INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

Cone Crusher
Raptor® 1100
Antapaccay
Tintaya 9232515940
March 2024
Copyright © 2024 by FLSmidth Inc., All Rights Reserved.

Documents, drawings, technical manuals, and all other information contained in this manual, provided in conjunction
with the purchase of FLSmidth products and services, are the proprietary property of FLSmidth. No part of this manual
may be disclosed, copied, duplicated, photocopied, reproduced, translated, or reduced to any electronic medium or
machine-readable form without prior written consent from FLSmidth.

The data included in this manual is not to be duplicated, used, or disclosed, in whole or in part, for any purpose other
than in the operation, maintenance, and service of the machine described. Nothing contained herein should be
construed to guarantee, modify, or enhance the operational capabilities as described in the machinery specification.
This manual does not imply liability to the manufacturer for any or all operational capabilities that may be affected by the
misuse or neglect in operating or servicing this machine.

English is the governing language. When manuals are translated into any other language, FLSmidth is not liable for
damages caused by errors in translation. The English translation will govern in case of discrepancies. In the event there
is confusion, notify your FLSmidth representative immediately. Refer to http://www.flsmidth.com/en-US/Contact for
applicable address and telephone numbers for the FLSmidth Office nearest you.
 i

Table of Contents
Chapter 1: Safety
1.1 Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Hazard Signal Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 Safety Signs and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2.1 Mandatory Action Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2.2 Prohibition Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2.3 Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Safe Working Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 General Safety Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.4 Lockout/Tagout (Energy Isolation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.5 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.6 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.7 Equipment Safety Signs and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8.1 Emergency Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8.2 Safety Trip Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.8.3 Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.8.4 Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 General Risks and Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1 Identifying and Controlling Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.2 Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.3 Scaffolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.4 Railings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.5 Elevated Work Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.6 Harness and Line (Fall-Arrest System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.7 Cranes and Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.8 Moving Parts on Stationary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.9 Remote Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.10 Confined Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.11 Welding, Cutting, and Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.12 High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.13 Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.14 Inclement Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.15 Noise and Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.16 Pinch and Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
ii

1.3.17 Electrical Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3.18 Fuels, Oils, and Lubricating Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.19 Surface Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.20 Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.21 Mechanical Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Hazardous Chemicals and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.1 Mineral Powders (Silica) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.2 Lime and Calcined Raw Meal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.3 Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.4 Acids and Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.5 Cyanide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.6 Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5 Emergency Preparedness Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 2: Introduction
2.1 FLS MissionZero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2.2 Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2.3 Installation and Start-Up Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Shipment and Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Parts and Repair Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Warranty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.6.1 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7 Accessory Equipment Manufacturer Information . . . . . . . . . . . . . . . . . . . . . . . . . .23
2.8 FLSmidth Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Chapter 3: Storage
3.1 Long-Term Storage Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.1.1 Maintaining Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.2 Storing OEM Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Outdoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.3 Covered or Indoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4 Equipment Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5 Preventing Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5.1 Shop Primer Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5.2 Protective Finishes or Seal Coats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.5.3 Machined and Non-Coated Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.6 Storing Elastomer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.7 Storing Fiberglass Reinforced Plastic Components . . . . . . . . . . . . . . . . . . . . . . . .29
3.8 Storing Equipment After Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.9 Storing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.10 Environmental Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
 iii

3.11 Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Chapter 4: Equipment Overview

4.1 Equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
4.1.1 Crusher Main Frame Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.1.1.1 Main Frame Seat Liner and Fulcrum Bar . . . . . . . . . . . . . . . . . . . . . . . . 34
4.1.1.2 Tramp Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1.1.3 Clamping Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1.1.4 Clearing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1.1.5 Open and Close Bowl Adjustment Circuits . . . . . . . . . . . . . . . . . . . . . . 37
4.1.1.6 Adjustment Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1.2 Drive Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1.2.1 Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.2.2 V-Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.2.3 Belt Tensioner and Jackshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.3 Countershaft and Sheave Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1.4 Eccentric Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1.4.1 Counterweight Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1.5 Socket Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1.6 Head, Mantle, and Feed Plate Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1.7 Bowl Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.1.8 Bowl Adjustment Mechanism Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1.8.1 Drive Ring Support System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1.9 Lubrication System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.1.9.1 Oil Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1.9.2 Lubrication System Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1.9.3 Air Seal Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1.9.4 Low Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1.9.5 Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1.9.6 Oil Temperature System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1.9.7 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1.10 Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2 Operation Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.2.1 Crusher Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Chapter 5: Installation
5.1 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.2 Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.2.1 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.2.2 Crusher Installation Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.2.3 Crusher and Sub-Assembly Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
iv

5.2.4 Feed Arrangement Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.2.5 Discharge Arrangement Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2.6 Maintenance Platform Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3 Crusher Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
5.3.1 Crusher Installation on Concrete Foundation . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3.2 Crusher Installation on Steel Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.4 Bowl Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
5.5 Accumulators Installation and Pre-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6 V-Belt Drive Installation (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.1 Belt Tensioner Frame Installation on Concrete . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.2 Belt Tensioner Frame Installation on a Steel Structure . . . . . . . . . . . . . . . . . 63
5.6.3 Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.6.4 V-Belts Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.6.5 Drive Guards Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.7 Direct Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.7.1 Sole Plate Installation on Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.7.2 Sole Plate Installation on Steel Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.7.3 Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.7.4 Drive Guards Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.8 Head Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
5.9 Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
5.10 Lubrication System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
5.10.1 Skid Mounted Lubrication System Installation . . . . . . . . . . . . . . . . . . . . . . . . 68
5.10.2 Heat Exchanger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.10.3 Piping Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.11 Air Seal Blower Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.12 Machine Instrumentation Package Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.12.1 Countershaft Box Temperature Sensor Installation . . . . . . . . . . . . . . . . . . . . 72
5.12.2 Oil Supply Temperature Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.12.3 Oil Supply Pressure Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.12.4 Eccentric Bushing RTD Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.12.5 Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.12.6 Speed Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.12.6.1 Direct Drive Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.12.6.2 V-Belt Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.12.7 Vibration Transducers Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.12.8 Level Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.12.9 Machine I/O Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.12.10 Junction Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.13 Feed, Discharge, and Platform Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
 v

Chapter 6: Operation
6.1 Post-Commissioning Automation Change Disclaimer . . . . . . . . . . . . . . . . . . . . . .82
6.2 Crusher Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
6.2.1 Group Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.2.2 Individual Auxiliary Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2.3 Verifying Vital Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.3 Hydraulic Power Unit Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
6.4 Normal Crusher Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
6.4.1 Setting the Crushed Product Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.4.1.1 Liner Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.4.1.2 Setting the Closed Side Setting Manually . . . . . . . . . . . . . . . . . . . . . . . 85
6.4.1.3 Setting the Closed Side Setting Through Automation . . . . . . . . . . . . . 86
6.5 Performing a Clearing Cycle for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
6.6 Clearing Lodged Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
6.6.1 Clearing Rock or Tramp from the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.6.2 Clearing Tramp Metal From the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.6.2.1 Removing Metal With an Overhead Lifting Device . . . . . . . . . . . . . . . . 89
6.6.2.2 Burning Metal From the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.7 Resetting the Tramp Release System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
6.8 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Chapter 7: Maintenance
7.1 Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
7.1.1 Welding and Weld Repair of Major Castings . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.1.3 Thermal Process for Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 96
7.2 Component Lifting and Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
7.2.1 Special Tools Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.2.2 Lifting the Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.2.3 Lifting the Bowl Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.2.4 Lifting the Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
7.3 Thread Wear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.4 Eccentric Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.4.1 Eccentric Bushing Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.4.2 Eccentric Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.4.3 Eccentric Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.5 Socket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.5.1 Socket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.5.2 Socket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.6 Creating a Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
vi

7.6.1 Backlash Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

7.6.2 Contact Pattern Inspection and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 107
7.7 Adjustment Ring Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.7.1 Determining Adjustment Ring Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.7.2 Adjustment Ring Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
7.7.3 Adjustment Ring Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.8 Main Frame Seat Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7.8.1 Determining the Main Frame Seat Liner Wear . . . . . . . . . . . . . . . . . . . . . . . .112
7.8.2 Main Frame Seat Liner and Fulcrum Removal . . . . . . . . . . . . . . . . . . . . . . . .113
7.8.3 Main Frame Seat Liner and Fulcrum Installation . . . . . . . . . . . . . . . . . . . . . . .114
7.9 Main Frame Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.9.1 Determining Main Frame Liner Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
7.9.2 Main Frame Liners Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
7.9.3 Main Frame Liners Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
7.10 Drive Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.10.1 Drive Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
7.10.2 Drive Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
7.11 Arm Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.11.1 Arm Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
7.11.2 Arm Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
7.12 V-Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.12.1 V-Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.12.2 V-Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.12.3 V-Belt Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
7.13 Shaft Sheave Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.13.1 Shaft Sheave Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.13.2 Shaft Sheave Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.13.3 Sheave and Belt Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.14 Air Seal Blower Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.15 Counterweight Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.15.1 Counterweight Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.15.2 Counterweight Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.16 Counterweight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.16.1 Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.16.2 Counterweight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.17 T-Seal and U-Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.17.1 T-Seal and U-Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.17.2 T-Seal and U-Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.18 Socket Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.18.1 Determining Socket Liner Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.18.2 Socket Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
 vii

7.18.3 Socket Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

7.19 Head Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.19.1 Head Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.19.2 Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.19.3 Head Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.19.4 Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.20 Mantle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.20.1 Mantle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.20.2 Mantle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.21 Lower Head Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.21.1 Lower Head Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.21.2 Lower Head Bore Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.21.3 Lower Head Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.22 Upper Head Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.22.1 Upper Head Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.22.2 Upper Head Bore Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.22.3 Upper Head Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.23 Bowl Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.23.1 Bowl Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.23.2 Determining Bowl Thread Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.23.3 Bowl Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.24 Bowl Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.24.1 Determining Bowl Liner Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.24.2 Bowl Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.24.3 Bowl Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.25 Bowl Adapter Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.25.1 Bowl Adapter Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.25.2 Bowl Adapter Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.26 Oil Strainer Basket Replacement (Lubrication Unit) . . . . . . . . . . . . . . . . . . . . . . . 156
7.26.1 Oil Strainer Basket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.26.2 Oil Strainer Basket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.27 Oil Filter Element Replacement (Lubrication Unit) . . . . . . . . . . . . . . . . . . . . . . . . 156
7.27.1 Oil Filter Element Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.27.2 Oil Filter Element Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.28 Changing the Oil Filter Cartridge (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.29 Manually Pressurizing and Bleeding the Tramp and Clamping Circuit . . . . . . . 157
7.29.1 Pressurizing the Tramp Release System Manually . . . . . . . . . . . . . . . . . . . 158
7.29.2 Bleeding the Tramp Release System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.29.3 Pressurizing the Clamping System Manually . . . . . . . . . . . . . . . . . . . . . . . . 159
7.29.4 Bleeding the Clamping System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.29.5 Charging and Verifying the Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
viii

7.29.6 Charging Assembly Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

7.29.7 Verifying the Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
7.29.8 Charging the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.29.9 Removal and Storage of the Charging Assembly . . . . . . . . . . . . . . . . . . . . . 163

Chapter 8: Troubleshooting
8.1 Main Frame Hub Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
8.2 Countershaft Box and Sheaves Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 166
8.3 Eccentric Assembly Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.4 Head, Mantle, and Feed Plate Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.5 Bowl Assembly Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
8.6 Lubrication System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.7 Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Appendix A: Lubrication
A.1 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
A.2 Lubricating Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
A.2.1 Crusher Lubrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
A.2.2 Crusher Operating Oil Temperature Requirements . . . . . . . . . . . . . . . . . . . 175
A.2.3 Thread Lubrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
A.2.4 Belt Tensioner Lubrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
A.2.5 Jackshaft Pillow Block Lubrication Requirements . . . . . . . . . . . . . . . . . . . . 177
A.3 Adding and Changing Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
A.4 Lubricating Oil Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
A.5 Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
A.5.1 Hydraulic Drive Assembly Lubrication Requirements . . . . . . . . . . . . . . . . . 178
A.5.2 Hydraulic Adjust Drive Lubrication Requirements . . . . . . . . . . . . . . . . . . . . 179
A.5.3 Cold Weather Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
A.5.4 Hot Weather Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
A.6 Adding and Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Appendix B: Commissioning
B.1 Initial Pre-Start-Up Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
B.2 No-Load Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
B.3 65% of Full Load Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
B.4 80% of Full Load Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
B.5 Full-Load Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Appendix C: Maintenance Schedule

C.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

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FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
 ix

C.1.1 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

C.1.2 Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
C.1.3 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
C.1.4 Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
C.1.5 At Liner Change Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Appendix D: Maintenance Log

D.1 Thread Wear Inspection Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
D.2 Backlash Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
D.3 Main Frame Seat Liner Thickness Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
D.4 Bowl Liner Wear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
D.5 Sheave and Belt Alignment Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
D.6 Adjustment Ring Wear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Appendix E: Parts List/Bill of Materials

E.1 1000975960: Parts List/Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Appendix F: Recommended Spare Parts List

F.1 Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Appendix G: Functional Specification

G.1 1000899112: Functional Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Appendix H: Drawing Package

H.1 1000855444: General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
H.2 1000896918: Foundation Bolt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
H.3 647092: Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
H.4 RXL1301-5000: Main Frame Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
H.5 1000687903: Adjustment Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
H.6 1000920546: Split Tramp Release Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
H.7 RXL1004-5003: Countershaft Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
H.8 677551: Eccentric Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
H.9 677550: Eccentric Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
H.10 677548: Counterweight Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
H.11 RXL1007-5005: Socket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
H.12 RXL1007-5004: Socket Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
H.13 677553: Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
H.14 RXL1008-5002: Head Stub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
H.15 RXL1316-5000: Adjustment Mechanism Assembly . . . . . . . . . . . . . . . . . . . . . . . . 321
H.16 RXL1016-5002: Adjustment Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

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x

H.17 RXL1016-5003: Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

H.18 RXL1016-5007: Pinion Shield Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
H.19 RXL1005-5006: Oil Piping Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
H.20 RXL1009-5002: Feed Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
H.21 RXL1010-5003: Liner Assembly, Standard Head Fine . . . . . . . . . . . . . . . . . . . . 328
H.22 648590: Bowl Assembly, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
H.23 RXL1012-5001: Hopper Assembly, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
H.24 RXL1017-5001: Tools Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
H.25 RXL1020-5001: Decal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333
H.26 1000690716: Sole Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
H.27 RXL1013-5001: Crusher Sheave Assembly, Ø40, 8V . . . . . . . . . . . . . . . . . . . . . 336
H.28 RXL1013-5009: Motor Sheave Assembly, Ø28, 8V . . . . . . . . . . . . . . . . . . . . . . . .337
H.29 RXL1023-5004: Countershaft Box Blower Assembly . . . . . . . . . . . . . . . . . . . . . 338
H.30 1000896923: Instrument Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
H.31 1000855586: Air Seal Blower General Arrangement . . . . . . . . . . . . . . . . . . . . . 342
H.32 1000894264: Electrical Load List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343
H.33 1000894004: Instrument List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
H.34 1000892011: Control and Instrumentation Diagram . . . . . . . . . . . . . . . . . . . . . . . 351
H.35 1000855581: Lubrication Unit General Arrangement . . . . . . . . . . . . . . . . . . . . . 358
H.36 1000855590: Lubrication Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
H.37 1000855583: Heat Exchanger General Arrangement . . . . . . . . . . . . . . . . . . . . 360
H.38 1000855555: Hydraulic Power Unit General Arrangement . . . . . . . . . . . . . . . . . 361
H.39 1000855588: Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
H.40 1000911692: Interconnection Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
H.41 1000890158: Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370
H.42 1000924365: Network Signal List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
H.43 1000907855: PLC Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379
H.44 1000907858: Machine RIO Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
H.45 1000907856: Lube RIO Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433
H.46 1000907857: HPU RIO Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
H.47 1000887465: Control System Design Datasheet . . . . . . . . . . . . . . . . . . . . . . . . .479

Appendix I: Final Mechanical Inspection

I.1 Final Mechanical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486

Appendix J: Automation
J.1 Operator Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
 1

Chapter 1: Safety
1.1 Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Hazard Signal Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 Safety Signs and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2.1 Mandatory Action Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2.2 Prohibition Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2.3 Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Safe Working Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 General Safety Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.4 Lockout/Tagout (Energy Isolation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.5 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.6 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.7 Equipment Safety Signs and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8.1 Emergency Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.8.2 Safety Trip Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.8.3 Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.8.4 Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 General Risks and Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1 Identifying and Controlling Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.2 Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.3 Scaffolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.4 Railings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.5 Elevated Work Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.6 Harness and Line (Fall-Arrest System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.7 Cranes and Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.8 Moving Parts on Stationary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.9 Remote Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.10 Confined Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.11 Welding, Cutting, and Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.12 High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.13 Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.14 Inclement Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
2 Chapter 1 Safety

1.3.15 Noise and Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3.16 Pinch and Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.17 Electrical Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.18 Fuels, Oils, and Lubricating Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.19 Surface Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.20 Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.21 Mechanical Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Hazardous Chemicals and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.1 Mineral Powders (Silica) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.2 Lime and Calcined Raw Meal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.3 Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.4 Acids and Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.5 Cyanide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.6 Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5 Emergency Preparedness Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Chapter 1 Safety 3

1.1 Important Safety Information

FLSmidth recommends that equipment be installed, operated, and maintained in accordance with all applicable
governmental safety and health laws, regulations, and generally recognized industrial standards.

The information provided in this chapter is intended to provide a general overview of safety guidelines recommended
by FLSmidth, and is not an exhaustive list of all standard safety procedures. The specific guidelines outlined below may
or may not apply to your particular equipment. FLSmidth is neither responsible nor liable for incorrect or unsafe
practices or policies.

Follow all governing safety standards and local jobsite procedures.

1.1.1 Hazard Signal Indicators

Danger, Warning, and Caution indicators are located throughout the manual at specific points of interest and alert the
reader to the relative degree of a hazard.

These notices are given to prevent personal injury, death, equipment damage, and improper service, and must be
followed to reduce or eliminate these risks. Always heed these notices, and practice common sense when performing
any maintenance or repair procedure.

Hazard Symbol Symbol Description

This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury and death.

“Danger” indicates an imminently hazardous situation which, if not avoided,

could result in death.

“Warning” indicates a potentially hazardous situation which, if not avoided,

could result in death, serious injury, or property damage.

“Caution” indicates a potentially hazardous situation which, if not avoided,

MAY result in minor or moderate injury and property damage. It may also
be used to alert against unsafe practices.

“Notice” is used to draw attention to detailed instructions. These notes are

intended to give further important information regarding the equipment or
a step in a procedure.

Table 1-1: Hazard Signal Indicators

1.1.2 Safety Signs and Symbols

Additional safety signs and symbols may appear along with the Danger and Caution indicators, and are used to specify
certain hazards. These warnings describe particular areas where special care and procedures are required in order to
prevent serious injury and possible death.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
4 Chapter 1 Safety

1.1.2.1 Mandatory Action Symbols

Mandatory Action Symbols are referred to as Personal Protective Equipment (PPE) and are identified by a blue circle
with a white symbol in the middle signifying the type of protective equipment required. These symbols indicate a
mandatory action required to safeguard personal health and avoid risk of personal injury.

FLSmidth recommends that personnel wear the correct PPE at all times, and that all PPE meet local country standards,
and where appropriate, international standards such as ISO, ANSI and EN. Follow all governing safety standards and
local jobsite procedures.

The following table contains the comprehensive list of mandatory action symbols and their descriptions. The symbols
below may or may not apply to your equipment.

Mandatory Action Description Mandatory Action Description

Symbols Symbols

General Mandatory Action Wear Protective Clothing

Refer to Instruction Manual Use Handrail

Wear Ear Protection Wear a Face Shield

Wear Eye Protection Wear Head Protection

Connect an Earth Terminal to the

Wear High Visibility Clothing
Ground

Disconnect Plug from Outlet Wear a Mask

Wear Opaque Eye Protection Wear a Safety Harness

Disconnect Before Carrying Out

Wear Safety Footwear
Maintenance or Repair

Wear Protective Gloves Use This Walkway

Table 1-2: Mandatory Action Symbols

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

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Chapter 1 Safety 5

1.1.2.2 Prohibition Symbols

FLSmidth recommends the use of prohibition symbols that are used to indicate a prohibited action. They are identified
by a red circle with a diagonal line running through and the black symbol in the middle (sometimes accompanied by
words). These symbols signify what you should not do or what is prohibited.

The following table contains the comprehensive list of prohibition symbols and their descriptions. The symbols below
may or may not apply to your equipment.

Prohibition Description Prohibition Description

Symbols Symbols

General Prohibition No Pushing

No Smoking No Sitting

No Open Flame, Fire, Open

No Stepping on the Surface
Ignition Source, or Smoking

No Thoroughfare Do Not Use Lift in Event of Fire

No Access for People with Active

No Eating or Drinking
Implanted Cardiac Devices

No Metallic Articles or Watches Do Not Use Lift for People

Do Not Touch No Running

No Heavy Load No Climbing

No Reaching In Do Not Enter

Table 1-3: Prohibition Symbols

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6 Chapter 1 Safety

1.1.2.3 Warning Symbols

FLSmidth recommends the use of warning symbols that are used to signify potential danger. These symbols are
identified by a triangle with a yellow background and a black symbol in the middle signifying the danger.

The following table contains the comprehensive list of warning symbols and their descriptions. The symbols below may
or may not apply to your equipment.

Warning Symbols Description Warning Symbols Description

General Warning Automatic Start-up

Explosive Material Crushing

Floor Level Obstacle Flammable Material

Drop Fall Sharp Element

Slippery Surface Corrosive Substance

Electricity Crushing of Hands

Forklift and Other Industrial

Counter Rotating Rollers
Vehicles

Overhead Load Battery Charging

Toxic Material Oxidizing Substance

Hot Surface Explosive Atmosphere

Table 1-4: Warning Symbols

There may be additional types of signage to those shown above depending on the country or site. Ensure that you
familiarize yourself with, and understand the signage that is used at your site.

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Chapter 1 Safety 7

1.2 Safe Working Practices

Safe working practices are essential when working in construction areas with heavy equipment. The high noise levels,
dust conditions, and ever-present danger of high-powered machinery demands that safety be observed by all personnel
on the jobsite, and most specifically by those working on or in the immediate area of the equipment.

Do not install, operate, maintain, or repair this equipment until you have read and fully understand the
instructions and warnings in this manual. Failure to follow these safety precautions could result in
personal injury, death, or property damage.

• Proper care is your responsibility.

• All maintenance and repair of this equipment shall be performed in accordance with safety warnings. Failure to do so
may result in personal injury or property damage.

1.2.1 Operator Responsibilities

Machinery is to be operated by those with prior experience operating sophisticated equipment and systems, and who
have been appropriately trained and certified in the proper use of this particular machinery.

FLSmidth recommends that equipment be installed, operated, and maintained in accordance with all applicable
governmental safety and health laws, regulations, and generally recognized industrial standards.

1.2.2 General Safety Recommendations

FLSmidth recommends that assembly, operation, and maintenance personnel observe the following general safety
guidelines.

• Perform both a pre-start inspection as well as a walk-around inspection. This can be done by the installer, operator,
or a designated maintenance technician.
• Do not put equipment into operation unless all regularly scheduled maintenance and any unscheduled, but
necessary, repairs have been performed.
• Adhere to the recommended maintenance schedule for machinery and component parts.
• Use all of the systems designed to keep people safe when in the area of the equipment, including proper safety
signs and any standards appropriate to the specific country where the site is located.
• Do not override any safety system.
• Engage the equipment controls slowly.
• Ease components into motion gradually to prevent shock load damage and unnecessary wear on gear cases and
other moving parts.
• Keep hands and anything you are holding out of any area with moving parts.
• Prevent tripping and falling hazards around the equipment according to your site requirements.
• Ensure all working components come to a complete stop before reversing the controls.
• Do not leave the operator’s station unattended while the equipment is in operation.
• Be familiar with the emergency shutdown procedures and locations where they can activate an emergency stop
system shutdown.

Note: FLSmidth cannot anticipate every possible circumstance that may involve a potential hazard, therefore,
the safety and informational prompts in this manual are not all-inclusive. If a tool, procedure, work method, or
maintenance technique not specifically recommended by FLSmidth is used, ensure its safety prior to use.
Ensure that lubrication, maintenance, or repair procedures don’t damage the machinery or make it unsafe for

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8 Chapter 1 Safety

operation. For more information on maintenance and repair procedures for items furnished but not
manufactured by FLSmidth, refer to the original equipment manufacturer instructions.

1.2.3 Unauthorized Modifications

Unauthorized modifications to the equipment may impair its function and capacity to operate safely, and may lead to
shortened equipment life and unsafe operating conditions. Do not take shortcuts on equipment repair. Read all
instructions thoroughly.

1.2.4 Lockout/Tagout (Energy Isolation)

The purpose of Lockout/Tagout (LOTO) and related procedures is to avoid electrocution or accidental start-up of the
machine(s) or parts during maintenance or service. An unwanted start or movement can lead to serious injury or death.

Follow all governing safety standards and local jobsite procedures.

Examples of potential risk include:

1. A machine that was switched off is suddenly restarted from a remote control panel or locally by mistake.

2. A machine unexpectedly energizes due to a failure in the machine control system.

3. Residual energy such as compressed gas or liquid, as well as spring or gravity loads, is suddenly released and
applies considerable force to one or more parts.

Further, FLSmidth recommends that chains, blocking, locking pins or other hardware be used for isolating, securing or
blocking machines or equipment from mechanical energy sources, including springs and gravity loads.

The equipment used for securing the machinery must be strong enough to effectively prevent movement of the
machine, for example, using a weak chain will provide a false sense of security as it may break.

Follow all governing safety standards and local jobsite procedures.

1.2.5 Fire Extinguishers

Fire is a major cause of loss of life and property throughout the world. While fire normally does not pose a grave danger
on open construction sites with steel and concrete as major materials, it may occur at any time and anywhere.

Have fire extinguishers available and know how to use them. Inspect and have them serviced as recommended on their
instruction plates.

Follow all governing safety standards and local jobsite procedures.

1.2.6 Emergency Procedures

The best way to deal with emergencies is to prevent them in the first place.

Follow all governing safety standards and local jobsite procedures.

Each site will have its own procedures, which you will learn at your site induction. If the emergency procedures are not
provided to you, it is your duty to seek out the emergency procedures, telephone numbers, and radio channels that are
used on site.

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Chapter 1 Safety 9

Always follow site procedures when dealing with an emergency situation. Use your site emergency call
procedure and be ready to provide relevant information.

1.2.7 Equipment Safety Signs and Labels

Equipment supplied by FLSmidth is fitted with safety signs and labels in accordance with global safety standards. Read
and understand all safety signs and labels on your equipment before installing, operating, lubricating, or maintaining this
equipment. Make sure safety signs and labels are legible.

Replace any safety signs and labels that are damaged or missing. If a safety sign or label is attached to a part that is
replaced, install a new safety sign or label on the replacement part.

1.2.8 Protective Devices

Your equipment may be fitted with devices that are designed to provide protection for personnel who are working on or
around the equipment. To maintain safety it is critical that these devices are kept in place and correctly maintained.

Protective devices may include the following:

• Emergency stop switches

• Safety trip wires
• Interlocks
• Guards

1.2.8.1 Emergency Stop Switches

Moving machines are typically fitted with emergency stop (E-stop) switches located at strategic places on the machine.
These E-stop switches will immediately cut off the power source to the machine, and, once triggered, require manual
(physical) reset before the machine may be started again either locally or from a remote control room.

Locate the nearest E-stop switch as close to moving parts as possible. In some cases, such as with a long belt conveyor,
this can be difficult to achieve. In this case, the conveyor could be fitted with cables running along the length of the
machine and tied to the E-stop switches. The belt can be stopped at any time by pulling a cable from any location. The
figure below is a typical E-stop switch fitted to a local control station in the field.

Figure 1-1: Emergency Stop Switch

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10 Chapter 1 Safety

1.2.8.2 Safety Trip Wire

Trip wire assembly and switches (one cord on each side) allow equipment to be stopped without using the control panel
push buttons.

Follow all governing safety standards and local jobsite procedures.

Trip wire cords are connected to E-stop switches. Once one of the trip wire cords is pulled, the wiring circuit is broken
and the motor will stop.

Note: If your equipment includes a vacuum pump motor, be advised that this is not stopped by the trip wire
system.

The following figure shows a typical trip wire switch that is often installed along each side of the equipment.

Figure 1-2: Emergency Trip Wire Switch

Never use a trip wire or emergency stop switch as a means of isolating equipment. Trip wire and
emergency stop switches are normally controlled through software systems and as such they do not
provide positive isolation.

1.2.8.3 Interlocks

Machines equipped with interlocks prevent a malfunction from having disastrous consequences. The power source may
be cut off if problems are detected, such as:

• Motor overload (current too large)

• Speed too slow (speed monitors)
• Part of machine out of normal range (proximity switch)
• Excessive vibrations (vibration detector)
• Excessive heating of machine (thermo couple)

Belt alignment switches are used on conveyor belts to monitor whether the belt is properly aligned, and notify the
operator if the belt is moving outside the roller path.

If you are operating a chain of transport equipment, a stop on any machine will automatically stop all upstream machines
to avoid overfilling the stopped machine. The downstream machines will, in most cases, be allowed to continue so that
they will empty themselves.

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Chapter 1 Safety 11

1.2.8.4 Guards

Guards prevent the possibility of personnel becoming entangled in moving parts. Keep guards intact and securely in
place at all times while the machine is operating.

If you need to remove guards to conduct maintenance work or clear a blockage, ensure that the equipment is shut
down, isolated, and rendered safe before doing so.

Follow all governing safety standards and local jobsite procedures.

Do not operate any part of the equipment if all guards are not securely in place.

There are some moving parts of the equipment for which guards are not practical. Such unguarded areas
have been evaluated as safe to work around with proper training and safe work practices.

1.3 General Risks and Hazards

Working at industrial sites unavoidably poses hazards from various activities and conditions. In the following sections,
several well-known industry hazards are outlined and precautions are described accordingly.

Follow all governing safety standards and local jobsite procedures.

1.3.1 Identifying and Controlling Hazards

It is important to identify and control hazards before beginning any work or task. This is called risk management. There
are four basic steps in risk management:

1. Identify the hazards: Before you begin any task on or around the equipment, inspect the area and consider the task
to ensure that you are able to identify hazards or potential hazards.

2. Assess the risks: When you have identified the hazards or potential hazards, assess each one to determine the
overall level of risk. Risk is determined as the potential severity of the hazard and the likelihood of an incident being
caused by it.

3. Eliminate or control the hazards: If the risk is too great, put controls in place to eliminate or control the hazard.
Controls will vary according to the situation so it is up to the established site procedures and the personnel
conducting the task to find methods that are suitable for the conditions.

4. Reassess the risks if conditions change: Whenever the conditions that existed when the initial assessment was
conducted change, carry out the assessment of the hazards and risks again. This is to ensure that the changed
conditions do not increase the likelihood of an incident or increase the severity of an incident.

1.3.2 Ladders
When the working height is greater than 1.8 m (6 ft) special considerations and equipment is required. Put site
emergency procedures in place when conducting work at heights to ensure any incident will be handled with a proper
emergency response.

Follow all governing safety standards and local jobsite procedures.

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12 Chapter 1 Safety

1.3.3 Scaffolds
Scaffolds are an important means of ensuring safety when working at heights. Ensure that anyone constructing or
climbing on scaffolds is aware of the basic safety precautions. Correct any scaffold deemed unsafe immediately.

Follow all governing safety standards and local jobsite procedures.

1.3.4 Railings
FLSmidth recommends that all stairways, open-sided floors, and loading docks contain perimeter or fall protection
devices such as a removable guardrail, a guardrail fence, or two chains strong enough to withstand the weight of
someone sitting on it.

Follow all governing safety standards and local jobsite procedures.

1.3.5 Elevated Work Conditions

Train personnel riding in or working from the following devices to the local jobsite requirements and maintain 100% tie-
off procedures.

• Personnel lifts
• Hoisting devices
• Elevated work platforms

1.3.6 Harness and Line (Fall-Arrest System)

FLSmidth recommends that fall arrest system components be properly rated and mutually compatible.

Follow all governing safety standards and local jobsite procedures.

1.3.7 Cranes and Lifting Operations

Operating cranes, whether mobile or fixed, present unique risks for both the operator and the equipment. Train crane
operators by approved site management.

Follow all governing safety standards and local jobsite procedures.

1.3.8 Moving Parts on Stationary Equipment

The primary risk associated with stationary machinery is that anyone close enough to the machine may get hands, arms,
feet, or loose clothing caught in the moving parts: shafts, rollers, cranks, v-belt drives, and so forth. This type of accident
often occurs when the victim is climbing on or gets too close to a machine that starts suddenly via a remote control, or is
already running. The consequences will be injuries (squeezing or crushing of extremities), but can also result in death.

Take care to ensure the safety of all personnel near moving equipment components. Ensure that all procedures are
followed, and equipment guards are in place and undamaged before starting work. Never place your body near any
moving parts, and always wear the correct PPE.

Follow all governing safety standards and local jobsite procedures.

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Chapter 1 Safety 13

1.3.9 Remote Starts

Remote starting of machines will normally be accompanied by a start warning: either audible (siren), visual (flashing
lights), or both. The start warning is intended to allow employees enough time to move to a safe distance away from the
machinery.

If maintenance or repair work is to be carried out, machines are furnished with a power source or controls that permit
Lockout/Tagout (LOTO).

Follow all governing safety standards and local jobsite procedures.

1.3.10 Confined Spaces

Confined Space Entry (CSE) is the entry of personnel into any space or structure not normally intended for human
occupancy, in which entry, movement within or exit is restricted, such as underground vaults, tanks, storage bins, pits
and diked areas, vessels, silos, and so forth. These enclosed or partially enclosed spaces:

• Are large enough for an employee to enter fully and perform assigned work.
• Are not designed for continuous occupancy by the employee.
• Have a limited or restricted means of entry or exit.

Follow all governing safety standards and local jobsite procedures.

1.3.11 Welding, Cutting, and Brazing

FLSmidth recommends that all welding and brazing operations have proper ventilation. Fumes such as those produced
when working with zinc, cadmium, and painted surfaces can be toxic.

Follow all governing safety standards and local jobsite procedures.

1.3.12 High Temperatures

Operations involving high air temperatures, radiant heat sources, high humidity, direct physical contact with hot objects,
or strenuous physical activities can have a high potential for causing heat-related illness/injury. Workplaces with these
conditions may include iron and steel foundries, nonferrous foundries, cement plants, rubber products factories,
electrical utilities (particularly boiler rooms), chemical plants, mining sites and smelters. Potential hazards are thermal
burns due to contact with hot equipment or exposure to high temperatures.

Follow all governing safety standards and local jobsite procedures.

1.3.13 Power Lines

Be aware of power lines in the area and consider all power lines energized unless proper measures have been taken for
de-energizing.

Follow all governing safety standards and local jobsite procedures.

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14 Chapter 1 Safety

1.3.14 Inclement Weather

The local Health and Safety Executive (HSE) or business management can provide a means to determine the weather
forecast for the project location. FLSmidth recommends that you take precautionary measures during severe conditions.

Follow all governing safety standards and local jobsite procedures.

1.3.15 Noise and Vibrations

Prolonged exposure to loud noise can impair hearing or cause permanent hearing loss. To protect from hearing loss,
FLSmidth recommends the following:

• Always wear PPE to protect against noise.

• Measure the noise levels for areas that may be considered a noise hazard.
• All personnel working in areas that exceed permissible exposure levels are required to wear jobsite-approved ear
protection.

Excessive noise can permanently damage your hearing. If you need to raise your voice to be heard, wear
hearing protection.

Some tools and equipment can expose employees to vibrations that can be harmful if not properly mitigated. Some
vibration when operating this equipment is to be expected. However, excessive vibration is often an indication of a
problem with the machine. Trace the sources of excessive vibration and rectify any problems as soon as possible. Do
not allow yourself to be exposed to vibration for long periods of time.

Follow all governing safety standards and local jobsite procedures.

1.3.16 Pinch and Crush Points

Pinch points or crush points are a major hazard for personnel working around equipment. Loose clothing or hand tools
that are placed anywhere near a pinch point can result in the person being dragged into rotating or moving equipment.

• Always be aware of pinch point hazards.

• Never attempt to remove material from a moving conveyor or other equipment.
• Never place your hands, any part of your body, or anything you are holding in a location where rotating or moving
parts could pinch the item and drag you in.
• Never work on any part of a conveyor or equipment that is running.
• Never work on a stopped conveyor unless it has been correctly shut down, isolated, locked out, and tagged out.

Crushing and shearing points can occur in the following locations on equipment:

• Between the belt and drive pulley.

• Between the belt and take-up rolls.
• Between the belt and idler rolls.

This equipment may be provided with casings and covers, specifically at the discharge and feeding points, to reduce
injuries from pinching or crushing. Have maintenance and repair work done only by specifically instructed personnel.

Follow all governing safety standards and local jobsite procedures.

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Chapter 1 Safety 15

1.3.17 Electrical Energy

Electrical hazards have the potential to cause serious injury to personnel or damage to equipment. FLSmidth
recommends that only trained, competent, and authorized personnel work on electrical components and equipment.
Follow correct isolation procedures when working on electrical equipment. FLSmidth further recommends that the
following precautions be taken:

• Do not override or bypass any electrical safety functions.

• Keep control panel doors closed at all times.
• Do not use oversized fuses, buss bars, or heaters.
• Connect the motor drives and accessories to an electrical ground, such as an underground water piping system, the
frame of a building, or other electrical ground.

Do not undertake electrical work if you are not trained, competent, and authorized to do so.

FLSmidth recommends that electrical systems comply with the relevant electrical provisions, and that all work done on
the electrical system be done by certified electricians. All electrical components must be interconnected and grounded
according to correct and safe electrical procedures.

Follow all governing safety standards and local jobsite procedures.

1.3.18 Fuels, Oils, and Lubricating Fluids

During the operation of this equipment, you may come into contact with fuels, coolant, lubricating oils, and specialized
greases. These products can be hazardous if safety procedures are not followed when handling them. FLSmidth
recommends that you do the following:

• Always read, understand, and follow the directions on the relevant Safety Data Sheet (SDS) before handling any
chemical, fluid, or grease.
• Use the correct PPE for any task you conduct. Some SDS sheets will specify extra PPE.
• Avoid long periods of contact between your skin and any fluids associated with this equipment.
• Avoid breathing mist and vapors from fluids associated with this equipment.
• Do not touch your eyes, mouth, or face with dirty hands.
• Clean up fluid spills immediately using approved jobsite procedures.
• Do not carry oily rags in your pockets.
• Change out of oil-soaked clothing as soon as possible.
• Ensure operators know what they are handling and whether it presents special problems. When the filtered product
has known hazardous characteristics, keep specific antidotes and appropriate first aid supplies in the immediate
area.
• Report any significant contact with fluids or greases to your supervisor.

Follow all governing safety standards and local jobsite procedures.

1.3.19 Surface Heat

Certain components on equipment can become hot during operation. Be aware of potential hot components in your
working area and treat them with caution.

FLSmidth recommends that if any components seem disproportionately hot, shut down the equipment and investigate
and report immediately. Excessively hot components can indicate a mechanical problem and may result in equipment
damage and unsafe situations for personnel.

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16 Chapter 1 Safety

During commissioning, operation, maintenance, repair, and shutdown, contact of hot machine components or electrical
equipment may occur. Instruct all personnel accordingly.

Never place your hands on any item of equipment until you are certain it is at a safe temperature.

1.3.20 Lines, Tubes, and Hoses

FLSmidth recommends that operators and maintenance personnel take precautions to isolate and de-pressurize, if
necessary, any pressurized lines or vessels before they are opened. Observe the following safety points:

• Inspect all lines, tubes, and hoses carefully.

• Do not use your bare hands to inspect for leaks.
• Tighten all connections to the recommended torque.
• Do not bend or strike high pressure lines.
• Do not install bent or damaged lines, tubes, or hoses.
• Repair any loose or damaged hydraulic oil lines, tubes, and hoses.

Leaks can cause fires.

Note: Even though the equipment is switched off and electrically isolated, the contents of pipes and vessels
may still be under high pressure.

If high-pressure water or air hoses are used, FLSmidth recommends that all quick-connectors are fitted with a safety clip
similar to one shown in the figure below.

Figure 1-3: Safety Clip

1.3.21 Mechanical Stability

The machine and its components are designed to minimize hazards due to insufficient mechanical stability; however,
during transport and assembly, maintenance, repair, shutdown, disposal, and storage, machine parts may tip or fall and
endanger the staff.

During commissioning FLSmidth recommends that extensive static and dynamic tests be carried out. Do not overload
the machine during operation, and use it only for its intended purpose.

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Chapter 1 Safety 17

1.4 Hazardous Chemicals and Materials

Many materials used in the industry contain hazardous ingredients that potentially pose health risks to employees.
FLSmidth recommends that the appropriate Safety Data Sheet (SDS) be obtained for all hazardous materials used on
site, and that the SDS be available for personnel and supervisors working with these chemicals. Careful study of the SDS
and adherence to the required safety precautions can improve on-site safety.

FLSmidth also recommends that chemicals be properly labeled.

Follow all governing safety standards and local jobsite procedures.

1.4.1 Mineral Powders (Silica)

Mineral powders may be natural, such as sand or gravel, but very often they are an intermediate product in the cement
or mining industry (ore concentration). Mineral powders will also be generated as dust from grinding or cutting
operations in stone or concrete, or by handling dry soil.

Follow all governing safety standards and local jobsite procedures.

1.4.2 Lime and Calcined Raw Meal

Lime and calcined raw meal is a fine powder consisting of a mixture of calcined (heat treated) natural minerals, primarily
calcined limestone (CaO) and clay/silicates. Smaller amounts of aluminum, iron and magnesium compounds as well as
reaction products such as calcium-silicates and calcium-aluminates may also be present in the mix, together with trace
amounts of other metal compounds.

Follow all governing safety standards and local jobsite procedures.

1.4.3 Cement
FLSmidth recommends that anyone who uses cement, or mixtures containing it, or is responsible for managing or
supervising its use, is aware that it may be a hazard to health and safety, and to use safe working practices to minimize
risks.

Follow all governing safety standards and local jobsite procedures.

1.4.4 Acids and Bases

Strong acids include nitric (HNO3), sulphuric (H2SO4), hydrochloric (HCl) and phosphoric (H3PO4) acid. Of especially
dangerous nature is hydrofluoric acid (HF). Strong acids give off heat when diluted with water, which may lead to vapor
explosions.

Some systems use an acid wash containing hydrochloric (muriatic) or other acids. These acids can cause severe burns,
irritation of mucous membranes, and skin irritation even in dilute solutions. Fumes may cause respiratory problems. Eye
protection, skin protection, and respiratory masks are required when working with this material.

Follow all governing safety standards and local jobsite procedures.

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18 Chapter 1 Safety

1.4.5 Cyanide
In some processes, including gold mining, the use of cyanide (calcium cyanide CaCN; potassium cyanide KCN; sodium
cyanide NaCN) is common. Any work with a direct risk of interacting with cyanide requires additional training.

Follow all governing safety standards and local jobsite procedures.

1.4.6 Solvents
The most abundant toxic materials are solvents; other toxic materials include pigments (lead), paint, binders (epoxies,
polyesters) and additives (organotin).

Follow all governing safety standards and local jobsite procedures.

1.5 Emergency Preparedness Plan

Refer to your site emergency preparedness plan.

Emergency preparedness plans are a critical component of safety.

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 19

Chapter 2: Introduction
2.1 FLS MissionZero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2.2 Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2.3 Installation and Start-Up Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Shipment and Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Parts and Repair Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Warranty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.6.1 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7 Accessory Equipment Manufacturer Information . . . . . . . . . . . . . . . . . . . . . . . . . .23
2.8 FLSmidth Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

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20 Chapter 2 Introduction

2.1 FLS MissionZero

MissionZero is the FLS sustainability program to reduce environmental impact and improve productivity. We aim to be
carbon neutral by 2030 and continually reduce the environmental impact of our own operations. Additionally, we
consider it our responsibility to be a key sustainability partner for our stakeholders, driving sustainable business
practices across the industry value chains.

To learn more about the FLS MissionZero program go to http://www.flsmidth.com/en-gb/company/sustainability.

2.2 Using This Manual

This manual describes the FLSmidth® Raptor® 1100 Cone Crusher and outlines its installation, maintenance, and
operational procedures. It also includes a number of FLSmidth-recommended best practices.

FLSmidth has designed this equipment to provide dependable, efficient, and economical operation throughout its entire
period of service. In order to achieve the desired level of performance and ensure full warranty coverage, it is required
that users thoroughly read, understand, and follow the contents of this manual before carrying out the installation of the
equipment, making any adjustments, or operating the equipment. Regular care and maintenance must also be
performed as outlined in this manual.

The accessory items, (items furnished but not manufactured by FLSmidth) shall be stored, installed, operated, and
maintained according to the original equipment manufacturer instructions for complete warranty protection.

