearing ring)

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 turning flank clearance between the bevel gear of the eccentric bush and the pinion assembly can be set using slotted spacer plates(74) arranged between the base and the bottom shell.

The axial step bearing ring (5) is provided with lubrication grooves and is arranged on the base plate. The eccentric bushing slides on the axial step bearing ring. The cylindrical pin (6) secures the axial step bearing ring against twisting.

The sealing cord (7) prevents oil losses (lubrication space - external bearing) and the in-gress of pollutants into the interior of the crusher.

Figure 3

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4.4.7 Lower main shaft bearing (axial step bearing)

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 pro-tection 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 bottom spherical disk (4) moves between them. Lubrication grooves are provided 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.

Figure 10

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4.4.8 Hydraulic cylinder and balance unit

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 pro-tect against overload. The separately arranged balance unit is used for vertical guidance of the piston, especially if the main shaft is sudden 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 compensa-tion cylinder (4) when the crushing chamber is empty.

As soon as the main shaft is lifted, the oil pressure in the hydraulic cylinder (5) drops because the piston is relieved of the load of the main shaft. The pressure in the com-pressed 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 is lowered, 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 deter-mined 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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Figure 11

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4.4.9 Crusher main drive motor and pinion assembly

See Figure 15

The drive refers to the connection between the electric motor and pinion assembly.

It consists of:

the multi-plate couplings (1) between the pinion assembly and the electric motor,

with intermediate piece/ spacer tube (2),

the safety coupling (3) between the multi-plate coupling and spacer tube,

Speed sensor (14)

Protection box (15) and

Motor bracket (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 distance tube allows the pinion assembly to be removed without shifting the drive motor.

The safety coupling is provided with a torque limiter with hydraulic torque setting. The ne-cessary releasing torque is set by varying the hydraulic pressure. See Chapter 5.8.5 "Transmission" and ANNEX 9.2 "Couplings".

Transmission

The pinion assembly is arranged in the pinion 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 eccen-tric 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 assembly housing (stand oil lubri-cation).

The contact pattern of the teeth of the bevel gear set and the backlash can be adjusted by changing the thickness of the disks (9) (see Chapter 7.3.9 "Drive and pinion assembly").

Resistance thermometers (10) and (11) are installed in the pinion assembly housing to monitor the temperature of the pinion assembly bearings.

The fluid switch (12) monitors the oil level of the pinion assembly housing.

Accelerometers (optional) (13) (including evaluation unit) monitor the condition of the roller bearings of the pinion assembly.

max. 85 C Warningmax. 92 C Depletion of crusher

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Figure 12 (similar illustration)

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4.4.10 Measuring and monitoring equipment

Monitoring of the oil circulating lubrication and hydraulic unit:

Filling 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 (flow meters for supply and return flow)

Shaft position via distance sensor, see Chapter 4.2 "Main components".

See also ANNEX "9.9 Oil circulating lubrication and hydraulic unit".

Grease lubrication unit for spider bearing

Filling level of reservoir, see Chapter 4.4.3 "Spider bearing with grease lubrication"

Grease filling level of the spider bearing, see Chapter 4.4.3

Flow function via a pulse counter in the grease lubrication line of the top axle mounting, see Chapter 4.4.3.

See also ANNEX "9.8 Central lubrication".

Transmission

See also Chapter 4.4.9 "Crusher main drive motor and pinion assembly"

Filling level monitoring unit of oil filling of pinion assembly housing

Temperature of the pinion assembly bearings

Monitoring of the torque

Accelerometer (optional).

The speed monitor (1) is arranged on a bracket (2) which is screwed to the flange of the transmission. Two diametrically opposite sheet metal strips (3) and (4) which function as cam switches are mounted on the flange of the multiple-disc clutch.

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Figure 13

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4.4.11 Oil circulating lubrication and hydraulic unit

See Figure 17 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 adjust-ment 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 con-ducted to the bearing points through the hydraulic cylinder (2). The oil for the external circuit (3) (outer eccentric bushing) is conducted to the bearing point via a separate pipe system.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 lubri-cating 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 volume, thereby adjusting the crushing gap.

The position of the piston, and thus the position of the main shaft, is measured by the inte-grated 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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Figure 14

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5 Transport, storage and installation

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 hooks

No hand truck here

Stacking limitation Clamp here Permitted tempera-ture range

Do not use fork lift truck here

Electrostatic sensitive device

Do not destroy barrier Tear off here Do not roll

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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.

CAUTIONSystem 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 forma-tion).

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.

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Check all components for transport damage after delivery to the site.

CAUTIONSystem 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.

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5.2 Hoisting devices and slinging equipment

5.2.1 Lifting gear

Usually, cranes and lifting gear is used for transporting heavy assembly groups and com-ponents. 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 slin-ging 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 adjust-ment ring. This allows loads to be supported mechanically and prevents their lowering.

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

INFORMATION

Before lifting heavy loads, attach a load cell to check the load.

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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 per-missible 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 slip-ping must be attached in such a way that it cannot slip if the slinging equipment beco-mes 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 slin-ging equipment has to be tightened by crane, make sure that no body parts get bet-ween the load and the slinging equipment, and keep hands and fingers safe.

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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.

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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 angleLoad bearing capac-

ity

%

max. permissible load per strand in rela-tion to 1000 kg

30 50,0 (500 kg)

45 70,7 (707 kg)

60 86,6 (866 kg)

90 100,0 (1000 kg)

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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 bea-ring 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.

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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).

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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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Rope diameterDiameter of the clamp-

ing yokeDistance between clips

Required minimum 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 pre-vents 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.

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).

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

Permissible loads for eye bolts with shoulders:

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.

Shank diameter Vertical lifting ope-ration

Tension at 60 to the shoulder level

Tension at 45 to the shoulder level

Tension at 90 or loose side pull

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

Inches mm Pounds kg Pounds kg Pounds kg Pounds kg

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

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

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

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

1-1/4 31,8 9000 4082 1300 590 800 363 900 408

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

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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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.

If shackles are used at load angles other than 90, the permissible load bearing capa-city is reduced; see table:

DANGER

Danger caused through the use of improper slinging equipment

Imminent danger of death or severe bodily injuries

Never replace shackle bolts with standard bolts. Danger of breaking!

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Diameter Single shackle ver-tical

Two shackles 60 Two shackles 45 Two shackles 30

Inches mm Americ. tonnes

tonnes Americ. tonnes

tonnes Americ. tonnes

tonnes Americ. tonnes

tonnes

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

5/16 7,9 1/2 0,5 1 0,9 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 supports under the load so that they are stable and level. Do not use supports that have rounded edges, are fragile or damaged.

Compensate unevenness under the supports.

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

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5.3 Storage requirements

5.3.1 General requirements

If the storage time is exceeded by a lengthy period (i.e. more than 2 months), all the bea-rings 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 sub-sequently 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 commissio-ned, the grease must be removed and the bearings cleaned and regreased (approx. 1/3 of the volume of bearing and housing).

All the machine and plant components must be stored at temperatures between + 5 C and + 45 C. Electrical equipment is to be stored dry and frost-free, temperatures between minimum + 5 C and maximum + 45 C.

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

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

CAUTIONSystem 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 sup-ports 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.

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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 ThyssenKrupp Resource Technolo