Note the following:

• The standard manual set includes an Installation, Operation, and Maintenance (IOM) Manual as well as an Original
Equipment Manufacturers (OEM) Manual containing documentation for items furnished but not manufactured by
FLSmidth.
• The procedures described in this manual do not relieve users of their responsibility to exercise caution and common
sense.
• Users are responsible for their own personal safety when operating this equipment.
• Users must comply with all safe working procedures and instructions relevant to their work site at all times.
• Pictures, descriptions, and technical data may not match your equipment in every aspect.
• The information, specifications, and illustrations in this manual are written according to information available at the
time it was produced, therefore, this information may change at any time. These changes could include one or more
of the following: lubrication, storage, installation instructions, maintenance, and so forth. FLSmidth reserves the right
to make changes without notice and without obligation to replace existing manuals.
• FLSmidth will not furnish editable electronic copies of any data, manuals, or drawings at any time and accepts no
liability whatsoever for unauthorized changes or alterations to the data provided.
• All information contained in this manual is the property of FLSmidth. None of the content may be copied or made
public without prior written consent from FLSmidth.
• English is the governing language. When manuals are translated into any other language, FLSmidth is not liable for
damages caused by errors in translation. The English translation will govern in case of discrepancies. In the event
there is confusion, notify your FLSmidth representative immediately. Refer to http://www.flsmidth.com/en-US/
Contact for applicable address and telephone numbers for the FLSmidth Office nearest you.
• FLSmidth accepts no liability to update the information contained in this manual. These materials are provided “AS
IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO,
THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR NON-
INFRINGEMENT. YOU ASSUME COMPLETE RESPONSIBILITY AND RISK FOR USE OF THESE MATERIALS. Some
jurisdictions do not allow the exclusion of implied warranties, so the above exclusion may not apply to you.
• BY USING THIS MANUAL YOU AGREE THAT YOU HAVE READ, UNDERSTAND, AND AGREE TO THE TERMS OF
USE.

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Chapter 2 Introduction 21

2.3 Installation and Start-Up Services

Experienced FLSmidth engineers and service personnel are available to assist in the installation, safety training, and
start-up of your FLSmidth equipment. These personnel have technical expertise and firsthand knowledge of this
equipment, as well as the backing of the engineering and research facilities of FLSmidth.

Service personnel instruct on proper safety, operating and maintenance procedures, advise on best practices and
troubleshooting assembly, and can supervise the entire installation and start-up.

To request this assistance, make arrangements at the earliest possible date, outlining the services required and the
approximate duration of needed service.

Refer to your FLSmidth representative or http://www.flsmidth.com/en-US/Contact to submit your request concerning the
availability and charges for these services.

2.4 Shipment and Receiving

Carefully inspect your shipment immediately upon receipt. Although every precaution is taken when shipping to ensure
your items arrive undamaged and as ordered, damage or other issues may occur during shipment. If equipment
packaging is damaged, immediately contact your FLSmidth representative for further instructions.

Note: All equipment must be stored in their original shipping containers, especially when such containers are
wooden crates or cardboard cartons as this will maintain necessary storage protection.

• Refer to the installation lifting instructions before handling the equipment.

• Carefully handle boxes when opening for inspection to prevent damage or loss of contents. Repack all parts, or store
them in a safe place with all protective covers reinstalled until assembly.

In case of damage or missing parts, immediately notify the carrier and your FLSmidth representative at http://
www.flsmidth.com/en-US/Contact.

You must notify FLSmidth within the time frame specified in your contract in the event of shortages or
discrepancies on the shipment. FLSmidth is not responsible for replacing items if notification occurs
outside the contractual time. If no time-frame has been specified in your contract, you must notify
FLSmidth within 30 days of shipment receipt.

2.5 Parts and Repair Orders

Please contact FLSmidth for parts, repair orders, and equipment service, referring to http://www.flsmidth.com/en-US/
Contact for the FLSmidth Office nearest you.

To make sure the right replacement parts are received and to avoid undue delay, please provide the following
information with each order:

• Size and Type of Unit: Raptor 1100 Cone Crusher

• Serial Number: PI-0000046732

Note: This is found on the unit nameplate.

• Customer Order Number: 200207-MW/2020

• Project Number: 9232515940
• FLS Order Number: 9232515940

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22 Chapter 2 Introduction

• MCN Number: 1000912341 1

• Specific Component Part Numbers and Descriptions: (See individual component part nameplates included on the
drawings for these part numbers.)
• Special Field Modifications: This is important if the original material or design has been changed. Include drawings
and other descriptive information.

2.6 Warranty Conditions

Your FLSmidth-provided equipment (the “Equipment”) is designed with dependability in mind. However, this unit can be
damaged through misuse and by failing to follow the storage, installation, and maintenance procedures outlined in this
manual.

FLSmidth will not be responsible for damage to the Equipment, component parts, or other related structures, nor will the
warranty coverage on the Equipment be valid if any of the following apply:

• The Equipment is operated in an incorrect or negligent manner.

• The Equipment is not maintained in accordance with provided instructions.
• Operating conditions fall outside those specified for the Equipment, as originally designed and supplied.

The Equipment must be installed only by trained personnel who have been thoroughly trained in the safety procedures
pertaining to it.

All drawings and erection or installation instructions must be followed. Drawings provided will always govern. In the
event of any discrepancies, notify your FLSmidth representative immediately, referring to http://www.flsmidth.com/en-
US/Contact for contact information.

2.6.1 Limited Warranty

a. FLSmidth warrants the Equipment to be free from defects in material and workmanship. Refer to your contract for
specific warranty terms and conditions.

b. FLSmidth warranties are subject to the Equipment being properly stored, erected, installed, maintained, and oper-
ated in accordance with FLSmidth instructions and good industry practice and exclude ordinary wear and tear,
improper loading of software or firmware, corrosion, erosion, chemical or abrasive action, power failures, power
surges, other fluctuations in power, excessive heat, improper lubrication, extended storage before start-up, unautho-
rized repair, replacement, modification or alteration of the Equipment; or application outside the contractual design
limitations of the Equipment.

c. Buyer shall provide FLSmidth with written notice of a defect in materials or workmanship, including a full description
thereof, within 14 days after the defect is or should have been detected and in any event before expiration of the
warranty period.

d. FLSmidth agrees to repair or, at its option, replace at its expense, FCA shipping point (Incoterms 2010) any Equip-
ment or parts and components thereof, excluding the costs of dismantling and re-installation of the Equipment or
parts and components, that prove during the warranty period to contain defects in materials or workmanship.

e. The remedies stated in this Article are Buyer’s exclusive remedies for breach of this FLSmidth warranty. In no event
shall the exclusive remedies in this Article be considered or alleged to have failed their essential purpose. Buyer
agrees that if there are any discrepancies or inconsistencies between this Limited Warranty and the warranty
terms and conditions accompanying the Contract, the warranty terms and conditions accompanying the Con-
tract shall always govern.

f. EXCEPT FOR THE EXPRESS WARRANTY STATED IN THIS ARTICLE, FLSMIDTH EXPRESSLY DISCLAIMS ALL
OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED, STATUTORY, AT LAW OR IN EQUITY. THERE ARE NO
IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS OF PURPOSE, OR OTHERWISE.

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Chapter 2 Introduction 23

2.7 Accessory Equipment Manufacturer

Information
Whenever the installation, lubrication, maintenance, or operation of an accessory piece of equipment (item which is
furnished by FLSmidth but is fabricated by a third party) is discussed in the FLSmidth instruction manual, this information
is provided only as a courtesy, as provided by the manufacturer at that time, and with no warranty expressed or implied.
This information must be verified by consulting the original equipment manufacturer (OEM) manuals, which are the ruling
documents for any accessory equipment.

As manufacturer instructions or recommendations may change over time, it is the user’s responsibility to periodically
consult the manufacturer to obtain the most up-to-date information, including maintenance instructions and recall
information.

In the event of any discrepancies between the information found in the FLSmidth instruction manual and
the information in the OEM manuals, notify your FLSmidth representative immediately, referring to http:/
/www.flsmidth.com/en-US/Contact.

As with any mechanical equipment, there are safety concerns associated with the installation of the primary and
accessory equipment. It is absolutely essential that installers, operators, maintenance personnel, and supervisors be
instructed in safe working practices.

2.8 FLSmidth Offices

After completion of the contract, all service and spare parts will be supported by the closest FLSmidth Regional
Headquarters. To find the FLSmidth office nearest you, refer to http://www.flsmidth.com/en-US/Contact.

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24 Chapter 2 Introduction

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 25

Chapter 3: Storage
3.1 Long-Term Storage Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.1.1 Maintaining Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.2 Storing OEM Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Outdoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.3 Covered or Indoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.4 Equipment Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5 Preventing Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.5.1 Shop Primer Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5.2 Protective Finishes or Seal Coats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.5.3 Machined and Non-Coated Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.6 Storing Elastomer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.7 Storing Fiberglass Reinforced Plastic Components . . . . . . . . . . . . . . . . . . . . . . . .29
3.8 Storing Equipment After Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.9 Storing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.10 Environmental Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.11 Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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26 Chapter 3 Storage

3.1 Long-Term Storage Introduction

The storage procedures in this manual are general guidelines and standard practices that aid in maintaining the
condition of the equipment during long-term and pre-commissioning storage. If storage time is between 3 and 24
months, the following procedures shall be followed. If storage time is to exceed 24 months, contact FLSmidth for further
instructions.

3.1.1 Maintaining Warranty

FLSmidth warranties are subject to the equipment being properly stored as outlined below.

• Items with bearings must be rotated (pulleys, idlers, motors, drives, and so forth) according to the bearing
manufacturer’s requirements.
• For items with lubrication requirements, refer to Appendix A: “Lubrication” on page 173 for more details. In addition,
follow all maintenance requirements from the original equipment manufacturer (OEM) to maintain component life.
Failure to follow these instructions, in addition to the manufacturer’s requirements, will void component warranty.

When storing items for extended periods—six months or longer—detailed records must be kept and regularly updated
for the duration of the storage period. In the event of a warranty claim, these records must be submitted to FLSmidth to
show that all equipment and components have been properly maintained during the storage period. A paid periodic
inspection by an FLSmidth service personnel may be required to maintain the warranty. For the specific terms and
conditions of your equipment warranty please contact your FLSmidth representative.

Failure to comply with these storage instructions will void the FLSmidth warranty.

3.1.2 Storing OEM Components

FLSmidth provides vendor documentation that includes installation, operation and maintenance manuals for all parts
supplied by FLSmidth, but manufactured by a sub-contractor. This can include, but is not limited to, the following:
actuators, bearings, blowers, compressors, gear boxes, heaters, HPU, and other instruments.

For long-term storage requirements of the equipment that is furnished but not built by FLSmidth, refer to the original
equipment manufacturer (OEM) instructions.

3.2 Outdoor Storage

Site selection for outdoor storage of FLSmidth supplied equipment and accessories shall be:

• Level, well-drained, firm surface, clean, and dry

• Isolated or barricaded from possibility of physical damage from transport vehicles
• Accessible for periodic inspection and maintenance
• Away from direct sunlight, moisture, and excessive vibration
• Away from high concentrations of dust or corrosive gas

Sensitive components must be covered with a well drained and ventilated tarp or tent structure.

Painted and protective corrosion-resistant coating must inspected on monthly intervals, repaired, re-applied, or replaced
as necessary.

In the event of substantial corrosion (other than loose surface rusting) consult FLSmidth for recommendations for
corrective action.

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Chapter 3 Storage 27

3.3 Covered or Indoor Storage

Covered storage consists of any structure with a roof to protect the equipment and components from the sun and rain.

Indoor storage consists of an enclosed structure that will protect from sun, rain, wind and dust.

Refer to Table 3-1 on page 30 for electrical sensors, wiring, and motor storing methods.

Covered or indoor storage require the following conditions:

• A constant temperature (between 5°C and 40°C [41°F and 104°F]), with no sudden temperature fluctuation
• A relative air humidity of ≤ 50%
• Relatively free of dirt or dust deposits

3.4 Equipment Support

Support all large fabricated equipment components in a manner that will allow free air flow under and around the
component being stored. Place supports (steel beams or wood timbers—not supplied by FLSmidth) of significant size
and strength at appropriate load-bearing locations. Store and support all components shipped on skids and pallets or in
crates and shipping containers in a manner that will allow free air flow under and around the skid, pallet, crate, or
shipping container.

3.5 Preventing Corrosion

Equipment that is in storage or that is out of service for more than 30 days must be protected against corrosion damage.

Regularly scheduled equipment inspections are critical for proper storage of FLSmidth supplied equipment and
components. These inspections include the following:

• Inspect primer paints, protective finishes, seal coats, and corrosion protection treatments thoroughly on a monthly
schedule.
• Repair, re-apply, or replace protective coatings as necessary.

If there is substantial corrosion (other than loose surface rusting), contact FLSmidth for recommendations for corrective
action.

FLSmidth will not be responsible for the condition of protective coatings after the equipment leaves the contracted
fabrication facility. FLSmidth assumes no responsibility for field surface preparation or touch-up of shipping damage to
protective coatings.

Identification tags that are removed for field painting prior to assembly must be reattached to the original components
for correct identification.

3.5.1 Shop Primer Paints

In some cases, equipment is supplied with shop primer paint only. Regularly inspect these finishes for deterioration.

Shop primer paints are intended to serve only as a bonding coat between metal surfaces and protective finishes or seal
coats and to act as a minimal protective finish. In such cases, protective finishes or seal coats shall be applied as soon as
possible. When this is not possible, remove rust or oxidation and re-apply shop primer paints as needed.

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28 Chapter 3 Storage

All shop primer paints must be applied using the paint manufacturer’s recommended processes and environmental
conditions. Shop primer paints for repair purposes are not supplied by FLSmidth.

3.5.2 Protective Finishes or Seal Coats

In most cases, equipment is supplied with a complete protective finish or seal coat. Regularly inspect these finishes for
deterioration. If rust or oxidation is found, clean the surfaces and re-apply the appropriate protective finishes.

All paint must be applied using the paint manufacturer’s recommended processes and environmental conditions.
Protective finishes or seal coats for repair purposes are not supplied by FLSmidth.

3.5.3 Machined and Non-Coated Surfaces

All machined and other non-coated surfaces (uncoated machined surfaces, shafting, mating surfaces, threaded holes,
piping flange faces, and so forth) must be clean and free of rust and other foreign matter. These surfaces must have a
corrosion protection treatment applied that is adequate for the selected storage conditions. All corrosion protection
treatments must be applied using the manufacturer’s recommended processes and environmental conditions.
Corrosion protection treatments for repair purposes are not supplied by FLSmidth. Some examples of corrosion
protection treatments include the following:

• A.W. Chesterton Company (740 Heavy Duty Rust Guard)

• Esgard Inc. (920 Equipment Kote)
• Tectyl Industrial Products (Tectyl 506EH-WD)
• Houghton International Inc. (Rust Veto 342)

Note: There are many other brands and types of corrosion protection treatments available in the market. If in
doubt about a particular product, contact FLSmidth for recommendations and approval of the product in
question.

3.6 Storing Elastomer Components

Elastomer and elastomer-covered (urethane, polyurethane, natural rubber, neoprene, nitrile, EPDM, M.O.R., and so forth)
products in storage can be adversely affected by temperature, humidity, ozone, sunlight, oils, solvents, corrosive liquids
and fumes, insects, rodents, and radiation. Proper care shall be taken to meet the following requirements.

• Elastomer parts shall be protected from physical damage by objects that can cut or tear.
• If stored below 0°C (32°F), some products may become stiff and will need to be warmed before being placed in
service. Do not store elastomer products near sources of heat, such as radiators and base heaters.
• To protect against the adverse effects of ozone, do not store elastomer products near electrical equipment that may
generate ozone or in geographical areas of known high ozone concentrations. Avoid exposure to direct and
reflected sunlight.
• Whenever feasible, store elastomer products in their original shipping containers, especially when such containers
are wooden crates or cardboard cartons, since this will provide protection against the deteriorating effects of oils,
solvents, and corrosive liquids. This will also afford some protection against ozone and sunlight.
• Since certain rodents and insects thrive on rubber products, provide adequate protection against them.
• Rotate all elastomer products on a first-in, first-out basis. Even if all above conditions are met, a prolonged length of
time in storage will result in the deterioration of elastomeric products.

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Chapter 3 Storage 29

3.7 Storing Fiberglass Reinforced Plastic

Components
Fiberglass reinforced plastic products (safety guards, receiver tanks, and so forth) in storage can be adversely affected
by temperature, ozone, sunlight, and corrosive liquids and fumes. Proper care shall be taken to meet the following
requirements.

• The ideal storage temperature for fiberglass reinforced plastics is 0°C to 32°C (32°F to 90°F) with a maximum limit of
38°C (100°F). If stored below 0°C (32°F), some products may become brittle and caution must be taken when placing
these components into service. Do not store fiberglass reinforced plastic products near sources of heat, such as
radiators and base heaters.
• Whenever feasible, fiberglass reinforced plastic products shall be stored in their original shipping containers,
especially when such containers are wooden crates or cardboard cartons, since this will provide protection against
the deteriorating effects of corrosive liquids and fumes and will also afford some protection against ozone and
sunlight.
• All fiberglass reinforced plastics products shall be on a first-in, first-out basis. Even if all above conditions are met, a
prolonged length of time in storage will result in the deterioration of fiberglass reinforced plastics products.

3.8 Storing Equipment After Operation

If the equipment will be removed from service for two months or longer after it has been in use, additional steps will be
required for proper storage. Refer to Chapter 7: “Maintenance” on page 93 for detailed instructions on properly storing
the equipment after operation.

3.9 Storing Methods

The table below provides a basic classification of parts supplied by FLSmidth, along with the preferred storage locations
for each part. Not all the parts listed in the table may apply to your particular equipment. Storage method will depend on
the size and quantity of the parts, as well as the preventative measures needed during storage.

Whenever possible, choose the preferred storage method from the table, along with the appropriate preventative
measures. If the preferred storage method is not possible, the optional storage method can be chosen. When neither
the preferred or optional storage methods are possible, contact FLSmidth for additional instructions on alternative
storage methods and preventative measures.

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30 Chapter 3 Storage

Part Classification Preferred Optional

Storage Method Storage Method

Covered

Covered
Outdoor

Outdoor
Storage

Storage

Storage

Storage

Storage

Storage
Indoor

Indoor
Heavy Fabrications X X
Bearing Housing and Shaft
X X
Assemblies (BHSAs)

Electric Motors X X

Gearboxes X X

Blowers X X

Compressors X X

Pumps X X

Hydraulic Power Units (HPUs) X X

Hydraulic and Pneumatic

X X
Actuators

Instruments X X

Valves X X

Bearings X X

Seals X X

Elastomer and Elastomer

X X
Covered Components

V-Belts X X

Sheaves and Bushings X X

Fiberglass Components X X

Table 3-1: Preferred Storage Methods

3.10 Environmental Precautions

The following table highlights the major environmental precautions that must be addressed in order to maintain proper
condition throughout and after long-term storage. Table 3-2 outlines the specific precautions for equipment that is
stored for up to six months.

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Chapter 3 Storage 31

Items Environmental Precautions

UV Exposure
Temperature

Cleanliness
Ventilation
Humidity
Metal and Machined Parts
No Yes Yes Yes No

Elastomer parts (Urethane, Polyurethane,

Rubber) Yes No Yes Yes Yes

Fiberglass Parts
Yes No No Yes Yes

Polypropylene/Polyethylene Filter
Components Yes Yes No No Yes

Table 3-2: Environmental Precautions - Storage up to Six Months

3.11 Equipment Disposal

For equipment disposal, refer to local laws and regulations.

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32 Chapter 3 Storage

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 33

Chapter 4: Equipment
Overview
4.1 Equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
4.1.1 Crusher Main Frame Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.1.1.1 Main Frame Seat Liner and Fulcrum Bar . . . . . . . . . . . . . . . . . . . . . . . . 34
4.1.1.2 Tramp Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1.1.3 Clamping Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1.1.4 Clearing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1.1.5 Open and Close Bowl Adjustment Circuits . . . . . . . . . . . . . . . . . . . . . . 37
4.1.1.6 Adjustment Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1.2 Drive Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1.2.1 Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.2.2 V-Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.2.3 Belt Tensioner and Jackshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.3 Countershaft and Sheave Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1.4 Eccentric Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1.4.1 Counterweight Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1.5 Socket Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1.6 Head, Mantle, and Feed Plate Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1.7 Bowl Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.1.8 Bowl Adjustment Mechanism Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1.8.1 Drive Ring Support System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1.9 Lubrication System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.1.9.1 Oil Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1.9.2 Lubrication System Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1.9.3 Air Seal Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1.9.4 Low Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1.9.5 Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1.9.6 Oil Temperature System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1.9.7 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1.10 Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2 Operation Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.2.1 Crusher Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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34 Chapter 4 Equipment Overview

4.1 Equipment Overview

4.1.1 Crusher Main Frame Description
The main frame, which is typically bolted to a foundation, provides a rigid support for the crusher components, while
transmitting the crushing force to the foundation.

To protect the inside of the frame from wear, main frame liners are welded to the frame, and arm guards protect the
arms of the frame.

The main shaft is secured in the main frame hub with an interference fit. The eccentric assembly rotates around the fixed
main shaft. The socket assembly is mounted on the top of the main shaft, and supports the head assembly.

A thrust bearing is bolted to the top of the main frame hub, and supports the rotating eccentric assembly. Shims located
under the thrust bearing can be inserted or removed, and are used to adjust the position of the gear and pinion relative
to one another.

Pins mounted in the adjustment ring match up with holes in the main frame bushings, and prevent the adjustment ring
from turning during crushing. The pins also serve as guides to properly re-seat the adjustment ring on the main frame
following the passing of tramp material.

Mounted around the top of the main frame gear well is a replaceable U-shaped seal. This seal, with its mating T-shaped
seal in the eccentric assembly, forms a labyrinth to prevent oil leaking from the crusher, and dust from entering the
crusher.

4.1.1.1 Main Frame Seat Liner and Fulcrum Bar

The main frame seat liner and fulcrum bar are welded to the top flange of the main frame. The bronze seat liner is a
softer material than the steel main frame and adjustment ring, providing a replaceable seating surface for the
adjustment ring.

The fulcrum bar is welded to the top of the main frame flange. Refer to Figure 4-1. There must always be clearance
between the top of the fulcrum bar and the underside of the adjustment ring. The clearance is greatest when the main
frame seat liners are replaced.

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Chapter 4 Equipment Overview 35

Image may not reflect exact equipment.

1 Fulcrum bar 2 Seat liner 3 Seating surface 4 Main frame

Figure 4-1: Main Frame Seat Liner and Fulcrum Bar

4.1.1.2 Tramp Release

Hydraulic tramp release cylinders hold the adjustment ring to the main frame during crushing. They also lift the
adjustment ring and bowl assembly from the main frame during clearing. The actual force employed by the cylinders is
determined by the hydraulic pressure applied to the tramp release cylinders; hydraulic pressure forces the barrel down
during crushing and upward during clearing. The piston and piston rod remain fixed during both operations.

When crushing forces exceed the tramp release forces, the hydraulic oil is displaced through a pressure relief valve
from the bottom side of the cylinder to the top side as well as to the accumulators. This allows the adjustment ring to lift,
and tramp material to pass through the crusher.

If for any reason the crusher stops with rock in the crushing cavity, the cylinders can be extended, lifting the adjustment
ring and bowl assembly off the main frame to open the crushing cavity enough to clear the crusher. This is accomplished
by depressurizing the rod side of all the tramp release cylinders, and pressurizing the piston side.

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36 Chapter 4 Equipment Overview

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1 Tramp cylinder 2 Adjustment ring 3 Accumulator

4 Tramp circuit 5 Clearing circuit
Figure 4-2: Tramp Release Assembly

4.1.1.3 Clamping Cylinders

Clamping cylinders are mounted in the clamping ring, and position it above the adjustment ring. The clamping ring
contains threads on its inner diameter. When the clamping cylinders are pressurized, the clamping ring lifts slightly and
locks the bowl assembly in place. This prevents the bowl from turning during crushing.

The dust shell and an integral seal are bolted to the top of the adjustment ring. The dust shell and its seal protect the
clamping ring, clamping cylinders, and bowl threads from dust and dirt.

The circuit is dead-headed, and pressurizes up to 193 bar (2,800 psi). Once the circuit is fully charged with oil, minimal
oil flow continues to replace any oil lost in leakage. Re-pressurization occurs automatically and rapidly, taking from two
to five seconds. A circuit accumulator dampens hydraulic pressure spikes, and provides make-up oil to minimize re-
pressurization cycles. A pressure transducer monitors the pressure.

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Chapter 4 Equipment Overview 37

Image may not reflect exact equipment. Cylinder is shown upside-down for clarity.

1 Piston 2 Piston retainer 3 Piston seal 4 Cylinder

Figure 4-3: Clamping Cylinder Travel

4.1.1.4 Clearing Circuit

The clearing circuit is a system of hydraulic cylinders (shared with the tramp release circuit) that lift the adjustment ring
when they are energized. The system lifts until it is dead-headed, and can operate up to the maximum hydraulic power
unit pressure of 207 bar (3,000 psi).

The clearing circuit cannot be energized until the tramp release circuit is de-pressurized and an open channel is made
for the oil to displace from the tramp release cylinders during the clearing cycle. The system pressure transducer
monitors the pressure in the clearing circuit.

4.1.1.5 Open and Close Bowl Adjustment Circuits

The hydraulic power unit (HPU) provides a flow of oil under pressure to the hydraulic drive assemblies such as the
motors, gear reducers, and brake. When opening or closing the bowl, the circuits operate with the lower flow of one of
two stacked pumps in the power unit. However, when the bowl is completely removed or installed, both stacked pumps
run to increase the speed of the process.

The oil makes a complete circuit through the hydraulic motors, and then flows back to the HPU reservoir. There is no
pressure or flow monitored in the open or close bowl adjustment circuits.

4.1.1.6 Adjustment Ring Assembly

The adjustment ring assembly is made up of the adjustment ring with welded mounting brackets for the hydraulic adjust
motors, clamp ring and clamp cylinders with interconnecting hoses, dust shell with seal, and fasteners.

The adjustment ring sits on the conical surface of the frame, and has threads on its inside diameter. The threads provide
the means for turning the bowl assembly into and out of the crusher. They also allow for adjustments to the crusher
closed side setting.

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38 Chapter 4 Equipment Overview

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1 Main frame 2 Adjustment ring 3 Clamping ring 4 Clamping cylinder

5 Dust shell 6 Dust shell seal 7 Main shaft 8 Lower U-seal
9 Arm guard 10 Main frame liner 11 Tramp cylinder 12 Fulcrum bar
13 Seat liners 14 Lower thrust bearing
Figure 4-4: Main Frame, Adjustment Ring, and Tramp Release Assemblies

4.1.2 Drive Description

The crusher drive can be operated using a directly coupled motor or through a V-belt drive with jackshaft arrangement.

The drive motor must be a squirrel cage induction motor rated for continuous duty. It must have a normal starting torque
of approximately 125% and a normal breakdown torque of approximately 200%, within +/-10% acceptable voltage
variance. It is recommended that the crusher be equipped with a reduced voltage starter.

Use a motor that meets the following requirements:

• The bearings must be sized to handle slight angular variations in the load; no overhung load compensation is
necessary.
• The motor shaft diameter must be able to withstand peak torque due to the crusher static inertia.
• The motor shaft must be an adequate length to accommodate the direct drive assembly.

Use stator thermostats and abrasive resistant insulation. TEFC motors are more durable in abrasive applications, but the
motor used may be open drip proof or enclosed fan cooled.

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Chapter 4 Equipment Overview 39

4.1.2.1 Direct Drive

A direct drive motor arrangement reduces shock loads by absorbing the excessive torque. A variable frequency drive
(VFD) or variable speed drive (VSD) changes the countershaft speed to fit different application requirements. If desired,
the speed may be locked in with a soft starter instead of a variable drive.

If using a direct drive motor, the motor must be designed to handle the vibration, axial thrusting, and peak torques that
can occur in this type of operation. Have the motor supplier contact FLSmidth regarding gear mesh frequency and RPMs
for motor design. Selection of the coupling joining the motor to the crusher requires special consideration, as it will be
exposed to shock and vibration.

4.1.2.2 V-Belt Drive

The crusher is driven with a set of banded V-belts. They reduce the load shocks being transmitted to the crusher drive
motor and reduce the change of rollover or belt whip. Various combinations of sheave diameters are used to change
the speed of the countershaft to fit different application requirements.

With the use of a V-belt drive, the motor bearings must be sized to handle overhung loads for the sheave and static belt
pull

4.1.2.3 Belt Tensioner and Jackshaft Drive

In order to transmit the required power and allow for power surges, very high tensioning forces must be applied to the
drive belts. This would require an expensive drive motor with a special shaft and bearings to handle this load if the
crusher driving sheave was mounted directly to the motor shaft. To reduce motor cost and increase reliability, the
crusher can be supplied with a driving sheave that is mounted on a supported intermediate shaft (jackshaft) coupled to
the drive motor.

The belt tensioner assembly provides a unique arrangement for setting and maintaining proper belt tension. An idler
pulley applies force to the top of the V-belts on the slack side (opposite from the pulling side). This force increases the
wrap on the drive sheave (smaller sheave), and maintains uniform tension to the drive belts. The force is achieved
through two lever arms and coil springs compressed to a specific setting. The increased wrap on the drive sheaves
significantly reduces the belt tension necessary to transmit the horse power, resulting in increased countershaft bushing
and jackshaft bearing life.

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40 Chapter 4 Equipment Overview

Image may not reflect exact equipment. Other arrangements exist for left hand and right hand configurations.

1 Crusher sheave 2 Idler pulley 3 Motor sheave 4 Drive motor

Figure 4-5: Example Belt Tensioner Configuration

4.1.3 Countershaft and Sheave Description

The countershaft assembly consists of cast steel housing, bronze sleeve bearings, a countershaft, and a pinion. The
rotating countershaft inputs rotation to the eccentric assembly, which rotates around the main shaft and is positioned 90
degrees to the countershaft.

An electric motor transmits power to the countershaft with a set of V-belts or direct drive equipment. The countershaft
has a bevel pinion gear mounted on one end, and it drives a gear that is mounted on the underside of the eccentric
assembly.

Two bronze sleeve bushings that are inserted in each end of the countershaft box support the countershaft. Dowels in
the countershaft box prevent any rotation of the bushings in the bores. The bushing flange absorbs thrust loads from the
pinion and the oil flinger.

An oil flinger is pressed onto the drive end of the countershaft. The centrifugal force of the rotating oil flinger prevents
oil from leaking past the drive end bushing. This oil then collects in the end of the countershaft box, and drains back to
the crusher sump area through a passage in the box. A piston ring oil seal is held in place by a tight fit in the cover. The
piston ring groove in the oil flinger forms a labyrinth seal, and rotates around the piston ring to keep oil from leaking past
the running clearance between the countershaft and cover bore.

The countershaft box is held in the main frame by a set of capscrews around the outer flange. An O-ring and wear ring
located on the pinion end of the countershaft box mate with surfaces on the main frame.

An analog temperature sensor is mounted near the countershaft box to measure the outer box bushing temperature.
The control system monitors the sensor, and the system signals and alarm when the temperature rises above the
setpoint.

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Chapter 4 Equipment Overview 41

Image may not reflect exact equipment.

1 Pinion 2 Countershaft 3 Oil flinger

4 Cover 5 Outer countershaft bushing 6 Inner countershaft bushing
7 Countershaft box 8 Piston ring seal
Figure 4-6: Countershaft Box Assembly

4.1.4 Eccentric Assembly Description

The eccentric is made up of a sleeve bushing and thrust bearing, the gear, and the counterweight.

The eccentric has a tilted and out-of-round outside diameter, and it rotates around the main shaft, which is fixed in the
main frame. The eccentric functions like a cam to produce the eccentric motion. The head has a bore that matches the
outside diameter of the eccentric, and follows an elliptical path as the eccentric is rotated. A bronze bushing is locked in
the eccentric bore; it provides a bearing for the main shaft. A bevel gear that is driven by the countershaft pinion is
bolted to the bottom of the eccentric. The eccentric assembly rests on a set of thrust bearings.

The rotating bronze upper thrust bearing is bolted to the bottom of the eccentric, with the fixed steel lower thrust
bearing bolted to the main frame. Shims are placed between the lower thrust bearing and the main frame to adjust the
backlash between the eccentric gear and the countershaft pinion. The eccentric has a bolted counterweight that has a
heavy side and a light side. The heavy side of the counterweight is located opposite the heavy side of the eccentric to
reduce the unbalanced forces associated with the rotating eccentric and head assemblies.

The outside of the counterweight has a bolted guard to protect it from wear caused by the discharge material.
Replaceable U- and T-shaped seals are mounted around the top and bottom of the counterweight. These seals, along
with adjoining seals in the head and main frame, form a labyrinth to prevent dust from entering the crusher and oil from
leaking out.

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42 Chapter 4 Equipment Overview

1 10

7
4
3

9 8

5 2 6
Image may not reflect exact equipment.

1 Eccentric 2 Eccentric bushing 3 Counterweight 4 Counterweight guard

5 Gear 6 Upper thrust bearing 7 Upper U-seal 8 Lower T-seal
9 Caulking 10 Alignment dowel
Figure 4-7: Eccentric Assembly

4.1.4.1 Counterweight Guard

The counterweight guard is a ring of abrasion resistant plate that protects the counterweight from wear caused by
crushed product and material buildup on the main frame arms.

4.1.5 Socket Assembly Description

The socket assembly consists of a socket and dowel pins that have an interference fit on the main shaft, and a bronze
socket liner that has a slight interference fit on the socket.

The socket assembly provides a spherical bearing surface on which the head gyrates during the crushing activities.

The socket assembly transfers the crushing force to the main frame. The socket is held in place on the main shaft by a
press fit and a series of bolts. The socket liner, which is mounted and doweled in a counter bore of the socket, provides
a bearing surface for the head ball. Pressurized lubricating oil is supplied to the grooves located in the spherical surface
of the socket liner to provide lubrication between the socket liner and head ball.

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Chapter 4 Equipment Overview 43

Image may not reflect exact equipment.

1 Straight pin 2 Socket flange 3 Main shaft

4 Capscrew with lock washer 5 Socket liner
Figure 4-8: Socket Assembly

4.1.6 Head, Mantle, and Feed Plate Description

The head, mantle, bowl, and liner make up the major components of the crushing chamber.

A torch ring is mounted on the top surface of the mantle, and a locking nut holds both in place. The feed plate is
mounted on top of the locking nut. The feed plate protects the locking nut from wear and helps distribute material
around the crushing cavity.

A head ball is secured in the head with an interference fit and sits in the socket liner mounted on top of the main shaft.

The head contains two bushings: an upper and a lower head bushing. The flanged lower head bushing provides bearing
support for the eccentric, and the upper head bushing provides bearing support for the top of the head during no-load
(non-crushing) operation.

A groove in the head contains a molded polyurethane T-shaped seal. This T-seal runs parallel with a similar U-shaped
seal mounted in the adjoining counterweight. Together, they form a labyrinth seal that protects the inside of the crusher
from dust infiltration and prevents excessive oil leakage.

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44 Chapter 4 Equipment Overview

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1 Feed plate 2 Locking nut 3 Torch ring

4 Mantle 5 Head 6 Head stub
Figure 4-9: Head, Mantle, and Feed Plate Assembly

4.1.7 Bowl Assembly Description

The outside diameter of the bowl contains greased heavy-duty right-hand threads that mate with corresponding threads
in the clamping and adjustment rings, and that allow the bowl position to be adjusted vertically. The bowl rotates
counterclockwise to open the closed side setting of the crushing cavity, and then rotates clockwise to close it.

The adjustment cap is mounted to the top of the bowl and contacts a rubber seal on the dust shell (which is bolted to the
adjustment ring). The seal, adjustment cap and dust shell protect the greased threads from dust contamination. When
pressurized, clamping cylinders (spaced around the top of the adjustment ring) provide a locking mechanism for holding
the bowl in position during crushing. The bowl assembly is turned by a hydraulic adjustment mechanism mounted on the
adjustment ring.

The feed hopper is designed to direct the feed into the crushing cavity. The flat bottom of the hopper provides a shelf
for the incoming feed to collect and form a dead bed that contributes to the hopper wear protection.

Wedges, wedge bolts, and an adapter secure the bowl liner to the bowl. They are designed to accommodate various
liner configurations.

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Chapter 4 Equipment Overview 45

Image may not reflect exact equipment.

1 Bowl liner 2 Adjustment cap 3 Bowl 4 Adapter ring

5 Wedge bolt 6 Wedge 7 Hopper
Figure 4-10: Bowl, Bowl Liner, and Hopper Assemblies

4.1.8 Bowl Adjustment Mechanism Description

The adjustment mechanism rotates the bowl assembly into and out of the adjustment ring assembly for bowl assembly
maintenance and adjustments to the crusher cavity setting.

The assembly consists of four hydraulic drive assemblies, the drive ring with four turning brackets, and six drive ring
support brackets. These parts turn the bowl for into and out of the crusher.

Before turning the bowl, the clamping circuit must be depressurized so it releases the bowl. After a brief delay to ensure
the clamping circuit pressure is completely released, the hydraulic drive motor mounted on the adjustment ring turns
pinions that are mounted on the drive assembly. The teeth of the pinions engage teeth in the drive ring. Turning
brackets on top of the drive ring match with lugs welded to the outside of the adjustment cap. The drive turns the bowl
to open or close the closed side setting of the crusher.

Two proximity sensors are mounted to one of the pinions’ covers; they count the pinion teeth, and the count is used to
monitor the setting changes and liner life.

4.1.8.1 Drive Ring Support System

As the drive ring rotates, three drive ring retainers hold it in the same plane as the adjustment mechanism pinion. The
retainers have a top and a bottom replaceable urethane support pad.

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46 Chapter 4 Equipment Overview

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1 Drive ring support 2 Drive ring retainer 3 Turning bracket 4 Adjustment ring
5 Drive ring 6 Drive ring support pads
Figure 4-11: Drive Ring Support

4.1.9 Lubrication System Description

The lubrication system is made up of a skid-mounted oil reservoir, one or two lubrication oil pump and motor
assemblies, an oil filter assembly, and a heat exchanger.

The lubrication system sends filtered oil to the crusher to cool and lubricate the bushings. Oil exiting the crusher gravity-
flows in one common return line back to the package lubrication system reservoir.

The skid-mounted lubrication systems consist of the following:

• Reservoir with a oil level sensor, temperature sensor, and oil heaters
• Oil pump attached to a horizontally-positioned electric drive motor, which is mounted under the oil reservoir
• Main system relief valve
• 20 micron filter system with 50 psi (0.34 bar) internal bypass monitored by two separate filter differential pressure
switches
• Various isolation valves
• Temperature transducers in the oil return line and the reservoir supply line
• Heat exchanger remotely mounted

The oil supply is piped to a T in the line near the crusher. Most of the oil flows to the bottom of the crusher main shaft
through the thick leg of the T, but some is diverted to the countershaft box bearings.

The large portion of the oil flows through a vertical gallery in the center of the crusher main shaft, where it lubricates the
head ball, socket liner, and (during no load operations) the upper head bushing. An intersecting cross gallery in the main
shaft carries the majority of the oil flow to lubricate the eccentric bushing and the lower head bushing. This oil flow
provides cooling (heat transfer) from the bearing surfaces within the crusher. Oil exiting the bearing surfaces gravity

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Chapter 4 Equipment Overview 47

flows through the slots in the counterweight, lubricating the gear and pinion on its way to the gear well and main frame
sump. The oil then flows back to the lubrication system reservoir.

The oil flowing to the countershaft box bearings drains from the countershaft box into the main frame oil sump. It
combines there with the rest of the lubricating oil. The oil flow to the countershaft box is controlled by the size of the
flexible supply line and fittings.

4.1.9.1 Oil Filtration

The package lubrication system (PLS) uses multiple oil filters with a differential pressure relief valve, replaceable filter
elements, and a differential pressure sensor to indicate dirty and plugged filter element conditions. These signals are
sent to and processed by the machine control system (MCS).

Under the oil tank cover is a removable and cleanable strainer basket that is designed to catch large particle
contamination as the drain oil falls back into the tank.

4.1.9.2 Lubrication System Breather

The oil reservoir, which is sealed from dust and moisture, has a breather on the top of the tank. The breather maintains
the reservoir atmospheric pressure.

4.1.9.3 Air Seal Blower

The air seal blower assembly introduces air into the eccentric and gear well to provide a positive pressure inside the
crusher. This prevents rock and dust from migrating past the T- and U-seals, and greatly reduces the contamination of
the lubrication oil and associated wear issues.

Image may not reflect exact equipment.

1 Countershaft box 2 Hose 3 Air seal blower

Figure 4-12: Crusher Air Seal Blower

4.1.9.4 Low Oil Level Sensor

The low oil level sensor is mounted on the side of the reservoir. The sensor monitors the oil level, and provides a signal
to the control system when the level becomes low.

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48 Chapter 4 Equipment Overview

4.1.9.5 Oil Pressure Sensor

An analog pressure sensor protects the crusher in case of lost oil pressure. The sensor is wired to the control system,
and a warning and alarm occurs when the pressure drops below acceptable levels.

4.1.9.6 Oil Temperature System

Oil Heater
The oil heater is mounted in the reservoir to maintain the oil temperature in cold operating conditions. The MCS
operates the oil heaters. Equipment required for the heater operation, such as a magnetic contactor and fuse protection,
is not provided with the crusher. The equipment must meet local electrical code requirements.

Heat Exchanger
The heat exchanger maintains the crusher drain oil temperature at 38° to 54°C (100° to 130°F).

There is a relief valve located in a bypass line on the cooler skid. This allows pressure relief due to plugged internal
passages or cold, thick oil. The valve is factory set; do not adjust it.

1 3

4 5

Image may not reflect exact equipment.

1 Air flow 2 Air-to-oil cooler 3 Fan motor

4 Pressure relief valve 5 Supply oil temperature transducer
Figure 4-13: Air-to-Oil Heat Exchanger

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Chapter 4 Equipment Overview 49

4.1.9.7 Temperature Sensors

There are two temperature transducers mounted on the oil reservoir. The transducers are wired to the automated
control system, and monitor the oil temperature from two locations on the lubrication system. Refer to drawing
“1000855583: Heat Exchanger General Arrangement” on page 360 for the transducer location on the heat exchanger.

Reservoir Oil Temperature

A temperature probe in the reservoir is connected to a temperature sensor in the electrical control panel. The control
system uses the sensor’s analog signal to control the oil heater and to manage the oil pump start permissive.

Return Oil Temperature

A temperature sensor probe in the return line connection on the side of the reservoir is connected to the return
temperature transducer. The control system uses the signal to activate the high oil temperature warning and alarm.

Supply Oil Temperature

The temperature sensor is mounted on the heat exchanger outlet piping. It provides an analog signal to the control
system.

4.1.10 Hydraulic System Description

The hydraulic power unit (HPU) is designed and sized to provide the necessary oil flow and pressure to operate the
bowl clamping, bowl adjustment, and tramp release system. The preset operating pressures have a critical effect on the
forces generated by the crusher; do not modify the HPU.

4.2 Operation Theory

4.2.1 Crusher Speed
The motor or drive sheave and the crusher or driven sheave combination is designed to provide optimum performance
for the specific given application. Eccentric speed relates to the countershaft speed, and has a major influence upon the
crusher productivity.

• Increasing the eccentric speed reduces both the throughput and the power draw, but makes the output particulate
distribution smaller.
• Decreasing the eccentric speed increases both the throughput and the power draw, but makes the output
particulate distribution larger.

Determining the correct countershaft speed is a balance between maximizing the crusher throughput, while keeping the
crusher operating within its power limitations. Therefore, the crusher must be operated at the speed specified by
FLSmidth applications personnel.

Sometimes, due to changes in feed conditions, it is necessary to change the crusher speed to optimize performance.
Other times, it may be necessary to make a change in mantle and bowl liner configurations. FLSmidth will provide the
assistance needed to ensure optimal performance.

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50 Chapter 4 Equipment Overview

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 51

Chapter 5: Installation
5.1 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.2 Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.2.1 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.2.2 Crusher Installation Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.2.3 Crusher and Sub-Assembly Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.2.4 Feed Arrangement Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.2.5 Discharge Arrangement Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2.6 Maintenance Platform Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3 Crusher Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
5.3.1 Crusher Installation on Concrete Foundation . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3.2 Crusher Installation on Steel Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.4 Bowl Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
5.5 Accumulators Installation and Pre-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6 V-Belt Drive Installation (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.1 Belt Tensioner Frame Installation on Concrete . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.2 Belt Tensioner Frame Installation on a Steel Structure . . . . . . . . . . . . . . . . . 63
5.6.3 Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.6.4 V-Belts Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.6.5 Drive Guards Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.7 Direct Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.7.1 Sole Plate Installation on Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.7.2 Sole Plate Installation on Steel Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.7.3 Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.7.4 Drive Guards Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.8 Head Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
5.9 Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
5.10 Lubrication System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
5.10.1 Skid Mounted Lubrication System Installation . . . . . . . . . . . . . . . . . . . . . . . . 68
5.10.2 Heat Exchanger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.10.3 Piping Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.11 Air Seal Blower Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.12 Machine Instrumentation Package Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
5.12.1 Countershaft Box Temperature Sensor Installation . . . . . . . . . . . . . . . . . . . . 72
5.12.2 Oil Supply Temperature Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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52 Chapter 5 Installation

5.12.3 Oil Supply Pressure Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5.12.4 Eccentric Bushing RTD Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.12.5 Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.12.6 Speed Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.12.6.1 Direct Drive Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.12.6.2 V-Belt Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.12.7 Vibration Transducers Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.12.8 Level Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.12.9 Machine I/O Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.12.10 Junction Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.13 Feed, Discharge, and Platform Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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Chapter 5 Installation 53

5.1 Installation Overview

This section provides tips and guidelines for erecting, assembling, and installing an FLSmidth Raptor 1100 Cone Crusher
and associated equipment. The recommendations in this chapter are based on FLSmidth’s previous field erection and
supervisory experience with similar projects. If you have problems or questions regarding installation, contact your
FLSmidth representative. Refer to http://www.flsmidth.com/en-US/Contact for the FLSmidth Office nearest you.

This equipment has been designed for a specific duty cycle. The project requirements and specifications, operating
conditions, and safety factors comprise the design parameters for this system. As its intended design use is specific, the
system must not be used for other purposes. If it is so used, the owner assumes full liability.

The instructions and recommendations in this installation chapter are general in nature. They are designed to
accommodate common variations in equipment designs. Therefore, the actual assembly requirements for your
equipment may vary somewhat from these guidelines. In all cases, the actual installation drawings in Appendix H:
“Drawing Package” on page 297 take priority over these instructions.

FLSmidth field service professionals are also available to guide site contractors through common variations to these
instructions. For assistance, refer to http://www.flsmidth.com/en-US/Contact for the FLSmidth Office nearest you.

5.2 Preparing for Installation

5.2.1 Foundation
Refer to drawing “1000855444: General Arrangement” on page 299 for foundation requirements, the mounting position
of the anchor bolts and drive motor, and the clearance required. A durable, solid, and level foundation is critical to the
safe operation of the crusher.

The foundation must be designed to accept the loadings. The customer is responsible for the design of the foundation.

5.2.2 Crusher Installation Envelope

Success of the operation and maintenance of the crusher relies on a well-planned installation. Crusher clearances must
be considered when designing the foundation, leaving adequate space in the following locations:

• Above the crusher for the installation and removal of the head and bowl assemblies
• In front of the foundation for the removal of the countershaft assembly
• In the discharge area between the crusher and the discharge conveyor
• Around feed equipment such as chutes, feed hoppers, conveyors, and other related equipment

Refer to drawing “1000855444: General Arrangement” on page 299 to determine the clearances required.

5.2.3 Crusher and Sub-Assembly Weights

Consider the crusher component weights when designing the crusher installation. Use the correct overhead lifting
equipment such as mobile or stationary cranes, chain hoists, cables, slings, and shackles according to the component
weight. Refer to Table 5-1: “Crusher and Sub-Assembly Weights” on page 54 for the weights of the crusher and
assemblies.

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54 Chapter 5 Installation

Note: The weights listed are nominal weights. Because the assemblies are built with major steel castings, it is
possible that the exact weights may vary by +/-5%.

Equipment Weight in kg (lb)

Complete crusher 151,848 (334,768)

Main frame assembly (including main shaft and frame liner) 53,453 (117,844)

Bowl assembly (including bowl liner and hopper assembly) 32,884 (72,497)

Adjustment ring (including clamping ring) 25,536 (56,297)

Head assembly (including feed plate assembly and mantle) 17,648 (38,907)

Countershaft box assembly 3,175 (7,000)

Eccentric assembly (including counterweight) 9,459 (20,854)

Mantle 5,413 (11,934)

Bowl liner 6,733 (14,844)

Belt tensioner (not including motor) 5,232 (11,535)

No Oil: 1,619 (3,569)

Hydraulic power unit
With Oil: 1,850 (4,079)

No Oil: 2,935 (6,471)

Lubrication unit
With Oil: 6,250 (13,779)

Heat exchanger No Oil: 1,420 (3,131)

Table 5-1: Crusher and Sub-Assembly Weights

5.2.4 Feed Arrangement Preparation

Prepare the area for the feed arrangement design, considering the following:

• The rubber skirt length must be capable of reaching inside the cone crusher hopper when the liner is worn. The skirt
must not contact the bottom of the hopper when a new liner is in place, and must be able to accommodate the
stroke length of tramp events. Refer to drawing “1000855444: General Arrangement” on page 299.
• Proper design of the crusher feed arrangement is critical in maximizing the crushing circuit efficiency. This involves
providing an adequate amount of feed material to the crusher. It also requires an even distribution of blended
material sizes within the crushing cavity.
• Feed must not enter the crusher hopper at or near free fall speed. Add ledges to the feed arrangement as needed to
limit the speed and free fall of the feed.
• Proper control of the feed material into the crusher maximizes capacity, product size, and life of components. An
inadequate amount of feed material causes the crusher to run unloaded, resulting in uneven distribution of forces
across the internal journal surfaces and burnt or damaged bushings.
• Design the feed circuits for crushers to provide a buildup of material above the feed plate (referred to as a “choke
fed” condition).
• Thoroughly mix the feed size and evenly distribute the feed around the crushing cavity. Uneven feed distribution can
result in oversize product, reduced capacity, and ring bounce.
• Ring bounce occurs when the adjustment ring lifts or bounces quickly on and off the main frame seat liners.
Extended periods of ring bounce can cause catastrophic damage to the adjustment ring, main frame seat liners,
main frame, and other associated crusher components.
• A feed box mounted over the crusher can serve as a backstop to ensure the material falls vertically onto the feed
plate. A feed spout mounted on the box and centered over the feed plate aids in providing a uniform distribution of
feed around the crushing cavity.

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Chapter 5 Installation 55

-5- -6-
Image may not reflect exact equipment.

1 Feed conveyor 2 Outer hopper 3 Rubber skirt

4 Inner hopper 5 Incorrect feed method 6 Correct feed method
Figure 5-1: Incorrect and Correct Feed Arrangement

• Place a screen in the circuit ahead of the crusher to remove the fines if more than 15% of the feed material is smaller
than the closed side setting while running in short head crusher application, or more than 20% is smaller than the
closed side setting while running in standard crusher application. Excessive fines in the feed results in ring bounce
or a feed rate reduction. Maintaining a low percentage of fines or wet, sticky material is essential in optimizing the
crusher performance. Improper feed conditions is one of the principal causes of breakdowns.
• Install a metal detector or magnet to remove any non-crushable items (called “tramp”) before they get into the
crushing cavity. Excessive amounts of tramp material passing through the crusher can cause ring bounce, burn the
drive belts, and possibly stall the crusher drive motor.

5.2.5 Discharge Arrangement Preparation

Prepare the necessary supplies for the discharge arrangement, considering the following:

• Follow the construction recommendations shown on drawing “1000855444: General Arrangement” on page 299.
• Use replaceable wear material to line the discharge compartment.
• Within the compartment, incorporate a shelf or ledge to make a dead bed for the crusher discharge material to fall
on. Design the dead bed to absorb most of the energy of the falling material before the material cascades onto the
conveying equipment.
• If a discharge chute is used, position it at 45 degrees or greater from horizontal. If wet discharge material is present,
then increase the chute angle.
• As shown on drawing “1000855444: General Arrangement” on page 299, maintain adequate clearance between the
discharge equipment and the crusher. The proper amount of clearance will prevent material from building up under
the crusher and eventually interfering with its operation. The minimum volumetric capacity at the discharge must be
approximately 150% of what the crusher and hopper combined can hold; this allows for clearing the crusher
chamber in the event that the discharge conveyor is down.

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56 Chapter 5 Installation

Image may not reflect exact equipment.

Figure 5-2: Discharge Arrangement

5.2.6 Maintenance Platform Preparation

The crusher must be equipped with a maintenance platform (not supplied with the crusher) in order to make
maintenance tasks easy and safe.

Prepare the necessary supplies for the maintenance platform, considering the following:

• Build the platform at the height of the drive ring.

• The platform steps must be equipped with handrails to prevent personnel from falling.
• Observe all international and national regulations on maintenance platforms for crushing equipment.

5.3 Crusher Installation

The Raptor 1100 Cone Crusher is shipped in sub-assemblies due to shipping and handling restrictions. When required
during installation, use the special lifting tools furnished with the crusher; refer to 7.2.1 “Special Tools Package” on
page 98. Refer to Chapter 7: “Maintenance” on page 93 for the installation of any sub-assemblies not detailed in this
chapter.

Refer to the following drawings during crusher installation:

• Drawing “1000855444: General Arrangement” on page 299

5.3.1 Crusher Installation on Concrete Foundation

1. Lift the main frame onto adequate safety blocking. Refer to 7.2.2 “Lifting the Main Frame Assembly” on page 100.

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Chapter 5 Installation 57

Note: Refer to Table 5-1: “Crusher and Sub-Assembly Weights” on page 54 for the component weights when
designing the safety blocking.

2. Clean the bottom of the crusher mounting flange, removing the dirt, rust, and loose paint.

3. Follow manufacturer's recommendation for concrete surface preparation.

4. Use an epoxy grout material with the following properties:

• Minimum Compressive Strength: 110 MPa (16,000 psi)

• Minimum Tensile Strength: 29 MPa (4,200 psi)
• Maximum Compression Modulus: 3,675 MPa (533,000 psi)
• Maximum Hardness (Shore D): 95

5. Remove all paint, primer, and rust preventative from all surfaces of the sole plates.

6. Set the sole plates in position as shown on drawing “1000855444: General Arrangement” on page 299.

7. Verify that the anchor bolt holes in the sole plates line up with the corresponding bolt holes in the foundation.

8. Level each sole plate with M20 jackscrews (not supplied with crusher).

• The entire top surface of each sole plate must be within 0.25 mm (0.01 in) of the top surfaces of each of the other
sole plates.
Note: It is recommended to take a minimum of five measurements on each sole plate.

• Leave a gap of approximately 30 mm (1.2 in) for epoxy between the sole plates and the foundation.

9. Place a dam under each of the sole plates around the bolt holes that are being used. This will keep the epoxy from
entering the foundation under the sole plates.

10. Seal all seams and joints with silicone caulk.

11. Mix and pour the epoxy according to the manufacturer’s instructions.

12. Wait until after the epoxy reaches a minimum of 103 MPa (14,938 psi) compressive strength before installing the
crusher. Refer to the manufacturer’s instructions for the estimated cure time.

Note: Cold climates may require the epoxy to be heated to limit the curing time.

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58 Chapter 5 Installation

Image may not reflect exact equipment.

1 Sole plates 2 Lifting holes 3 Jacking holes

4 Discharge opening 5 Foundation 6 Countershaft opening
Figure 5-3: Sole Plate Installation Top View

Image may not reflect exact equipment.

1 Main frame 2 Sole plate 3 Epoxy

Figure 5-4: Sole Plate Installation Side View

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Chapter 5 Installation 59

1 5

3
Image may not reflect exact equipment.

1 Crusher 2 Foundation 3 Mounting hardware

4 Epoxy grout 5 Sole plate
Figure 5-5: Crusher Grouting

13. Lift the crusher on the steel sole plates. Refer to 7.2.2 “Lifting the Main Frame Assembly” on page 100.

14. Inspect for a soft foot condition with a feeler gauge. There must be zero clearance.

15. Ensure that all four machined pads on the bottom of the crusher rest firmly on the sole plates.

16. Shim the crusher as needed to achieve proper level, using shims the size of the sole plates if the crusher is being set
on sole plates.

17. Install the anchor bolts according to the civil planner’s recommendations.

5.3.2 Crusher Installation on Steel Structure

1. Lift the main frame onto adequate safety blocking. Refer to 7.2.2 “Lifting the Main Frame Assembly” on page 100.

Note: Refer to Table 5-1: “Crusher and Sub-Assembly Weights” on page 54 for the component weights when
designing the safety blocking.

2. Clean the bottom of the crusher mounting flange, removing the dirt, rust, and loose paint.

3. Engineer the steel structure to withstand the static and dynamic loads present during operation. Meet all clearance
requirements for normal operation and maintenance; refer to 5.2.2 “Crusher Installation Envelope” on page 53.

4. Remove all weld spatter and slag from the area where the crusher is to be mounted. Ground all protruding welds
flush on the adjacent surfaces.

5. Lift the crusher into position on the steel structure or shims as needed. Refer to 7.2.2 “Lifting the Main Frame
Assembly” on page 100.

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60 Chapter 5 Installation

Image may not reflect exact equipment.

1 Main frame flange 2 Shim 3 Steel structure or trailer

Figure 5-6: Main Frame Flange Spacers

6. Inspect for a soft foot condition with a feeler gauge. There must be zero clearance.

7. Shim the crusher as needed to achieve proper level, using shims the size of the crusher mounting pad. Refer to
drawing “1000855444: General Arrangement” on page 299.

8. Tighten the anchor bolt nuts to firmly seat the crusher, in accordance with the civil planner’s recommendations.

9. Inspect the anchor bolts for tightness after one day, one month, six months, and one year, and tighten them if
necessary.

5.4 Bowl Assembly Installation

Refer to 7.23.3 “Bowl Assembly Installation” on page 147.

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Chapter 5 Installation 61

5.5 Accumulators Installation and Pre-

Charge
The accumulators are shipped loose. Install them once the crusher main frame is mounted to the foundation.

Perform the following steps for each accumulator.

1. Position the accumulator pads on the concrete pad or steel structure at the location designated during foundation
planning. Refer to 5.2.1 “Foundation” on page 53.

2. Anchor the pads into the foundation with post-installed anchors (not supplied with the crusher).

3. Attach a nylon lifting strap around the accumulator using a choker hitch. Lift the accumulator into position on the
accumulator pad.

4. Hold the accumulator as vertical as possible, and fasten the accumulator clamp bracket to the accumulator.

5. Assemble the hydraulic fittings to the bottom of the accumulator.

6. Pre-charge the accumulator. Refer to 7.29.5 “Charging and Verifying the Accumulators” on page 160.

Image may not reflect exact equipment.

1 Accumulator 2 Hose fittings 3 Stand

Figure 5-7: Accumulator Mounting

5.6 V-Belt Drive Installation (if

applicable)
5.6.1 Belt Tensioner Frame Installation on Concrete
Follow the manufacturer's recommendation for concrete surface preparation.

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62 Chapter 5 Installation

1. Use an epoxy grout material with the following properties:

• Minimum resistance class: C20, as DIN1045-1 standard

• Minimum Compression Tension: 20 MPa (2901 psi)

2. Remove all paint, primer, and rust preventative from all surfaces of the belt tensioner footing.

3. Verify that the anchor bolt holes in the belt tensioner footing line up with the corresponding bolt holes in the
foundation.

4. Remove all dirt, grease, and other foreign material from the anchor bolts.

5. Wrap three to four layers of masking tape around the straight segment of the anchor bolts. The tape allows the bolts
to later be tensioned without damaging the grout.

6. Lift the anchor base high enough that the anchor bolts can be installed.

7. Insert the anchor bolts into the anchor base until the top of the bolt is 1 to 2 mm (0.04 to 0.08 in) above the top of the
nut.

8. Place the anchor base in position on the concrete. Slide the anchor bolts into the grouting niches.

9. Insert supporting plates on the leveling screws so that the anchor base rests on the plates.

10. Level the anchor base to within +/- 1 mm (0.04 in) at the motor mounting pads, using the leveling screws under the
base.

11. Grout the anchor bolt niches, and then wait for the grout to cure. Refer to the grout manufacturer’s instructions.

12. Remove the bolt-on coupling guard and idler guard from the jackshaft frame.

13. Lift the drive motor onto the anchor base.

14. Tighten the anchor bolts to 50% of the required torque designated by the civil planner.

15. Install the drive sheave assembly. Refer to 7.13.2 “Shaft Sheave Assembly Installation” on page 122.

Note: Mounting the drive sheave either below the countershaft or within 45 degrees of the vertical centerline
requires a change in the mounting position of the outer countershaft bushing oil groove. Contact FLSmidth if
either of these mounting positions is going to be used so the bushing can be installed correctly prior to
shipment of the crusher.

16. Install and align the crusher sheave assembly. Refer to 7.13.2 “Shaft Sheave Assembly Installation” on page 122.
a. If needed, loosen the anchor bolts to adjust the sheaves until they are properly aligned. Then re-tighten the
anchor bolts to 50% of the required torque.

Note: Do not install the belts at this time.

17. Verify that the anchor base is level.

a. As needed, loosen the anchor bolts to make adjustments until the anchor base is level. Then re-tighten the
anchor bolts to 50% of the required torque.

18. Remove the drive motor from the anchor base and set it aside.

19. Build a dam around the anchor base to prevent the grout from leaking.

20. Wedge the anchor base into place against the concrete to prevent any movement during grouting.

21. Grout the space between the anchor base and the concrete, and around the anchor bolt. Wait for the grout to cure.
Refer to the grout manufacturer’s instructions.

22. Tighten the anchor bolts to the nominal required torque, as designated by the civil planner.

23. Install the drive side coupling if it is not already installed. Refer to the original equipment manufacturer (OEM)
manual.

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Chapter 5 Installation 63

5.6.2 Belt Tensioner Frame Installation on a Steel

Structure
The steel structure must be stiff enough to accept the loads with deflection limited to less than the acceptable
misalignment condition of the flexible coupling. Refer to the original equipment manufacturer (OEM) manual.

1. Verify that the surface where the sole plates will be mounted is flat within 0.08 mm/m from motor foot to motor foot.
Use stainless steel shims as needed to level the surface.

Note: Do not use more than three shims at a maximum of 5 mm (0.2 in).

2. Remove all paint, primer, and rust preventative from all surfaces of the belt tensioner footings.

3. Verify that the anchor bolt holes in the belt tensioner footings line up with the corresponding bolt holes in the
structure.

4. Remove all dirt, grease, and other foreign material from the anchor bolts.

5. Lift the belt tensioner frame high enough that the anchor bolts can be installed.

6. Insert the anchor bolts into the belt tensioner footings until the top of the bolt is 1 to 2 mm (0.04 to 0.08 in) above the
top of the nut.

7. Place the belt tensioner frame in position on the structure. Slide the anchor bolts into position, and torque the bolts
to 50% of the required torque as designated by the civil planner.

8. Using stainless steel shims, level the belt tensioner frame feet to within +/- 1 mm (.04 in) of each other.

9. Install the drive sheave assembly. Refer to 7.13.2 “Shaft Sheave Assembly Installation” on page 122.

Note: Mounting the drive sheave either below the countershaft or within 45 degrees of the vertical centerline
requires a change in the mounting position of the outer countershaft bushing oil groove. Contact FLSmidth if
either of these mounting positions is going to be used so the bushing can be installed correctly prior to
shipment of the crusher.

10. Install and align the crusher sheave assembly. Refer to 7.13.2 “Shaft Sheave Assembly Installation” on page 122.

a. If needed, loosen the anchor bolts to adjust the sheaves until they are properly aligned. Then re-tighten the
anchor bolts to 50% of the required torque.

Note: Do not install the belts at this time.

11. Tighten the anchor bolts to the final torque, as designated by the civil planner.

12. Install the drive side coupling if it is not already installed. Refer to the original equipment manufacturer (OEM)
manual.

5.6.3 Drive Motor Installation

An electric motor weighs up to 5,200 kg (5.2 t). Handle the motor with care.
When setting up the tackle, keep it tight. Keep clear of hanging loads.

1. Install the motor side coupling if it is not already installed. Refer to the original equipment manufacturer (OEM)
manual.

2. Lift the motor onto the tensioner frame supporting pads.

3. Shim the motor to achieve the required alignment of the two coupling halves, and secure all the frame jackscrews.
Refer to the original equipment manufacturer (OEM) manual.

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64 Chapter 5 Installation

Note: The jackshaft frame is designed for a nominal of 3.2 mm (0.13 in) shims beneath each motor mounting
foot.

4. Torque the motor fastening bolts to 914 N-m (674 ft-lb).

5. Remove the lifting equipment.

6. Install the electric cables in the motor’s terminal box.

7. Jog the drive motor to verify it rotates counterclockwise as viewed from the front of the crusher sheave.

5.6.4 V-Belts Installation

Refer to 7.12.2 “V-Belt Installation” on page 120.

5.6.5 Drive Guards Installation

Refer to drawing “1000855444: General Arrangement” on page 299 when installing the drive guards.

1. Install the coupling guard on the jackshaft frame using the provided fasteners.

2. Install the tensioner guard on the jackshaft frame using the provided fasteners.

3. Install the V-belt guard. The V-belt guard anchor bolts are not supplied by FLSmidth.

5.7 Direct Drive Installation

5.7.1 Sole Plate Installation on Concrete
1. Prepare the concrete surface according to the manufacturer's recommendation.
2. Select an epoxy grout material with the following properties:

• Minimum resistance class: C20, as DIN1045-1 standard

• Minimum compression tension: 20 MPa (2,901 psi)

3. Remove all paint, primer, and rust preventative from all of the sole plate surfaces.

4. Verify that the anchor bolt holes in the sole plates line up with the corresponding bolt holes in the foundation.

5. Remove all dirt, grease, and other foreign material from the anchor bolts.

6. Wrap three to four layers of masking tape around the straight segment of the anchor bolts. The tape allows the bolts
to later be tensioned without damaging the grout.

7. Lift the sole plates high enough that the anchor bolts can be installed.

8. Insert the anchor bolts into the sole plates until the top of the bolt is 1 to 2 mm (0.04 to 0.08 in) above the top of the
nut.

9. Place the sole plate in position on the concrete. Slide the anchor bolts into the grouting niches.

10. Insert supporting plates under the leveling screws.

11. Install the torque limiter onto the crusher drive shaft. Refer to the original equipment manufacturer (OEM) manual.

12. Remove the motor side half of the flexible coupling.

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Chapter 5 Installation 65

13. Install the drive shaft assembly.

14. Apply Loctite 243, and torque the bolts in a crisscross pattern to 500 N-m (368.8 ft-lb).

15. Using the leveling screws, level the sole plates to within +/- 0.04 mm (1.5 mils) of each other. Use the drive shaft or
coupling to establish a reference.

16. Grout the anchor bolt niches, and wait for the grout to cure. Refer to the grout manufacturer’s instructions.

17. Lift the drive motor onto the sole plates.

18. Tighten the anchor bolts to 50% of the required torque, as designated by the civil planner.

19. Inspect the sole plate alignment.

20. Realign the sole plates as necessary.

a. Remove the anchor bolt tension.

b. Adjust the leveling screws.

c. Tighten the anchor bolts to 50% of the required torque.

d. Re-inspect the sole plate alignment.

e. Repeat the sole plate realignment as needed until attaining alignment.

21. Remove the drive motor from the sole plates, and set it aside.
22. Build a dam around each sole plate to prevent the grout from leaking.

23. Wedge the sole plate into place against the concrete to prevent any movement during grouting.

24. Grout the space between the sole plate and the concrete, and around the anchor bolt. Wait for the grout to cure.
Refer to the grout manufacturer’s instructions.

25. Tighten the anchor bolts to the nominal required torque, as designated by the civil planner.

5.7.2 Sole Plate Installation on Steel Structure

The steel structure must be stiff enough to accept the loads with deflection limited to less than the acceptable
misalignment condition of the flexible coupling. Refer to the original equipment manufacturer (OEM) manual.

1. Verify that the surface where the sole plates will be mounted is flat within 0.08 mm/m from motor foot to motor foot.
Use stainless steel shims as needed to level the surface.

Note: Do not use more than three shims at a maximum of 5 mm (0.2 in).

2. Remove all paint, primer, and rust preventative from all surfaces of the sole plates.

3. Verify that the anchor bolt holes in the sole plates line up with the corresponding bolt holes in the structure.

4. Remove all dirt, grease, and other foreign material from the anchor bolts.

5. Lift the sole plates high enough that the anchor bolts can be installed.

6. Insert the anchor bolts into the sole plates until the top of the bolt is 1 to 2 mm (0.04 to 0.08 in) above the top of the
nut.

7. Place the sole plate in position on the structure. Slide the anchor bolts into position, and torque the bolts to 50% of
the required torque as designated by the civil planner.

8. Install the torque limiter onto the crusher drive shaft. Refer to the original equipment manufacturer (OEM) manual.

9. Remove the drive shaft assembly ring hub and fasteners, and set it aside.

10. Install the drive shaft assembly.

11. Apply Loctite 243, and torque the bolts in a crisscross pattern to 500 N-m (368.8 ft-lb).

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66 Chapter 5 Installation

12. Using stainless steel shims, level the sole plates to within +/- 0.04 mm (1.5 mils) of each other. Use the drive shaft or
coupling as a reference.

13. Tighten the anchor bolts to the nominal required torque, as designated by the civil planner.

5.7.3 Drive Motor Installation

1. Install the ring hub on the motor shaft. Refer to the original equipment manufacturer (OEM) manual.

2. Place the motor on the machined mounting pads on the sole plates.

3. Shim the motor to achieve the required alignment of the two coupling halves, and secure all the motor mounting.
Refer to the original equipment manufacturer (OEM) manual.
4. Torque the motor fastening bolts to 914 N-m (674 ft-lb).

5. Install at least two dowel pins in diagonally-opposite motor feet.

a. Deepen the dowel holes in the motor feet by punching through to the sole plate.

b. Thin the motor and sole plate holes with a reaming tool.

c. Insert the tapered dowel pins in the holes.

6. Install the electrical cables in the motor’s terminal box.

7. Jog the drive motor to verify it rotates counterclockwise as viewed from the front of the crusher sheave.

8. Install the fasteners connecting the ring hub and flex hub. Torque the fasteners according to the instructions given in
the original equipment manufacturer (OEM) manual.

5.7.4 Drive Guards Installation

Install the drive guards. Refer to drawing “1000855444: General Arrangement” on page 299.

5.8 Head Assembly Installation

Refer to 7.19.4 “Head Installation” on page 133.

5.9 Hydraulic System Installation

1. Place the hydraulic power unit (HPU) skid in an area that is protected from falling rock and is no more than 25 m (82
ft) from the crusher.

2. Use shims (not provided with the skid) as necessary to level the skid on the foundation.

3. Bolt the skid to the foundation (bolts are not provided with the skid).

4. Disconnect the remote mounted push button panel from the HPU.

Note: The panel is pre-fixed to the HPU and is connected to the wiring terminal box with a multi-conductor
electrical cord. It can be removed from the HPU and remotely mounted by changing the electrical cord.

5. Mount the remote mounted push button panel in a location that allows the operator to observe the crusher during
clearing or while making setting adjustments. The panel is pre-wired to the HPU terminal box.

Note: The supplied control panel electrical cable is 9 m (30 ft) long.

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Chapter 5 Installation 67

6. Connect the six hydraulic hoses to the HPU and crusher.

a. Match the stamped markings on the HPU to the main manifold block.

b. Shorten the hoses as needed, and reattach the reusable couplings on the cut end.

Note: This prevents the safety hazards caused by coiled hydraulic hoses.

c. Connect the hydraulic hoses in the matched connections.

7. Verify the voltage, frequency, phase, and electrical connection requirements from the motor nameplate meet the
electrical requirements.

8. Verify the hydraulic power unit pump motor rotation direction.

a. Fully open both the tramp release and clamping circuit dump valves.

b. Briefly start the motor. The motor must rotate counterclockwise as viewed from the motor end, and the arrow on
top of the motor must match the rotation direction.

9. Fill the tank with hydraulic fluid. Refer to A.5 “Hydraulic Oil Specifications” on page 178.

10. Disconnect the piping from the crusher. Either flush the lubrication pump and piping for approximately 10 minutes or
clean out the piping with a pig before operating with new piping.

6
3
1

Image may not reflect exact equipment.

1 Clearing circuit hose connection 2 Tramp release circuit hose connection 3 Clamping circuit
4 Hydraulic motor (bowl closed) circuit 5 Hydraulic motor (bowl open) circuit 6 Hydraulic motor brake circuit
Figure 5-8: Hydraulic Power Unit Hose Connection

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68 Chapter 5 Installation

Image may not reflect exact equipment.

1 Clearing circuit hose connection 2 Tramp release circuit hose connection 3 Clamping circuit
4 Hydraulic motor (bowl closed) circuit 5 Hydraulic motor (bowl open) circuit 6 Hydraulic motor brake circuit
Figure 5-9: Release and Clearing System Hose Connections

Image may not reflect exact equipment.

1 A-port on hydraulic motor (close) 2 B-port on hydraulic motor (open) 3 Brake

Figure 5-10: Hydraulic Adjust Drive Hose Connection Block

5.10 Lubrication System Installation

5.10.1 Skid Mounted Lubrication System Installation
1. Install the lubrication system below and as near the crusher as possible.

a. Refer to 5.10.3 “Piping Installation” on page 70 for assistance in determining placement.

b. Refer to drawing “1000855581: Lubrication Unit General Arrangement” on page 358 for assistance in
determining the correct placement.

2. The bottom of the reservoir must be at least 3.6 m (12 ft) below the underside of the crusher mounting flange to
obtain the proper flow of drain oil from the crusher to the lubrication system reservoir.

a. For every 0.3 m (12 in) the lubrication system is away from the crusher horizontally, the bottom of the reservoir
must be at least 1.24 m (49 in) below the underside of the crusher mounting flange.

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Chapter 5 Installation 69

1 2
4

5 6

Image may not reflect exact equipment.

1 Pump and motor assemblies 2 Tank 3 Crusher

4 Oil drain line 5 Horizontal and vertical distance 6 Oil supply line
Figure 5-11: Lubrication System Installation Location

3. Use shims (not provided with the skid) as necessary to level the package lubrication skid on the foundation.

4. Bolt the skid to the foundation (bolts are not provided with the skid).

5. Verify the voltage, frequency, phase, and electrical connection requirements from the motor nameplate meet the
electrical requirements.

6. Wire the pump motor. All wiring must meet site and local electrical code requirements.

7. Verify the direction of motor rotation by briefly starting the motor. The motor must rotate in the same direction as the
arrow on top of the motor indicates.

8. Fill the lubrication tank. Refer to A.2 “Lubricating Oil Specifications” on page 174.

5.10.2 Heat Exchanger Installation

1. Install the air-to-oil heat exchanger (air cooler assembly) between the package lubrication system and the crusher if
possible.

Note: If the heat exchanger is installed in a lubrication room, the room needs to be properly vented to
provide the necessary in-flow of ambient air to efficiently cool the oil.

2. Place the assembly on a foundation where it is not subjected to excessive vibrations.

3. Use shims (not provided with the skid) as necessary to level the heat exchanger on the foundation.

4. Bolt the heat exchanger to the foundation (bolts are not provided with the skid).

5. Verify the voltage, frequency, phase, and electrical connection requirements from the heat exchanger motor
nameplate matches the site specifications.

6. Wire the heat exchanger motor. All wiring must meet site and local electrical code requirements.
7. Verify the direction of fan rotation by briefly starting the motor. The fan must rotate to force air through the radiator
from the motor side. If the motor is rotating the fan in the wrong direction, change the fan motor wiring and then
verify the direction of airflow is correct.

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70 Chapter 5 Installation

1 2 1

6
6
Image may not reflect exact equipment.

1 Outlet 2 Fan 3 Air flow

4 Drive motor 5 Drain 6 Inlet
Figure 5-12: Heat Exchanger Assembly

5.10.3 Piping Installation

Refer to the drawing “1000855581: Lubrication Unit General Arrangement” on page 358 for piping connection size and
locations. It is recommended that the piping for the feed and return lines meet the following requirements:

• Clean rust, scale, cutting chips, and debris from the piping before assembling it.
• The slope of the return piping from the crusher to the lubrication package is recommended to be a minimum of 25
mm (1 in) of vertical change for every 305 mm (12 in) of horizontal change.
• The supply and return piping must be as direct and short as possible, with a minimum number of turns, dead
pockets, and other obstructions.
• Install a flexible coupling in the supply oil line and the return oil line to dampen the vibrations between the crusher
and the remaining oil lines.
• Install unions or bolted, flanged joints in various locations to assist in removing piping or lubricating equipment when
required.
• Avoid long vertical drops in the drain piping. Such drops create an excessive vacuum inside the crusher, and may
cause dust to be pulled into the crusher past the T- and U-seals.
• If a return line with a vertical drop of 1.22 m (4 ft) cannot be avoided, follow it with an approximately 500 mm (19.7
in) vertical rise, and then place an air breather in the line to break the vacuum that may otherwise result. Ensure
that the air breather is away from any dust.

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Chapter 5 Installation 71

Image may not reflect exact equipment.

1 Air breather 2 Vertical drop 3 Vertical rise

Figure 5-13: Air Breather Installation in Return Line

• Supply piping must be capable of supporting the designed pressure. Refer to original equipment manufacturer
documentation provided separately by the manufacturer.

5.11 Air Seal Blower Installation

1. Install the air seal blower filter away from the crusher in a relatively dust free area, but no more than 3.7 m (12 ft) away
from the crusher.

2. Verify the voltage, frequency, phase, and electrical connection requirements from the pump motor nameplate
matches the site specifications.

3. Wire the pump motor. All wiring must meet site and local electrical code requirements.

4. Verify the direction of motor rotation by briefly starting the motor. The motor must rotate in the same direction as the
arrows on the fan indicate.

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72 Chapter 5 Installation

Image may not reflect exact equipment.

1 Turbo blower 2 Filter housing 3 102 mm (4 in) flexible hose 4 Countershaft box
5 Crusher main frame 6 Drip shield 7 Outlet damper
Figure 5-14: Countershaft Box Blower and Filter Assembly

5.12 Machine Instrumentation Package

Installation
5.12.1 Countershaft Box Temperature Sensor Installation
The temperature sensor is shipped loose to avoid damage during transit.

1. Locate the temperature sensor, cover, temperature probe, mounting adapter, mounting clamp, and cable from one
of the shipping crates. Refer to Figure 5-15 for the proper mounting location.

2. Remove the pipe plug from the tapped hole where the sensor will mount, and install the mounting adapter.

3. Slide the temperature probe into the adapter until the probe contacts the countershaft box bushing.

4. Tighten the nut on the mounting adapter to secure the probe in place.

Note: Do not over-tighten the nut. This can cause damage to the probe cable.

5. Using the supplied mounting clamp, install the sensor near the crusher in an easily accessible area. This provides
easy viewing of the local display on the sensor.

6. Wire the sensor. Refer to drawing “1000896923: Instrument Assembly” on page 339.

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Chapter 5 Installation 73

3
2

1
4
3

6
7

Image may not reflect exact equipment.

1 Temperature sensor 2 Temperature transmitter 3 To the control system 4 Pressure transmitter

5 6.35 mm (0.25 in) 18 national 6 Oil line connection (not 7 RTD wire leads
pipe thread (NPT) supplied with the crusher)
Figure 5-15: Countershaft Box Sensors

5.12.2 Oil Supply Temperature Sensor Installation

The temperature sensor is shipped with the heat exchanger.

1. Locate the temperature sensor, cover, temperature probe, mounting adapter, mounting clamp, and cable from one
of the shipping crates. Refer to drawing “1000855444: General Arrangement” on page 299 for the proper mounting
location.

2. Remove the pipe plug from the tapped hole where the sensor will mount, and install the mounting adapter. Refer to
drawing “1000855581: Lubrication Unit General Arrangement” on page 358.

3. Install the thermowell and temperature probe.

4. Tighten the nut on the mounting adapter to secure the probe in place.

Note: Do not over-tighten the nut. This can cause damage to the probe cable.

5. Wire the sensor. Refer to drawing “1000896923: Instrument Assembly” on page 339.

5.12.3 Oil Supply Pressure Sensor Installation

The pressure sensor is shipped loose to avoid damage during transit.

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74 Chapter 5 Installation

1. Locate the pressure sensor, cover, mounting adapter, mounting clamp, and cable from one of the shipping crates.
Refer to Figure 5-15 for the proper mounting location.

2. Remove the pipe plug from the tapped hole where the sensor will mount, and install the mounting adapter. Refer to
Figure 5-15.

3. Attach the pressure sensor to the adapter.

Note: Do not over-tighten the nut. This can cause damage to the probe cable.

4. Using the supplied mounting clamp, install the sensor near the crusher in an easily accessible area. This provides
easy viewing of the local display on the sensor.

5. Wire the sensor. Refer to drawing “1000896923: Instrument Assembly” on page 339.

5.12.4 Eccentric Bushing RTD Installation

The resistance temperature detector (RTD) is factory installed, and the cables are coiled and placed in the oil sump area.

1. Rout the two RTD wire leads from the oil sump area in the main frame, through the return line assembly, to the two
cord grips. Refer to Figure 5-15.

2. Slide the RTD wire leads through the body of the cord grips, then through the cord grips’ lubricated bushings, rings,
and nuts.

3. Pull the slack out of the RTD wire leads.

4. Tighten the cord grips nuts to create a liquid seal.

5. Route the RTD wires to the machine I/O box.

6. Coil the excess RTD wire length in the box for later use.

7. Wire the sensor. Refer to drawing “1000896923: Instrument Assembly” on page 339.

5.12.5 Proximity Sensors

1. Install the proximity sensors in either of the indicated adjustment mechanism locations using the provided hardware.
Refer to Figure 5-16.

2. Verify that the mounting bracket is 20 mm (0.79 in) from the pinion.

3. Ensure that the tip of the probe is 6.5 mm (0.25 in) from the pinion tooth.

4. Wire the sensors. Refer to drawing “1000896923: Instrument Assembly” on page 339.

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Chapter 5 Installation 75

2
4
3

Image may not reflect exact equipment.

1 Adjustment mechanism 2 Distance between the mounting 3 Distance between the probe 4 Adjustment mechanism
locations bracket and pinion tip and the pinion tooth assembly
Figure 5-16: Adjustment Mechanism Locations

5.12.6 Speed Sensor Installation

5.12.6.1 Direct Drive Speed Sensor

1. Remove the M20 hex head capscrew (HHCS) from the countershaft box cover, and remove the cover. Refer to
Figure 5-17.

2. Install the proximity sensor using the provided hardware.

3. Ensure that the tip of the probe is the 15 mm (0.6 in) or less from the target plate. Refer to Figure 5-18.

4. Wire the sensor. Refer to drawing “1000896923: Instrument Assembly” on page 339.

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76 Chapter 5 Installation

Image may not reflect exact equipment.

Figure 5-17: Direct Drive Access

Image may not reflect exact equipment.

Figure 5-18: Direct Drive Instrumentation

5.12.6.2 V-Belt Speed Sensor

1. Remove the M20 hex head capscrew (HHCS) from the countershaft box cover, and remove the cover. Refer to
Figure 5-19.

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Chapter 5 Installation 77

2. Install the proximity sensor using the provided hardware.

3. Ensure that the tip of the probe is 22.2 mm (0.87 in) or less from the target plate. Refer to Figure 5-19.

Note: The target bracket is secured with two M10 HHCS and lock washers.

4. Wire the sensor. Refer to drawing “1000896923: Instrument Assembly” on page 339.

5
2 3 4
Image may not reflect exact equipment.

1 Distance the probe tip to the target plate 2 Target bracket 3 Speed sensor bracket 4 Proximity sensor
5 Proximity sensor cord 6 Spacer 7 Crusher sheave bushing
Figure 5-19: Speed Sensor Target Plate Mounting for V-Belt Drive

5.12.7 Vibration Transducers Installation

Vibration transducers are provided with a drop loop and a minimum of 15 cm (6 in) to allow for crusher vertical
movement.

1. Insert the vibration transducers into the adjustment ring. Refer to Figure 5-20.

2. Wire the sensors. Refer to drawing “1000896923: Instrument Assembly” on page 339.

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78 Chapter 5 Installation

1
1

2
Image may not reflect exact equipment.

1 Required vibration transducer location 2 Potential vibration transducer location 3 Typical vibration transducer
Figure 5-20: Vibration Transducer Placement

5.12.8 Level Sensor Installation

1. Place the sensor and controller in a suitable location.

a. The sensor must be able to detect a minimum level at the feed plate.

b. The sensor must be able to detect a maximum level as determined by the customer-provided feed arrangement,
crusher throughput, and controls.

2. Wire the sensor. Refer to drawing “1000896923: Instrument Assembly” on page 339.

5.12.9 Machine I/O Box Installation

Using the provided cable, install the machine I/O box in a location convenient to the crusher configuration. Use
additional cable (not provided) as needed. Refer to drawing “1000896923: Instrument Assembly” on page 339.

5.12.10 Junction Box Installation

Using the provided cable, install the junction box in a location convenient to the crusher configuration. Use additional
cable (not provided) as needed. Refer to drawing “1000896923: Instrument Assembly” on page 339.

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Chapter 5 Installation 79

5.13 Feed, Discharge, and Platform

Installation
1. Install the feed arrangement (not supplied with the crusher) according to the site plan. Refer to 5.2.4 “Feed
Arrangement Preparation” on page 54.

1. Install the feed arrangement (not supplied with the crusher) according to the site plan.

2. Connect a rubber skirt (not supplied with the crusher) to the source bin and set within the crusher hopper inside
diameter. The skirt must match the dimensions given on drawing “1000855444: General Arrangement” on
page 299.

3. Install the discharge arrangement (not supplied with the crusher) according to the site plan. Refer to 5.2.5
“Discharge Arrangement Preparation” on page 55.

4. Install the maintenance platform (not supplied with the crusher) according to the site plan. Refer to 5.2.6
“Maintenance Platform Preparation” on page 56.

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80 Chapter 5 Installation

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 81

Chapter 6: Operation
6.1 Post-Commissioning Automation Change Disclaimer . . . . . . . . . . . . . . . . . . . . . .82
6.2 Crusher Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
6.2.1 Group Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.2.2 Individual Auxiliary Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2.3 Verifying Vital Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.3 Hydraulic Power Unit Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
6.4 Normal Crusher Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
6.4.1 Setting the Crushed Product Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.4.1.1 Liner Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.4.1.2 Setting the Closed Side Setting Manually . . . . . . . . . . . . . . . . . . . . . . . 85
6.4.1.3 Setting the Closed Side Setting Through Automation . . . . . . . . . . . . . 86
6.5 Performing a Clearing Cycle for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
6.6 Clearing Lodged Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
6.6.1 Clearing Rock or Tramp from the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.6.2 Clearing Tramp Metal From the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.6.2.1 Removing Metal With an Overhead Lifting Device . . . . . . . . . . . . . . . . 89
6.6.2.2 Burning Metal From the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.7 Resetting the Tramp Release System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
6.8 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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82 Chapter 6 Operation

6.1 Post-Commissioning Automation

Change Disclaimer
Crusher automation touch screen options, language settings, and software navigation are finalized during the on-site
assembly and commissioning of the machine. A revision to this manual may be issued once the final screen options are
confirmed and documented for this machine. To inquire about and obtain the latest revision of the manual available for
this machine, contact the FLSmidth Office nearest you (refer to http://www.flsmidth.com/en-US/Contact) and provide this
project number: 9232515940. Refer to J.1 “Operator Manual” on page 492 for the pre-commissioning automation
information.

6.2 Crusher Start-Up

Perform the following steps every time the crusher is started:

1. Start the air seal blower. Adjust the control valve until 381 mm (15 in) of water column difference is achieved.

Note: This value may change after the first liner change reveals if an increase or decrease in flow is required.
Record and use the new value for future crusher start-ups.

2. Start the crusher and run it empty (no-load) for five minutes.

Note: This allows the machine control MCS to verify the proper vital signs and respond if necessary.

3. Start the feed of material to the crusher, and gradually increase the feed rate until the choke fed conditions are
reached.

4. As the feed level in the cavity approaches normal operating levels, slow the feeder speed to prevent it from
overfilling the crusher cavity.

Due to design characteristics, the crusher must never be continuously operated below 50% of the drive
motor full load amps.

6.2.1 Group Start

A single start auxiliary command is sent to the cone crusher MCS to start all the auxiliary equipment that must be running
prior to starting the crusher's main drive. When the start interlocks for all groups are met, the auxiliary ready signal is
sent to the PCS. Upon receipt of the start command, each equipment group is either started (the lubrication unit, for
example) or put into an autostart mode where the equipment can start automatically when the function is called to
operate (the hydraulic system, for example). When each group has reached its operating state, the auxiliaries running
feedback is set to the PCS. At this point, the main drive can be started with a similar exchange of signals.

With the Location control permission selected as MCS or PCS and the Overview navigation group active:

1. Set AUXILIARIES to START. Once the "All Selected Running" status is displayed, a "Lube timer" will begin counting
down. Upon the "Lube timer" reaching zero, the interlock for the main drive will be satisfied.

2. Verify vital signals. Refer to 6.2.3 “Verifying Vital Signals” on page 84.

3. Set CRUSHER MAIN DRIVE to START.

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Chapter 6 Operation 83

Figure 6-1: Crusher Start-Up Via Auxiliaries and Main Drive

6.2.2 Individual Auxiliary Start

With the local control permission selected as MCS or PCS, perform the following steps:

• Within the Lubrication navigation group:

1. Set LUBRICATION HEATING to START.

2. Set LUBRICATION SYSTEM to START.

3. A "Lube timer" will begin counting down until the interlock is satisfied.

• Within the Hydraulic navigation group:

1. Set HYDRAULIC SYSTEM to START.

2. Verify vital signals. Refer to 6.2.3 “Verifying Vital Signals” on page 84.

• Within the Main Drive navigation group:

1. Set CRUSHER MAIN DRIVE to START.

Note: In extremely cold conditions, it may be necessary to constantly run the heater and lubrication system to
maintain the required pump start-up oil temperature during long periods of down time.

Figure 6-2: Crusher Start-Up Via Individual Groups

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84 Chapter 6 Operation

6.2.3 Verifying Vital Signals

1. Access the inspection cover on the lubrication tank to verify oil flow.

If there is only a small stream of oil or no flow at all, do not start the crusher. Operating the crusher in this
situation will cause extreme crusher bearing failure. Troubleshoot the issue as needed, referring to
Table 8-6, “Lubrication System Troubleshooting,” on page 171.

2. Verify that the heat exchanger outlet temperature in the MCS is identical to the physical sensor on the equipment.

3. Verify that the crusher inlet pressure in the MCS is identical to the physical sensor on the equipment.

6.3 Hydraulic Power Unit Start-Up

The hydraulic power unit has two modes of operation: Normal and Manual. The toggle selector is found within the
Hydraulic navigation group.

The hydraulic power unit can be started in either MCS or PCS Location control. For the hydraulic power unit to operate
in either mode:

1. Pull out the EMERGENCY STOP button.

2. Select the HYDRAULIC SYSTEM START button.

With the Location control permission selected as PCS, the hydraulic power unit is controlled by the PCS and all functions
in the MCS are disabled except for the EMERGENCY STOP and the HYDRAULIC SYSTEM buttons. Leave the Location
control selection as PCS during normal crushing operations. Refer to the following list of operations that must be done
with location permissions set to MCS:

• Motor rotation verification (bump test)

• Verify direction and refer to the original equipment manufacturer (OEM) manual.
• 6.4.1.2 “Setting the Closed Side Setting Manually” on page 85
• 6.5 “Performing a Clearing Cycle for Inspection” on page 87
• 6.6 “Clearing Lodged Material” on page 88
• 6.7 “Resetting the Tramp Release System Pressure” on page 90
• 7.26 “Oil Strainer Basket Replacement (Lubrication Unit)” on page 156
• 7.29 “Manually Pressurizing and Bleeding the Tramp and Clamping Circuit” on page 157
• 7.29.5 “Charging and Verifying the Accumulators” on page 160

When the Location control permission selection is PCS, the control system monitors the tramp release pressure,
clamping circuit pressure, and automatically pressurizes the circuits as required. Normal closed side setting adjustments
can be made from the plant control system. In both modes, the pump motor will be off and will only start if any type of
hydraulic power unit operation is performed. Once the operation has been completed, the motor automatically shuts off.
The clamping circuit pressure drops to 0 bar during setting adjustments.

6.4 Normal Crusher Operation

The crusher is designed to only run counterclockwise as viewed from the crusher sheave. Do not change
the crusher rotation for any reason.

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Chapter 6 Operation 85

Proper operation of the crusher is critical to maximize the crusher life. Operate as close to full power as
possible without exceeding power draw peaks of 110%. Running at a 90% average power draw is typically
necessary to avoid excessive power draw peaks.

Do not continuously operate the crusher at or below 50% power.

Although far less critical, than operating at too low a power, minimize starting and stopping the feed in
order to maximize production. However, if the crusher will not have feed for more than 20 minutes, it is
better to shut the crusher down and then restart it when feed is available.

6.4.1 Setting the Crushed Product Size

The size of the crushed product is controlled by the closed side setting, which is the gap in the parallel zone between
the mantle and the bowl liner. Set the closed side setting to slightly less than the maximum product size required.

The MCS logs the liner wear as a KPI to aid the operator in assessment of the liner’s condition. Select KPI from the
Overview navigation group.

6.4.1.1 Liner Calibration

Calibration is performed while the main drive motor is off. If the main drive is not off, the MCS will warn the user that
proceeding will cause a shutdown sequence to allow the calibration to continue.

This function can be accomplished with Location control permission as either MCS or PCS. Perform the following steps
within the Overview navigation group:

New Liner
1. Select the CALIBRATION button. The “Calibration” window will be displayed.

2. Select “New Liners” and change liner configuration if required.

3. Select “Proceed” and follow the prompts.

General
1. Select the CALIBRATION button. The “Calibration” window will be displayed.

2. Select “General”.

3. Select “Proceed” and follow the prompts.

6.4.1.2 Setting the Closed Side Setting Manually

With the Location control permission selected as MCS and the Hydraulic navigation group active:

1. Set HYDRAULIC MODE to MANUAL.

2. Select and hold the OPEN or CLOSE button until the desired actual CSS value is achieved, as shown in the Overview
navigation group.

a. OPEN will increase the CSS value, causing the product size to increase.

b. CLOSE will decrease the CSS value, causing the product size to decrease.

Note: There is an initial three second delay while the clamp pressure is automatically relieved.

3. Release the selected button.

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86 Chapter 6 Operation

Setting the closed side setting too tightly causes ring bounce.

If the HYDRAULIC MODE toggle is changed to NORMAL, the CSS will automatically be adjusted to be close to the
desired CSS and within the programmed CSS limits. If the desired CSS is not within the programmed limits, a warning
will be displayed and NORMAL operation will not be possible.

Image may not reflect exact equipment.

1 Bowl rotation 2 Bowl translation 3 Bowl liner

4 Mantle 5 Product size 6 Increase product size
7 Decrease product size
Figure 6-3: Setting the Crushed Product Size

6.4.1.3 Setting the Closed Side Setting Through Automation

This function can be accomplished with Location control permission as either MCS or PCS. Perform the following steps
within the Overview navigation group:

1. Select the CSS button. The "Adjust CSS" window will be displayed.

2. Enter the desired CSS within the limits shown.

3. Select "Proceed" and follow the prompts.

• If the actual CSS measured at the product is not being achieved, a calibration may need to be performed to account
for accumulated liner wear.

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Chapter 6 Operation 87

6.5 Performing a Clearing Cycle for

Inspection
With the Location control permission selected as MCS and the Hydraulic navigation group active:

1. De-energize the main drive motor and lock it out, following the site lock-out tag-out procedures.

2. Set HYDRAULIC MODE to MANUAL.

3. Select and hold the CLEAR button until the adjustment ring reaches the limit of travel (approximately 30 seconds).

4. While holding the CLEAR button, place safety blocks between the adjustment ring and main frame at the main frame
pin locations. Do not seat safety blocks on the main frame pin bushing. Refer to Figure 6-4.

While placing the safety blocks, continue holding the TRAMP PRESSURE RESET/CLEAR switch in the
CLEAR position. If the switch is released, the adjustment ring and bowl will lower.

Image may not reflect exact equipment.

1 Adjustment ring 2 Safety block 3 Main frame

4 Main frame bushing
Figure 6-4: Safety Blocking

5. Release the CLEAR button. This will allow the adjustment ring and bowl assemblies to lower onto the safety blocks.

6. Inspect the desired components. Refer to 7.9.1 “Determining Main Frame Liner Wear” on page 115 and 7.7.1
“Determining Adjustment Ring Wear” on page 109.

7. Once the inspection is complete, select and hold the CLEAR button until the adjustment ring lifts off the safety
blocks.

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88 Chapter 6 Operation

8. Remove the safety blocks.

9. Release the CLEAR button. The adjustment ring and bowl assemblies will slowly lower back onto the main frame.

10. Visually verify that the adjustment ring and bowl have properly seated back onto the main frame. If they have not,
perform the above steps again.

Never pressurize the tramp release cylinders if the adjustment ring is not sitting level on the main frame.
Doing so will damage the tramp release system components, main frame, and adjustment ring.

11. Reset the tramp release system pressure. Refer to 6.7 “Resetting the Tramp Release System Pressure” on page 90.

12. Select the RESET button to repressurize the tramp release hydraulic circuit to its normal operating pressure.

13. Set HYDRAULIC MODE to NORMAL.

14. Re-energize the main drive motor, following the site lock-out tag-out procedures.

6.6 Clearing Lodged Material

If the crusher stops while crushing (under load), do not attempt to restart it with the crushing cavity full of material. Trying
to restart the crusher with a full crushing cavity will severely damage the machine and drive motor.

The crusher may stop during a crushing cycle for a number of reasons, including:

• Power bumps or outages

• Operating too close to the motor control limits, causing the motor to shut down
• Rapid loss of oil pressure, causing an emergency shutdown
• Crushed product buildup under the crusher
• Tramp material too large for the tramp release system to pass
• Improper belt tension, causing slipping or burned drive belt

Inform all personnel in the area that the crusher is about to be cleared. Verify that no one is near the
adjustment ring.

6.6.1 Clearing Rock or Tramp from the Crusher

With the Location control permission selected as MCS and the Hydraulic navigation group active:

1. De-energize the main drive motor and lock it out, following the site lock-out tag-out procedures.

2. Set HYDRAULIC MODE to MANUAL.

3. Select and hold the CLEAR button until the adjustment ring reaches the limit of travel (approximately 30 seconds).

Note: Material trapped in the crusher will usually be dislodged while the crushing cavity is enlarged during a
clearing cycle.

4. Release the CLEAR button. This will allow the adjustment ring and bowl assemblies to lower onto the main frame
seating surface. Continue holding the TRAMP PRESSURE RESET/CLEAR switch in the CLEAR position.

5. Ensure the adjustment ring is seated on the main frame without any gaps or misalignment.

If the material in the crushing cavity is too large to slide out of the crusher (if the adjustment ring did not seat on the main
frame correctly, for example), perform the following steps:

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Chapter 6 Operation 89

1. Perform a clearing cycle for inspection. Refer to 6.5 “Performing a Clearing Cycle for Inspection” on page 87 and
follow steps 1 through 6.

2. With the adjustment ring and bowl assemblies resting securely on the safety blocks, stand on the adjustment ring
and deflect the rubber skirt that seals the bottom of the feed chute and the rock hopper in the bowl assembly (if
possible).

3. Remove any material that was too large to pass through the cavity with a long bar. Refer to 6.6.2 “Clearing Tramp
Metal From the Crusher” on page 89.

Do not attempt to remove any material from the crushing cavity unless the equipment is locked out and
safety blocks have been placed between the main frame and the adjustment ring to hold the ring in a
raised position.

The safety blocks will protect hands and arms from being caught between the crushing members. The
safety blocks will protect hands and arms from being caught between the crushing members.
Never place feet or hands between the main frame and the adjustment ring, even when the safety blocks
are in place. The safety blocks will protect hands and arms from being caught between the crushing
members.

4. Once all the material has cleared, complete the clearing cycle. Refer to 6.5 “Performing a Clearing Cycle for
Inspection” on page 87 and follow steps 7 through 14.

6.6.2 Clearing Tramp Metal From the Crusher

Determine which of the following methods is most likely to be the safest for removing the tramp metal:

• Use an overhead lifting device to pull the tramp metal out of the crusher. Refer to 6.6.2.1 “Removing Metal With an
Overhead Lifting Device” on page 89.
• Burn the metal out of the crusher. Refer to 6.6.2.2 “Burning Metal From the Crusher” on page 90.

The stored energy in the steel crusher components may be applying significant force on the tramp metal.
Removing tramp metal can be very dangerous because metal can be expelled from the crushing cavity
with enough velocity to do bodily harm.

Both methods present some danger because a person must have a clear view of the jammed metal in the
crushing cavity. The metal will normally be ejected upward toward the head feed plate. Carefully follow
all given instructions for the chosen method.

6.6.2.1 Removing Metal With an Overhead Lifting Device

With the Location control permission selected as MCS and the Hydraulic navigation group active:

1. De-energize the main drive motor and lock it out, following the site lock-out tag-out procedures.

2. Set HYDRAULIC MODE to MANUAL.

3. Select and hold the CLEAR button until the adjustment ring reaches the limit of travel (approximately 30 seconds).

The metal is most likely to shoot upward toward the head feed plate; standing aside at 90 degrees from
the metal is necessary to remain outside the path of the metal.

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90 Chapter 6 Operation

4. Once the metal is loose in the cavity, pull it out. The metal will be hot.

5. Re-energize the hydraulic power unit motor, following the site lock-out tag-out procedures.

6. Monitor the crusher closely, paying particular attention to the oil temperature, oil pressure, and unusual sounds. If
anything is out of the ordinary, shut down the crusher for a maintenance inspection and repairs.

6.6.2.2 Burning Metal From the Crusher

1. Use a long pole or rod to slip a hook or sling around the tramp metal.

2. Connect the free end of the hook or sling to an overhead lifting device.

3. Secure a hot work permit from the appropriate site management. Follow all site policies and procedures.

4. Protect the discharge conveyor and any other flammable materials in the crusher discharge area.

5. Stand to the side of the crusher, approximately 90 degrees to the jammed metal.

The metal is most likely to shoot upward toward the head feed plate; standing aside at 90 degrees from
the metal is necessary to remain outside the path of the metal.

6. Burn the metal. Work on the narrowest section of the metal possible without burning into the manganese steel liners.

7. Burn slowly to allow the metal to collapse on itself.

8. Once the metal is loose in the cavity, attempt to push it through or pull it out. The metal will be hot.

9. Re-energize the hydraulic power unit motor, following the site lock-out tag-out procedures.

10. Once the metal is loose in the cavity, attempt to push it through or pull it out. The metal will be hot.

11. Monitor the crusher closely, paying particular attention to the oil temperature, oil pressure, and unusual sounds. If
anything is out of the ordinary, shut down the crusher for a maintenance inspection and repairs.

6.7 Resetting the Tramp Release System

Pressure
With the Location control permission selected as MCS and the Hydraulic navigation group active:

1. Verify that the accumulator is charged. Refer to 7.29.5 “Charging and Verifying the Accumulators” on page 160.
Pressurizing the accumulator without first charging it damages the bladder, requiring replacement.

2. Set HYDRAULIC MODE to MANUAL.

3. Manually close the dump valve for the tramp release circuit.

4. Select the RESET button. This will automatically pressurize the tramp release circuit.

Note: The low tramp pressure warning should disappear.

5. Close the tramp release circuit dump valve.

6. Set HYDRAULIC MODE to NORMAL.

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Chapter 6 Operation 91

6.8 Shutdown
1. Shut the feed off to the crusher and allow the crusher to run empty for five minutes.

2. Turn the power off to the crusher drive motor and monitor the time it takes for the crusher to coast to a stop. Coast-
down time will be 60 to 90 seconds.

Note: The MCS monitors the coast down time and logs the data.
3. Under normal operating oil temperatures, allow the lubrication system to run an additional five minutes before
shutting down.

4. If the return oil temperature is in a warning or alarm condition, continue operating the lubrication system until the
temperature drops to within the normal operating temperature range.

5. In extremely cold conditions, if the crusher will not be down for more than four hours leave the lubrication system
running if possible.

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92 Chapter 6 Operation

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 93

Chapter 7: Maintenance
7.1 Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
7.1.1 Welding and Weld Repair of Major Castings . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.1.3 Thermal Process for Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 96
7.2 Component Lifting and Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
7.2.1 Special Tools Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.2.2 Lifting the Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.2.3 Lifting the Bowl Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.2.4 Lifting the Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
7.3 Thread Wear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.4 Eccentric Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.4.1 Eccentric Bushing Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.4.2 Eccentric Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.4.3 Eccentric Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.5 Socket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.5.1 Socket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.5.2 Socket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.6 Creating a Contact Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.6.1 Backlash Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.6.2 Contact Pattern Inspection and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 107
7.7 Adjustment Ring Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.7.1 Determining Adjustment Ring Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.7.2 Adjustment Ring Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
7.7.3 Adjustment Ring Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.8 Main Frame Seat Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7.8.1 Determining the Main Frame Seat Liner Wear . . . . . . . . . . . . . . . . . . . . . . . .112
7.8.2 Main Frame Seat Liner and Fulcrum Removal . . . . . . . . . . . . . . . . . . . . . . . . 113
7.8.3 Main Frame Seat Liner and Fulcrum Installation . . . . . . . . . . . . . . . . . . . . . . 114
7.9 Main Frame Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.9.1 Determining Main Frame Liner Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
7.9.2 Main Frame Liners Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
7.9.3 Main Frame Liners Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.10 Drive Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.10.1 Drive Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

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94 Chapter 7 Maintenance

7.10.2 Drive Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

7.11 Arm Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.11.1 Arm Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
7.11.2 Arm Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
7.12 V-Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.12.1 V-Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.12.2 V-Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.12.3 V-Belt Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
7.13 Shaft Sheave Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.13.1 Shaft Sheave Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.13.2 Shaft Sheave Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.13.3 Sheave and Belt Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.14 Air Seal Blower Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.15 Counterweight Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.15.1 Counterweight Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.15.2 Counterweight Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.16 Counterweight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.16.1 Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.16.2 Counterweight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.17 T-Seal and U-Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.17.1 T-Seal and U-Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.17.2 T-Seal and U-Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.18 Socket Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.18.1 Determining Socket Liner Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.18.2 Socket Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.18.3 Socket Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.19 Head Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.19.1 Head Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
7.19.2 Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
7.19.3 Head Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
7.19.4 Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.20 Mantle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.20.1 Mantle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.20.2 Mantle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.21 Lower Head Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.21.1 Lower Head Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
7.21.2 Lower Head Bore Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.21.3 Lower Head Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.22 Upper Head Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.22.1 Upper Head Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

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Chapter 7 Maintenance 95

7.22.2 Upper Head Bore Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

7.22.3 Upper Head Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.23 Bowl Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.23.1 Bowl Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.23.2 Determining Bowl Thread Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.23.3 Bowl Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.24 Bowl Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.24.1 Determining Bowl Liner Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.24.2 Bowl Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.24.3 Bowl Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.25 Bowl Adapter Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.25.1 Bowl Adapter Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.25.2 Bowl Adapter Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.26 Oil Strainer Basket Replacement (Lubrication Unit) . . . . . . . . . . . . . . . . . . . . . . . 156
7.26.1 Oil Strainer Basket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.26.2 Oil Strainer Basket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.27 Oil Filter Element Replacement (Lubrication Unit) . . . . . . . . . . . . . . . . . . . . . . . . 156
7.27.1 Oil Filter Element Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.27.2 Oil Filter Element Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.28 Changing the Oil Filter Cartridge (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.29 Manually Pressurizing and Bleeding the Tramp and Clamping Circuit . . . . . . . 157
7.29.1 Pressurizing the Tramp Release System Manually . . . . . . . . . . . . . . . . . . . 158
7.29.2 Bleeding the Tramp Release System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.29.3 Pressurizing the Clamping System Manually . . . . . . . . . . . . . . . . . . . . . . . . 159
7.29.4 Bleeding the Clamping System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.29.5 Charging and Verifying the Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.29.6 Charging Assembly Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.29.7 Verifying the Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.29.8 Charging the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.29.9 Removal and Storage of the Charging Assembly . . . . . . . . . . . . . . . . . . . . 163

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96 Chapter 7 Maintenance

7.1 Maintenance Overview

This chapter provides detailed information on maintaining the equipment and its systems safely and efficiently. Regular
care and maintenance must be performed as outlined in this chapter.

For maintenance instructions specific to an accessory piece of equipment (item which is furnished by FLSmidth but is
fabricated by a third party) refer to the original equipment manufacturer documentation.

Do not install, operate, maintain, or repair this equipment unless you have read and understand the
instructions and warnings in Chapter 1: “Safety”. Failure to follow these safety precautions could result in
personal injury, death, or property damage.

7.1.1 Welding and Weld Repair of Major Castings

The main frame, bowl, head, and adjustment ring are critical components in the function of the crusher.
These specific parts are cast using high alloy steel that has special welding requirements. Before doing
any welding on these specific parts, a certified welder must submit a weld procedure specification (WPS)
to FLSmidth engineering for review. The failure to provide a WPS for review voids the crusher warranty.

7.1.2 Introduction

Exercise great care while performing maintenance to avoid damaging the crusher components.

Take the following precautions when working on the crusher:

• Handle parts with care if they have bearings, or machined or journal surfaces. These parts are either designed to
close tolerances or are critical surfaces.
• Do not allow these parts to contact hard surfaces. Support the parts on wooden blocking or rubber mats.
• Do not install any part that has a bearing or journal surface without first coating it with oil.
• Handle and install bronze bushings with great care.
• Bronze is soft; ramming or pounding a bushing during installation may cause distortion or other damage.
• Coat mating parts that have either a press or sliding fit with light oil to prevent rusting in place.
• Thoroughly clean and oil any machined parts prior to installation.

7.1.3 Thermal Process for Removal and Installation

Thermal procedures are required for the removal and subsequent installation of some components.

• The components can be damaged by improper heating techniques. Whenever possible, heat the components in an
oil bath, temperature-controlled oven, or induction heater.
• Establishing a uniform, soaking heat of the minimum temperature necessary.

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Chapter 7 Maintenance 97

• Do not use cutting torches as a heating tool. Concentrated heat from a cutting torch will result in hot spots that may
cause dimensional distortions or cause residual stress concentrations and can adversely surface harden parts.
Excessive localized heating can cause stress cracks.
• Oxygen acetylene or oxygen propane torches are not recommended; only use these torches if it is the only method
available, and only with great care. Use a burner tip that provides a diffused flame if the torch is used.
• If flame heating of gearing must be used, avoid direct flame contact with the hardened surfaces. Instead, warm the
bore and internal faces, and allow the heat to slowly soak to the outside.
• Do not exceed the provided target temperature. Overheating can damage parts by affecting the metallurgy and
causing residual stress concentrations.
• Apply heat rapidly and evenly when heating parts for removal, and then remove the part as quickly as possible to
minimize heat transfer to the mating part.
• Do not quench parts in liquid to cool them. If fast cooling is required, limit the cooling speed to that which can be
attained with a fan or compressed air stream.

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98 Chapter 7 Maintenance

7.2 Component Lifting and Transport

7.2.1 Special Tools Package

10 12
4 14
8

9 6

3
1

11

13
5

Image may not reflect exact equipment.

1 Ring bolts 2 Head turning plate 3 Hoist ring 4 Line-up studs

5 Charging assembly 6 75 mm pitch thread template 7 Safety block 8 Bowl lifting pin
9 Locking nut wrench 10 Threaded rod 11 Head lifting plate 12 Lifting eye nut
13 Eccentric lifting ring 14 Jacking bolts
Figure 7-1: Tools Package

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Chapter 7 Maintenance 99

Refer to Table 7-1 for the tool items required for lifting the crusher components involved in standard installation and
maintenance.

Items

Threaded Rod M20 × 100

Eccentric Lifting Ring

M20 Lifting Eye Nut

Head Turning Plate
Head Lifting Plate

HHCS M20 × 220

HHCS M30 × 100

HHCS M30 × 150

HHCS M30 × 120

HHCS M36 × 140

Lifting Hooks On
Adjustment Cap
Bowl Lifting Pin

M64 Hoist Ring

M36 Hoist Ring
M100 Ring Bolt
M20 Ring Bolt
M30 Ring Bolt
M36 Ring Bolt
M10 Ring Bolt
M16 Ring Bolt

Line-Up Stud
Main frame assembly 4

Head assembly (with mantle and locking

1 4 1
nut, without feed plate)

Head assembly (to turn head over

1 2 4 4 2 1
without mantle and feed plate)

Counterweight 4

Upper head bushing 4

Lower head bushing 2

Locking nut 2

Socket liner 4

Locking nut wrench 4 2

Arm guard 2 3

Bowl assembly 4

Bowl (to turn bowl over without liner and

2 2
adjustment cap)

Clearing cylinder assembly 1

Driveshaft Plate 1

Eccentric (without counterweight) 1 3 2

Eccentric assembly 1 3 2

Drive ring 2

Clamping ring 2

Socket 2 4

Table 7-1: Standard Maintenance Tools Assemblies

Refer to Table 7-2 for the tool items required for lifting the crusher components involved in advanced maintenance. All
advanced maintenance tools are shipped with the crusher, but the maintenance procedures are restricted to personnel
trained in advanced maintenance by FLSmidth. Contact FLSmidth for training.

Items Threaded Rod M20 M10 Ring Bolt M12 Ring Bolt M16 Ring Bolt M36 Ring Bolt
× 175

Head stub 2

Main shaft 4

Main frame pin 1

Main frame pin bushing 2

Lower thrust bearing 2

Upper thrust bearing 2

Table 7-2: Advanced Maintenance Tools Assemblies

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100 Chapter 7 Maintenance

Items Threaded Rod M20 M10 Ring Bolt M12 Ring Bolt M16 Ring Bolt M36 Ring Bolt
× 175

Countershaft 1

Countershaft box arm guard 1

Eccentric bushing 2

Gear 2

Hydraulic adjust pinion 2

Table 7-2: Advanced Maintenance Tools Assemblies

7.2.2 Lifting the Main Frame Assembly

The maximum main frame assembly lift is achieved with the following components installed. Refer to Table 5-1: “Crusher
and Sub-Assembly Weights” on page 54 for the component weights.

1. Strap cables around the main frame lifting trunnions. Verify that shipping caps have been installed in the cylinder
ports and hose ends.

2. If the main frame is fastened to a shipping stand, unfasten it.

The angle of the lifting cables must not exceed 45 degrees from vertical.

7.2.3 Lifting the Bowl Assembly

Bowl threads are coated with grease. Spare bowls threads have a protective coating applied, such as Cosmoline. Do not
remove the packing from a new bowl until it is ready to be installed in the crusher.

Attach suitable cable slings and clevises to the four lifting ears on the adjustment cap of the bowl assembly.

Image may not reflect exact equipment.

1 Lifting cable 2 Feed hopper 3 Adjustment cap 4 Bowl

Figure 7-2: Lifting the Bowl

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Chapter 7 Maintenance 101

7.2.4 Lifting the Head Assembly

1. Remove the feed plate.

2. Secure the M64 hoist ring (supplied in the special tools package) in the off-centered tapped hole on the top of the
head lifting plate.

3. Bolt the head lifting plate to the locking nut using the M30 × 100 hex head capscrews (supplied in the special tools
package).

4. Using a spirit level, verify that the head lifting plate hoist ring is positioned toward the closed side of the crushing
cavity (thick portion of the eccentric), and that the lifting equipment is relatively centered over the head.

Note: The off-center position of the hoist ring slightly tilts the head into a position that will not damage the
lower head bushing when installing or removing the head assembly.

If the hoist ring is not correctly positioned, the lower head bushing will be damaged.

7.3 Thread Wear Inspection

The maintenance log is required for this procedure. Refer to D.1 “Thread Wear Inspection Log” on
page 194.

Inspect the threads on the bowl assembly, adjustment ring, and clamping ring for galling and wear whenever the bowl
assembly is removed from the crusher.

1. Remove all grease and dirt from the thread.

2. Use the thread inspection template (supplied in the special tools package) to measure the gap between the
template and the thread flats in four locations equal distances apart for all three of the components. Refer to
Figure 7-3.
a. Measure the adjustment ring and clamping threads at four locations aligned with the main frame pins.

b. Measure the bowl at four locations aligned with the start or end of thread and at the midplane of the bowl height.

Image may not reflect exact equipment.

1 Adjustment ring and clamping ring threads 2 Bowl threads 3 Thread inspection template 4 Distance to be measured
Figure 7-3: Inspecting Thread Wear

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102 Chapter 7 Maintenance

3. Find the average of the gap measurements from the four locations.

4. Sum the average gap measurements for the bowl assembly, adjustment ring, and clamping ring.

5. Add the average gap measurements sum to the designated thread clearance of 6.37 mm (0.25 in).

6. If the value matches or exceeds 12 mm (0.5 in), contact FLSmidth.

7. Record the measurements, averages, and sums in the maintenance log. Refer to D.1 “Thread Wear Inspection Log”
on page 194.

8. Remove all upsets and gouged steel caused by galling of the bowl, adjustment ring, and clamping ring threads.
Smooth all surfaces.

9. Lubricate the threads. Refer to A.2.3 “Thread Lubrication Requirements” on page 175.

7.4 Eccentric Assembly Maintenance

7.4.1 Eccentric Bushing Storage
After removing the eccentric bushings, only store them vertically. If they are left on their side, they will become out of
round over time. This makes re-installation difficult and may lead to scraping the bushing.

7.4.2 Eccentric Assembly Removal

1. Remove the socket. Refer to 7.5.1 “Socket Removal” on page 104.

2. Attach the eccentric lifting ring using three M30 × 100 hex head capscrews (supplied in the special tools package).

Note: Do not use ring bolts in the tapped holes on the top of the eccentric to attempt to lift the assembly.

3. Position the eccentric lifting ring with an eyebolt in the center of the thickest portion of the eccentric. Any other
position will cause the load to be unbalanced, and the eccentric will tip.

4. Attach two M36 hoist rings (supplied in the special tools package) and rigging to the eccentric lifting ring (supplied in
the special tools package), and center the rigging. Refer to Table 5-1: “Crusher and Sub-Assembly Weights” on
page 54.

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Chapter 7 Maintenance 103

Image may not reflect exact equipment.

1 Lifting cables 2 Hoist rings 3 Heavy side of eccentric

4 Main shaft 5 Lifting ring
Figure 7-4: Lifting Eccentric Assembly

5. Slowly lift the eccentric assembly, making sure the rigging is centered to prevent swinging once it clears the main
shaft. If the eccentric assembly swings, it can damage the main shaft.

6. Place the eccentric assembly on wood blocking or another protective material. Use caution to avoid damaging the
gear.

7.4.3 Eccentric Assembly Installation

1. Thoroughly clean the top of the main shaft, main frame gear well, eccentric bushing bore, upper thrust bearing
(bolted to the underside of the eccentric), and lower thrust bearing (bolted to the main frame).

2. Remove any scratches, burrs, or nicks.

3. Verify the capscrews that secure the upper and lower thrust bearings are sufficiently torqued. Refer to drawing
“677551: Eccentric Assembly” on page 313.

4. Attach the eccentric lifting plate with two M36 hoist rings (supplied in the special tools package) to the eccentric
using three M30 × 100 hex head capscrews. Refer to Figure 7-4 “Lifting Eccentric Assembly.”

5. Apply a light coat of oil to the main shaft, upper and lower thrust bearings, and eccentric bushing bore. Use the same
lubrication oil as is used in the crusher lubrication system.

6. Carefully lower the eccentric assembly onto the main shaft until it is seated on the lower thrust bearing.

7. Inspect the backlash between the gear and pinion. Refer to 7.6 “Creating a Contact Pattern” on page 106.

8. Install the socket. Refer to 7.5.2 “Socket Installation” on page 104.

7.5 Socket Replacement

The socket has an interference fit on the main shaft.

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104 Chapter 7 Maintenance

7.5.1 Socket Removal

1. Remove the socket liner. Refer to 7.18.2 “Socket Liner Removal” on page 129.

2. Remove the hex capscrews and washers that attach the socket to the main shaft.

3. Install two M16 ring bolts (supplied in the special tools package) in the socket.

4. Apply anti-seize to any size of the jackscrews that will fit (supplied in the special tools package), and insert them into
the socket until they bottom out on the top of the main shaft.

Image may not reflect exact equipment.

1 Jackscrews 2 Socket 3 Main shaft

4 Lower portion of socket 5 Socket lifting ring bolts
Figure 7-5: Socket Removal

5. Heat the lower flange of the socket evenly until it achieves a temperature difference of 76°C (136°F) from the socket.

• Heat the lower flange of the socket as rapidly as possible with two propane gas burners or acetylene rose bud
torches.
• Keep the torches moving during heating. If the torch is held in one spot too long, it can create stress
concentrations in the high strength alloy steel and lead to cracking.

6. In a crisscross pattern, tighten each jackscrew in small increments.

7. Continue heating the socket lower flange until the jackscrews move the socket easily. Then turn off the heat, and
quickly tighten the jackscrew incrementally as rapidly as possible.

Note: Use an air impact tool to tighten the jackscrews incrementally. It is generally best to have two people
evenly tightening the jackscrews at once.

8. Lift the socket off the main shaft with the attached socket lifting rings.

7.5.2 Socket Installation

1. Install four line-up studs (supplied in the special tools package) in the tapped holes at the top of the main shaft. Refer
to Figure 7-6.

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Chapter 7 Maintenance 105

Image may not reflect exact equipment.

1 Removal hardware 2 Lifting ring bolts 3 Socket

4 Alignment studs 5 Main shaft
Figure 7-6: Socket Mounting

2. Install two M16 ring bolts (supplied in the special tools package) in the top of the socket.

3. Attach the ring bolts to suitable, equal length cable slings or chains, and lift the socket to approximately waist height.

4. Verify the socket is level before lowering it onto the main shaft.

5. Heat the socket to approximately 76°C (136.8°F) above the ambient temperature of the crusher main shaft. Use at
least two gas burners, and keep the flame moving along the surface. Slowly spin the socket to evenly distribute the
heat.

Note: One gas burner is not enough to evenly heat the socket to the designated temperature above the
ambient temperature.

6. Align the socket with the alignment studs, and quickly lower it onto the main shaft.

7. Use a feeler gauge to verify that the socket is seated tightly against the top of the main shaft.

8. Remove the alignment studs, install the capscrews with lock washers down through the socket, and secure the
socket to the main shaft.

9. In a crisscross pattern, tighten the capscrews in small increments until they are tightened to 1,490 N-m (1,099 ft-lb).

10. Reinspect the torque after the socket has cooled to the same temperature as the main shaft.

11. Install the socket liner. Refer to 7.18.3 “Socket Liner Installation” on page 130.

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106 Chapter 7 Maintenance

Image may not reflect exact equipment.

1 Feeler gauge 2 Socket 3 Clearance measurement 4 Main shaft

Figure 7-7: Socket Contact Inspection

7.6 Creating a Contact Pattern

7.6.1 Backlash Inspection and Adjustment

The maintenance log is required for this procedure. Refer to D.2 “Backlash Log” on page 195.

1. Install the eccentric assembly. Refer to 7.4.3 “Eccentric Assembly Installation” on page 103.

2. Install the countershaft assembly. Refer to the advanced maintenance manual (available from FLSmidth).

3. Pull outward on the countershaft until the pinion is tight against the inner countershaft bushing.

4. Remove all bearing clearance between the eccentric bushing and the main shaft by placing a hydraulic jack
between the inner wall of the main frame and counterweight at the thickest section of the eccentric, which is also
called the counterweight light side.

Note: Use only enough force to push the eccentric bushing against the main shaft. If too much force is used,
the eccentric will tip slightly and the measurement will not be accurate.

5. Place the transverse backlash measurement tool on the pinion countershaft in the location shown in Figure 7-8:
“Countershaft and Backlash Tool” on page 107.

Note: Contact FLSmidth if backlash tool drawings are needed. The dial indicator must be located at a radial
distance equal to half the pitch diameter for the pinion gear, and it must be mounted as shown in Figure 7-8.

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Chapter 7 Maintenance 107

Image may not reflect exact equipment.

1 Countershaft box 2 Countershaft box cover 3 Backlash tool

4 Countershaft 5 Main frame
Figure 7-8: Countershaft and Backlash Tool

6. Using a light force, rotate the countershaft clockwise until the pinion gear stops against the mating gear. Record the
dial indicator movement in millimeters in Table D-2, “Backlash Log,” on page 195. This is the transverse backlash for
the assembled gear set.

Note: If necessary, take multiple dial indicator readings and average the results.

7. Record the backlash in Table D-2, “Backlash Log,” on page 195.

8. Compare the backlash with requirement given in Table 7-3.

Tooth Type Assembled Transverse Backlash with Dial Indicator

Curved tooth spiral Klingelnberg 2.38—2.69 mm

Curved tooth spiral Gleason 2.32—2.69 mm

Table 7-3: Assembled Backlash Gear Requirement

9. Make any necessary backlash adjustments.

a. Increase the backlash value by adding shims under the lower thrust bearing on the main frame.

b. Decrease the backlash value by removing shims from under the lower thrust bearing on the main frame.

c. Measure the transverse backlash again and compare the values with the gear assembly requirement in Table 7-
3.

a. Continue adjusting the backlash until it is satisfactory.

10. Tighten the countershaft box hex head cap screws.

7.6.2 Contact Pattern Inspection and Adjustments

1. Create a contact pattern. Refer to 7.6.1 “Backlash Inspection and Adjustment” on page 106.

2. Remove the eccentric assembly. Refer to 7.4.2 “Eccentric Assembly Removal” on page 102.

3. Inspect the contact pattern on the eccentric gear.

4. Compare the contact pattern with the patterns shown in Figure 7-9 “Optimal Contact Pattern” and Figure 7-10
“Contact Pattern Corrections.”

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108 Chapter 7 Maintenance

Image may not reflect exact equipment.

1 Gear 2 Pinion
Figure 7-9: Optimal Contact Pattern

3 4

5 6

Image may not reflect exact equipment.

1 Gear 2 Pinion 3 Pinion out too far

4 Gear too low 5 Pinion in too far 6 Gear too high
Figure 7-10: Contact Pattern Corrections

5. Make any necessary contact adjustments.

a. Add or remove shims as needed to move the countershaft assembly in or out of the main frame until the contact
location is centralized on the tooth face.

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Chapter 7 Maintenance 109

b. Measure the backlash again, and compare the measurement to the required value. Refer to 7.6.1 “Backlash
Inspection and Adjustment” on page 106.

6. Mount the countershaft sheave and bushing. Refer to 7.13.2 “Shaft Sheave Assembly Installation” on page 122.

7.7 Adjustment Ring Assembly

Maintenance
7.7.1 Determining Adjustment Ring Wear

The maintenance log is required for this procedure. Refer to D.6 “Adjustment Ring Wear Log” on
page 199.

When the frame seat liner and fulcrum bar are replaced, there is a necessary gap between the top of the fulcrum bar
and the underside of the adjustment ring. Refer to Figure 7-11. Over time, the adjustment ring seating surface wears.
Eventually, the adjustment ring seating surface wears enough that the necessary gap is not maintained, even with the
replacement of the frame seat liners and fulcrum bar.

Image may not reflect exact equipment.

1 Fulcrum bar 2 Bronze main frame seat liner 3 Gap between fulcrum bar segment
4 Gap between main frame seat liner segments
Figure 7-11: Determining the Adjustment Ring Wear

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110 Chapter 7 Maintenance

Perform the following steps to determine the gap between the adjustment ring and the fulcrum bar. Refer to 6.5
“Performing a Clearing Cycle for Inspection” on page 87 to raise and lower the adjustment ring.

1. Insert balls of clay or putty at various spots on top of the fulcrum bar.

2. Place the adjustment ring on the main frame, making sure it’s properly seated.

3. Lift the adjustment ring off the frame, and measure the thickness of the clay or putty.

4. Record the clay or putty measurements. Refer to D.6 “Adjustment Ring Wear Log” on page 199.

5. If the clay or putty is 4 mm (0.16 in) thick or more where it contacted the adjustment ring, replace the main frame seat
liners and fulcrum bar. Refer to 7.8 “Main Frame Seat Liner Maintenance” on page 112.

6. Repeat the above steps to re-determine the adjustment ring wear.

a. If the clay or putty is 1 mm (0.04 in) thick or less where it contacted the adjustment ring, machine the top of the
fulcrum bar to obtain the proper clearance.

b. If the clay or putty is 4 mm (0.16 in) thick or more where it contacted the adjustment ring, build up the top of the
fulcrum bar with welding and then machine the bar as needed to obtain the proper clearance. Contact FLSmidth
customer service for the fulcrum bar dimensions.

c. If the clay or putty varies in thickness by 6 mm (0.25 in) or more from one side of the crusher to the other where
it contacted the adjustment ring, the adjustment ring seating surface has worn excessively on one side and is
tilted on the main frame. Recondition the adjustment ring seating surface; refer to the advanced maintenance
manual (available from FLSmidth).

7.7.2 Adjustment Ring Assembly Removal

1. Remove the bowl assembly from the crusher. Refer to 7.23.1 “Bowl Assembly Removal” on page 146.

2. Remove the drive ring from the crusher. Refer to 7.10.1 “Drive Ring Removal” on page 116.

Do not, under any circumstances, disconnect any of the hoses from any of the components in the release
system without first verifying that there is zero pressure in the system. A hose being disconnected under
high pressure is very dangerous, and can cause serious harm from the escaping high velocity oil and the
possibility of being hit by a whipping hose.

With the Location control permission selected as MCS and the Hydraulic navigation group active:

3. Set HYDRAULIC SYSTEM to OFF.

4. Manually press the EMERGENCY STOP on the HPU control panel.

5. De-energize the hydraulic power unit motor and lock it out, following the site lock-out tag-out procedures.

6. Dump the pressure in the clamping and tramp release systems using the dump valves on the respective valve block.

7. Ensure the tramp and clamping circuit pressure indicated on the respective transducers is zero.

8. Remove the nut from the top of the tramp release cylinder. These nuts secure the cylinders to the adjustment ring
and were factory installed with Loctite. Apply heat not exceeding 205°C (400°F) and use an impact spanner if Loctite
is present between components.

9. If tramp cylinders are not to be removed, they must be secured with a strap and blocking. Place a strap around all of
the tramp release cylinders located between the cylinder tube and the bypass tube.

10. Install wooden wedges between the tramp release cylinders and the main frame. The strap and wooden wedges will
hold the tramp release cylinders in a vertical position, not allowing them to fall when the adjustment ring is lifted off
of the main frame.

11. Verify that the clamping circuit pressure is zero.

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Chapter 7 Maintenance 111

12. Disconnect the hose that supplies hydraulic oil to the clamping cylinders from the hydraulic power unit. It is located
opposite the countershaft on the adjustment ring.

13. Unbolt the dust shell, and remove it from the top of the adjustment ring.

14. Remove the hex head capscrews, washers, and spacers used to attach the clamping ring to the adjustment ring.
Refer to Figure 7-12.

15. Disconnect and lock out the electricity to the proximity sensors.

16. Remove the vibration sensors from the adjustment ring. Be careful not to damage the cords, as they are permanently
secured to the sensors.

17. Attach four suitably sized, equal length cables or chains and clevises to the cast on the adjustment ring bosses.
Refer to Table 5-1, “Crusher and Sub-Assembly Weights,” on page 54 for the equipment weight.

Note: The clevises must be capable of spanning 50 mm (1.97 in) cast-on lifting bosses.

18. Remove the adjustment ring.

19. Inspect the adjustment ring, clamping ring, and bowl threads. Refer to 7.3 “Thread Wear Inspection” on page 101.
Recondition the threads at the same time as reconditioning the frame seat liner and fulcrum bar.

Image may not reflect exact equipment.

1 Clamping ring 2 Capscrew 3 Flat washer

4 Tube spacer 5 Adjustment ring
Figure 7-12: Clamping Ring Spacers and Capscrews

7.7.3 Adjustment Ring Assembly Installation

1. Remove the protective coating from the machined surfaces on the adjustment ring assembly and connecting
surfaces, such as the main frame seating surface and threads.

2. Attach four suitably sized, equal length, cables or chains and clevises to the cast on the adjustment ring bosses.

Note: The clevises must be capable of spanning 50 mm (1.97 in) cast-on lifting bosses. It may be necessary to
remove the dust shell if the lifting cables or chains are too short and a four-way spreader is not available.

3. Apply a light coat of anti-seize compound to the main frame seat liners.

4. Lift the adjustment ring assembly, align it with the main frame pin bushings, and lower it into position.

5. If the tramp release cylinders are attached to the main frame, carefully lower the adjustment ring and guide the
cylinder rods into the mating holes.

6. Connect the hydraulic supply hose from the adjustment ring to the clamping cylinder hose loop. Verify that all hose
connections are tight.

7. Insert tube spacers into the clamping ring holes, and then insert the capscrews with washers mounted on them.

8. Lift and place the dust shell on the top of the adjustment ring, and bolt it in place.

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112 Chapter 7 Maintenance

9. Thread the spherical nuts onto the top of the tramp release cylinders.

10. Lift and replace the drive ring and its support brackets. Refer to 7.10.2 “Drive Ring Installation” on page 116.

11. Reconnect electricity to the motor and proximity sensor cables.

12. Connect the vibration sensors to the drive ring support brackets. Refer to 5.12.7 “Vibration Transducers Installation”
on page 77.

13. Apply grease to the adjustment ring and clamping ring threads. Refer to A.2.3 “Thread Lubrication Requirements” on
page 175.

7.8 Main Frame Seat Liner Maintenance

7.8.1 Determining the Main Frame Seat Liner Wear

The maintenance log is required for this procedure. Refer to D.3 “Main Frame Seat Liner Thickness Log”
on page 196.

Inspect the main frame seat liner and fulcrum bar weekly and after every tramp event. Deviations in feed to the crusher
and slight movement between the adjustment ring and main frame can cause small amounts of wear. This wear
increases if an excessive amount of ring bounce is allowed.

Note: If the maximum allowable clearance between the top of the fulcrum bar and the adjustment ring is no
longer achievable after replacing the main frame seat liners, recondition the adjustment ring seating surface.
Refer to the advanced maintenance manual (available from FLSmidth).

The adjustment ring may crack if it directly contacts the fulcrum bar during crushing operations.

1. Perform a crusher clearing cycle to lift the adjustment ring. Refer to 6.5 “Performing a Clearing Cycle for Inspection”
on page 87.

2. Inspect the seat liner segments for detachment or cracked welds.

3. For initial measurements:

a. Starting with the main frame pin boss to the left of the countershaft box, number each of the four bosses in a
clockwise direction, using paint or stamps to permanently affix the numbers. Refer to Figure 7-13.

b. Measure and record the gap between the top of the main frame pin boss and the bottom of the adjustment ring.
Refer to Figure 7-13 and D.3 “Main Frame Seat Liner Thickness Log” on page 196.

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Chapter 7 Maintenance 113

Image may not reflect exact equipment.

1 Adjustment ring 2 Main frame pin 3 Location to paint or stamp numbers

4 Location for wear dimension measurement 5 Seat liner 6 Main frame
7 Fulcrum bar 8 Clearance
Figure 7-13: Determining the Seat Liner Wear

4. For subsequent measurements (every 6 months and after a known period of excessive ring bounce):

a. Measure and record gap measurements between the top of the main frame pin boss and the bottom of the
adjustment ring. Refer to D.3 “Main Frame Seat Liner Thickness Log” on page 196.

b. Use the difference between the current measurement and the initial measurement to determine whether any
wear has taken place.

Note: Due to casting variations, this gap is the only place to take accurate measurements.

5. The maximum allowable difference between the initial and the subsequent measurements is 8 mm (0.31 in).

Note: Once the wear has reached this level, only 2 mm (0.08 in) of seat liner remains, and the seat liner and
fulcrum bar must be replaced.

• If the gap difference varies by 6 mm (0.25 in) or more from one side of the crusher to the other, the seat liner has
worn on one side and the adjustment ring is tilted. If this occurs, the seat liner and fulcrum bar must be replaced.

7.8.2 Main Frame Seat Liner and Fulcrum Removal

The fulcrum bar must be replaced at the same time as the seat liners.

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114 Chapter 7 Maintenance

1. Remove the bowl assembly. Refer to 7.23.1 “Bowl Assembly Removal” on page 146.

2. Remove the adjustment ring. Refer to 7.7.2 “Adjustment Ring Assembly Removal” on page 110.

3. Remove the worn seat liners and fulcrum bar segments from the main frame by grinding off the welds.

Note: Do not use an air arc, as this can infuse carbon into the steel of the main frame, and cause
embrittlement.

7.8.3 Main Frame Seat Liner and Fulcrum Installation

The main frame, bowl, head, and adjustment ring are critical components in the function of the crusher.
These specific parts are cast using high alloy steel that has special welding requirements. Before doing
any welding on these specific parts, a certified welder must submit a weld procedure specification (WPS)
to FLSmidth engineering for review. The failure to provide a WPS for review voids the crusher warranty.

1. Weld each segment of the seat liner to the frame individually. Do not butt-weld the vertical joints. Refer to Figure 7-
14.
a. Use a 4 mm (0.16 in) welding rod such as AMPCO-ROD #10, AWS #E CU AL-A2, or #R CU AL-A2. These rods
require an amp setting between 130 A and 190 A, and reverse polarity.

b. Preheat the welding surfaces 39° to 56°C (70° to 100°F) above ambient temperature to remove all moisture and
ensure a proper weld penetration.

Image may not reflect exact equipment.

1 Fulcrum bar 2 Bronze main frame seat liner 3 Gap between fulcrum bar segment
4 Gap between main frame seat liner segments
Figure 7-14: Main Frame Seat Liner and Fulcrum Bar Installation

2. Weld each segment of the fulcrum bar to the main frame individually.

a. Use a 7018 weld rod to mount the fulcrum bar to the main frame.

b. Preheat the welding surfaces 39° to 56°C (70° to 100°F) above ambient temperature to remove all moisture and
ensure a proper weld penetration. Refer to Figure 7-14.

3. Inspect the clearance between the fulcrum bar and the underside of the adjustment ring, and make any needed
adjustments. Refer to 7.8.1 “Determining the Main Frame Seat Liner Wear” on page 112.

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Chapter 7 Maintenance 115

4. Once the gap is correct, reinstall the adjustment ring. Refer to 7.7.3 “Adjustment Ring Assembly Installation” on
page 111.

7.9 Main Frame Liner Replacement

7.9.1 Determining Main Frame Liner Wear
Inspect the main frame liners during every mantle and bowl liner change. After removing the head assembly, the main
frame liners are easily accessible for inspection and replacement if required.

Do not weld additional plate onto the liners. Adding material changes the ore trajectories within the
crusher and ultimately at the discharge.

1. Cover the socket assembly, eccentric assembly, and gear well area with a clean tarp or another plastic material to
keep the crusher components clean while working on the main frame liners.

2. Place a straight edge over the liner section vertical face.

3. Measure the distance from the straight edge to the exposed surface of the main frame liner.

a. The liner must be replaced when the measurement is 50% or less of the new liner measurement.

Note: New liners are made of 12.7 mm (0.5 in) thick abrasion resistant plate.

4. Inspect each liner section.

7.9.2 Main Frame Liners Removal

1. Weld D-rings or lifting eyes to a segment of the worn main frame liner, and attach rigging.
Note: The main frame liners are made of abrasion resistant steel. Use the appropriate welding procedures.

2. Support the main frame liner with a suitable lifting device.

3. Cut the worn liner’s vertical splice welds with a suitable cutting tool.

Avoid cutting into the main frame.

4. Remove the main frame clamps.

5. Lift and remove the worn liner.

Do not allow anybody to stand under the suspended load. Serious injuries can occur if the liner falls on a
person.

7.9.3 Main Frame Liners Installation

1. Transfer the locations and size of the port holes from a used liner to the new liners. Cut the holes as marked.

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116 Chapter 7 Maintenance

2. Place each segment of the new frame liner into the main frame relative to the arm guards to allow for welding.

3. Lift the liner into position, and hang it on the liner blocks that are welded to the main frame. Note the contour at the
bottom of the liner, and verify that it will fit properly with the main frame arms after the arm guards are installed.

4. Trim the sides and bottom of the liner if necessary to establish a clearance fit.

5. Weld the new frame liners to the vertical splice bar using 6 mm staggered welds on both sides, 75 mm long, spaced
on 125 mm centers.

6. Replace the upper shield.

Image may not reflect exact equipment.

1 Main frame 2 Main frame liner

Figure 7-15: Main Frame Liner

7.10 Drive Ring Replacement

The drive ring must be removed to perform some other types of maintenance, particularly when performing
maintenance on the adjustment ring.

7.10.1 Drive Ring Removal

1. Unbolt and remove the pinion shield from the drive pinion.

2. Unbolt and remove the drive ring retainers from the drive ring support brackets that are mounted on the adjustment
ring.

3. Attach two M36 ring bolts (supplied in the special tools package) to the lifting holes in the drive ring, and remove it.

7.10.2 Drive Ring Installation

1. Mount the turning brackets on the drive ring if they are not already installed.

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Chapter 7 Maintenance 117

2. Mount the drive ring support pads.

3. Set the drive ring with the attached turning brackets on the drive ring support pads. Verify that the teeth in the drive
ring engage with the teeth in the pinion. Refer to Figure 7-17 "Positioning Bowl Adjust Pinion" on page 117.

Image may not reflect exact equipment.

1 Drive ring support 2 Drive ring retainer 3 Turning bracket 4 Adjustment ring
5 Drive ring 6 Drive ring support pads
Figure 7-16: Drive Ring Support

4. Mount the drive ring retainers.

5. Carefully turn both the pinion and drive ring until the teeth of the pinion are positioned relative to the teeth in the
drive ring.

6. Turn the jacking bolts on the mounting adapter to obtain the correct root clearance. Refer to drawing “RXL1316-
5000: Adjustment Mechanism Assembly” on page 321

Image may not reflect exact equipment.

1 Drive ring 2 Drive pinion 3 Clearance

Figure 7-17: Positioning Bowl Adjust Pinion

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118 Chapter 7 Maintenance

7. Tighten the locking nuts and the bolts that secure the mounting adapter to the mounting weldment. Refer to
Figure 7-18 "Jacking Bolts" on page 118.

8. Rotate the drive ring 360 degrees in both directions to verify that the pinion and drive ring teeth do not bind or slip.

a. If binding or slippage occurs while turning the bowl assembly, adjust the pinion to the drive ring root clearance.

9. Adjust the bolts in the turning brackets and the pinion to the drive ring root clearance using the jacking screws.

Image may not reflect exact equipment.

1 Jacking bolts 2 Locking nut

Figure 7-18: Jacking Bolts

10. Install the bowl. Refer to 7.23.3 “Bowl Assembly Installation” on page 147.

11. With the Location control permission selected as MCS and the Hydraulic navigation group active:

a. Set HYDRAULIC SYSTEM to RUNNING.

b. Set HYDRAULIC MODE to MANUAL.

Crush hazard. Exposed gears or moving parts can cause severe injury. Keep all loose items and hands
clear.

c. Select and hold OPEN. Verify tooth engagement.

d. Select and hold CLOSE. Verify tooth engagement.

e. Adjust the bolts in the turning brackets and the pinion to the drive ring root clearance using the jacking screws.

f. Re-install the cover shield to protect the pinion and drive ring teeth.

12. Rotate the drive ring 360 degrees in both directions to verify that the pinion and drive ring teeth do not bind or slip.

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Chapter 7 Maintenance 119

7.11 Arm Guard Replacement

Inspect the arm guards and their liners for wear during every mantle and bowl liner change. After removing the head
assembly, the arm guards are easily accessible for inspection and replacement if required.

7.11.1 Arm Guard Removal

1. Remove the bowl assembly. Refer to 7.23.1 “Bowl Assembly Removal” on page 146.

2. Remove the head assembly. Refer to 7.19.2 “Head Removal” on page 131.

3. Remove the socket assembly. Refer to 7.5.1 “Socket Removal” on page 104.

4. Remove the eccentric assembly. Refer to 7.4.2 “Eccentric Assembly Removal” on page 102.

5. Attach three M20 lifting eye nuts (supplied in the special tools package) to the arm guard.

Do not weld lifting eyes to the arm guards. They are made of a high chrome, white iron casting; the
guards can crack and cause injury if they are welded.

6. Remove the guards with the lifting eye nuts.

Image may not reflect exact equipment.

1 Liner welded to main frame 2 Main frame liner 3 Arm guard 4 Main frame
Figure 7-19: Main Frame Arm Guard

7.11.2 Arm Guard Installation

1. Attach three M20 lifting eye nuts (supplied in the special tools package) to the arm guard.

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120 Chapter 7 Maintenance

Do not weld lifting eyes to the arm guards. They are made of a high chrome, white iron casting; the
guards can crack and cause injury if they are welded.

2. Lift the arm guards into place using lifting straps or a lifting device.

3. Install the arm guards.

4. Install the eccentric assembly. Refer to 7.4.3 “Eccentric Assembly Installation” on page 103.

5. Install the socket assembly. Refer to 7.5.2 “Socket Installation” on page 104.

6. Install the head assembly. Refer to 7.19.4 “Head Installation” on page 133.

7. Install the bowl assembly. Refer to 7.23.3 “Bowl Assembly Installation” on page 147.

7.12 V-Belt Maintenance

Inspect the V-belts weekly for tension and wear. Re-tension or replace the belts as needed.

Belt wear and sheave wear can cause the belt ribs to ride deeply in the groove and either touch the bottom of the
sheave groove or the top of the belt band (webbing) of banded belts. The belts’ ability to transmit power is reduced the
more deeply the ribs ride in the groove. When this occurs, replace the worn belts and sheaves.

Replace banded V-belts as a complete drive set to ensure equal stretch between the banded ribs. Do not replace only
the banded ribs or single belts.

7.12.1 V-Belt Removal

1. Turn off the drive motor, and lock it out according to site policy.

2. Remove the belt guard.

3. Remove the belt tension by rotating the hex head on top of the rod until the belt can be safely removed.

7.12.2 V-Belt Installation

1. Route the belts according to the supplied tensioner. Refer to Figure 7-20 and Figure 7-21.

1
2

Image may not reflect exact equipment.

1 Crusher sheave 2 Idler pulley

Figure 7-20: Top Idler U-Right V-Belt Tensioner Configuration

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Chapter 7 Maintenance 121

Image may not reflect exact equipment.

1 Idler pulley 2 Crusher sheave

Figure 7-21: Bottom Idler U-Left V-Belt Tensioner Configuration

2. Align the V-belt. Refer to 7.13.3 “Sheave and Belt Alignment” on page 123.

3. Tension the V-belt. Refer to 7.12.3 “V-Belt Tensioning” on page 121.

4. Inspect the belt tension after eight hours of operation. Re-tension the belts as needed.

5. Inspect the belt tension after 24 hours of operation. Re-tension the belts as needed.

7.12.3 V-Belt Tensioning

Belts adjusted too tightly cause high countershaft box and drive motor bearing temperatures, with the possibility of
bearing failure. Belts adjusted too loosely cause belt slip, possibly stalling the crusher.

If the FLSmidth self-tensioning belt tensioner is not being used, use slide rails or a similar means of belt tightening.

If tensioning is performed with the slide rails, do not use the maximum force recommended by the belt manufacturers,
as this force may exceed the capabilities of the bronze sleeve bearings in the countershaft box assembly. Banded belts
use the elongation method or sonic tensioner for accurate measurements. Instead use the middle length or middle force
(average of the maximum and minimum) specified by the belt manufacturer to tension the V-belts.

Note: It is better to be forced to adjust the belts more frequently than for the countershaft box bushing to
overheat.

Belt slip during start-up is normal; do not increase the tension of the belts during start-up. Only increase
the tension if the belts slip during operation.

1. Turn off the drive motor, and lock it out according to site policy.

2. Adjust the top of the tension spring (indicated by the orange band on the gauge) to the starting point, marked with
an ‘A’ on the gauge, by rotating the hex head on top of the rod.

3. Adjust the spring on the opposite side of the V-belt, and tighten lock nuts at the bottom of the rods.

4. Monitor the springs during operation. Any time the top of the spring moves outside the gauge’s green working band,
re-tension both springs.

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122 Chapter 7 Maintenance

7.13 Shaft Sheave Assembly Replacement

7.13.1 Shaft Sheave Assembly Removal
1. Remove the belt guard.

2. Wrap a lifting sling around the sheave, and apply just enough tension to take the slack out of the sling. This will
prevent the sheave from sliding off the shaft when it breaks loose from the tapered fit on the sheave bushing.

3. Remove the capscrews from the sheave hub.

4. Lubricate the threads on two of the capscrews, and insert them into the tapped holes in the sheave hub.

5. In a crisscross pattern, tighten the capscrews against the sheave bushing flange until the sheave breaks loose.

a. If there is difficulty in breaking the sheaves loose, hit the end of the shaft with a babbitt hammer while applying
pressure to the sheave bushing flange.

b. If force does not work, heat the outside of the sheave in the area of the belts. Once the heat expands the sheave,
hit the end of the shaft with a babbit hammer until the sheave breaks free.
Note: Use an oxygen propane torch, not an oxygen acetylene torch. Distribute the heat evenly.

6. Loosen the sheave bushing clamp screw.

7. Slide the bushing off of the shaft.

Note: Use a wedge or screwdriver in the split of the bushing to remove it from the shaft if required.

7.13.2 Shaft Sheave Assembly Installation

1. Inspect the sheave bushing tapered surface and bore, and the sheave tapered bore. Remove any dirt, paint, rust,
lubricants, and scratches from the surfaces.

Note: The bushing and sheave bore surfaces must be clean to ensure that the sheave will be secure to the
shaft following installation.
Note: Do not lubricate the bushing or the sheave bore.

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Chapter 7 Maintenance 123

2
4
1
3

Image may not reflect exact equipment.

1 Sheave faces 2 Shave bushing 3 Sheave 4 Capscrews

Figure 7-22: Shaft Standard Mounting

2. Loosen the sheave bushing clamp screw, and slide the bushing onto the shaft flange side first.

a. For crusher sheave assembly installation, slide the bushing onto the countershaft until it is tight against the oil
flinger.

Note: Use a wedge or screwdriver in the split of the bushing to install it on the shaft if required.

3. Tighten the clamp screw to lock the bushing into place on the shaft.

4. Align the two sheave faces. Refer to Figure 7-22 “Shaft Standard Mounting” and 7.13.3 “Sheave and Belt Alignment”
on page 123.

5. Lift and slide the sheave onto the sheave bushing, and align the holes in the sheave with the tapped holes in the
bushing flange.

6. Install the capscrews in the sheave, and screw them into the tapped holes in the sheave bushing flange.

7. Tighten the bolts in small increments using a crisscross pattern until they are torqued to 610 Nm (450 ft-lb).

Over-tightening the bolts may cause the sheave to crack.

7.13.3 Sheave and Belt Alignment

The maintenance log is required for this procedure. Refer to D.5 “Sheave and Belt Alignment Logs” on
page 198.

1. Tie a string to the shaft.

a. Ensure the string remains straight, without any bends or breaks.

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124 Chapter 7 Maintenance

2. Using the string, measure the angular misalignment (alpha). The misalignment must be no greater than 0.5 degrees.
Refer to Figure 7-20, Figure 7-21, and Figure 7-23.

 Y 2 – Y 1
 = tan– 1  -------------------
 X1 

Image may not reflect exact equipment.

Figure 7-23: V-Belt Angular Misalignment (Alpha)

3. Using the string, measure the parallel misalignment (beta). The misalignment must be no greater than 0.5 degrees.
Refer to Figure 7-24.

Y
 = tan– 1  ---
 L

Image may not reflect exact equipment.

Figure 7-24: V-Belt Parallel Misalignment (Beta)

4. Determine the total angular misalignment (alpha + beta). The total angular misalignment must be less than 0.5
degrees.

5. Record the angular misalignment measurements and sum in the maintenance log. Refer to D.5 “Sheave and Belt
Alignment Logs” on page 198.

7.14 Air Seal Blower Maintenance

1. Inspect and replace the filter as needed.

2. Reset the air seal blower damper as needed.

• If the T- or U-seal has oil in it, decrease the air flow by closing the damper.
• If the T- or U-seal has dust in it, increase the air flow by opening the damper.

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Chapter 7 Maintenance 125

7.15 Counterweight Guard Replacement

Inspect the crusher discharge area daily, ensuring that no material buildup or bridging has occurred on the main frame
arms or foundation discharge. Buildup and bridging can wear the bottom of the counterweight.

A bolt-on replaceable counterweight guard protects the counterweight from discharge material wear. If the guard is not
regularly inspected and replaced, the counterweight will wear, requiring costly repairs. Unwanted counterweight wear
can also create an out of balance condition, causing foundation problems.

When replacing the counterweight guard, inspect the condition of the T-seals and U-seals, and replace them as needed.
Refer to 7.17 “T-Seal and U-Seal Replacement” on page 127.

7.15.1 Counterweight Guard Removal

1. Remove the counterweight. Refer to 7.16.1 “Counterweight Removal” on page 125.

2. Remove the fasteners. The fasteners were installed with Loctite, so heat may be required for removal.

3. Lift the guard clear of the counterweight.

7.15.2 Counterweight Guard Installation

1. Clean the old Loctite from the hex head capscrews.

2. Remove any remaining Silastic sealing material from the bottom outer edge of the counterweight.

3. Install the guard on the counterweight, and align the holes in the top of the guard with the threaded holes in the
counterweight.

4. Apply Loctite 271 to the guard bolt holes, and then bolt the guard into place. The Loctite will seal the bolts.

5. Using Silastic material, seal the seam between the bottom inner diameter of the guard and the bottom outer
diameter of the counterweight, except in the area of the two drain holes spaced 180 degrees apart.

6. Install the counterweight. Refer to 7.16.2 “Counterweight Installation” on page 126.

7.16 Counterweight Replacement

7.16.1 Counterweight Removal
1. Remove the eccentric assembly, and then place it on wood blocking. Refer to 7.4.2 “Eccentric Assembly Removal”
on page 102.

2. Verify the blocking is under the eccentric assembly’s gear, not under the counterweight. Refer to Figure 7-25.

3. Remove the counterweight guard. Refer to 7.15.1 “Counterweight Guard Removal” on page 125.

4. Install four M36 ring bolts (supplied in the special tools package) in the tapped lifting points in the counterweight
flange (where the capscrews were previously removed).

5. Attach suitable rigging to the counterweight and lift it off the eccentric.

a. If the counterweight does not lift out of the eccentric, insert jacking screws into he counterweight flange tapped
holes to remove it.

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126 Chapter 7 Maintenance

Image may not reflect exact equipment.

1 Capscrew connecting cover to counterweight 2 Counterweight 3 Eccentric

4 Eccentric bushing 5 Eccentric to gear capscrew 6 Upper thrust bearing
7 Gear 8 Alignment dowel 9 Eccentric lifting rings
Figure 7-25: Lifting Counterweight and Eccentric

7.16.2 Counterweight Installation

1. If a new gear was installed, inspect and adjust the backlash. Refer to 7.6 “Creating a Contact Pattern” on page 106.

2. Install four M36 ring bolts (supplied in the special tools package) in the counterweight hole locations.

3. Lift the counterweight, and lower it onto the eccentric flange. Line up the dowel in the eccentric with the matching
hole in the counterweight.

4. Clean the threads on the capscrews connecting the gear to the counterweight with an oil-free solvent such as
acetone or alcohol.

5. Apply Loctite 271 to the capscrew threads, and install them with hardened washers in the tapped holes in the gear.

6. Install the hex head capscrews using a crisscross pattern, and torque the capscrews to 2,733 N-m (2,016 ft-lb).

Using an impact gun may break the Loctite, allowing the bolts to loosen and back out.

7. Rotate the countershaft to inspect the pinion teeth for damage or wear before reinstalling the eccentric.

8. Install the eccentric and inspect the gear backlash, following the instructions detailed in 7.4.3 “Eccentric Assembly
Installation” on page 103 and 7.6 “Creating a Contact Pattern” on page 106.

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Chapter 7 Maintenance 127

7.17 T-Seal and U-Seal Replacement

A replaceable one-piece T-shaped seal is located in a groove on the underside of the counterweight. A replaceable
one-piece U-shaped seal is located in a groove around the top of the counterweight. The two seals are designed to
prevent dust from getting into the crusher.

Inspect the seals for damage, wear, and oil and dust buildup any time the counterweight is removed, and replace them
as needed.

7.17.1 T-Seal and U-Seal Removal

1. Remove the counterweight. Refer to 7.16.1 “Counterweight Removal” on page 125.

2. Remove the damaged seal, and scrape out any residue from the groove.

3. Clean the groove completely with an oil-free solvent such as acetone or alcohol, and let it dry.

7.17.2 T-Seal and U-Seal Installation

1. If applicable, remove the mold release agent from the new seal’s bottom and sides using coarse sandpaper.
Remove just enough of the coating to remove the shine that indicates the agent is present.

Note: The adhesive will not adhere to any parts of the seal with the release agent. The seal may fall out of the
groove during operation if the release agent is not completely removed from the seal.

2. Apply a thin coat of activator to the bottom and sides of the seal. Too much activator will create a partial cure that
may not provide a complete bond.

3. Apply a thin coat of adhesive to the groove. Apply just enough that a minimal amount will be pressed from it when
the seal is inserted into the groove.

4. Quickly place the seal into the groove. Apply a steady force to the seal to maintain contact between the bottom of
the groove and the seal. A handling bond will occur in approximately three minutes.

5. Reinstall the counterweight. Refer to 7.16.2 “Counterweight Installation” on page 126.

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128 Chapter 7 Maintenance

Image may not reflect exact equipment.

1 Counterweight 2 Upper U-seal 3 Portion of seal to be cleaned if applicable 4 Lower T-seal

Figure 7-26: T-Seal and U-Seal Replacement

7.18 Socket Liner Maintenance

7.18.1 Determining Socket Liner Wear
The liner must be replaced when the oil grooves wear.

Measure the depth of the oil grooves in the spherical surface of the liner.

• The groove depth must be at least 4.5 mm (0.177 in).

• The liner maximum allowable vertical travel from wear is 2.4 mm (0.096 in).

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Chapter 7 Maintenance 129

Image may not reflect exact equipment.

1 Groove depth 2 Socket liner 3 Oil groove 4 Depth gauge

Figure 7-27: Measuring Socket Liner Oil Groove Depth

7.18.2 Socket Liner Removal

The socket liner is typically removed from the socket due to oil groove wear or to gain access to the eccentric assembly.

1. Install four M16 ring bolts (supplied in the special tools package) in the tapped holes around the outside diameter of
the socket liner. Refer to Figure 7-28 “Socket Liner Lifting.”

Image may not reflect exact equipment.

1 Lifting cables 2 Lifting ring bolt 3 Socket liner

Figure 7-28: Socket Liner Lifting

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130 Chapter 7 Maintenance

2. Lubricate four M20 × 2.5 × 200 mm full threaded bolts (supplied in the special tools package) with an anti-seize
compound, and then install them into the socket liner until they bottom out on the socket.

Image may not reflect exact equipment.

1 Socket liner 2 Full threaded bolts 3 Upper portion of socket

4 Main shaft 5 Socket
Figure 7-29: Socket Liner Removal

3. In a crisscross pattern, tighten each bolt in small increments, working in a circular pattern, to avoid cocking the liner
in the socket during the removal.

Note: The socket liner has a slight interference fit with the socket, and can normally be removed using the
bolts. However, it may be necessary to apply a small amount of heat to the upper portion of the socket flange
to aid in removing the liner. If heat is necessary, use an oxygen propane torch, and distribute the heat evenly
on the socket flange upper portion.

4. Lift the socket liner out of the crusher using the ring bolts around the sides of the liner.

7.18.3 Socket Liner Installation

1. Ensure the socket liner dowel pins are installed in socket liner.

2. Install four M16 ring bolts (supplied in the special tools package) into the tapped holes located around the outside
diameter of the socket liner. Refer to Figure 7-28 “Socket Liner Lifting.”

3. Cool the socket liner or heat the socket until achieving a 30°C (54°F) temperature difference.

4. Lift the socket liner, and lower it over the locating dowels in the socket until it has seated firmly on the socket.

5. Remove the ring bolts from the socket liner.

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Chapter 7 Maintenance 131

7.19 Head Maintenance

7.19.1 Head Storage
If the head is to be stored, it must be stored vertically. Leaving it on its side will cause it to become out of round over
time. This makes re-installation difficult and may lead to scraping inside the crusher.

7.19.2 Head Removal

1. Slowly lift the head assembly straight up and out of the crusher. Refer to 7.2.4 “Lifting the Head Assembly” on
page 101.

2. Place the head on suitable cribbing.

Image may not reflect exact equipment.

1 Head lifting plate 2 Thick side of eccentric

Figure 7-30: Head Assembly

7.19.3 Head Handling

1. If the mantle is connected to the head, remove the mantle. Refer to 7.20.1 “Mantle Removal” on page 134.

2. Verify that the locking nut is securely screwed into the head stub and ball.

3. Bolt the head lifting plate to the locking nut.

4. Lift the head, and place it on suitable cribbing. Refer to 7.2.4 “Lifting the Head Assembly” on page 101 and Figure 7-
31 "Handling the Head" on page 133.

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132 Chapter 7 Maintenance

5. Attach two head turning plates and M64 hoist ring (supplied in the special tools package) to the tapped holes in the
underside of the head using two M36 × 140 and four M30 × 120 hex head capscrews.

6. Connect a second lifting cable to the ring. Refer to Figure 7-31 "Handling the Head" on page 133.

7. To position the head on its side:

Note: Position the head on its side to remove the upper or lower head bushings, and before turning the head
upside down.

a. Lift the head off the blocking while slowly and carefully turning it.

b. Set the head down on the floor.

c. Place blocking on both sides of the head so it will not roll when the lifting equipment is removed.

8. To position the head upside down:

Note: Position the head upside down to install the stub, ball, and head bushing.

a. Position the head on its side.

b. Connect lifting cables to the second hoist ring under the head.

c. Carefully lift and turn the head until it is upside down.

d. Place the head on a steel frame (not supplied with the crusher).

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Chapter 7 Maintenance 133

Image may not reflect exact equipment.

1 Lifting cables attached to hoist ring while on 2 Lifting cables attached to prepare for upper 3 Head on steel frame
cribbing or lower head bushing removal
Figure 7-31: Handling the Head

7.19.4 Head Installation

1. Mount the mantle to the head. Refer to 7.20.2 “Mantle Installation” on page 138.

2. Clean the eccentric, socket liner, head bushing bores, head ball, and oil passages with an industrial de-greaser.

3. Smooth out any scratches or nicks in the upper and lower head bushings with fine emery paper.

4. Using the same lubrication oil as is used in the lubrication system, coat all the bearing surfaces on the eccentric,
socket liner, head bushing bores, and head ball.

5. Lift the head assembly, and center it over the crusher. Refer to 7.2.4 “Lifting the Head Assembly” on page 101.

6. Slowly lower the head assembly down into the crusher.

7. Lift the head assembly approximately 25 mm (1 in), and suspend the head assembly in the crusher.

8. Run the lubrication pump for 10 minutes. This will wash away any contamination and will lubricate the critical bearing
surfaces in the crusher.

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134 Chapter 7 Maintenance

9. Lower the head assembly onto the socket liner.

Image may not reflect exact equipment.

1 Feed plate 2 Locking nut 3 Torch ring

4 Mantle 5 Head 6 Head stub
Figure 7-32: Head Installation

10. Remove the lifting plate and hardware.

11. Mount the feed plate onto the locking nut. Refer to Figure 7-32 “Head Installation.”

12. Secure the feed plate mounting bolts.

13. Fill the counterbore with RTV silicone.

Note: This operation will prevent dust and water from packing around the bolt making removal of the bolt
easier at the next removal.

7.20 Mantle Replacement

7.20.1 Mantle Removal
1. Remove the head assembly from the crusher. Refer to 7.19.2 “Head Removal” on page 131.

2. Grind off all welds between the mantle, torch ring, and feed plate.

Note: Crushing forces create a self-tightening action that keeps the locking nut tight against the torch ring
and mantle. To relieve this stress, it is necessary to cut the torch ring.

3. Cut through the torch ring. Refer to Figure 7-33.

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Chapter 7 Maintenance 135

Use caution to avoid damaging the locking nut and the head.

Image may not reflect exact equipment.

1 Torch ring 2 Cutting torch direction

Figure 7-33: Cutting the Torch Ring

4. Unscrew the locking nut by hand, and remove it from the head.

Note: After cutting through the torch ring, the locking nut no longer has the preload pressure on it, so it is
easily removed.

Image may not reflect exact equipment.

1 Feed plate 2 Fill with Silastic 3 Mantle

4 Torch ring 5 Locking nut
Figure 7-34: Mantle Replacement

5. If damage exists to the locking nut or head stub threads, or for another reason the bolt cannot be turned by hand:

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136 Chapter 7 Maintenance

a. Mount the locking nut wrench (supplied in the special tools package) on the locking nut with the wrench pins
engaging the holes in the locking nut.

b. Use four M30 × 150 hex head capscrews (supplied in the special tools package) to hold the wrench in place on
the locking nut.

c. With the wrench firmly attached, strike the side of the wrench with a sledge hammer or a suspended weight so
the locking nut turns counterclockwise. Continue until the locking nut can be removed by hand.

Accidental release of the hammer during use may cause the hammer to become a projectile. Take
appropriate measures to protect all personnel and prevent damage to the equipment.
Wear all PPE required by site policy.

Avoid awkward positions when using the wrench to prevent strains.

d. Unscrew the locking nut by hand, and remove it from the head.

1
2

4
5

Image may not reflect exact equipment.

1 Locking nut 2 Locking nut wrench 3 Torch ring

4 Mantle 5 Head
Figure 7-35: Locking Nut Wrench

6. Design two steel lifting lugs for the mantle.

• Width: 102 mm (4 in)

• Width from midpoint of lifting eye: 51 mm (2 in)
• Edge of eye to edge of lug: 51 mm (2 in)
• Radius curvature of lug edge: 51 mm (2 in)
• Length from midpoint of lifting eye: 51 mm (2 in)

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Chapter 7 Maintenance 137

Image may not reflect exact equipment.

1 Width 2 Width from midpoint of lifting eye 3 Edge of eye to edge of lug
4 Radius curvature of lug edge 5 Length from midpoint of lifting eye
Figure 7-36: Lifting Lug Design

7. Weld the two lifting lugs to the mantle so they are equally spaced.

Ensure the lifting lugs are strong enough to support the weight. Use the proper weld rod to weld the steel
lugs to the manganese mantle. FLSmidth recommends stainless steel welding rod when welding
manganese to the lugs.

The main frame, bowl, head, and adjustment ring are critical components in the function of the crusher.
These specific parts are cast using high alloy steel that has special welding requirements. Before doing
any welding on these specific parts, a certified welder must submit a weld procedure specification (WPS)
to FLSmidth engineering for review. The failure to provide a WPS for review voids the crusher warranty.

8. Lift the mantle off the head using the two equally spaced, welded lifting lugs on the mantle.

Image may not reflect exact equipment.

1 Lifting cables 2 Mantle 3 Lifting lugs welded to mantle

Figure 7-37: Lifting the Mantle

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138 Chapter 7 Maintenance

9. Chip off all backing material left on the head after removing the mantle.

7.20.2 Mantle Installation

If the mantle comes loose due to poor installation, it can cause serious damage to the head. The seating surface will
require repair, and the head may crack under the loose mantle’s repetitive impacts.

1. Clean and inspect the mantle seating surface on the head for excessive wear, ridges, and other upsets that may
affect the ability of the new mantle to properly seat.

Note: Damage to the seating surface is typically caused by operating with a worn or loose mantle.

2. Grind any ridges to provide a smooth surface.

a. If the seating surface of the head has worn to the point that it is flush with the wear indication groove, refurbish
the head. Contact FLSmidth for instructions.

3. Clean the locking nut threads and the mating threads on the head stub and ball.

a. Inspect both sets of threads for nicks, burrs, and other damage. Recondition the threads as necessary to remove
any noted problems.

4. Inspect the locking nut where the torch ring seats, and remove any upsets to achieve proper contact.

5. Coat the locking nut and mating threads with a moly based anti-seize grease.

6. Wipe a light coat of grease or oil on the head to prevent the backing material from adhering.

7. Lower the mantle onto the head with the lifting hooks in the bottom of the mantle.

2
2

3
5

Image may not reflect exact equipment.

1 Locking nut 2 Equal distance all around 3 Mantle

4 Head 5 Torch ring
Figure 7-38: Seating the Mantle

8. Set the torch ring into place on the mantle.

9. Install the locking nut.

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Chapter 7 Maintenance 139

a. Insert the locking nut, and twist it down until it is close to the torch ring.

b. Verify that the distance between the torch ring and the locking nut is relatively uniform around the entire
circumference.

Note: This ensures that the mantle is centered on the head, and that it will seat properly on the head when
the locking nut is tightened.

c. If the distance is not uniform, either bump the top of the mantle to reposition it on the head or lift the bottom of
the mantle on the low side.

Note: Keep in mind that the mantle must also seat properly on the head seating surface.

d. After the locking nut is even, finish tightening it until it is snug.

A loose or improperly seated mantle will damage the head seating surface.

e. Mount the locking nut wrench to the locking nut. Ensure the wrench pins engage the holes in the locking nut.

f. Set up a suspended weight that is a minimum of 100 kg.

Improper setup of the suspended weight can result in serious injury or equipment damage. Do not allow
the suspended weight to strike a person or unintended object.

g. With the wrench firmly attached, strike the side of the wrench with the suspended weight so the locking nut turns
clockwise. Continue until each strike only achieves a 1 mm (0.04 in) turn of the bolt. Determine the strike
advancement by making a mark between the locking nut and the torch ring.

h. Inspect the contact between the mantle and the head at the bottom of the mating seating surface with a 0.25
mm (0.01 in) feeler gauge. The feeler gauge must not attain full depth for more than 20% of the seating surface.
Refer to Figure 7-39: “Installing the Mantle” on page 140.

i. Apply caulk or sealant at the bottom of the seating surface to keep backing material from flowing out when it is
later poured into the void between the mantle and the head.

j. Verify that the mantle is centered on the head.

10. Fill the space between the head and the mantle with high performance epoxy. Figure 7-39 “Installing the Mantle.”

a. Heat or cool the head and mantle to between 16° and 33°C (60° and 90°F). If needed due to a cold ambient
temperature, heat each component individually prior to pouring the epoxy.

Note: If the metal is too cool, the exothermic reaction may stop and the backing material will not set properly.
If the metal is too hot, the backing material may set prior to flowing to the bottom of the void between the
mantle and head.

b. Create a pouring trough from any flexible sheet material such as cardboard to pour the epoxy into the pouring
holes in the mantle.

c. Using the trough, pour high performance epoxy into the pouring holes to fill the space between the head and the
mantle to the top of the pouring holes.

Note: The cure time for the epoxy backing material is normally approximately 8 hours. However, it can be up
to 24 hours if the ambient temperature is 16°C (60° F) or lower.

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140 Chapter 7 Maintenance

Store the epoxy backing material kit at 16° to 33°C (60° to 90° F).
Follow the epoxy backing manufacturer’s mixing, pouring, and safety instructions.

2
5

3
6

Image may not reflect exact equipment.

1 Epoxy backing material 2 Pouring trough 3 Mantle

4 Feeler gauge 5 Head 6 Clearance
Figure 7-39: Installing the Mantle

11. Weld the locking nut to the torch ring, and the torch ring to the mantle. This ensures that the assembly self-tightens
as the locking nut follows the torch ring and mantle when the mantle attempts to rotate under the crushing forces.

Note: FLSmidth recommends qualified personnel use a properly selected stainless steel rod with appropriate
preheat when welding the torch ring to the manganese mantle. It is acceptable to use either four equally
spaced groove welds that are each 10 × 127 mm (0.39 × 5.00 in), or a continuous weld.

Note: Inspect temperature of components before welding. Preheat may not be required if temperature has
already been achieved.

12. Install the head assembly in the crusher. Refer to 7.19.4 “Head Installation” on page 133.

7.21 Lower Head Bushing Replacement

The lower head bushing has an interference fit in the head.

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Chapter 7 Maintenance 141

7.21.1 Lower Head Bushing Removal

1. Turn the head on its side. Refer to 7.19.3 “Head Handling” on page 131.

2. Remove the capscrews and lock washers that secure the retaining ring to the head and bushing.

Note: The capscrews were installed with Loctite, so heat is likely needed to remove them.

3. Remove the retaining ring.

4. Make two cuts on the bushing flange that are 12 to 20 mm (0.5 to 0.75 in) apart, using a heavy-duty circular saw that
is equipped with a metal cutting blade.

a. Set the saw blade depth to slightly less than 19.5 mm (0.768 in) (the thickness of the bushing) so the saw blade
does not contact the head. The lower head bushing is made from leaded bronze.

b. Make a sample cut, ensuring the saw blade depth allows the blade to just clear the head bore when sawing the
bushing. Make a blade depth adjustment if needed.

Note: If sparks appear, the saw blade is set too deeply.

Wear a dust respirator whenever cutting or grinding leaded bronze bushings.

Image may not reflect exact equipment.

1 Circular saw 2 Area between saw cuts 3 Lower head bushing 4 Blade depth
Figure 7-40: Sawing Head Bushing Wall

5. Place a chisel against the bushing saw cut, and hit it with a hammer.

Note: This will remove the cut portion of the bushing out from the bore, allowing the bushing to collapse.

6. Lift the bushing out of the head bore.

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142 Chapter 7 Maintenance

7.21.2 Lower Head Bore Inspection

1. With the lower head bushing removed, inspect the bore for any rough areas or scoring. Smooth out any roughed or
scored areas with an emery cloth.

2. Measure the bore at the top, center, and bottom, 90 degrees apart at each location.

3. Verify the following:

• Dimensions: 840/840.1
• Maximum allowed difference between measurements: 0.05

Note: This will determine whether the lower head bore has become undersized due to wear or shrinkage
caused by overheating.

7.21.3 Lower Head Bushing Installation

Do not try to install a bushing in a bore that is undersized or pulled in.

1. Clean the outside diameter of the bushing and head bore using a wire brush.

2. Cool the bushing to 24°C (43°F) cooler than the head bore.

3. Measure the head bore and the bushing outside diameters to verify that the bushing has shrunk enough to be
inserted in the head bore.

4. Install two M20 ring bolts (supplied in the special tools package) in the bushing flange.

5. With the bushing positioned above the head bore, use threaded aligning bolts (not supplied with the crusher) to
align the countersunk holes in the bushing flange with the mating tapped holes in the head.

6. Quickly lower the head bushing into the head until the bushing flange bottoms on the head. Refer to Figure 7-41.

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Chapter 7 Maintenance 143

Image may not reflect exact equipment.

1 Lower head bushing 2 Head 3 Steel ring 4 Steel frame

Figure 7-41: Head Bushing Installation

7. Once the bushing returns to ambient temperature, install the eight capscrews and lock washers in the head. Torque
the capscrews to 233 Nm (171.9 ft-lb).

8. Turn the head right side up. Refer to 7.19.3 “Head Handling” on page 131.

7.22 Upper Head Bushing Replacement

The upper head bushing is secured in the head with an interference fit and bolted keys.

Note: The upper head bushing can be replaced without removing the lower head bushing. Protect the lower
head bushing surface when replacing the upper head bushing.

7.22.1 Upper Head Bushing Removal

1. Turn the head on its side. Refer to 7.19.3 “Head Handling” on page 131.

2. Remove the four keys used to hold the upper head bushing by cutting the wires on the bolts that hold the locking
plates, and then loosening and removing the capscrews. Refer to Figure 7-42 “Removing Upper Head Bushing.”

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144 Chapter 7 Maintenance

Image may not reflect exact equipment.

1 Key 2 Hex bolts 3 Safety wire

Figure 7-42: Removing Upper Head Bushing

3. Position two small portable power jacks between the head ball and the underside of the upper head bushing. Use a
small piece of rubber to protect the head ball surface.

4. Move the jacks evenly around the bushing until they remove the upper head bushing.

Note: It may be possible to remove the upper head bushing by hand if it has been damaged as a result of a
high heat event due to a lack of proper lubrication.

5. If portable power jacks are not available, perform the following steps to remove the bushing:

a. Fabricate a steel bushing removal plate (not supplied with the crusher). Refer to Figure 7-43.

• The plate must be 25 mm (1 in thick)

• The plate width must be narrower than the inside of the bushing
• The plate height must be taller than the inside of the bushing
• Weld a 25 mm (1 in) hex nut to the center of the plate

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Chapter 7 Maintenance 145

Image may not reflect exact equipment.

1 Center of bushing 2 Countershaft bushing 3 Steel bushing removal plate 4 Width

5 Height 6 Plate thickness 7 Hex nut
Figure 7-43: Bushing Plate Removal

b. Slide the narrow part of the steel bushing removal plate into the bushing until it is positioned behind the bushing.

c. Turn the plate 90 degrees until it contacts the bushing.

d. Hold the plate in place and thread a 25 mm (1 in) diameter rod that is threaded on both ends into the nut on the
removal plate.

Note: The rod must be a few inches longer than the bushing.

e. Drill a 30 mm (1.12 in) hole in the center of a 25 × 75 × 305 mm (1 × 3 × 12 in) steel bar.

f. Place the bar onto the threaded rod and hold it in place with a 25 mm (1 in) hex nut.

g. Slide a timber or a piece of pipe into the opposite end of the box, and ram it against the removal plate to force
the bushing out of the box bore.

7.22.2 Upper Head Bore Inspection

1. With the upper head bushing removed, inspect the bore for any rough areas or scoring. Smooth out the rough or
scored areas with an emery cloth.

2. Measure the bore at the top and bottom, 60 degrees apart at each location.

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146 Chapter 7 Maintenance

3. Contact FLSmidth to verify that the measurements are within factory specifications. If they are not, FLSmidth will
provide further instructions.

Note: This will determine whether the upper head bore has become undersized due to wear or shrinkage
caused by overheating.

7.22.3 Upper Head Bushing Installation

Do not attempt to install a bushing in a bore that is undersized or pulled in.

1. Clean the outside diameter of the bushing and head bore with a wire brush.

2. Cool the bushing until it is 23°C (41°F) cooler than the head bore.

3. Measure the head bore and the bushing outside diameter to verify that the bushing has shrunk enough to be
inserted in the head bore.

4. Install four M10 ring bolts (supplied in the special tools package) in the upper head bushing. Verify that the ring bolt
eyes are not perpendicular to the upper head bushing; perpendicular ring bolts will not allow the bushing to be
lowered into the head assembly.

a. Use washers as needed to correctly orient the ring bolts.

5. Lift the upper head bushing, and position it above the head bore.

6. Align the slots in the bushing with the four sets of bushing key mounting holes in the head before the bushing warms
up.

7. Quickly lower the upper head bushing into the head until it seats firmly.

8. Mount the four keys into place.

9. Tighten the hex head capscrews and wire them into place. Refer to Figure 7-42 “Removing Upper Head Bushing.”

10. Turn the head right side up. Refer to 7.19.3 “Head Handling” on page 131.

7.23 Bowl Assembly Replacement

When the clamping cylinders are pressurized, they slightly raise the clamping ring and lock the bowl assembly into
place. The extreme crushing forces inevitably wear the threads. As thread wear approaches the maximum travel of the
clamp cylinders, the bowl becomes increasingly difficult to hold in position during crushing until it becomes impossible
to maintain the desired closed side setting.

Bowl replacement requires two operators. One person must visually verify the location of the bowl threads when
installing and removing the bowl to avoid damaging the thread ends.

7.23.1 Bowl Assembly Removal

During bowl assembly removal, using an overhead crane to support a minimum of 50% of the weight of the bowl will
extend the thread life. Refer to Table 5-1, “Crusher and Sub-Assembly Weights,” on page 54 for the bowl weight.

1. If possible, lift a portion of the bowl weight.

a. Connect four lifting cables or chains of equal length to the lifting lugs on the top of the bowl assembly adjustment
cap.

b. Center the crane over the bowl assembly, and lift a a slight strain with the overhead crane to take a minimum of
50% of the bowl assembly weight off of the adjustment ring, clamp ring, and bowl threads.

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Chapter 7 Maintenance 147

2. With the Location control permission selected as MCS and the Hydraulic navigation group active:

Note: You must be logged in as a UAC Engineer.

a. Manually open the clamp dump valve. Visually verify the pressure is zero at the respective pressure transmitter.

b. Select and hold the OPEN button. Hold the button until the end of the bottom bowl thread just passes the start of
the top clamping ring thread.

Note: This will cause a slight tilt.

c. Release the OPEN button.

If the bowl is turned a full turn past the start of top clamping ring thread, the bowl will drop the 51 mm (2
in) of one full thread. Such a drop may cause thread damage.

3. Referring to 7.2.3 “Lifting the Bowl Assembly” on page 100, lift the bowl assembly out of the crusher, and place it on
hard-wood blocking. Ensure the weight is being supported by the bowl liner.

4
Image may not reflect exact equipment.

1 Lifting cable 2 Feed hopper 3 Adjustment cap 4 Bowl

Figure 7-44: Lifting the Bowl

7.23.2 Determining Bowl Thread Wear

Inspect the bowl thread and lubricate it whenever the bowl assembly is removed from the crusher. Refer to 7.3 “Thread
Wear Inspection” on page 101 and A.2.3 “Thread Lubrication Requirements” on page 175.

7.23.3 Bowl Assembly Installation

1. Inspect the dust shell seal condition, and replace the seal as needed.

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148 Chapter 7 Maintenance

2. Thoroughly clean the bowl, adjustment ring, and clamping ring threads.

Note: Spare and replacement assemblies have a protective coating material, such as Cosmoline, applied to
the threads, which must be removed. Use methyl etyth ketone (MEK) to clean the threads.

3. Using a paintbrush, apply a liberal coat of the supplied 3% molybdenum disulfide (moly) based anti-seize compound
to the bowl, adjustment ring, and clamping ring threads. This provides initial protection to the bowl threads until they
harden during crushing.

4. Lift the bowl assembly with the hopper installed, and slowly set it in the crusher on the clamping ring threads. Keep
most of the weight supported by the overhead lifting equipment, resting the bowl lightly on the clamp ring threads.
Refer to 7.2.3 “Lifting the Bowl Assembly” on page 100.

5. Ensure that the adjustment cap guide bars engage the turning brackets mounted to the drive ring.

6. Open the clamping circuit pressure dump valve.

Note: This prevents the bowl and adjustment ring threads from being damaged during the thread
engagement.

With the Location control permission selected as MCS and the Hydraulic navigation group active:

Note: You must be logged in as a UAC Engineer.

1. Verify that the clamp pressure has been manually released: PI1 = zero bar.

2. Set HYDRAULIC MODE to MANUAL.

3. Select and hold the CLOSE button until the bowl rotation stops. Release the CLOSE button.

4. Select and hold the OPEN button until the bowl has made two full revolutions. Release the OPEN button.

5. Close the clamp pressure release valve.

6. Set HYDRAULIC MODE to NORMAL.

7. Refer to 6.4.1 “Setting the Crushed Product Size” on page 85 for instructions on calibrating the crusher closed side
setting.

7.24 Bowl Liner Replacement

Monitor the bowl liner wear regularly. If the liner is allowed to become too thin, it can become loose, crack, or flex
excessively; serious damage to the bowl and head seating surfaces may result.

7.24.1 Determining Bowl Liner Wear

The maintenance log is required for this procedure. Refer to D.4 “Bowl Liner Wear Log” on page 197.

FLSmidth offers liner wear analysis. To use this service, cut vertical slots in the worn mantle and bowl liner. Using a piece
of cardboard, outline the profiles of the wear surfaces. Identify the liner part number on the cardboard, and send the
cardboard to the FLSmidth engineering department. The profiles will be converted into CAD, and a profile analysis will
be provided.

1. Perform an initial liner measurement after new liners are installed and the bowl is set to the desired closed side
setting. Record the measurements in the maintenance log. Refer to D.4 “Bowl Liner Wear Log” on page 197.

a. Measure and record the distance from the bottom of the adjustment cap to the bottom of the dust shell.

b. Notate the closed side setting.

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Chapter 7 Maintenance 149

2. Monitor the liner wear throughout the liner life. Record all measurements in the maintenance log. Refer to D.4 “Bowl
Liner Wear Log” on page 197.

a. Retrieve the recorded liner measurement that was made after the bowl liner installation.

b. Measure the distance from the bottom of the adjustment cap to the bottom of the dust shell.

c. Compare the measurement from immediately following installation to the current measurement.

d. Replace the liner when it wears to the minimum height of the adjustment cap with worn liners.

3. Perform an end of liner life measurement before replacing it. Record all measurements in the maintenance log. Refer
to D.4 “Bowl Liner Wear Log” on page 197.

Note: After several liner changes, the difference between new and worn liners will likely be relatively
consistent using the same liner configuration and closed side setting. Establishing an average vertical travel
of the bowl enables the customer to determine when the liners will need to be changed.

Driver ring teeth in one complete bowl revolution 120

Vertical travel of bowl per tooth 0.625 mm (0.025 in)

Change in crusher setting per tooth 0.42 mm (0.017 in)

Table 7-4: Driver Ring Teeth and Bowl Information

1
2

4
Image may not reflect exact equipment.

1 Adjustment cap 2 Bowl 3 Height of adjustment cap with worn liners 4 Adjustment ring
Figure 7-45: Position of Adjustment Cap with Worn Liners

7.24.2 Bowl Liner Removal

1. Support the bowl assembly with the bottom of the bowl liner resting on wooden blocking. This will support the bowl
liner when removing the bowl.

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150 Chapter 7 Maintenance

Without this support, the bowl liner may expel a wedge or wedge bolt with enough force to cause
injuries.

2. Remove the old grease and dirt from the bowl threads. If the grease is clean and reusable, protect it with plastic.

3. Inspect the threads for galling and repair them as needed. Refer to 7.3 “Thread Wear Inspection” on page 101.

4. Attach suitable lifting equipment to the four lifting holes spaced 90 degrees apart at the top of the hopper, and lift it
out of the bowl. This will provide access to the wedges that hold the bowl liner in place.

Image may not reflect exact equipment.

1 Lockplate 2 Bolt stop 3 Square head bolt

4 Spherical nut 5 Wedge 6 Cotter pin
Figure 7-46: Wedge Assembly

5. Remove the cotter pins and lock plates from each of the wedges.

6. Clean the wedge bolt threads with a wire brush and lubricate them.

7. Unscrew the spherical nuts approximately 13 mm (0.5 in). These nuts hold the wedges tightly against the liner.

a. If any of the wedges do not loosen after backing off the spherical nut, place a blunt chisel against the wedge and
strike the chisel with a hammer.

8. With all the wedges loose, unscrew all the spherical nuts far enough to allow for removal of the square head bolts
and wedges.

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Chapter 7 Maintenance 151

Backing material may have broken up during operation. Avoid standing close to the bowl as it is lifted off
the liner.

Follow the wedge removal steps as outlined above. Removing them in other ways may cause the wedges
to propel outward when they break loose, potentially leading to injury.

Image may not reflect exact equipment.

1 Bolt stop 2 Loosened nut 3 Cotter pin

4 Wedge 5 Bowl liner 6 Epoxy backing
7 Spherical nut 8 Square head bolt 9 Bowl
10 Lock plate 11 Wood blocking
Figure 7-47: Bowl, Wedge, and Liner Parts

9. With all of the liner retention hardware removed, lift the bowl off the bowl liner.

Note: The liner must be installed into the bowl with a light coat of oil in the area of the backing material. This
ensures that the backing material will not stick to the bowl. If the bowl liner was improperly installed, and
some of the backing material remains attached to the bowl, it may be necessary to use a heavy object to
remove the backing material from the bowl liner.

10. Set the bowl on wood blocking.

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152 Chapter 7 Maintenance

11. Inspect the seating surface of the bowl for ridges or steps caused by the removed bowl liner. Grind any
discontinuities to maintain a continuous conical bowl liner seating surface in the bowl. If the ridge or step is
abnormally deep, the bowl liner must be replaced.

Improper seating of the bowl liner in the bowl may cause ridges or steps in the bowl seating surface. This
condition can cause the liner to come loose in the bowl during operation, leading to additional seating
surface damage.

7.24.3 Bowl Liner Installation

If the bowl liner configuration is being changed (such as from standard to short head), the adapter ring may need to be
changed as well.

1. Place the bowl liner on wood blocking, and verify that it is approximately level. Ensure the blocking allows the liner
to fully seat on the bowl.

2. Remove all the paint from the seating surface.

3. Draw chalk marks at the high points of the helix on the bowl liner.

Image may not reflect exact equipment.

1 High points of helix 2 Bowl liner

Figure 7-48: Helix High Point Location

4. Clean the inside of the bowl, and apply a coat of light oil to prevent the epoxy backing from adhering to the bowl.

5. Lower the bowl onto the bowl liner, verifying that the chalk marks on the bowl liner are centered between the stop
blocks on the adapter ring.

6. Measure from the bowl liner flange to the inside of the bowl in four places 90 degrees apart to verify that the bowl is
properly centered in the bowl liner.

a. If the four measurements are not approximately equal, re-seat the bowl on the bowl liner, or use a large pry bar
to bump the bowl so it re-seats on the bowl liner.

b. Continue re-seating the bowl until the four measurements are approximately equal.

Note: A misaligned bowl liner can come loose during operation, damaging the bowl seating surface.

7. Thoroughly clean the threads on each square head bolt and apply an anti-seize compound to the threads. Install the
spherical nuts, ensuring that the spherical side faces away from the bolt head.

Note: Replace any damaged or questionable square head bolts.

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Chapter 7 Maintenance 153

8. Inspect the inclined surface on the nose of each wedge to verify that there are no gouges, heavy indentations, or
proud surfaces. Smooth out any existing gouges with a high speed grinder to create a smooth upward, ramping
surface.

9. Place the wedges on the adapter ring between the stop blocks, and push the wedges forward until they contact the
bowl liner. Refer to Figure 7-49.

10. Each of the wedges must contact the helix of the bowl liner midway up the inclined surface of the wedge.

a. Add or remove shims under the wedges to obtain the desired contact points on the helix. Do not exceed 25 mm
(0.94 in) shim height.

11. Tack weld the shims in place.

Image may not reflect exact equipment.

1 Lock plate 2 View showing lockplate 3 Bolt stop, welded to bowl

4 Wedge 5 Inclined midpoint 6 Adapter block
7 Required clearance 8 Bowl liner 9 Bowl
10 Location to tack weld shim (if required) 11 Square head bolt
Figure 7-49: Bowl Liner Installation

12. Place the square head bolts with spherical nuts behind the wedges. Ensure each bolt is horizontal and each bolt
head is under the horizontal bolt retainers that are welded in the bowl slots.

Note: If the bolts slide up during operation, the bowl liner will come loose.

a. If the liner configuration is changed, causing the adapter ring to also change, the bolt stops may need to be
relocated.

13. In a crisscross pattern, tighten each spherical nut until all the wedges are tight in the bowl liner helices.

14. Verify that the sides of each spherical nut are vertical. Do not back off a nut to achieve vertical orientation.

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154 Chapter 7 Maintenance

15. Use a 0.25 mm (0.010 in) feeler gauge around the bottom of the bowl liner to verify that the bowl liner is seated
tightly against the bowl. Caulk any openings caused by bowl seating surface wear to prevent the backing material
from leaking out. Refer to Figure 7-50.

Note: Most commercially available silicone caulk cures in 24 hours.

16. Fill the entire space behind the bowl liner with high performance epoxy. Stop pouring when the backing compound
reaches just below the level of the adapter ring.

Carefully follow the epoxy backing manufacturer’s mixing, pouring, and safety instructions.

17. After the epoxy has cured, reinspect each of the spherical nuts to ensure that they are all tight.

a. Normal curing time is approximately eight hours at 21° to 27°C (70° to 80°F). If the bowl and bowl liner are cold,
heat them; the curing time is temperature dependent.

b. If time does not permit waiting for the epoxy to cure, still re-tighten the spherical nuts before moving on to the
next step.

Image may not reflect exact equipment.

1 Bowl 2 Fiberglass insulation 3 Bowl liner 4 Epoxy backing material

5 Blocking 6 Feeler gauge 7 Clearance
Figure 7-50: Inspecting Bowl Liner Seating Surface

18. Place the lock plates over the spherical nuts, and attach them to the wedges using cotter pins. The lock plates
prevent the spherical nuts from loosening; in turn, this prevents the bowl liner from loosening.

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Chapter 7 Maintenance 155

19. Cover the entire area above the wedge bolt assemblies with fiberglass insulation all the way around. This prevents
dirt and dust from accumulating around these parts, while making it easier to remove them during the next liner
change.

20. Apply silicone to the seam between the mating face of the bowl liner and the underside of the hopper.

21. Lift and place the hopper into the bowl, ensuring that the hopper engages the bars in the top of the adjustment cap.

22. Lubricate the bowl, clamping ring, and adjustment ring threads. Refer to A.2.3 “Thread Lubrication Requirements” on
page 175.

23. Install the bowl assembly into the crusher. Refer to 7.23.3 “Bowl Assembly Installation” on page 147.

24. Measure and record the distance from the bottom of the adjustment cap to the bottom of the dust shell. Refer to
7.24.1 “Determining Bowl Liner Wear” on page 148 and D.4 “Bowl Liner Wear Log” on page 197.

Note: Take this measurement after the installation and setting of each new set of liners, as liner thickness
varies somewhat from set to set.

25. Mark a line on the dust shell at the bottom of the adjustment cap to allow for later liner comparisons.

7.25 Bowl Adapter Ring Replacement

If a change is made to the type of liner (such as from short head medium to standard fine), a change to the adapter ring
in the bowl may also be required.

Image may not reflect exact equipment.

1 Bowl adapter ring 2 Bowl 3 Socket head capscrews and lockwasher

Figure 7-51: Bowl Adapter Ring

7.25.1 Bowl Adapter Ring Removal

1. Remove the socket head capscrews and lock washers holding the adapter ring in the bowl.

2. Lift the existing adapter ring out of the bowl.

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156 Chapter 7 Maintenance

7.25.2 Bowl Adapter Ring Installation

1. Place the adapter ring in the bowl.

2. Re-install the socket head capscrews and lock washers.

7.26 Oil Strainer Basket Replacement

(Lubrication Unit)
A removable and cleanable strainer basket is under the oil tank cover to catch large particle contamination from the oil
as the oil drains back into the tank.

7.26.1 Oil Strainer Basket Removal

1. Disconnect the electrical connector.

2. Unscrew the top cover of the filter.

3. Pull out the oil strainer basket using the element handle.

7.26.2 Oil Strainer Basket Installation

1. Replace the oil strainer basket in the oil tank.

2. Screw on the top cover of the filter.

3. Connect the electrical connector.

7.27 Oil Filter Element Replacement

(Lubrication Unit)
The oil filter element must be replaced when it becomes dirty, as indicated by the DIRTY FILTER WARNING shown in the
MCS.

7.27.1 Oil Filter Element Removal

1. Move the handle on the three-way valve 180 degrees. Refer to H.34 “1000892011: Control and Instrumentation
Diagram” on page 351.

Note: This valve changes the oil flow from one bank of filters to the other without interrupting operations.

2. Remove the filter top cover.

3. Remove the filter element.

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Chapter 7 Maintenance 157

7.27.2 Oil Filter Element Installation

1. Insert the new filter element.

2. Replace the filter top cover.

7.28 Changing the Oil Filter Cartridge

(HPU)
The oil filter element must be replaced when it becomes dirty, as indicated by the DIRTY FILTER WARNING shown in the
MCS. The lubrication unit is supplied with a single filter. The hydraulic power unit must be stopped to replace the filter
element.

With the Location control permission selected as MCS and the Hydraulic navigation group active:

1. Set HYDRAULIC SYSTEM to OFF.

2. Manually press EMERGENCY STOP on the HPU control panel.

3. De-energize the hydraulic power unit motor and lock it out, following the site lock-out tag-out procedures.

4. Manually open the clamp and tramp release dump valves. Visually verify the pressure at the respective pressure
transmitters.

5. Remove the dirty element from the housing, and clean the housing with a mild solvent.

6. Place the new element in the clean housing, centering it on the element locater.

7. Inspect the canister O-ring and replace it if necessary.

8. Install the canister and hand tighten it.

9. Pull out the EMERGENCY STOP button on the HPU control panel.

10. Re-energize the hydraulic power unit motor, following the site lock-out tag-out procedures.
11. Set HYDRAULIC SYSTEM to ON.

12. Set HYDRAULIC MODE to MANUAL.

13. Bleed the air the from filter.

a. Remove the electrical connector from solenoid SV1 at the manifold.

b. Select and hold the CLAMP button for a few seconds.

c. Loose the bleeder valve at the top of the filter canister to remove any trapped air.

d. Release the CLAMP button.

e. Connect the electrical connector to solenoid SV1 at the manifold.

14. Set HYDRAULIC MODE to NORMAL.

7.29 Manually Pressurizing and Bleeding

the Tramp and Clamping Circuit
Note: Most of these actions will require two or more personnel.

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158 Chapter 7 Maintenance

With the Location control permission selected as MCS and the Hydraulic navigation group active:

Set HYDRAULIC MODE to MANUAL.

7.29.1 Pressurizing the Tramp Release System Manually

When pressurizing the tramp release circuit for the first time, monitor the oil level sight gauge and add oil as required.
Refer to A.1 “Lubrication Schedule” on page 174. DO NOT fill above the recommended level. Return oil from the circuit
during maintenance will raise the level in the tank.

1. Pre-charge the tramp release accumulator. Refer to 7.29.5 “Charging and Verifying the Accumulators” on page 160.

Pressurizing the system without pre-charging the accumulator will damage the bladder, requiring
replacement.

2. Manually close the dump valve for the tramp release circuit.

3. Select and hold the TRAMP button until the normal operating pressure shown in the MCS is achieved.

a. The pump will automatically shut off once the pressure is achieved.

4. Release the TRAMP button.

5. Set HYDRAULIC MODE to NORMAL.

7.29.2 Bleeding the Tramp Release System

Bleed the hydraulic hoses to remove trapped air during initial start-up and whenever the tramp release circuit
components have been disconnected.

Do not attempt to bleed the tramp release system when the circuit is pressurized. A loose connection
may break free allowing high pressure oil to escape, potentially causing bodily harm.
Always wear suitable eye protection when bleeding any of the circuits.

1. Verify the oil level is at the normal operating level. Fill if needed.

2. Manually open the dump valve for the tramp release circuit. Visually verify the pressure at the respective pressure
transmitter.
3. Select and hold the TRAMP button.

4. While still holding the TRAMP button, close the tramp system dump valve until 14 bars (200 psi) of pressure is
maintained, as indicated on the tramp release pressure gauge located near the tramp system dump valve.

Note: This pressure is more than adequate to maintain an appropriate flow of oil necessary to bleed the
system without creating a hazardous high-pressure condition.

5. While still holding the TRAMP button, loosen the upper hose connection on each tramp release cylinder.

6. Monitor the bleeding line until only oil is leaking from the hose connection and then tighten the hose connection.
7. With all the tramp release cylinders bled, release the TRAMP button.

8. Close the tramp system dump valve.

9. Verify the oil level is at the normal operating level. Fill if needed.

10. Select and hold the TRAMP button until normal pressure shown in the MCS is achieved.

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Chapter 7 Maintenance 159

11. Release the TRAMP button.

12. Inspect all the tramp release system connections to ensure there are no leaks.

13. Set HYDRAULIC MODE to NORMAL.

7.29.3 Pressurizing the Clamping System Manually

When pressurizing the clamping circuit for the first time, monitor the oil level sight gauge and add oil as required. Refer
to A.1 “Lubrication Schedule” on page 174. DO NOT fill above the recommended level. Return oil from the circuit during
maintenance will raise the level in the tank.

1. Verify that the clamping accumulator is charged. Refer to 7.29.5 “Charging and Verifying the Accumulators” on
page 160.

Pressurizing the system without pre-charging the accumulator will damage the bladder, requiring
replacement.

2. Manually close the dump valve for the clamp circuit.

3. Select and hold the CLAMP button until the normal operating pressure shown in the MCS is achieved.

4. The pump will automatically shut off once the pressure is achieved.

5. Release the CLAMP button.

6. Set HYDRAULIC MODE to NORMAL.

7.29.4 Bleeding the Clamping System

Bleed the hydraulic hose whenever the clamping system components have been disconnected. This removes any
trapped air.

Do not attempt to bleed the tramp release system when the circuit is fully pressurized. A loose
connection may break free, allowing high pressure oil to escape and potentially causing bodily harm.
Always wear suitable eye protection when bleeding any circuit.

1. Verify the oil level is at the normal operating level. Fill if needed.

2. Manually open the dump valve for the clamp circuit. Visually verify the pressure at the respective pressure
transmitter.

3. Select and hold the CLAMP button.

4. Adjust the clamping system dump valve until 14 bar (200 psi) of pressure is maintained, as indicated on the clamping
system pressure transducer located near the circuit manifold block.

Note: This pressure is more than adequate to maintain the appropriate flow of oil necessary to bleed the
system without creating a hazardous high pressure condition.

5. While still holding the CLAMP button, loosen either the hose connection at the adjustment ring or the bleeder valve
above the last clamping cylinder in the chain.

6. Monitor the bleeding line or bleeder valve until only oil is leaking, and then tighten the connection.

7. With the clamping circuit completely bled, release the CLAMP button.

8. Manually close the dump valve for the clamp circuit.

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160 Chapter 7 Maintenance

9. Select and hold the CLAMP button until the normal operating pressure shown in the MCS is achieved.

10. Inspect all the clamping system connections to ensure there are no leaks.

11. Set HYDRAULIC MODE to NORMAL.

7.29.5 Charging and Verifying the Accumulators

Confirm there is an adequate supply and pressure of dry nitrogen gas available. Use the commercially-available oil
pumped dry nitrogen (not supplied by FLSmidth).

The clamping circuit has a 1-gallon accumulator inside the hydraulic power unit. The accumulator must be pre-charged
to 69 bar +/- 3 bar (1,000 +/- 50 psi).

The tramp release circuit has four 10-gallon accumulators mounted on stands. The accumulators must be pre-charged to
103 +/- 3 bar (1,500 +/- 50 psi).

7.29.6 Charging Assembly Setup

With the Location control permission selected as MCS and the Hydraulic navigation group active:

1. Set HYDRAULIC SYSTEM to OFF.

2. Manually press EMERGENCY STOP on the HPU control panel.

3. De-energize the hydraulic power unit motor and lock it out, following the site lock-out tag-out procedures.

4. Manually open the clamp and tramp release dump valves. Visually verify the pressure at the respective pressure
transmitters.

5. Remove the valve guard, cap, and washer from the gas valve stem of the gas cylinder.

Image may not reflect exact equipment.

1 Accumulator 2 Gas valve stem 3 Valve cap

4 Valve guard 5 Washer
Figure 7-52: Accumulator Valve

6. Turn the charging assembly T-handle on the air chuck counterclockwise all the way out (open), or until it bottoms
and the bleeder screw is all the way in.

7. Screw the charging assembly onto the gas cylinder valve stem until it is hand tight, and then a quarter turn further
with a hand wrench to compress the seal.

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Chapter 7 Maintenance 161

Do not tighten the assembly more than a quarter turn past hand tight. Over-tightening can twist off the
valve stem and damage the copper washer, causing leakage.

7.29.7 Verifying the Charge

1. Complete the steps in 7.29.6 “Charging Assembly Setup” on page 160.

2. Turn the T-handle in on the air chuck clockwise until the shaft depresses the valve core in the accumulator stem.

3. Verify that the pressure gauge on the gas-charging valve is appropriate for the respective circuit.

4. If the pressure is above the range:

a. Slowly open the bleeder valve on the bottom of the gas-charging valve to exhaust the excessive nitrogen gas
out of the accumulator bladder.

b. When the pressure falls into the range, quickly close the bleeder valve.

Image may not reflect exact equipment.

1 Screw 2 Bleeder valve 3 Gas charging valve

4 Pressure gauge 5 Handle 6 Air chuck
7 Swivel 8 Gas valve stem 9 Accumulator
Figure 7-53: Accumulator Depressurization

5. If the pressure is below the specified limits, refer to 7.29.8 “Charging the Accumulator” on page 162.

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162 Chapter 7 Maintenance

7.29.8 Charging the Accumulator

1. Complete the steps in 7.29.6 “Charging Assembly Setup” on page 160.

2. Complete the steps in 7.29.7 “Verifying the Charge” on page 161.

3. Connect the charging assembly to the accumulator with the swivel end of the 3 m (10 ft) hose and adapter fittings
supplied with the charging assembly, leaving the connection loose.
4. Connect the other end of the hose assembly to the regulator on top of a nitrogen gas cylinder. Use commercially-
available oil pumped dry nitrogen.

Note: The charging adapter (supplied in the special tools package) may be required to connect the gland nut
to the pressure regulator valve, depending on the type of nitrogen bottle used.

5. Slowly open the bleeder valve to release any residual oxygen from the hose.

6. Hand tighten the charging assembly hose on the accumulator.

7. Close the bleeder valve.

8. For a nitrogen gas regulator, use the air chuck to initially set the pressure to 2.41 bar (35 psi). Open the nitrogen gas
valve, and then adjust the pressure to the desired bar (psi).

Note: Nitrogen gas regulators are strongly recommended for charging the accumulators.

9. For other regulator configurations, open the gas valve very slowly. The regulator cannot preset a desired pressure.

10. Close the nitrogen bottle valve at frequent intervals to allow the gas charging pressure gauge to settle.

11. After reaching the necessary pre-charge pressure, quickly close the nitrogen bottle valve.

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Chapter 7 Maintenance 163

Image may not reflect exact equipment.

1 Accumulator 2 Screw 3 Bleeder valve 4 Swivel connector

5 Gas charging valve 6 Pressure gauge 7 T-handle 8 Air chuck
9 Swivel 10 Gas valve stem 11 Hose assembly 12 Coupling
13 Gland 14 Gland nut 15 Pressure regulator 16 Nitrogen bottle
Figure 7-54: Charging and Gauging Assembly

7.29.9 Removal and Storage of the Charging Assembly

1. Turn the charging assembly T-handle on the air chuck counterclockwise all the way out (open), or until it bottoms.

Note: This decompresses the valve core, allowing it to seat in the accumulator stem.

2. Use the bleeder valve to bleed off pressure in the hose.

3. Disconnect the charging assembly from the accumulator and the nitrogen gas cylinder.

4. Disconnect the air chuck from the accumulator valve stem.

5. Store the hose assembly, gauging assembly, and nitrogen bottle in a dust-free atmosphere that is out of the
weather.

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164 Chapter 7 Maintenance

6. Plug the ports on the gauging assembly and both ends of the hose assembly to keep them free of dust and
contaminates.

7. Brush a soapy solution on the gas valve to inspect for any gas leakage. Depress the core once or twice to seat it if
any leaks are found.

a. If the leakage continues, tighten the core further until the leak stops or replace it.

8. Thread the valve cap onto the valve stem.

9. Thread the valve guard onto the accumulator.

10. Close the clamping or tramp release system pressure dump valve.

11. Unlock the hydraulic power unit pump motor, and energize the motor.

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 165

Chapter 8: Troubleshooting
8.1 Main Frame Hub Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
8.2 Countershaft Box and Sheaves Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 166
8.3 Eccentric Assembly Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.4 Head, Mantle, and Feed Plate Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.5 Bowl Assembly Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
8.6 Lubrication System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.7 Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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166 Chapter 8 Troubleshooting

8.1 Main Frame Hub Troubleshooting

The following chart describes a potential main frame hub problem or operating condition, defines the most common
cause or source of the problem, and then provides suggestions for corrective actions.

Problem Possible Cause Corrective Action

a. Ring bounce is causing the adjustment

1. Cyclic overload ring to pound on the main frame, leading to 1. Refer to the ring bounce troubleshooting steps.
main frame and adjustment ring fatigue.

a. The feed contains excessive tramp

1. Improve the feed screening.
material.

b.The crusher is being run with too tight of a

1. Adjust the closed side setting.
closed side setting.

c. The liner configuration is incorrect. 1. Use a different liner configuration.

2. Ring bounce d. The feed is wet. 1. Switch to dry feed.

e. The feed is not evenly distributed, with

1. Improve the feed distribution around the feed
fines migrating to one side and course
opening.
migrating to the other side.

f. The feed contains excessive fines, which

fill the voids needed by larger rocks as they 1. Improve the feed screening.
are crushed.

3. The tramp circuit is a. A tramp circuit internal leak is causing a

1. Replace or rebuild the tramp release cylinder.
repressurized excessively. loss of pressure.

4. Oil is leaking from either the

top of the cylinder or the
a. A tramp circuit external leak is occurring. 1. Replace or rebuild the tramp release cylinder.
breather at the bottom of the
cylinder.

Table 8-1: Main Frame Hub Troubleshooting

8.2 Countershaft Box and Sheaves

Troubleshooting
The following chart describes a potential countershaft box and sheaves problem or operating condition, defines the
most common cause or source of the problem, and then provides suggestions for corrective actions.

Problem Possible Cause Corrective Action

1. The countershaft box outer

a. The drive belts are set to too high of a
bushing temperature is too 1. Adjust the drive belts tension.
tension.
high.

a. An incorrect gear-to-pinion backlash 1. Replace the pinion.

setting is damaging the tooth contact. 2. Adjust the gear/pinion backlash setting.

2. The pinion is prematurely 1. Replace the pinion.

b. The lubrication system oil is dirty.
damaged or excessively worn. 2. Change the lubrication oil more frequently.

c. The crusher is being operated in an 1. Replace the pinion.

overloaded condition. 2. Reduce the crusher feed.

Table 8-2: Countershaft Box and Sheaves Troubleshooting

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Chapter 8 Troubleshooting 167

8.3 Eccentric Assembly Troubleshooting

The following chart describes a potential eccentric assembly problem or operating condition, defines the most common
cause or source of the problem, and then provides suggestions for corrective actions.

Problem Possible Cause Corrective Action

a. The upper thrust bearing is worn, causing

1.Over time, a change occurs to 1. Place shims under the steel lower thrust bearing
the gear at the bottom of the eccentric to
the backlash measurement. to re-establish the proper backlash setting.
lower relative to the pinion teeth.

2. Over time, the lubrication

a. The upper thrust bearing is worn,
amount drops until excessive 1. Replace the bearing once the minimum groove
changing the size and shape of the oil
heat and potentially bearing depth is reached.
grooves.
failure occurs.

a. An incorrect number or size of shims 1. Replace the worn gear.

under the lower thrust bearing is causing 2. Add or remove shims under the lower thrust
the wrong backlash setting. bearing to re-establish the proper backlash setting.
3. Excessive gear wear is
present, causing a step worn in 1. Replace the worn gear.
b. The crusher is being operated
the teeth profile, or pitting and
overloaded for an extensive period of time. 2. Reduce crusher loading.
galling of the profile.
1. Replace the worn gear.
c. The lubrication oil is excessively dirty.
2. Change the lubrication oil more frequently.

Table 8-3: Eccentric Assembly Troubleshooting

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168 Chapter 8 Troubleshooting

8.4 Head, Mantle, and Feed Plate

Troubleshooting
The following chart describes a potential head, mantle, and feed plate problem or operating condition, defines the most
common cause or source of the problem, and then provides suggestions for corrective actions.

Problem Possible Cause Corrective Action

1. Ensure trained and competent persons carry out

the assembly.
a. The assembly is incorrect.
2. Ensure correct assembly procedures are carried
out using directions from this IOM manual.

1. Ensure there is little to no tramp material entering

b. Tramp material is present. the crusher.

2. Inspect belt magnets for operation.

1. Ensure the correct liner material properties are

present
c. Liner material properties are incorrect.
Note: Liners grow during crushing. Incorrect
manganese contents can limit growth potential.

1. Ensure correct backing material is used.

2. Ensure backing is up to date.

1. The head nut is loose.
d. Backing material is compromised. 3. Ensure backing is poured at the correct
temperature.

4. Ensure backing meets OEM specifications for

compressive and elasticity strength.

1. Backing material is out of date.

e. Backing is not cured correctly. 2. Backing material is outside of the temperature
workable range.

1. Ensure a sufficiently-sized battering ram is used

to obtain correct force on head nut.
f. Head nut is not tightened correctly.
2. Ensure head nut, torch ring, and mantles align
correctly and are not cocked.

1. Ensure sufficient welds are placed onto the head

g. Head nut is not welded and secured.
nut to torch ring and onto torch ring to mantle.

a. Operation time has been exceeded. 1. Change out liners more frequently.

2. A liner is cracked. 1. Prevent the presence of tramp material.

b. Tramp material is present.
2. Check the belt magnet for operation.

1. Remove the head and carry out a dye pen and

3. Oil is leaking from a liner. a. The head is cracked.
mag particle inspection.

Table 8-4: Head, Mantle, and Feed Plate Troubleshooting

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Chapter 8 Troubleshooting 169

Problem Possible Cause Corrective Action

1. Ensure a sufficiently-sized battering ram is used

to obtain correct force on head nut.

2. Ensure trained and competent persons carry out

a. The head nut is not tightened securely.
the assembly.

3. Ensure correct assembly procedures are carried

out as per the IOM manual.

1. Ensure welding is done to the correct WPS.

2. Ensure the welder is trained and competent.

b. Incorrect weld procedure for torch ring.
4. A weld is broken from torch
ring. 3. Ensure the correct welding rod is used for the
application.

1. Refer to the correct WPS.

c. The weld on the torch ring is insufficient.
2. Refer to the FLSmidth Engineering team.

1. Refer to the correct WPS.

d. The welds on the liner are insufficient.
2. Refer to the FLSmidth Engineering team.

1. Refer to the correct WPS.

e. The welding rod is incorrect.
2. Refer to the FLSmidth Engineering team.

1. Remove the head and carry out a dye pen and/or

a. The head is cracked.
mag particle inspection to the head.

1. Remove the head and head nut. If applicable,

5. Oil is leaking from the head
b. The anti spin blank plate is loose. check bolts on the anti-spin cover. Tighten where
nut location.
necessary.

1. Remove head and head nut. If applicable, remove

c. Anti spin blank plate gasket failure.
anti-spin cover and replace the gasket and O-ring.

1. Check Q.A. docs for suitability.

a. The feed plate is incorrect. 2. Fit the feed plate as designed and manufactured
by FLSmidth.

1. Replace bolts. Ensure sufficient tightness. Tack

b. Bolts are dislodged or loose.
weld nuts if required to prevent them coming loose.

1. Check bolts for type of failure – including over-

tightening, elongation, or sheer fatigue.
6. Feed plate is loose and 2. Ensure the feed plate has been fitted correctly
falling off. c. Bolts are broken. and is flush. Any clearance between the feed plate
and head nut will cause bolt failure.

3. Ensure correct bolt grade, length, and type are

used.

1. Replace the feed plate.

d. The feed plate is worn out. 2. Check wear on the feed plate and check feed
top size to ensure crushing isn't taking place on the
feed plate (oversized feed).

Table 8-4: Head, Mantle, and Feed Plate Troubleshooting

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170 Chapter 8 Troubleshooting

8.5 Bowl Assembly Troubleshooting

The following chart describes a potential bowl assembly problem or operating condition, defines the most common
cause or source of the problem, and then provides suggestions for corrective actions.

Problem Possible Cause Corrective Action

1. Clean the threads.

a. A thread grease not recommended by
2. Recondition the threads as needed.
FLSmidth has been used.
3. Lubricate the threads with the proper grease.

1. Clean the threads.

2. Recondition the threads as needed.

b. The thread was not properly lubricated.
3. Lubricate the threads with the proper grease.

4. Lubrication the threads more often.

1. Clean the threads.

1. The bowl is turning with
difficulty due to galled or c. A damaged or worn dust shell seal has 2. Recondition the threads as needed.
damaged thread. allowed dust and other particles to
contaminate the thread grease. 3. Lubricate the threads with the proper grease.

4. Replace the dust shell seal.

1. Refer to the ring bounce troubleshooting in

d. There is excessive ring bounce.
Figure 8-1 “Main Frame Hub Troubleshooting”.

1. At least once per month, rotate the bowl one full

turn and then set it back into the desired crushing
e. The crusher operates with the bowl in the position.
same position for extended periods of time. 2. Lubricate the adjustment ring and bowl threads
monthly rather than every liner change if liner
changes are not often required.

1. Contact the FLSmidth customer service

department to discuss one of the following actions
to remove the bowl:

1a. Feed a small amount of rock into the crusher

with the crusher running and the bowl unclamped.
(This process may need to be repeated a few times
2. The bowl will not move using
a. Thread damage and galling is extreme. to free the bowl.)
the hydraulic adjust motor.
1b. Pour penetrating oil or antifreeze around the
threads and through the grease fittings. Let the
crusher sit for a few hours to allow the solution to
soak in, and then attempt again to turn the bowl.
(This process may need to be repeated a few times
to free the bowl.)

Table 8-5: Bowl Assembly Troubleshooting

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Chapter 8 Troubleshooting 171

8.6 Lubrication System Troubleshooting

The following chart describes a potential lubrication system problem or operating condition, defines the most common
cause or source of the problem, and then provides suggestions for corrective actions. Refer to the original equipment
manufacturer (OEM) manual for additional information.

Problem Possible Cause Corrective Action

1. The heat exchanger efficiency a. The relief valve is stuck open, allowing
1. Replace the relief valve.
has fallen. un-cooled oil to bypass the cooler.

2. The lubrication system a. Dust and debris was allowed to build up

1. Replace the breather. It is not cleanable.
breather is dirty. around the breather.

a. The water strainer on the water inlet side

1. Clean out the water strainer.
of the cooler is plugged with debris.

b. The supply line is damaged, plugged,

1. Inspect for, and address, issues found in the
kinked, or is otherwise supplying an
water supply line (not supplied by FLSmidth).
inadequate water supply or pressure.

c. Blockage under the control valve seat is

1. Remove the blockage.
preventing the valve from closing.

1. Clean the temperature sensor bulb.

3. The water control valve is not
holding a steady temperature, d. The water control valve will not open. 2. Place the temperature sensor bulb in hot water. If
or the oil is not being cooled the valve does not open, the bulb must be replaced
enough. due to gas leakage.

1. The valve must be replaced. This leakage is

indicative of a loose internal part or a damaged
e. Water is leaking from the valve body.
bellows. Both conditions require valve
replacement.

1. Inspect, and tighten, any loose parts near the

f. Parts in or near the valve have come valve.
loose. This issue will cause the valve to
chatter. 2. If there are no loose parts near the valve, the
loose parts are within the valve. Replace the valve.

Table 8-6: Lubrication System Troubleshooting

8.7 Hydraulic System Troubleshooting

Refer to the original equipment manufacturer (OEM) manual for information.

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172 Chapter 8 Troubleshooting

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 173

Appendix A: Lubrication
A.1 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
A.2 Lubricating Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
A.2.1 Crusher Lubrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
A.2.2 Crusher Operating Oil Temperature Requirements . . . . . . . . . . . . . . . . . . . 175
A.2.3 Thread Lubrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
A.2.4 Belt Tensioner Lubrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
A.2.5 Jackshaft Pillow Block Lubrication Requirements . . . . . . . . . . . . . . . . . . . . 177
A.3 Adding and Changing Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
A.4 Lubricating Oil Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
A.5 Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
A.5.1 Hydraulic Drive Assembly Lubrication Requirements . . . . . . . . . . . . . . . . . 178
A.5.2 Hydraulic Adjust Drive Lubrication Requirements . . . . . . . . . . . . . . . . . . . . 179
A.5.3 Cold Weather Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
A.5.4 Hot Weather Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
A.6 Adding and Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

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174 Appendix A Lubrication

A.1 Lubrication Schedule

Lubricated Part Lubricant Frequency Method

Change every 2,000

Oil ISO 150 with EP (630-770 SUS
Crusher Circulating Oil operating hours (if Circulation
at 37.8°C [100°F])
required)

Bowl and Head Surfaces Contacting Epoxy Oil ISO VG220 with EP additives
Every liner change Manual, brush
Backing (do not oil the mantle or bowl liner) (220-240 cSt at 40°C [104°F])

Grease Lithium Base NLGI No. 1 40 operating hours

Bowl, Clamping Ring, and Adjustment Ring Grease fittings
with 3% Molybdenum Disulfide
Threads (unclamp the bowl before greasing) Every liner change manual, brush
(by weight)

Grease Lithium Base NLGI No. 1

Locking Nut Threads with 3% Molybdenum Disulfide Every liner change Manual, brush
(by weight)

Grease Lithium Base NLGI No. 1

Main Frame and Adjustment Ring Seating
with 3% Molybdenum Disulfide 2,000 operating hours Manual, brush
Surface
(by weight)

Standard: Oil ISO 32 (135-165 SUS

at 37.8°C [100°F])

Hot Weather: Oil ISO 46 (46 cSt at Change every 2,000

Hydraulic Power Unit Circulation
40°C [104°F]) hours (If required)

Cold Weather: Oil ISO 10 (10 cSt at

54°C [130°F])

Change every 1,000

Hydraulic Drive Assembly Oil EP80W90 Gear Oil Pour
hours (If required)

Grease lithium soap based

Every 3 months, change Hand powered
Belt Tensioner Grease Zerks grease with a mineral based oil,
every 8,000 hours grease gun
NLGI #1 or 2

As determined necessary by the

Jackshaft Pillow Block Every 5,000 hours Pour
lubrication expert

Table A-1: Lubrication Schedule

A.2 Lubricating Oil Specifications

For crusher lubrication, use high-grade paraffin (not naphthalene) based ISO EP 150 gear oil that meets the following
requirements:

• High film strength

• High adhesiveness to metal surfaces
• Stable physical and chemical properties
• Extreme pressure (EP) properties such as sulfur phosphorus or another anti-weld agent that is compatible with the
crusher metals.
• EP oil is preferred over straight industrial oil because of the higher pour point.
• High viscosity index
• Rapid water separation
• Resists foaming
• Provides rust and corrosion protection
• Includes anti-wear additives

If the crusher is to operate under abnormal conditions such as crushing hot materials or operating in extreme climates,
contact FLSmidth’s customer service for special lubricating oil recommendations.

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Appendix A Lubrication 175

The crusher lubricating oil used must meet the above requirements to protect its working parts. Using improper oil can
damage the crusher in a short period of time and void warranties. The oil may be purchased for any major oil company
that makes oil which meets the above requirements. If your local oil supplier cannot furnish the necessary oil, contact
FLSmidth customer service for assistance.

ISO EP Acceptable Viscosity Range

cSt (Centistokes) SUS (Saybolt Universal Seconds)

135-165 cSt at 40°C 680-850 SUS at 38°C (100°F)

150 (104°F) 70+ SUS at 99°C (210°F)

13+ cSt at 100°C (212°F) Viscosity index of 90 or higher

Table A-2: ISO-VG Acceptable Viscosity for 150 Oil

A.2.1 Crusher Lubrication Requirements

The lubrication system is designed and sized to provide the necessary supply of clean and cooled lubrication oil. Do not
modify the lubrication system.

The crusher oil pressure is highly temperature dependent. Assess oil pressure issues at normal operating temperatures.

Oil Pressure at Crusher Required Oil to Fill System

Reservoir

1.4-2.6 bar (20-38 psi) 1420 L (375 gal)

Table A-3: Crusher System Oil Requirements

A.2.2 Crusher Operating Oil Temperature Requirements

The preferred operating temperature of the lubrication oil supplied to the crusher is 38° to 54°C (100° to 130°F).

Note: If the return oil line temperature reaches 60°C (140°F), the crusher will automatically shut down.

A.2.3 Thread Lubrication Requirements

It is critical that the threads in the bowl, adjustment ring, and clamping ring are kept well lubricated.

Evenly distributed grease fittings are located around the perimeter of the adjustment ring to provide proper thread
lubrication. The relationship of the bowl, adjustment ring, and clamping ring threads in both the crushing and adjusting
positions is illustrated in Figure A-1.

After the initial can of moly grease (25% moly) is empty, use a lithium-based grease such as NLGI Number 1 containing 5
to 10% molybdenum disulfide by weight. The grease provides a barrier to keep the thread surfaces from galling as they
slide past each other.

• The crusher was initially assembled with an anti-seize compound that contains 25% molybdenum disulfide by
weight. The anti-seize compound protects the threads until they work-harden during operation. Under severe
conditions, it may be necessary to continue using the same compound as a thread lubricant.
• After refurbishing threads, use 25% molybdenum disulfide by weight on the threads. The lubrication is available
through FLSmdith. Using the proper break-in grease has a significant affect on the wear of new or rebuilt threads.

Note: If a high temperature material is being crushed, use high temperature grease with the same 5 to 10%
molybdenum disulfide by weight.

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176 Appendix A Lubrication

Image may not reflect exact equipment.

1 Grease fitting 2 Adjustment ring 3 Main frame

Figure A-1: Grease Fittings

Image may not reflect exact equipment.

1 Adjustment ring 2 Bowl 3 Crushing position 4 Released or turning position

Figure A-2: Bowl Thread Engagement With Adjustment Ring

A.2.4 Belt Tensioner Lubrication Requirements

Grease the 14 tensioner assembly zerks (excluding the electric motor) with a hand-powered grease gun rather than a
powered grease gun to preclude blowing seals. Use NLGI #1 or 2 lithium soap based grease with a mineral base oil.

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Appendix A Lubrication 177

Apply the required amount of grease to each zerk every three months. For the amount of grease required for each zerk,
refer to original equipment manufacturer documentation provided separately by the manufacturer.

Lubricate the zerks every three months, and change the grease in the idler bearings every 8,000 operating hours.

A.2.5 Jackshaft Pillow Block Lubrication Requirements

Lubricate the jackshaft pillow block with a high quality mineral base oil that has rust and oxidation inhibitors.

The unit is factory-filled with VG 220 oil, but confer with local lubrication experts to determine the ideal operating
lubricant based on local conditions.

While the crusher is operating with a full lubrication tank, add a fill mark on the sight glass. The oil may be later filled
while the crusher is running by using the operating fill mark.

Monitor the oil during operation, and add oil as needed to keep the tank full. Change the oil every 5,000 operating
hours; the tank holds 2 qts of oil.

A.3 Adding and Changing Lubricating Oil

1. Monitor the oil level daily, and add oil as needed to keep the oil level in the marked range on the sight gauge.

2. Inspect the oil strainer basket daily. Refer to 7.26 “Oil Strainer Basket Replacement (Lubrication Unit)” on page 156.

3. Replace the oil every 2,000 hours of operation, after any major crusher bushing failure that results in high lubricating
oil temperatures, and as determined necessary by oil sampling or visual inspections.

Note: After a crusher failure causes high oil temperatures, the oil will smell burnt.

a. For water cooled lubrication systems, clean the lubrication system temperature sensor portion of the control
valve every oil change.

A.4 Lubricating Oil Contamination

Use of contaminated oil, or oil that has lost its properties, will accelerate bearing wear and create expensive parts
replacement requirements.

Take oil samples and analyze them on a regular basis. Most crusher operations involve taking the samples and
analyzing them every month. If sample analysis shows an unusual increase in any of the contaminants listed in Table A-
4, “Oil Contamination Guidelines,” make a thorough inspection of the crusher to find the source(s) of the contamination.
The type of contamination may indicate whether the source is internal due to metallic contact or a result of dust
infiltration.

Oil analyses can also provide possible sources of contamination which leads to excessive bushing and socket liner
wear. Silica limits must be interpreted in relationship to copper and iron levels. If high silica is accompanied by high
copper or iron, it is considered abrasive and the oil is rated unacceptable.

Contaminant Acceptable High

Copper (Cu) Below 100 PPM Above 210 PPM

Aluminum (Al) Below 5 PPM Above 10 PPM

Iron (Fe) Below 20 PPM Above 50 PPM

Silica (Si) Below 25 PPM Above 65 PPM

Table A-4: Oil Contamination Guidelines

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178 Appendix A Lubrication

Contaminant Acceptable High

Chromium (Cr) Below 0.5 PPM Above 1.5 PPM

Lead (Pb) Below 70 PPM Above 190 PPM

Contamination Level (Total Solids) Below 0.1% Above 0.2%

Water Below 0.1% Above 1.0%

Table A-4: Oil Contamination Guidelines

A.5 Hydraulic Oil Specifications

Use high-grade paraffin (not naphthalene) based ISO-VF 32 industrial hydraulic oil that meets the following
requirements:

• High film strength

• High adhesiveness to metal surfaces
• Stable chemical and physical properties
• High viscosity index
• Rapid water separation
• Resist foaming
• Provide rust and corrosion protection
• Include anti-wear additives

Do not use fire resistant hydraulic oil. This type of hydraulic oil may not be compatible with packing seals,
accumulator bladders, hoses, and other parts of the power unit. It will adversely damage the special paint
used inside the reservoir as well as reduce the life of the pump.

The hydraulic oil used must meet the above requirements to protect its working parts. Using improper oil can damage
the system in a short period of time and void any warranties. The oil may be purchased for any major oil company that
makes oil which meets the above requirements. If your local oil supplier cannot furnish the necessary oil, contact
FLSmidth’s customer service for assistance.

ISO-VG Acceptable Viscosity Range

cSt (Centistokes) SUS (Saybolt Universal Seconds)

135-165 SUS at 38°C (100°F)

29-35 cSt at 40°C (104°F)
32 45+ SUS at 99°C (210°F)
6+ cSt at 100°C (212°F)
Viscosity index of 140 or higher

Table A-5: ISO-VG Acceptable Viscosity for 32 Oil

A.5.1 Hydraulic Drive Assembly Lubrication

Requirements
Grease the grease fitting at the labyrinth seal at the top of the planetary gear reducer every six months.

Change the oil in the planetary gear reducer every 12 months of operation. Due to the complicated and precise design
of the drive assembly, only trained service technicians may disassemble the drive or work on the internal parts.

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Appendix A Lubrication 179

A.5.2 Hydraulic Adjust Drive Lubrication Requirements

Inspect the hydraulic adjust drive lubricant level every 1,000 hours of crusher operation.

Drive Component Required Lubrication Amount of Lubricant

Grade

Gear Box GL-5 EP 80/90

Brake ATF Type F 0.06 L (2 fl oz)

Table A-6: Hydraulic Adjust Drive Lubrication Requirements

A.5.3 Cold Weather Specifications

Cold hydraulic oil will not flow freely through the hydraulic system, causing it to be almost solid. This is particularly bad
for the tramp release circuit, in which the hydraulic oil must flow freely to and from the accumulator when the crusher
passes tramp iron or stalls.

Note: Do not use cold weather hydraulic oil all year round. Since the oil is designed for use in cold ambient
conditions, occasional leakage past the tramp release and clamping cylinders may occur during warmer
conditions.

Change the entire hydraulic system oil to a cold weather oil any time the ambient temperature may be -20°C (0°F) or less
for more than a few days.

If the correct oil for a cold weather environment is not used, the power unit and crusher components may
be damaged.

ISO-VG Acceptable Viscosity Range

cSt (Centistokes)

10 cSt (min) at 54.4°C (130°F)

10 500 cSt (max) at -40°C (-40°F)

Pour Point of -59.4°C (-75°F) max

Table A-7: ISO-VG Acceptable Viscosity for 10 Oil (Cold Weather)

A.5.4 Hot Weather Specifications

Change the entire hydraulic system oil to a hot weather oil any time the ambient temperature may be in excess of 41°C
(105°F).

ISO-VG Acceptable Viscosity Range

cSt (Centistokes)

46 cSt (min) at 40°C (104°F)

46
6.8 cSt (max) at 100°C (212°F)

Table A-8: ISO-VG Acceptable Viscosity for 10 Oil (Hot Weather)

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180 Appendix A Lubrication

A.6 Adding and Changing Hydraulic Oil

1. Before filling the hydraulic power unit tank with oil:

a. Inspect the inside of the reservoir thoroughly for contaminants. Remove any material with a clean lint-free rag.

b. Inspect the suction strainer for any material that may be stuck to the screen, and clean it if necessary.

2. Fill the reservoir to the top of the oil level gauge.

3. Keep the oil at the center of the oil level gauge during normal operation.

Note: Monitor the oil level regularly.

4. Replace all hydraulic oil a minimum of once per year.

a. When replacing the oil, thoroughly clean the reservoir and remove all contaminants from the reservoir and
suction strainer.

Hydraulic Power Unit Tank Clamping, Release, and Clearing System

757 L (200 gal) 379 L (100 gal)

Table A-9: Required Amount of Hydraulic Oil

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 181

Appendix B: Commissioning
B.1 Initial Pre-Start-Up Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
B.2 No-Load Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
B.3 65% of Full Load Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
B.4 80% of Full Load Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
B.5 Full-Load Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

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182 Appendix B Commissioning

B.1 Initial Pre-Start-Up Inspection

Perform the following inspection before starting the crusher for the first time and after relocating or rebuilding the
crusher.

Commissioning Step Reference Commissioner Sign- FLSmidth Service Rep Sign-

Off Off

Appendix I: “Final
Complete the final mechanical inspection. Mechanical Inspection” on
page 485

A.2 “Lubricating Oil

Verify the proper lubricating oil and
Specifications” on page 174
hydraulic oil is installed in the respective
and A.5 “Hydraulic Oil
reservoirs.
Specifications” on page 178

Advanced maintenance
Verify that the countershaft end float is 0.51
manual (available from
to 0.64 mm (0.002 to 0.025 in).
FLSmidth)

5.10.1 “Skid Mounted

Lubrication System
Installation” on page 68,
5.10.2 “Heat Exchanger
Bump all motors to verify they are rotating
Installation” on page 69, 5.9
in the proper direction.
“Hydraulic System
Installation” on page 66, and
5.6.3 “Drive Motor
Installation” on page 63

Run the lubrication system to verify there

are no leaks.

Operate the HPU, and pressurize or cycle

all hydraulic circuits to verify that there are 6.8 “Shutdown” on page 91
no leaks.

Verify all component and ancillary

component fasteners are secure.

Verify that the mantle does not touch the 6.4.1 “Setting the Crushed
bowl liner. Product Size” on page 85

Verify that the equipment feeding the

crusher is functioning properly.

NOTES AND COMMENTS:

Table B-1: Initial Pre-Start-Up Inspection

_________________________________ _________________
(Commissioner) (Date)

_________________________________ _________________
(FLSmidth Service Representative) (Date)

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Appendix B Commissioning 183

B.2 No-Load Inspection

Perform the initial pre-start-up inspection before performing the no-load inspection.

Run the crusher without a load for at least two hours to complete the no-load run. Rebuilt crushers may require a longer
no-load run to allow the new bushings to conform to the old journal surfaces.

Note: In very cold climates, it may be necessary to perform the no-load run until the return oil temperature
reaches 27°C (80°F). During the run, perform the following inspection.

Commissioning Step Reference Commissioner Sign- FLSmidth Service Rep Sign-

Off Off

Verify the lubrication oil drain line

temperature is above 27°C (80°F).

Inspect for lubrication oil and hydraulic oil

leaks.

Verify the head spin speed is within an

acceptable range.

Record the crusher speed [(motor sheave

diameter)/(crusher sheave diameter)] ×
motor rpm = crusher rpm

Record the crusher drive motor no-load

amps.

Record the temperature at which the

lubrication unit mounted relief valve
stopped bypassing.

Verify the crusher has run with no load for

two hours without any issues.

Record the coast-down time.

NOTES AND COMMENTS:

Table B-2: No-Load Inspection

_________________________________ _________________
(Commissioner) (Date)

_________________________________ _________________
(FLSmidth Service Representative) (Date)

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184 Appendix B Commissioning

B.3 65% of Full Load Inspection

Perform the no-load inspection before performing the 65% of full load inspection.

Run the crusher with 65% of a full load for two hours to complete the run. At the end of the run, perform the following
inspection.

Commissioning Step Reference Commissioner Sign- FLSmidth Service Rep Sign-

Off Off

Verify that the feed material is hitting the

center of the feed plate, and the feed
distribution is adequate.

Verify that the crusher ran at 65% of full

load for two hours without any issues.

NOTES AND COMMENTS:

Table B-3: 65% of Full Load Inspection

_________________________________ _________________
(Commissioner) (Date)

_________________________________ _________________
(FLSmidth Service Representative) (Date)

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Appendix B Commissioning 185

B.4 80% of Full Load Inspection

Perform the 65% of full load inspection before performing the 80% of full load inspection.

Run the crusher with 80% of a full load for four hours to complete the run. At the end of the run, perform the following
inspection.

Commissioning Step Reference Commissioner Sign- FLSmidth Service Rep Sign-

Off Off

Verify that the crusher ran at 80% of full

load for four hours without any issues.

Record the coast-down time after an 80%

load run.

NOTES AND COMMENTS:

Table B-4: 80% of Full Load Inspection

_________________________________ _________________
(Commissioner) (Date)

_________________________________ _________________
(FLSmidth Service Representative) (Date)

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186 Appendix B Commissioning

B.5 Full-Load Inspection

Perform the 80% of full load inspection before performing the eight hours of full-load inspection.

Run the crusher with a full load for eight hours to complete the run. At the end of the run, perform the following
inspection.

Commissioning Step Reference Commissioner Sign- FLSmidth Service Rep Sign-

Off Off

Verify that the feed material is hitting the

center of the feed plate, and the feed
distribution is adequate.

Verify that the tramp release and clamping

circuit pressures hold without re-
pressurizing more than eight times an hour
after the system stabilizes from the initial
commissioning.

Record the full-load amps from the crusher

drive motor nameplate.

Record the lubrication oil return line

temperature.

Record whether the fan is on or off at the

time the temperature is taken.

Record the supply oil temperature.

Record whether the fan is on or off at the

time the temperature is taken.

Record the eccentric supply oil pressure.

Record the socket liner supply oil pressure.

Record the closed side setting.

Record the crusher drive motor power

draw.

Inspect the drive belts, and re-tension 7.12.3 “V-Belt Tensioning”

them as required. on page 121

Table B-5: Full Load Inspection

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Appendix B Commissioning 187

Commissioning Step Reference Commissioner Sign- FLSmidth Service Rep Sign-

Off Off

NOTES AND COMMENTS:

Table B-5: Full Load Inspection

_________________________________ _________________
(Commissioner) (Date)

_________________________________ _________________
(FLSmidth Service Representative) (Date)

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188 Appendix B Commissioning

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 189

Appendix C: Maintenance
Schedule
C.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
C.1.1 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
C.1.2 Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
C.1.3 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
C.1.4 Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
C.1.5 At Liner Change Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

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190 Appendix C Maintenance Schedule

C.1 Maintenance Schedule

To keep the crusher in a good operating condition, schedule daily, weekly, monthly, and yearly inspections with a
written log of what was done and found. Repairs can be made in advance to avoid major breakdowns.

C.1.1 Daily Maintenance

Maintenance Operation Comments and References Completed

Verify the hydraulic oil tank level.

A.2 “Lubricating Oil Specifications” on

Read the lubrication oil pressure at the crusher.
page 174

Take the oil inlet temperature at the crusher. Normal condition: 38° to 54°C (100°F to 130°F)

6.4 “Normal Crusher Operation” on page 84

Verify the cavity level and power draw.
Normal condition: 1.4 to 2.8 bar (20 to 40 psi)

6.4.1.3 “Setting the Closed Side Setting

Verify the closed side setting.
Through Automation” on page 86

Inspect the oil piping for leaks.

7.29.1 “Pressurizing the Tramp Release System

Verify the tramp release circuit pressure. Manually” on page 158

Normal condition: 124 bar (1,800 psi)

7.29.3 “Pressurizing the Clamping System

Verify the clamping circuit pressure. Manually” on page 159

Normal condition: 193 bar (2,800 psi)

7.29.5 “Charging and Verifying the

Verify the clamping circuit accumulator pre-charge Accumulators” on page 160
pressure. Normal condition: 69 bar +/- 3 bar (1,000 +/- 50
psi)

5.2.4 “Feed Arrangement Preparation” on

Verify the feed distribution in crushing cavity.
page 54

Inspect the crusher discharge area to ensure it is clear and

the discharge conveyor is running properly.

Inspect the main frame arms for material buildup.

Take the crusher coast-down time. Normal condition: 60 to 90 seconds

Inspect for any loose fasteners.

Inspect for any unusual noises.

7.8.1 “Determining the Main Frame Seat Liner

Determine the remaining liner life.
Wear” on page 112

Inspect the adjustment ring for movement.

Inspect the oil tank strainer basket under the inspection 7.26 “Oil Strainer Basket Replacement
cover in the lubrication tank for debris and drain line oil flow. (Lubrication Unit)” on page 156

Table C-1: Daily Maintenance

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Appendix C Maintenance Schedule 191

C.1.2 Weekly Maintenance

Maintenance Operation Comments and References Completed

7.14 “Air Seal Blower Maintenance” on

Inspect the condition of the air seal blower filter.
page 124

Inspect the condition of the lubrication and hydraulic power

unit tank breathers. Replace dirty breathers; they are not
cleanable.

Ensure dust and debris is not built up around the lubrication

system breather.

Inspect the V-belts for tightness and alignment. 7.12.3 “V-Belt Tensioning” on page 121

Table C-2: Weekly Maintenance

C.1.3 Monthly Maintenance

Maintenance Operation Comments and References Completed

Inspect the engagement of the adjust motor pinion teeth

7.10.2 “Drive Ring Installation” on page 116
with the drive ring teeth.

Inspect and lubricate the adjust motor according to the

manufacturer's specifications.

Have the lubrication and hydraulic oils analyzed; change the A.4 “Lubricating Oil Contamination” on
oil if required. page 177

Advanced maintenance manual (available from

FLSmidth)
Verify the countershaft end float.
Normal condition: 0.51 to 0.64 mm (0.002 to
0.025 in).

If the closed side setting has not changed more than one 6.4.1 “Setting the Crushed Product Size” on
inch, turn the bowl in and out a few times. page 85

Inspect for cracked, loose, or worn liners.

7.29.5 “Charging and Verifying the

Verify the tramp release circuit accumulator pre-charge Accumulators” on page 160
pressure. Verify the pre-charge monthly for new or repaired
accumulators. Normal condition: 103 +/- 3 bar (1,500 +/- 50
psi)

Inspect the feed plate, bowl liner, and mantle for wear and
tightness.

Ensure the adjustment ring threads are lubricated with the

7.3 “Thread Wear Inspection” on page 101
bowl unclamped; use the recommended grease.

Clean the heat exchanger to remove the dust and dirt

buildup in the core.

Table C-3: Monthly Maintenance

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192 Appendix C Maintenance Schedule

C.1.4 Annual Maintenance

Maintenance Operation Comments and References Completed

Completely disassemble the crusher. Inspect all bearing

Chapter 7: “Maintenance” on page 93
surfaces and the gear and pinion contact for wear.

Inspect the main frame, head, and bowl for signs of fatigue
cracking.

Inspect all piping and fasteners for tightness.

Inspect the fit of the main shaft in the main frame bore.

Table C-4: Annual Maintenance

C.1.5 At Liner Change Maintenance

Maintenance Operation Comments and References Completed

Inspect and re-condition the seating surfaces on the bowl

and head if necessary.

Inspect the head bushing, head ball, socket liner, eccentric,

and dust shell for wear.

Inspect the head locking nut and feed plate for wear;
replace if required.

Inspect the main frame liners, arm guards, countershaft box

guards, and counterweight guard for wear, and recondition
if necessary.

Inspect for thread galling and wear on the bowl, adjustment

ring, and clamping ring.

Table C-5: At Liner Change Maintenance

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 193

Appendix D: Maintenance
Log
D.1 Thread Wear Inspection Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
D.2 Backlash Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
D.3 Main Frame Seat Liner Thickness Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
D.4 Bowl Liner Wear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
D.5 Sheave and Belt Alignment Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
D.6 Adjustment Ring Wear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

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194 Appendix D Maintenance Log

D.1 Thread Wear Inspection Log

Refer to 7.3 “Thread Wear Inspection” on page 101 for instructions on inspecting thread wear.

Bowl Clamping Ring Adjustment Ring

Initial Installation Date

Initial Measurement

Serial Number

Date: Item Description:

Measurement Previous Current Comments Inspector

Number Measurement Measurement

Average

Date: Item Description:

Measurement Previous Current Comments Inspector

Number Measurement Measurement

Average

Date: Item Description:

Measurement Previous Current Comments Inspector

Number Measurement Measurement

Average

Table D-1: Thread Wear Inspection Log

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Appendix D Maintenance Log 195

D.2 Backlash Log

Refer to 7.6.1 “Backlash Inspection and Adjustment” on page 106 for instructions on measuring the backlash.

Equipment Number: Model Number:

Date Transverse Backlash (mm)

Table D-2: Backlash Log

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196 Appendix D Maintenance Log

D.3 Main Frame Seat Liner Thickness Log

Refer to 7.9.1 “Determining Main Frame Liner Wear” on page 115 for instructions on Inspecting the main frame seat liner
wear.

Equipment Number: Model Number:

Initial Thickness (mm): Maximum allowable gap measurement (mm):

Installation Date:

Date Measurement Average Comments

1 2 3 4

Table D-3: Main Frame Seat Liner Thickness Log

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Appendix D Maintenance Log 197

D.4 Bowl Liner Wear Log

Refer to 7.24.1 “Determining Bowl Liner Wear” on page 148 for instructions on Inspecting the bowl liner wear.

Equipment Number: Model Number:

Initial Measurement (mm): Closed Side Setting: Date:

End of Life Measurement (mm): Closed Side Setting: Date:

Date Measurement Closed Side Setting Adjusted Closed Side Setting

(if applicable)

Table D-4: Bowl Liner Wear Log

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198 Appendix D Maintenance Log

D.5 Sheave and Belt Alignment Logs

Refer to 7.13.3 “Sheave and Belt Alignment” on page 123 for instructions on aligning the sheaves and belt.

Equipment Number: Model Number:

Drive Sheave Ø Profile 8V / SPC

Crusher Sheave Ø Profile 8V / SPC

Shaft Center/Center Dimension

Angular Misalignment  
Parallel Misalignment  
Table D-5: Sheave Alignment Maintenance Record

Equipment Number: Model Number:

Quantity of Belts Required

Shaft Center/Center Dimension

Banded YES / NO

Belt Length

Angular Misalignment  
Parallel Misalignment  
Table D-6: Belt Alignment Maintenance Record

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Appendix D Maintenance Log 199

D.6 Adjustment Ring Wear Log

Refer to 7.7.1 “Determining Adjustment Ring Wear” on page 109 for instructions on inspecting the adjustment ring wear.

Equipment Number: Model Number:

Date Ring Installed:

Date Clay Ball Measurement Average Comments

Thickness
1 2 3 4

Table D-7: Adjustment Ring Wear Log

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200 Appendix D Maintenance Log

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 201

Appendix E: Parts List/Bill

of Materials
E.1 1000975960: Parts List/Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
202 Appendix E Parts List/Bill of Materials

E.1 1000975960: Parts List/Bill of Materials

Original
List

Cone crusher, R1100

Created by:Jeremy Winebrenner Doc:1000975960

Approved by:Jeffery Wilkerson Rev:1
FLSmidth,08-Mar-2024

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited
purposes of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this
document is not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 203

1000975960: Parts List/Bill of Materials (Sheet 2)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 2 of 54

Parts list report explanation

This parts list consists of pages in the following sequence:

A) General information section:

Cover - Identifies the specific parts number from which the parts list has been drawn. Explanation - provides
explanation of parts list structure.

B) Table of Contents - Provides an overall view of all assemblies in parts list report

C) Parts Lists
Column 1: Find No - Identifies the parts on the corresponding assembly drawing.
Column 2: Description - Contains a defining description of component or equipment.
Column 3: Part No. - Provides the part number associated to the component described.
Column 4: Document No. - Provides drawing number (if any) for part.
Column 5: Qty - The quantity of a component needed for the equipment/assembly.
Column 6: UOM - Indicates unit of measure for quantity value. Empty field means each.
Column 7: Material. - States a code for the material to be used for the Find Number. The code refers to
material data sheet in the FLSmidth material list. Alternatively a specific material specification
may be included on the drawing. If the two codes or specifications are different, this parts list
specification shall be used.
Column 8: Total Weight kg. - Indicates total weight for the quantity of components listed.
The weight is rounded up to a whole number.

All units of measure are in millimeters unless specified otherwise.

Common parts list report structure:

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
204 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 3)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 3 of 54

Table of Contents

Description Part Part No. Document No. Qty. Total Weight Level Page
Rev. kg. No.

Crusher, Master, R1100 1 1000873424 169679 Top 5

asm.

Assembly, crusher, R1100 1 1000873483 1.0 153515 1 6

Assembly, core, R1100 3 1000873485 1.0 111784 2 7
Assy, Main Frame 5 647092-SLC1 647092-SLC1 1.0 53399 3 8
Assembly, Main Frame, Sub 2 RXL1301-5000- RXL1301-5000- 1.0 45665 4 10
SLC1 SLC1
GUARD, ARM 4 RXL1001-0020- RXL1001-0020- 2.0 500 4 11
SLC1 SLC1
GUARD BOX ARM 4 RXL1001-0021- RXL1001-0021- 1.0 412 4 12
SLC1 SLC1
Assembly, adjustment ring, R1300 1 1000687903 1000687903 1.0 19541 3 13
Assembly, tramp release, split, R1100 / R1300 1 1000920546 1000024420 1.0 8195 3 15
1000920546
ASSY, COUNTERSHAFT BOX 13 RXL1004-5003- RXL1004-5003- 1.0 3193 3 17
SLC1 SLC1
ASSY, ECCENTRIC, MAIN 2 677551-SLC1 677551-SLC1 1.0 8438 3 19
ASSY, ECCENTRIC, SUB 2 677550-SLC1 677550-SLC1 1.0 3851 4 20
ASSY, COUNTERWEIGHT 2 677548-SLC1 677548-SLC1 1.0 2578 4 21
COUNTERWEIGHT 2 677547-SLC1 677547-SLC1 1.0 2135 5 22
Socket Assembly XL1100 2 RXL1007-5005- RXL1007-5005- 1.0 875 3 23
SLC1 SLC1
ASSY, SUB, SOCKET, ANTI-SPIN 7 RXL1007-5004- RXL1007-5004- 1.0 481 4 24
SLC1 SLC1
ASSY, HEAD 2 677553-SLC1 677553-SLC1 1.0 11135 3 25
HEAD 2 677552-SLC1 677552-SLC1 1.0 9677 4 26
ASSY, HEAD STUB 2 RXL1008-5002- RXL1008-5002- 1.0 391 4 27
SLC1 SLC1
Assembly, Adjustment Mechanism 4 RXL1316-5000- RXL1316-5000- 1.0 6027 3 28
SLC1 SLC1
Assy Adjustment Drive 8 RXL1016-5002- RXL1016-5002- 4.0 5.4 4 31
SLC1 SLC1
ASSY, GEARBOX XL1100 7 RXL1016-5003- RXL1016-5003- 1.0 0.9 5 32
SLC1 SLC1
ASSY, SUB, PINION SHIELD 3 RXL1016-5007- RXL1016-5007- 4.0 199 4 33
SLC1 SLC1
RING, DRIVE 3 RXL1016-0022- RXL1016-0022- 1.0 2067 4 34
SLC1 SLC1
ASSY, OIL PIPING 4 RXL1005-5006- RXL1005-5006- 1.0 195 2 35
SLC1 SLC1
Supply Oil Pipe Assembly 5 RXL1005-0001- RXL1005-0001- 1.0 18 3 37
SLC1 SLC1
Oil Drain Assembly 5 RXL1005-0002- RXL1005-0002- 1.0 38 3 38
SLC1 SLC1
ASSY, FEED PLATE 8 RXL1009-5002- RXL1009-5002- 1.0 1060 2 39
SLC1 SLC1
LINER ASSEMBLY, STANDARD FINE 11 RXL1010-5003- RXL1010-5003- 1.0 12465 2 40
SLC1 SLC1
ASSY, BOWL STD XL1300 Use With 3 648590-SLC1 648590-SLC1 1.0 22493 2 41
RXL1100 XL1300 BOWL FOR USE WITH
XL1100

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 205

1000975960: Parts List/Bill of Materials (Sheet 4)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 4 of 54
Description Part Part No. Document No. Qty. Total Weight Level Page
Rev. kg. No.

Assembly, Hopper, Standard 3 RXL1012-5001- RXL1012-5001- 1.0 3158 2 42

SLC1 SLC1
TOOLS ASSEMBLY, XL1100 15 RXL1017-5001- RXL1017-5001- 1.0 1227 2 43
SLC1 SLC1
ASSY, DECAL 10 RXL1020-5001- RXL1020-5001- 1.0 3.3 2 45
SLC1 SLC1
Assembly, Foundation bolt 1 1000896918 1000896918 1.0 1131 2 46
Assembly, Sole plate 1 1000690716 1000690716 1.0 601 3 47
Assembly, drive, R1100 1 1000896530 1.0 10148 1 48
Assy, Ø40", 8V, Crusher Sheave 5 RXL1013-5001- RXL1013-5001- 1.0 979 2 49
SLC1 SLC1
Ø28" 8V Motor Sheave Assembly 5 RXL1013-5009- RXL1013-5009- 1.0 555 2 50
SLC1 SLC1
ASSY, COUNTERSHAFT BOX BLOWER D RXL1023-5004- RXL1023-5004 1.0 200 1 51
SLC1 Rev C-SLC1
HOUSING, INLET FILTER (OBSOLETE BY 5 RXL1023-0002- RXL1023-0002- 1.0 6.0 2 53
MANUFACTURER. USE 1000388827 AS SLC1 SLC1
REPLACEMENT)
Assembly, Instrument 1 1000896923 1000896923 1.0 12 1 54

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
206 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 5)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 5 of 54

Part No.: 1000873424

Crusher, Master, R1100 Rev. No.: 1
Unit Weight: 169679 kg

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 Assembly, crusher, R1100 1000873483 1.0 EA 153515

2 Assembly, drive, R1100 1000896530 1.0 EA 10148
3 Assembly, Lubrication Unit 1000884299 1000884299 1.0 EA 2935
4 Assembly, Hydraulic Power Unit 1000884300 1000884300 1.0 EA 1619
5 Assembly, Heat Exchanger, Air 1000884301 1000884301 1.0 EA 1124
Cooled
6 ASSY, COUNTERSHAFT BOX RXL1023-5004-SLC1 RXL1023-5004 1.0 EA 200
BLOWER Rev C-SLC1
7 Assembly, Automation and Controls 1000896933 1.0 EA 125
8 Assembly, Instrument 1000896923 1000896923 1.0 EA 12

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 207

1000975960: Parts List/Bill of Materials (Sheet 6)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 6 of 54

Part No.: 1000873483

Rev. No.: 1
Assembly, crusher, R1100 Unit Weight: 153515 kg

Parent Assembly Part No.: 1000873424

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 Assembly, core, R1100 1000873485 1.0 EA 111784

2 ASSY, OIL PIPING RXL1005-5006-SLC1 RXL1005-5006- 1.0 EA 195
SLC1
3 ASSY, FEED PLATE RXL1009-5002-SLC1 RXL1009-5002- 1.0 EA 1060
SLC1
4 LINER ASSEMBLY, STANDARD RXL1010-5003-SLC1 RXL1010-5003- 1.0 EA 12465
FINE SLC1
5 ASSY, BOWL STD XL1300 Use 648590-SLC1 648590-SLC1 1.0 EA 22493
With RXL1100 XL1300 BOWL
FOR USE WITH XL1100
6 Assembly, Hopper, Standard RXL1012-5001-SLC1 RXL1012-5001- 1.0 EA 3158
SLC1
7 TOOLS ASSEMBLY, XL1100 RXL1017-5001-SLC1 RXL1017-5001- 1.0 EA 1227
SLC1
8 ASSY, DECAL RXL1020-5001-SLC1 RXL1020-5001- 1.0 EA 3.3
SLC1
9 Assembly, Foundation bolt 1000896918 1000896918 1.0 EA 1131

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
208 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 7)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 7 of 54

Part No.: 1000873485

Rev. No.: 3
Assembly, core, R1100 Unit Weight: 111784 kg

Parent Assembly Part No.: 1000873483

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 Assy, Main Frame 647092-SLC1 647092-SLC1 1.0 EA 53399

2 Assembly, adjustment ring, R1300 1000687903 1000687903 1.0 EA 19541
3 Assembly, tramp release, split, 1000920546 1000024420 1.0 EA 8195
R1100 / R1300 1000920546
4 ASSY, COUNTERSHAFT BOX RXL1004-5003-SLC1 RXL1004-5003- 1.0 EA 3193
SLC1
5 ASSY, ECCENTRIC, MAIN 677551-SLC1 677551-SLC1 1.0 EA 8438
6 Socket Assembly XL1100 RXL1007-5005-SLC1 RXL1007-5005- 1.0 EA 875
SLC1
7 ASSY, HEAD 677553-SLC1 677553-SLC1 1.0 EA 11135
8 Assembly, Adjustment Mechanism RXL1316-5000-SLC1 RXL1316-5000- 1.0 EA 6027
SLC1
9 WELDMENT, SHIPPING STAND ECT000-5094-SLC1 ECT000-5094- 1.0 EA ASTM A500 981
SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 209

1000975960: Parts List/Bill of Materials (Sheet 8)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 8 of 54

Part No.: 647092-SLC1

Assy, Main Frame Rev. No.: 5
Unit Weight: 53399 kg

Drawing No: 647092-SLC1

Parent Assembly Part No.: 1000873485

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 CAPSCR, HEX HD, M5 X 16MM RXL000-0215-016-SLC1 10.0 EA ZINC PLATED 0.0

STL, CL8.8
2 Lock Washer, M5 RXL000-0040-003-SLC1 RXL000-0040 R 16.0 EA Steel, DIN 798 0.0
EV C-SLC1 0
3 CAPSCR, HEX HEAD M24 x 70 RXL000-0007-007-SLC1 8.0 EA ZINC PLATED 2.0
STL, CL 8.8
4 CAPSCR, HEX HEAD M24 x 50 RXL000-0007-003-SLC1 24.0 EA CL 8.8, ZNC 7.4
5 WASHER, LOCK M24 RXL000-0024-007-SLC1 24.0 EA TEMPERED S 0.2
PRING STL, ZI
NC PLATED
6 WASHER, LOCK M20 RXL000-0024-006-SLC1 8.0 EA TEMPERED S 0.1
PRING STL, ZI
NC PLATED
7 CAPSCR, HEX HEAD M20 x 50 RXL000-0006-006-SLC1 8.0 EA CL 8.8 ZNC 1.6
LG
8 Assembly, Main Frame, Sub RXL1301-5000-SLC1 RXL1301-5000- 1.0 EA 45665
SLC1
9 MAIN SHAFT RXL1001-0007-SLC1 RXL1001-0007- 1.0 EA ASTM A668, C 4523
SLC1 lass MH
10 SHIM, MAIN FRAME, 27 GAUGE RXL1001-0008-SLC1 RXL1001-0008- 2.0 EA ASTM A1008 3.6
SLC1
11 SHIM, MAIN FRAME, 22 GAUGE RXL1001-0009-SLC1 RXL1001-0009- 2.0 EA ASTM A1008 6.6
SLC1
12 SHIM, MAIN FRAME, 15 GAUGE RXL1001-0010-SLC1 RXL1001-0010- 2.0 EA ASTM A1008 15
SLC1
13 SHIM, MAIN FRAME, 11 GAUGE RXL1001-0011-SLC1 RXL1001-0011- 1.0 EA ASTM A1008 13
SLC1
14 Bearing, lower thrust RXL1301-0010-SLC1 RXL1301-0010- 1.0 EA AISI 4140 188
SLC1
15 Main Frame Pin RXL1001-0013-SLC1 RXL1001-0013- 8.0 EA 4140/4142 Ste 251
SLC1 el
16 RETAINER, PIN RXL1001-0017-SLC1 RXL1001-0017- 8.0 EA ASTM A36 14
SLC1
17 U-SEAL, LOWER RXL1001-0016-SLC1 RXL1001-0016- 1.0 EA POLY-U 7.3
SLC1
18 LINER, MAIN FRAME RXL1301-0003-SLC1 RXL1301-0003- 1.0 EA AR400 1658
SLC1
19 CLAMP, LINER RXL1001-0023-SLC1 RXL1001-0023- 24.0 EA ASTM A36 38
SLC1
20 SENSOR, RTD RXL1001-0040-SLC1 RXL1001-0040- 2.0 EA 0.2
SLC1
21 GUARD, ARM RXL1001-0020-SLC1 RXL1001-0020- 2.0 EA 500
SLC1
22 GUARD BOX ARM RXL1001-0021-SLC1 RXL1001-0021- 1.0 EA 412
SLC1
23 LOCTITE,KIT RXL000-0062-SLC1 RXL000-0062- 1.0 EA 0.1
SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
210 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 9)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 9 of 54
Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

24 LOCTITE 222MS, 50ml, LOW, RXL000-0044-003-SLC1 1.0 EA 0.1

PURPLE
25 LOCTITE 277, 50ml, HIGH, RED RXL000-0044-006-SLC1 1.0 EA 0.1
26 SILASTIC RTV-732 RXL000-0059-SLC1 RXL000-0059- 1.0 EA 0.1
SLC1
27 CLAMP, WIRE RXL000-0214-SLC1 6.0 EA Stainless Steel 0.6
28 PLUG, HEX, O-RING RXL002-0008-003-SLC1 1.0 EA STL 0.1
29 SCREW, SET 10-24 X 0.500 RXL000-0213-005-SLC1 4.0 EA BLK FINISH, 0.0
B18.3
30 COVER, RTD WIRES RXL1301-0011-SLC1 RXL1301-0011- 1.0 EA AISI 1018 0.7
SLC1
32 COVER, PORTHOLE RXL2001-0026-SLC1 RXL2001-0026- 3.0 EA ASTM A36 43
SLC1
33 PLUG, RUBBER PORTHOLE RXL1301-0006-SLC1 RXL1301-0006- 3.0 EA Neoprene 18
SLC1
34 LINER, PORTHOLE RXL1301-0007-SLC1 RXL1301-0007- 3.0 EA ASTM A36/A 29
SLC1 R400
35 Flat Washer M24 RXL000-0011-007-SLC1 3.0 EA ZINC PLATED 0.1
STL
36 NUT, HEX M24 RXL000-0028-008-SLC1 3.0 EA STYLE 2, B18 0.3
.2.4.2M-ISO, 4
033, STL, AST
M A562M
37 HHCS, M5 x 12, CL8.8, ZNC RXL000-0215-012-SLC1 RXL000-0215 R 6.0 EA STL, CL 8.8, Z 0.0
EV 00-SLC1 NC

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 211

1000975960: Parts List/Bill of Materials (Sheet 10)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 10 of 54

Part No.: RXL1301-5000-SLC1

Assembly, Main Frame, Sub Rev. No.: 2
Unit Weight: 45665 kg

Drawing No: RXL1301-5000-SLC1

Parent Assembly Part No.: 647092-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 Main Frame, One Piece, XL1300 RXL1301-0008-SLC1 RXL1301-0008- 1.0 EA ASTM A148 G 45322
SLC1 RADE 80-50
2 Liner, main frame seat (8 piece kit) RXL1001-0015-SLC1 RXL1001-0015- 1.0 EA C26800 Half- 226
SLC1 Hard
3 Fulcrum Bar (Qty 1 = 16 equal RXL1001-0019-SLC1 RXL1001-0019- 1.0 EA ASTM A36 86
segments) SLC1
4 BLOCK, LINER RXL301-0017-SLC1 RXL301-0017- 24.0 EA ASTM A36 31
SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
212 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 11)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 11 of 54

Part No.: RXL1001-0020-SLC1

GUARD, ARM Rev. No.: 4
Unit Weight: 250 kg

Drawing No: RXL1001-0020-SLC1

Parent Assembly Part No.: 647092-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

01 GUARD, ARM RXL1001-0020-SF-SLC1 RXL1001-0020- 1.0 EA ASTM A532-9 250

SF-SLC1 3A Class 1 Ty
pe A
02 NUT, HEX M20, STYLE 2, RXL000-0028-007-SLC1 1.0 EA ASTM A562M 0.1
B18.2.4.2M-ISO, 4033
03 ADHESIVE EPOXY RXL000-0310-SLC1 1.0 EA 0.1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 213

1000975960: Parts List/Bill of Materials (Sheet 12)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 12 of 54

Part No.: RXL1001-0021-SLC1

GUARD BOX ARM Rev. No.: 4
Unit Weight: 412 kg

Drawing No: RXL1001-0021-SLC1

Parent Assembly Part No.: 647092-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

01 GUARD, BOX ARM RXL1001-0021-SF-SLC1 RXL1001-0021- 1.0 EA ASTM A532-9 412

SF-SLC1 3A CL 1 type A
02 NUT, HEX M20, STYLE 2, RXL000-0028-007-SLC1 1.0 EA ASTM A562M 0.1
B18.2.4.2M-ISO, 4033
03 ADHESIVE EPOXY RXL000-0310-SLC1 1.0 EA 0.1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
214 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 13)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 13 of 54

Part No.: 1000687903

Assembly, adjustment ring, R1300 Rev. No.: 1
Unit Weight: 19541 kg

Drawing No: 1000687903

Parent Assembly Part No.: 1000873485

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 RING, ADJUSTMENT RXL1302-0001-SLC1 RXL1302-0001- 1.0 EA ASTM A148 G 15093

SLC1 R 80-50
2 DUST SHELL RXL1302-0002-SLC1 RXL1302-0002- 1.0 EA ASTM A36 355
SLC1
3 PIN COVER RXL1002-0005-SLC1 RXL1002-0005- 8.0 EA ASTM A106/A 51
SLC1 STM A36
4 BRACKET, CLAMPING RXL1002-0015-SLC1 RXL1002-0015- 16.0 EA ASTM A36 6.4
CYLINDER SLC1
5 CLAMP RING SEGMENT RXL1002-0018-SLC1 RXL1002-0018- 4.0 EA ASTM A36 55
SLC1
6 DUST SHELL SEAL RXL1002-0019-SLC1 RXL1002-0019- 1.0 EA Black Neoprene 11
SLC1
7 SHIM, 0.76mm THICK RXL1002-0021-SLC1 RXL1002-0021- 16.0 EA A1011 1.6
SLC1
8 SHIM, 0.53mm THICK RXL1002-0022-SLC1 RXL1002-0022- 16.0 EA A1011 0.6
SLC1
9 Hose Assembly, 279 mm RXL1002-0026-SLC1 RXL1002-0026- 1.0 EA 0.5
SLC1
10 Hose Assembly RXL1002-0029-SLC1 RXL1002-0029- 15.0 EA 7.5
SLC1
11 Hose Assembly RXL1002-0030-SLC1 RXL1002-0030- 1.0 EA 0.5
SLC1
12 ADAPTER, ORB-JIC LONG RXL1002-0031-SLC1 RXL1002-0031- 16.0 EA Steel 1.6
SLC1
13 CLAMPING RING RXL1002-0036-SLC1 RXL1002-0036- 1.0 EA ASTM A536 G 3207
SLC1 R 80-60-03
14 Clamping cylinder assembly, R1300 1000687266 1000687266 16.0 EA 373
15 Clamp-Tubing Machined RXL000-0307-SLC1 RXL000-0307 Re 9.0 EA Steel/rubber 0.0
v 00-SLC1
16 BUSHING, MAIN FRAME PIN RXL1002-0044-SLC1 RXL1002-0044- 8.0 EA UNS C95400 A 130
SLC1 LUMINUM BR
ONZE
17 Flat Washer, M16 RXL000-0011-005-SLC1 16.0 EA ZINC PLATED 0.2
STL
18 WASHER, SPRING M10, DIN RXL000-0040-006-SLC1 32.0 EA PLAIN CARB 0.3
7980 ON STL
19 HEX NUT, M14 X 2 RXL000-0028-016-SLC1 RXL000-0028 R 40.0 EA STYLE 2, B18 0.8
EV B-SLC1 .2.4.2M-ISO, 4
033, STL, AST
M A563M
20 CAPSCR, HEX HEAD, M48 X RXL000-0171-021-SLC1 8.0 EA ZINC PLATED 44
320, CL8.8ZNC STL, CL 8.8
21 SPACER, CLAMPING RING RXL1002-0004-SLC1 RXL1002-0004- 8.0 EA AISI 1008/1010 18
SLC1
22 WASHER RXL2002-0015-SLC1 RXL2002-0015- 8.0 EA ASTM A36 4.8
SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 215

1000975960: Parts List/Bill of Materials (Sheet 14)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 14 of 54
Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

23 PIN, 40MM X 140MM RXL000-0151-009-SLC1 8.0 EA CARBON STL, 0.8

C36-C42 ROC
KWELL
24 WASHER, LOCK M10 RXL000-0024-003-SLC1 32.0 EA TEMPERED S 0.3
PRING STL, ZI
NC PLATED
25 CAPSCR, HEX HEAD M10 X 50 RXL000-0003-008-SLC1 RXL000-0003- 64.0 EA ZINC PLATED 0.6
SLC1 STL, CL 8.8
26 SPRING PIN, 10mm DIA X 30mm 362709-SLC1 16.0 EA STL 0.0
27 SPACER RXL1002-0016-SLC1 RXL1002-0016- 32.0 EA A53, 3/8" SCH 1.0
SLC1 40 PIPE
28 ADAPTER, 90 DEGREE, JIC RXL002-0005-008-SLC1 1.0 EA STEEL 0.1
29 ADAPTER,STRAIGHT,JIC-ORB RXL002-0006-016-SLC1 2.0 EA STEEL 0.2
30 ADAPTER, JIC TO PIPE RXL002-0019-006-SLC1 8.0 EA 0.8
31 Grease Hose Assembly RXL1002-0039-SLC1 RXL1002-0039- 8.0 EA 0.0
SLC1
32 FITTING, GREASE, 0.25 IN NPT RXL000-0192-SLC1 RXL000-0192- 16.0 EA 0.2
SLC1
33 CAP, GREASE FITTING, RXL000-0048-SLC1 16.0 EA POLY-E 0.2
YELLOW
34 CAP, JIC RXL002-0010-005-SLC1 1.0 EA STEEL 0.0
35 HEX. HEAD CAP SCREW, M14 X RXL000-0193-006-SLC1 RXL000-0193 R 40.0 EA Steel 2.4
50, Zinc Plated EV 00-SLC1
36 PLUG, PIPE, HEX HD, 0.25-18 RXL000-0097-002-SLC1 8.0 EA 0.1
NPT
37 ADAPTER, BRANCH TEE RXL002-0004-004-SLC1 16.0 EA STEEL 1.6
38 LOCTITE, 680 RXL000-0044-011-SLC1 RXL000-0044 R 1.0 EA 0.1
EV D-SLC1
39 GREASE, 3% MOLY RXL000-0054-SLC1 1.0 EA 54
40 EPOXY MASTIC RXL000-0301-SLC1 RXL000-0301 R 1.0 EA 9.1
EV 00-SLC1
41 ANTI-SEIZE, MOLY GRADE RXL000-0079-SLC1 1.0 EA 19
42 SILASTIC RTV-732 RXL000-0059-SLC1 RXL000-0059- 1.0 EA 0.1
SLC1
43 HANDLING BRACE RXL1002-0041-SLC1 RXL1002-0041- 1.0 EA ASTM A500/A 85
SLC1 STM A36
44 ADAPTER, 90 DEGREE 4 JIC X 6 RXL002-0002-003-SLC1 RXL002-0002 R 1.0 EA Steel 0.1
JIC SWIVEL EV 00-SLC1
45 ADAPTER, 4 JIC SWIVEL X RXL000-0266-002-SLC1 RXL000-0266 R 1.0 EA Steel 0.1
1/4-18 NPT EV 00-SLC1
46 ADAPTER, BLEEDER, PORT RXL000-0267-SLC1 1.0 EA STEEL 0.1
47 ASSEMBLY, HOSE RXL1302-0004-SLC1 RXL1302-0004- 1.0 EA 0.1
SLC1
48 CAPSCR, HEX HEAD M16 X 35 RXL000-0005-003-SLC1 16.0 EA ZINC PLATED 1.4
STL, CL 8.8
49 Metric Flat Washer, M14 RXL000-0011-018-SLC1 RXL000-0011 R 40.0 EA ZINC PLATED 0.4
EV B-SLC1 STL
50 METRIC SPRING WASHER, M14 RXL000-0040-008-SLC1 RXL000-0040 R 40.0 EA PLAIN CARB 0.4
EV C-SLC1 ON STL
51 METRIC SPRING WASHER, M16 RXL000-0040-009-SLC1 RXL000-0040 R 16.0 EA PLAIN CARB 0.2
EV C-SLC1 ON STL
52 LOCTITE 569, 50ml, HIGH, RXL000-0044-004-SLC1 1.0 EA 0.1
BROWN

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
216 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 15)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 15 of 54

Part No.: 1000920546

Assembly, tramp release, split, R1100 / R1300 Rev. No.: 1
Unit Weight: 8195 kg

Drawing No: 1000024420, 1000920546

Parent Assembly Part No.: 1000873485

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 Assembly, tramp release cylinder, 1000687267 1000687267 16.0 EA 5120

R1300
2 Support, Tramp cylinder RXL1303-0015-SLC1 RXL1303-0015- 16.0 EA AISI 1045 1040
SLC1
3 CAPSCR, HEX HEAD M36 x 170 RXL000-0009-011-SLC1 64.0 EA CL8.8 ZNC 64
LG
4 WASHER, LOCK M36 RXL000-0024-009-SLC1 64.0 EA TEMPERED S 6.4
PRING STL, ZI
NC PLATED
5 WASHER, LOWER SPHERICAL RXL1303-0014-SLC1 RXL1303-0014- 16.0 EA 4340 80
SLC1
6 CUP, LOWER SPHERICAL RXL503-0004-SLC1 RXL503-0004- 16.0 EA 4340 38
SLC1
7 SEAL, ROD DUST RXL1303-0012-SLC1 16.0 EA Neoprene 4.8
8 ADHESIVE RXL000-0152-SLC1 RXL000-0152- 1.0 EA 0.1
SLC1
9 CLAMP COLLAR RXL503-0003-SLC1 RXL503-0003- 16.0 EA 1045 64
SLC1
10 WASHER, LOCK M16 RXL000-0024-005-SLC1 32.0 EA TEMPERED S 0.3
PRING STL, ZI
NC PLATED
11 SOCKET HEAD CAP SCREW RXL000-0071-003-SLC1 32.0 EA CL8.8 BLK O 3.2
M16 x 35 XD
12 CUP, SPHERICAL RXL1303-0017-SLC1 RXL1303-0017- 16.0 EA 4340 59
SLC1
13 WASHER, UPPER SPHERICAL RXL1303-0016-SLC1 RXL1303-0016- 16.0 EA 4340 62
SLC1
14 ANTI-SEIZE, MOLY GRADE RXL000-0079-SLC1 1.0 EA 19
15 CAP, CYLINDER RXL503-0007-SLC1 RXL503-0007- 16.0 EA A36 STL 75
SLC1
16 CAPSCR, SOCKET HD, M10 x 25 RXL000-0039-004-SLC1 64.0 EA CL12.9 1.9
LG, CL12.9
17 WASHER, LOCK M10 RXL000-0024-003-SLC1 64.0 EA TEMPERED S 0.6
PRING STL, ZI
NC PLATED
18 FLANGE KIT, CODE 62 #16 RXL002-0036-SLC1 64.0 EA 45
19 HOSE ASSEMBLY RXL1303-0020-SLC1 12.0 EA 23
20 HOSE ASSEMBLY RXL1303-0019-SLC1 8.0 EA 14
21 ADAPTER, JIC #16, 90 DEG RXL002-0047-SLC1 4.0 EA 2.0
22 TEE, RUN, JIC-JIC-JIC SWIVEL RXL002-0022-015-SLC1 4.0 EA 4.0
23 HOSE ASSEMBLY RXL1303-0026-SLC1 2.0 EA 3.2
24 HOSE ASSEMBLY RXL1303-0024-SLC1 2.0 EA 3.2
25 Accumulator Mount RXL2003-0026-SLC1 RXL2003-0026- 4.0 EA A36 STL 384
SLC1
26 ACCUMLATOR, 10 GALLON RXL1003-0030-SLC1 RXL1003-0030- 4.0 EA 400
SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 217

1000975960: Parts List/Bill of Materials (Sheet 16)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 16 of 54
Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

27 RING, ACCUMULATOR MOUNT RXL403-0083-SLC1 RXL403-0083- 4.0 EA Rubber 0.8

SLC1
28 ADAPTER,STRAIGHT,JIC-ORB RXL002-0006-057-SLC1 4.0 EA STEEL 0.4
29 ADAPTER, BRANCH TEE RXL002-0004-010-SLC1 4.0 EA STEEL 0.4
30 CLAMP, ACCUMULATOR, RXL403-0068-SLC1 RXL403-0068- 4.0 EA 4.0
MOUNTING SLC1
31 CAPSCR, HEX HEAD M12 X 30 RXL000-0004-004-SLC1 8.0 EA ZINC PLATED 0.8
STL
32 WASHER, LOCK M12 RXL000-0024-004-SLC1 8.0 EA TEMPERED S 0.1
PRING STL, ZI
NC PLATED
33 Flat Washer, M12 RXL000-0011-004-SLC1 8.0 EA ZINC PLATED 0.1
STL
34 NUT, HEX M12, ISO 4033 RXL000-0028-005-SLC1 8.0 EA STYLE 2, B18 0.1
.2.4.2M-ISO, 4
033, STL, AST
M A562M
35 HOSE ASSEMBLY RXL1303-0021-SLC1 8.0 EA 48
36 HOSE ASSY RXL403-0058-SLC1 2.0 EA 24
37 TEE, UNION, JIC #12-JIC #12-JIC 1000903727 2.0 EA STL 592
#12
38 CAP, JIC RXL002-0010-008-SLC1 2.0 EA STL 0.0
39 Hose assembly RXL1003-0062-SLC1 RXL1003-0062- 1.0 EA 0.1
SLC1
40 Plug, flange head, 1 in code 62 1000122771 8.0 EA Plain Carbon S 1.8
teel
41 EXPANDER, REDUCER, JIC RXL002-0012-033-SLC1 4.0 EA STL 0.0
42 Hose, tee to tramp cylinders, 1000903732 1000903732 4.0 EA 5.2
R1100 / R1300

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
218 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 17)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 17 of 54

Part No.: RXL1004-5003-SLC1

ASSY, COUNTERSHAFT BOX Rev. No.: 13
Unit Weight: 3193 kg

Drawing No: RXL1004-5003-SLC1

Parent Assembly Part No.: 1000873485

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

01 Countershaft Box RXL1004-0021-SLC1 RXL1004-0021- 1.0 EA AISI 1018/1020 1852

SLC1
TR000-0022-
SLC1
02 COUNTERSHAFT RXL1004-0002-SLC1 RXL1004-0002- 1.0 EA AISI 1045 554
SLC1
03 BUSHING, COUNTERSHAFT RXL1004-0003-SLC1 RXL1004-0003- 2.0 EA UNS C96800 131
SLC1
04 Pinion, bevel (Curved teeth) RXL1004-0004-SLC1 2.505640-PDB1 1.0 EA See drawing 450
RXL1004-0004-
SLC1
1000685493
RXL1006-0015-
SLC1
70008181-PDB1
70008178-PDB1
3.504314-PDB1
1000685492
70017081-PDB1
1.515850-PDB1
70008580-PDB1
70008179-PDB1
1000711425
520530-PDB1
05 OIL FLINGER RXL1004-0005-SLC1 RXL1004-0005- 1.0 EA ASTM A27 GR 44
SLC1 ADE 70-36
06 COVER, COUNTERSHAFT BOX RXL1004-0006-SLC1 RXL1004-0006- 1.0 EA ASTM A27 GR 112
SLC1 ADE 70-36
07 KEY, OIL FLINGER RXL1004-0007-SLC1 RXL1004-0007- 1.0 EA AISI 1020 0.0
SLC1
08 PISTON RING RXL1004-0008-SLC1 RXL1004-0008- 1.0 EA CAST IRON 0.6
SLC1
09 GASKET, COVER RXL1004-0009-SLC1 RXL1004-0009- 1.0 EA GARLOCK 29 0.4
SLC1 00
11 SHIM, COUNTERSHAFT BOX, RXL1004-0012-SLC1 RXL1004-0012- 1.0 EA A1008 0.9
27 GAUGE SLC1
12 SHIM, COUNTERSHAFT BOX, RXL1004-0013-SLC1 RXL1004-0013- 1.0 EA A1008 1.7
22 GAUGE SLC1
13 SHIM, COUNTERSHAFT BOX, RXL1004-0014-SLC1 RXL1004-0014- 1.0 EA A1008 3.7
15 GAUGE SLC1
14 SHIM, COUNTERSHAFT BOX, RXL1004-0015-SLC1 RXL1004-0015- 1.0 EA A1008 6.7
11 GAUGE SLC1
17 O-RING RXL1004-0018-SLC1 RXL1004-0018- 1.0 EA Neoprene, Blac 0.1
SLC1 k, 70 Duromete
r, Shore A
19 PLUG, PIPE, SQ HD .50-14 NPT RXL000-0098-004-SLC1 1.0 EA 0.0
20 PLUG, PIPE, HEX HD, 1.00-11.50 RXL000-0097-006-SLC1 1.0 EA 0.0
NPT
21 CAPSCR, HEX HEAD M42 x 140 RXL000-0010-005-SLC1 6.0 EA ZINC PLATED 13
STL

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 219

1000975960: Parts List/Bill of Materials (Sheet 18)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 18 of 54
Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

22 WASHER, LOCK M42 RXL000-0024-010-SLC1 6.0 EA TEMPERED S 0.6

PRING STL, ZI
NC PLATED
23 Metric Flat Washer M42 RXL000-0011-010-SLC1 6.0 EA ZINC PLATED 1.2
STL
24 CAPSCR, HEX HEAD M20 X 80 RXL000-0006-011-SLC1 7.0 EA ZINC PLATED 1.4
LG STL
25 WASHER, LOCK M20 RXL000-0024-006-SLC1 7.0 EA TEMPERED S 0.1
PRING STL, ZI
NC PLATED
26 PIN, M20 x 50 RXL000-0135-001-SLC1 4.0 EA CARBON STL, 0.5
C36-C42 ROC
KWELL
27 ANTI-SEIZE, MOLY GRADE RXL000-0079-SLC1 1.0 EA 19
28 PLUG, PIPE, SQ HD 1.50-11.50 RXL000-0098-008-SLC1 1.0 EA 0.0
NPT

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
220 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 19)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 19 of 54

Part No.: 677551-SLC1

ASSY, ECCENTRIC, MAIN Rev. No.: 2
Unit Weight: 8438 kg

Drawing No: 677551-SLC1

Parent Assembly Part No.: 1000873485

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 ASSY, ECCENTRIC, SUB 677550-SLC1 677550-SLC1 1.0 EA 3851

2 ASSY, COUNTERWEIGHT 677548-SLC1 677548-SLC1 1.0 EA 2578
3 Gear, bevel (Curved teeth) RXL1006-0015-SLC1 70008580-PDB1 1.0 EA See drawing 1980
1000685493
2.505639-PDB1
70017081-PDB1
1000685492
3.504314-PDB1
1.515849-PDB1
70008178-PDB1
70008181-PDB1
RXL1006-0015-
SLC1
RXL1004-0004-
SLC1
70008179-PDB1
1000711425
520530-PDB1
4 CAPSCR, HEX HEAD, M36 X 260 RXL000-0175-017-SLC1 10.0 EA ZINC PLATED 25
STL, CL10.9
5 CAPSCR, HEX HEAD, M36 X 200 RXL000-0175-014-SLC1 2.0 EA ZINC PLATED 4.0
STL, CL10.9
6 Flat Washer, M36 RXL000-0011-009-SLC1 RXL000-0011 R 10.0 EA ZINC PLATED 0.1
EV B-SLC1 STEEL
7 LOCTITE 277, 50ml, HIGH, RED RXL000-0044-006-SLC1 1.0 EA 0.1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 221

1000975960: Parts List/Bill of Materials (Sheet 20)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 20 of 54

Part No.: 677550-SLC1

ASSY, ECCENTRIC, SUB Rev. No.: 2
Unit Weight: 3851 kg

Drawing No: 677550-SLC1

Parent Assembly Part No.: 677551-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 ECCENTRIC 677549-SLC1 677549-SLC1 1.0 EA ASTM A536 G 3201

R. 80-60-03
2 BUSHING, ECCENTRIC RXL1006-0004-SLC1 RXL1006-0004- 1.0 EA UNS C93800 431
SLC1
3 BEARING, THRUST, UPPER RXL1006-0001-SLC1 RXL1006-0001- 1.0 EA UNS C93200 206
SLC1
4 WASHER, LOCK M20 RXL000-0024-006-SLC1 8.0 EA TEMPERED S 0.1
PRING STL, ZI
NC PLATED
5 PIN, M20 x 80 RXL000-0135-004-SLC1 1.0 EA CARBON STL, 0.2
C36-C42 ROC
KWELL
6 LOCTITE, 680 RXL000-0044-011-SLC1 RXL000-0044 R 1.0 EA 0.1
EV D-SLC1
7 CAPSCR, HEX HEAD M20 x 50 RXL000-0006-006-SLC1 8.0 EA CL 8.8 ZNC 1.6
LG
8 LOCKING COMPOUND, 6.25 lb RXL000-0075-SLC1 4.0 EA 11
Kit

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
222 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 21)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 21 of 54

Part No.: 677548-SLC1

ASSY, COUNTERWEIGHT Rev. No.: 2
Unit Weight: 2578 kg

Drawing No: 677548-SLC1

Parent Assembly Part No.: 677551-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 COUNTERWEIGHT 677547-SLC1 677547-SLC1 1.0 EA 2135

2 GUARD, COUNTERWEIGHT RXL1006-0020-SLC1 RXL1006-0020- 1.0 EA AR400 427
SLC1
3 EXPANDING FOAM RXL000-0161-SLC1 RXL000-0161- 1.0 EA 0.1
SLC1
4 T-SEAL, LOWER RXL1006-0005-SLC1 1.0 EA POLY-U 7.5
5 U-SEAL, UPPER RXL1006-0006-SLC1 RXL1006-0006- 1.0 EA POLY-U 7.7
SLC1
6 CAPSCR, HEX HEAD M24 x 55 RXL000-0007-004-SLC1 9.0 EA ZINC PLATED 0.9
STL
7 SILASTIC RTV-732 RXL000-0059-SLC1 RXL000-0059- 1.0 EA 0.1
SLC1
8 LOCTITE,KIT RXL000-0062-SLC1 RXL000-0062- 1.0 EA 0.1
SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 223

1000975960: Parts List/Bill of Materials (Sheet 22)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 22 of 54

Part No.: 677547-SLC1

COUNTERWEIGHT Rev. No.: 2
Unit Weight: 2135 kg

Drawing No: 677547-SLC1

Parent Assembly Part No.: 677548-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 Counterweight 677546-SLC1 677546-SLC1 1.0 EA ASTM A27 Gr 2134

ade 70-40
2 LEAD RXL000-0126-SLC1 RXL000-0126- 1.0 EA UNS L50049 - 1.0
SLC1 ASTM B29-62
PURE LEAD

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
224 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 23)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 23 of 54

Part No.: RXL1007-5005-SLC1

Socket Assembly XL1100 Rev. No.: 2
Unit Weight: 875 kg

Drawing No: RXL1007-5005-SLC1

Parent Assembly Part No.: 1000873485

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 ASSY, SUB, SOCKET, ANTI- RXL1007-5004-SLC1 RXL1007-5004- 1.0 EA 481

SPIN SLC1
2 LINER, SOCKET RXL1007-0006-SLC1 RXL1007-0006- 1.0 EA C93800 LEAD 386
SLC1 ED BRNZ
3 CAPSCR, HEX HEAD M36 x 110 RXL000-0009-005-SLC1 4.0 EA CL 8.8, ZNC 8.0
LG
4 WASHER, LOCK M36 RXL000-0024-009-SLC1 4.0 EA TEMPERED S 0.4
PRING STL, ZI
NC PLATED

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 225

1000975960: Parts List/Bill of Materials (Sheet 24)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 24 of 54

Part No.: RXL1007-5004-SLC1

ASSY, SUB, SOCKET, ANTI-SPIN Rev. No.: 7
Unit Weight: 481 kg

Drawing No: RXL1007-5004-SLC1

Parent Assembly Part No.: RXL1007-5005-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

01 SOCKET, ANTI-SPIN RXL1007-0004-SLC1 RXL1007-0004- 1.0 EA 4140/4142 FOR 477

SLC1 GED STL HT
02 PIN, 40MM X 90MM RXL000-0151-005-SLC1 4.0 EA CARBON STL, 3.6
C36-C42 ROC
KWELL
03 LOCTITE, 680 RXL000-0044-011-SLC1 RXL000-0044 R 1.0 EA 0.1
EV D-SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
226 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 25)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 25 of 54

Part No.: 677553-SLC1

ASSY, HEAD Rev. No.: 2
Unit Weight: 11135 kg

Drawing No: 677553-SLC1

Parent Assembly Part No.: 1000873485

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 HEAD 677552-SLC1 677552-SLC1 1.0 EA 9677

2 Upper T-Seal RXL1008-0002-SLC1 RXL1008-0002- 1.0 EA POLYURETH 6.1
SLC1 ANE, 90 SHOR
E A DURO., R
UST COLOR
3 BUSHING, UPPER HEAD RXL1008-0004-SLC1 RXL1008-0004- 1.0 EA UNS C95400 A 185
SLC1 LUM BRNZ
4 Bushing, head, lower RXL1008-0033-SLC1 RXL1008-0033- 1.0 EA UNS C93800 L 440
SLC1 EADED BRNZ
5 HEAD BALL, ANTI-SPIN RXL1008-0007-SLC1 RXL1008-0007- 1.0 EA AISI 4340 362
SLC1
6 ASSY, HEAD STUB RXL1008-5002-SLC1 RXL1008-5002- 1.0 EA 391
SLC1
7 KEY RXL1008-0015-SLC1 RXL1008-0015- 4.0 EA ASTM A36 6.0
SLC1
8 WIRE, CARBON STL, 0.080, 1 LB RXL000-0233-010-SLC1 1.0 EA ZINC GALV 0.0
SPOOL
9 WASHER, SPRING M12, DIN RXL000-0040-007-SLC1 16.0 EA PLAIN CARB 0.2
7980 ON STL
10 PIN, 40MM X 120MM RXL000-0151-008-SLC1 4.0 EA CARBON STL, 4.7
C36-C42 ROC
KWELL
11 CAPSCR, HEX DRILLED HD, RXL000-0232-007-SLC1 16.0 EA ZINC PLATED 0.8
M12 X 45 STL, CL 8.8
12 CAPSCR, HEX HD, M24 X 100 RXL000-0281-011-SLC1 16.0 EA ZINC PLATED 8.0
LG STL, CL 10.9
13 CAPSCR, SOCKET HEAD RXL000-0166-010-SLC1 2.0 EA BLK OXIDE S 1.0
M24X100 TL, CL12.9
14 WASHER, LOCK M24 RXL000-0024-007-SLC1 2.0 EA TEMPERED S 0.0
PRING STL, ZI
NC PLATED
15 LOCTITE 271, 50ml, HIGH, RED RXL000-0044-007-SLC1 1.0 EA 0.1
16 LOCTITE,KIT RXL000-0062-SLC1 RXL000-0062- 1.0 EA 0.1
SLC1
17 PLUG, PIPE, HEX SOCKET, RXL000-0196-008-SLC1 6.0 EA GALV ZINC P 0.6
1-1/2"-11.5 NPT LATED STL
18 LOCTITE 592, 50ml, MED, RXL000-0044-002-SLC1 1.0 EA 0.0
WHITE
19 Ring, lower head bushing RXL1008-0032-SLC1 RXL1008-0032- 1.0 EA ASTM A36 39
SLC1
20 CAP, HEAD, STUB/BALL 676333-SLC1 676333-SLC1 1.0 EA ASTM A36 13
21 CAPSCR, SOCKET HD, M10 x 40 RXL000-0039-007-SLC1 8.0 EA ALLOY STL 0.2
LG, CL 12.9
22 WSHR, NORDLOCK, M10 593955-SLC1 8.0 EA ZINC 0.1
23 O-RING, CAP, HEAD STUB/ 676334-SLC1 676334-SLC1 1.0 EA PARKER V11 0.1
BALL 64-75

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 227

1000975960: Parts List/Bill of Materials (Sheet 26)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 26 of 54

Part No.: 677552-SLC1

HEAD Rev. No.: 2
Unit Weight: 9677 kg

Drawing No: 677552-SLC1

Parent Assembly Part No.: 677553-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 HEAD, SEMI-FIN RXL1008-0018-SF-SLC1 RXL1008-0018- 1.0 EA ASTM A148 G 9674

SF-SLC1 rade 90-60
2 LOCKING COMPOUND, 6.25 lb RXL000-0075-SLC1 1.0 EA 2.8
Kit
3 Plug, solid, tapered, pushin, size 11 677545-15-SLC1 677545-SLC1 6.0 EA 0.1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
228 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 27)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 27 of 54

Part No.: RXL1008-5002-SLC1

ASSY, HEAD STUB Rev. No.: 2
Unit Weight: 391 kg

Drawing No: RXL1008-5002-SLC1

Parent Assembly Part No.: 677553-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

01 STUB, HEAD, ANTI-SPIN RXL1008-0008-SLC1 RXL1008-0008- 1.0 EA ASTM A668 C 389

SLC1 lass-MH
02 PIN, STRAIGHT 25mm x 50 RXL000-0056-SLC1 8.0 EA C36-C42 Rock 1.6
well

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 229

1000975960: Parts List/Bill of Materials (Sheet 28)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 28 of 54

Part No.: RXL1316-5000-SLC1

Assembly, Adjustment Mechanism Rev. No.: 4
Unit Weight: 6027 kg

Drawing No: RXL1316-5000-SLC1

Parent Assembly Part No.: 1000873485

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 Mounting Weldment RXL1002-0042-SLC1 RXL1002-0042- 4.0 EA ASTM A36 1363

SLC1
2 DRIVE RING SUPPORT RXL1002-0043-SLC1 RXL1002-0043- 6.0 EA ASTM A36 564
SLC1
3 BRACKETS, HOSE SUPPORT RXL1002-0037-SLC1 RXL1002-0037- 5.0 EA 13
SLC1
4 WASHER, LOCK M30 RXL000-0024-008-SLC1 44.0 EA TEMPERED S 2.2
PRING STL, ZI
NC PLATED
5 CAPSCR, HEX HEAD M30 x 80 RXL000-0008-004-SLC1 44.0 EA ZINC PLATED 31
STL
6 WASHER, SPRING M10, DIN RXL000-0040-006-SLC1 20.0 EA PLAIN CARB 0.2
7980 ON STL
7 HHCS, M10 X 45 CL 8.8 RXL000-0003-007-SLC1 RXL000-0003- 20.0 EA ZINC PLATED 4.0
SLC1 STL
8 WASHER, LOCK M20 RXL000-0024-006-SLC1 80.0 EA TEMPERED S 0.8
PRING STL, ZI
NC PLATED
9 NUT, HEX M20, STYLE 2, RXL000-0028-007-SLC1 64.0 EA ASTM A562M 5.1
B18.2.4.2M-ISO, 4033
10 CAPSCR, HEX HEAD M20 x 100 RXL000-0006-013-SLC1 24.0 EA ZINC PLATED 7.2
LG STL
11 RETAINER,ADJUSTMENT RXL1016-0002-SLC1 RXL1016-0002- 6.0 EA ASTM A36 209
DRIVE RING SLC1
12 CAPSCR, SOCKET HD, M10 x 40 RXL000-0039-007-SLC1 12.0 EA ALLOY STL 0.3
LG, CL 12.9
13 CAPSCR, HEX HEAD M20 x 90 RXL000-0006-012-SLC1 40.0 EA ZINC PLATED 8.8
LG STL
14 PAD, DRIVE RING SUPPORT RXL1016-0005-SLC1 RXL1016-0005- 6.0 EA NYLATRON 5.4
SLC1 GSM
15 WASHER, LOCK M36 RXL000-0024-009-SLC1 16.0 EA TEMPERED S 1.6
PRING STL, ZI
NC PLATED
16 NUT, HEX M36 RXL000-0028-010-SLC1 16.0 EA ASTM A562M 4.8
17 PLATE, ADAPTER RXL1016-0015-SLC1 RXL1016-0015- 4.0 EA 532
SLC1
18 Assy Adjustment Drive RXL1016-5002-SLC1 RXL1016-5002- 4.0 EA 5.4
SLC1
19 BRACKET, PROX SWITCH MTG RXL1016-0016-SLC1 RXL1016-0016- 4.0 EA ASTM A36 2.4
SLC1
20 Pinion RXL1016-0007-SLC1 RXL1016-0007- 4.0 EA AISI 1045 446
SLC1
21 WASHER, RUBBER RXL1016-0021-SLC1 RXL1016-0021- 16.0 EA NAT RBR 0.6
SLC1
22 ASSY, SUB, PINION SHIELD RXL1016-5007-SLC1 RXL1016-5007- 4.0 EA 199
SLC1
23 ADAPTER, JIC TO PIPE RXL002-0019-006-SLC1 4.0 EA 0.4

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
230 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 29)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 29 of 54
Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

24 ADAPTER, JIC TO PIPE RXL002-0013-006-SLC1 4.0 EA STEEL 0.0

25 ZERK, GREASE RXL1016-0012-SLC1 RXL1016-0012- 4.0 EA 0.0
SLC1
26 CAPSCR, HEX HEAD M20 x 40 RXL000-0006-004-SLC1 16.0 EA ZINC PLATED 3.2
LG STL
27 RING, DRIVE RXL1016-0022-SLC1 RXL1016-0022- 1.0 EA 2067
SLC1
28 TURNING BRACKET ASSY 648588-SLC1 648588-SLC1 4.0 EA AISI 1018 452
29 Clamp, mounting, hose, 1-1/4" RXL1003-0080-SLC1 RXL1003-0080- 10.0 EA Zinc Chromate 3.0
SLC1 finish Steel
30 Clamp, mounting, hose, 13/16" RXL1003-0079-SLC1 RXL1003-0079- 5.0 EA Zinc Chromate 1.0
SLC1 finish Steel
31 ADAPTER, 90 DEGREE, JIC-ORB RXL002-0001-009-SLC1 4.0 EA STL 0.2
32 ADAPTER,STRAIGHT,JIC-ORB RXL002-0006-038-SLC1 8.0 EA STL 1.1
33 Adapter, branch tee RXL002-0004-007-SLC1 RXL002-0004 R 4.0 EA 0.4
EV A-SLC1
34 ADAPTER,90 DEGREE,JIC-JIC RXL002-0002-015-SLC1 4.0 EA STL 0.5
SWVL
35 Adapter, union tee RXL002-0003-014-SLC1 RXL002-0003 R 2.0 EA STL 0.0
EV 00-SLC1
36 Adapter, union tee RXL002-0003-005-SLC1 RXL002-0003 R 3.0 EA 0.3
EV 00-SLC1
37 ADAPTER, 90 DEGREE, JIC RXL002-0005-008-SLC1 2.0 EA STEEL 0.2
38 HOSE ASSY, 4 JIC RXL1016-0020-SLC1 RXL1016-0020- 4.0 EA 0.4
SLC1
39 Hose assembly, elbow to motor RXL1003-0108-SLC1 RXL1003-0108- 4.0 EA 0.4
SLC1
40 Hose assembly, tee to motor RXL1316-0001-SLC1 RXL1316-0001- 2.0 EA 2.4
SLC1
41 Hose assembly, tee to motor, long RXL1316-0002-SLC1 RXL1316-0002- 2.0 EA 3.0
SLC1
42 Hose assembly, motor to motor RXL1316-0003-SLC1 RXL1316-0003- 4.0 EA 10
SLC1
43 Hose assembly, tee to brake RXL1316-0004-SLC1 RXL1316-0004- 1.0 EA 0.4
SLC1
44 Hose assembly, tee to brake, long RXL1316-0005-SLC1 RXL1316-0005- 1.0 EA 0.5
SLC1
45 Hose assembly, brake to brake RXL1316-0006-SLC1 RXL1316-0006- 2.0 EA 1.6
SLC1
46 WELDMENT, HOSE CLAMP RXL1302-0003-SLC1 RXL1302-0003- 1.0 EA 0.2
SLC1
47 Flat Washer, M10 RXL000-0011-003-SLC1 12.0 EA ZINC PLATED 0.1
STL
48 CAPSCR, HEX HEAD M36 x 120 RXL000-0009-006-SLC1 16.0 EA ZINC PLATED 15
LG STL
49 Flat Washer, M36 RXL000-0011-009-SLC1 16.0 EA ZINC PLATED 0.2
STL
50 CAPSCR, HEX HEAD M10 X 25 RXL000-0003-003-SLC1 RXL000-0003- 8.0 EA ZINC PLATED 0.2
SLC1 STL
51 WASHER, LOCK M10 RXL000-0024-003-SLC1 8.0 EA TEMPERED S 0.1
PRING STL, ZI
NC PLATED
52 CAPSCR, HEX HEAD M24 x 110 RXL000-0007-012-SLC1 16.0 EA ZINC PLATED 8.0
STL
53 WASHER, LOCK M24 RXL000-0024-007-SLC1 48.0 EA TEMPERED S 0.5
PRING STL, ZI
NC PLATED

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 231

1000975960: Parts List/Bill of Materials (Sheet 30)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 30 of 54
Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

54 CAPSCR, HEX HEAD M24 x 100 RXL000-0007-011-SLC1 40.0 EA ZINC PLATED 20

STL
55 CAPSCR, HEX HEAD M36 x 90 RXL000-0009-003-SLC1 4.0 EA ZINC PLATED 4.4
LG STL
56 NUT HEX JAM M36 RXL000-0153-011-SLC1 RXL000-0153- 4.0 EA STL 0.3
SLC1
57 Hose assembly RXL1003-0062-SLC1 RXL1003-0062- 2.0 EA 0.2
SLC1
58 HOSE ASSY RXL403-0058-SLC1 2.0 EA 24

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
232 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 31)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 31 of 54

Part No.: RXL1016-5002-SLC1

Assy Adjustment Drive Rev. No.: 8
Unit Weight: 1.4 kg

Drawing No: RXL1016-5002-SLC1

Parent Assembly Part No.: RXL1316-5000-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

01 ASSY, GEARBOX XL1100 RXL1016-5003-SLC1 RXL1016-5003- 1.0 EA 0.9

SLC1
02 HYDRAULIC ADJUST MOTOR RXL1016-0008-SLC1 RXL1016-0008- 1.0 EA 0.0
SLC1
03 GASKET, MOTOR RXL1016-0018-SLC1 RXL1016-0018- 1.0 EA 0.0
SLC1
04 CAPSCR, HEX HD 1/2 X 1 1/4 RXL000-0018-004-SLC1 4.0 EA 1/2-13, GR5, Z 0.4
Full Thrd INC PLATED
STL
05 WASHER, LOCK, 1/2 RXL000-0025-005-SLC1 4.0 EA TEMPERED S 0.0
PRING STL, Z
INC PLATED,
B27.1
06 LOCTITE 271, 50ml, HIGH, RED RXL000-0044-007-SLC1 1.0 EA 0.1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 233

1000975960: Parts List/Bill of Materials (Sheet 32)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 32 of 54

Part No.: RXL1016-5003-SLC1

ASSY, GEARBOX XL1100 Rev. No.: 7
Unit Weight: 0.9 kg

Drawing No: RXL1016-5003-SLC1

Parent Assembly Part No.: RXL1016-5002-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

01 DRIVE, GEAR RXL1016-0010-SLC1 RXL1016-0010- 1.0 EA 0.1

SLC1
03 BRAKE RXL1016-0009-SLC1 RXL1016-0009- 1.0 EA 0.1
SLC1
04 CAPSCR, HEX HD 1/2 X 5 1/2 RXL000-0018-018-SLC1 4.0 EA 1/2-13, GR5, Z 0.6
INC PLATED
STL
05 ZERK, GREASE RXL1016-0012-SLC1 RXL1016-0012- 1.0 EA 0.0
SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
234 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 33)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 33 of 54

Part No.: RXL1016-5007-SLC1

ASSY, SUB, PINION SHIELD Rev. No.: 3
Unit Weight: 50 kg

Drawing No: RXL1016-5007-SLC1

Parent Assembly Part No.: RXL1316-5000-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

01 WASHER, LOCK M8 RXL000-0024-002-SLC1 13.0 EA TEMPERED S 0.1

PRING STL, ZI
NC PLATED
02 WASHER, LOCK M10 RXL000-0024-003-SLC1 7.0 EA TEMPERED S 0.1
PRING STL, ZI
NC PLATED
03 WASHER FLAT METRIC M8 RXL000-0011-002-SLC1 13.0 EA ZINC PLATED 0.1
STL
04 NUT, HEX M8 RXL000-0028-003-SLC1 13.0 EA ASTM A562M 0.1
05 NUT, HEX M10, ISO 4033 RXL000-0028-004-SLC1 7.0 EA STYLE 2, B18 0.1
.2.4.2M-ISO, 4
033, STL, AST
M A562M
06 CAPSCR, HEX HEAD M10 X 30 RXL000-0003-004-SLC1 RXL000-0003- 7.0 EA ZINC PLATED 0.1
SLC1 STL
07 CAPSCR, HEX, M8 x 25 300615-SLC1 13.0 EA CL 8.8, ZNC 0.1
08 SHIELD, PINION RXL1016-0017-SLC1 RXL1016-0017- 1.0 EA ASTM A36 47
SLC1
09 SKIRT, ROCK RXL1016-0019-SLC1 RXL1016-0019- 1.0 EA Neoprene 0.6
SLC1
10 PLATE, BACKING RXL1016-0025-SLC1 RXL1016-0025- 1.0 EA ASTM A36 0.7
SLC1
11 PLATE, BACKING RXL1016-0024-SLC1 RXL1016-0024- 2.0 EA ASTM A36 0.4
SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 235

1000975960: Parts List/Bill of Materials (Sheet 34)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 34 of 54

Part No.: RXL1016-0022-SLC1

RING, DRIVE Rev. No.: 3
Unit Weight: 2067 kg

Drawing No: RXL1016-0022-SLC1

Parent Assembly Part No.: RXL1316-5000-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

01 CASTING, DRIVE RING RXL1016-0022-SF-SLC1 RXL1016-0022- 4.0 EA C-1040 2066

SF-SLC1
02 PIN, M20 x 50 RXL000-0135-001-SLC1 8.0 EA CARBON STL, 1.0
C36-C42 ROC
KWELL
03 LOCTITE, 680 RXL000-0044-011-SLC1 RXL000-0044 R 1.0 EA 0.1
EV D-SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
236 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 35)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 35 of 54

Part No.: RXL1005-5006-SLC1

ASSY, OIL PIPING Rev. No.: 4
Unit Weight: 195 kg

Drawing No: RXL1005-5006-SLC1

Parent Assembly Part No.: 1000873483

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 Supply Oil Pipe Assembly RXL1005-0001-SLC1 RXL1005-0001- 1.0 EA 18

SLC1
2 Oil Drain Assembly RXL1005-0002-SLC1 RXL1005-0002- 1.0 EA 38
SLC1
3 HOSE ASSY, COUNTERSHAFT RXL1005-0003-SLC1 RXL1005-0003- 1.0 EA BUNA-N/SBR 1.0
BOX SLC1 BLEND, OIL-R
ESISTENT
4 JOINT, EXPANSION 3" (3 PC RXL1005-0006-SLC1 RXL1005-0006- 1.0 EA GALV/NEOP 7.2
KIT) SLC1
5 JOINT, EXPANSION RXL1005-0007-SLC1 RXL1005-0007- 1.0 EA GALV/NEOP 25
SLC1
6 MOUNT, PIPE SUPPORT RXL1005-0008-SLC1 RXL1005-0008- 1.0 EA ASTM A36 5.5
SLC1
7 8" Pipe Support U-Bolt XL1100 RXL1005-0011-SLC1 RXL1005-0011- 1.0 EA Galvanized St 0.7
SLC1 eel
8 3" Pipe Support U-Bolt XL1100 RXL1005-0012-SLC1 RXL1005-0012- 1.0 EA Galvanized St 0.3
SLC1 eel
9 CAPSCR, HEX HEAD M16 X 60 RXL000-0005-008-SLC1 8.0 EA ZINC PLATED 1.0
STL
10 WASHER, LOCK M16 RXL000-0024-005-SLC1 8.0 EA TEMPERED S 0.1
PRING STL, ZI
NC PLATED
11 CAPSCR, HEX HEAD M20 x 90 RXL000-0006-012-SLC1 8.0 EA ZINC PLATED 1.8
LG STL
12 WASHER, LOCK M20 RXL000-0024-006-SLC1 8.0 EA TEMPERED S 0.1
PRING STL, ZI
NC PLATED
13 NUT, HEX M20, STYLE 2, RXL000-0028-007-SLC1 8.0 EA ASTM A562M 0.6
B18.2.4.2M-ISO, 4033
14 Lock Washer, 1/2" RXL000-0013-005-SLC1 RXL000-0013 R 4.0 EA TEMPERED S 0.0
EV B-SLC1 PRING STEEL
15 Nut, Hex 1/2"-13, ASME B18.2.2 RXL000-0057-009-SLC1 RXL000-0057 R 4.0 EA ZINC PLATED 0.1
GR 5 EV A-SLC1 STL
16 HHCS 5/8-11 x 2.25 LG RXL000-0020-006-SLC1 RXL000-0020 R 8.0 EA ZINC PLATED 1.0
EV 00-SLC1 STL
17 WASHER, LOCK 5/8 RXL000-0013-006-SLC1 8.0 EA TEMPERED S 0.1
PRING STEEL
18 CAPSCR, HEX, 3/4-10 x 2.5 301660-SLC1 16.0 EA GR 5 3.5
19 WASHER, LOCK 3/4 RXL000-0013-007-SLC1 16.0 EA TEMPERED S 0.3
PRING STEEL
20 GASKET, FLANGE, 3.5" RXL000-0154-002-SLC1 RXL000-0154- 1.0 EA GARLOCK 29 0.1
SLC1 00
21 GASKET, FLANGE, 8" RXL000-0154-003-SLC1 RXL000-0154- 1.0 EA GARLOCK 29 0.1
SLC1 00
22 PLUG, PIPE, SQ HD .25-18 NPT RXL000-0098-002-SLC1 1.0 EA 0.0
23 NIPPLE, PIPE, SCH 40, 1 X 2 1/2, 356455-SLC1 1.0 EA BLACK 0.0
MPT

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 237

1000975960: Parts List/Bill of Materials (Sheet 36)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 36 of 54
Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

24 ELBOW, 90 DEG X 1.0IN RXL000-0080-005-SLC1 1.0 EA MALLEABLE 0.1

IRON/GALV
25 GRIP, CORD RXL000-0216-SLC1 2.0 EA 0.2
26 ELBOW, CAST FLANGED RXL1001-0035-SLC1 RXL1001-0035- 1.0 EA A216, GR WC 86
SLC1 B, CAST CAR
BON STL
27 CAPSCR, HEX HEAD M24 x 60 RXL000-0007-005-SLC1 12.0 EA ZINC PLATED 3.6
STL
28 WASHER, LOCK M24 RXL000-0024-007-SLC1 12.0 EA TEMPERED S 0.1
PRING STL, ZI
NC PLATED
29 GASKET, FLANGE, 12" RXL000-0154-004-SLC1 RXL000-0154- 1.0 EA GARLOCK 29 0.1
SLC1 00

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
238 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 37)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 37 of 54

Part No.: RXL1005-0001-SLC1

Supply Oil Pipe Assembly Rev. No.: 5
Unit Weight: 18 kg

Drawing No: RXL1005-0001-SLC1

Parent Assembly Part No.: RXL1005-5006-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 LAP JOINT FLANGE, 3.5, 150 RXL000-0172-SLC1 RXL000-0172 Re 1.0 EA ASTM A105, 5.5
PSI, 3.5" PIPE SIZE v A-SLC1 FORGED STE
EL
2 LAP JOINT FLANGE, 3.5, 150 RXL000-0173-SLC1 RXL000-0173 Re 1.0 EA ASTM A234 G 2.7
PSI, 3.5" PIPE SIZE v 00-SLC1 RADE B, FOR
GED STEEL
3 REDUCER, 3.5 X 3 NOM. RXL000-0156-SLC1 RXL000-0156 R 1.0 EA 1.1
EV 00-SLC1
4 ELBOW, 3" RXL000-0157-SLC1 1.0 EA 1.4
5 ELBOW, 3 NOM. X 45 DEGREE RXL000-0174-SLC1 RXL000-0174 R 1.0 EA 1.3
EV 00-SLC1
6 HALF-COUPLING, 1/4" NPT RXL000-0037-002-SLC1 1.0 EA 0.2
7 CPLNG, HALF PIPE, 1-11 1/2 RXL000-0037-006-SLC1 RXL000-0037 re 1.0 EA ASTM A53 0.0
NPT, 150 PSI v B-SLC1
8 WELDING NECK FLANGE, 3" RXL000-0159-SLC1 1.0 EA 5.4

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 239

1000975960: Parts List/Bill of Materials (Sheet 38)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 38 of 54

Part No.: RXL1005-0002-SLC1

Oil Drain Assembly Rev. No.: 5
Unit Weight: 38 kg

Drawing No: RXL1005-0002-SLC1

Parent Assembly Part No.: RXL1005-5006-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 WELDING NECK FLANGE, 150 RXL000-0148-SLC1 RXL000-0148 Re 2.0 EA ASTM A105, 38

PSI, 8" PIPE SIZE v 00-SLC1 FORGED STE
EL
3 HALF PIPE COUPLINGS, 150 RXL000-0037-004-SLC1 RXL000-0037 re 2.0 EA ASTM A53 0.0
PSI, 3/8-18 NPT v B-SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
240 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 39)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 39 of 54

Part No.: RXL1009-5002-SLC1

ASSY, FEED PLATE Rev. No.: 8
Unit Weight: 1060 kg

Drawing No: RXL1009-5002-SLC1

Parent Assembly Part No.: 1000873483

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

01 SILASTIC RTV-732 RXL000-0059-SLC1 RXL000-0059- 1.0 EA 0.1

SLC1
02 NUT, LOCKING RXL1009-0004-SLC1 RXL1009-0004- 1.0 EA AISI 1040 515
SLC1
03 Feed Plate RXL1009-0003-SLC1 RXL1009-0003- 1.0 EA ASTM A128A 535
SLC1 Aust. Mn
1000134858
1000024423
04 CAPSCR, HEX HEAD M36 x 180 RXL000-0009-012-SLC1 4.0 EA ZINC PLATED 7.6
LG STL
05 Flat Washer, M36 RXL000-0011-009-SLC1 4.0 EA ZINC PLATED 0.0
STL
06 WASHER, LOCK M36 RXL000-0024-009-SLC1 4.0 EA TEMPERED S 0.4
PRING STL, ZI
NC PLATED
07 NUT, HEX M36 RXL000-0028-010-SLC1 4.0 EA ASTM A562M 1.2

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 241

1000975960: Parts List/Bill of Materials (Sheet 40)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 40 of 54

Part No.: RXL1010-5003-SLC1

LINER ASSEMBLY, STANDARD FINE Rev. No.: 11
Unit Weight: 12465 kg

Drawing No: RXL1010-5003-SLC1

Parent Assembly Part No.: 1000873483

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 BOWL LINER, STD FINE RXL1010-B004-SLC1 RXL1010- 1.0 EA A128A AUST 6733
B004-SLC1 MANG STL
2 Mantle, Standard RXL1010-M001-SLC1 RXL1010- 1.0 EA SM330 5413
M001-SLC1
1000134858
1000024423
3 WEDGE RXL1010-0001-SLC1 RXL1010-0001- 8.0 EA CAST 4140/41 112
SLC1 42
4 BOLT, SQUARE HEAD RXL1010-0002-SLC1 RXL1010-0002- 8.0 EA 1040 GR 8.8 50
SLC1
5 NUT, SPHERICAL RXL1010-0003-SLC1 RXL1010-0003- 8.0 EA 1040 GR 5 8.0
SLC1
6 TORCH RING RXL1010-0004-SLC1 RXL1010-0004- 1.0 EA ASTM A36 85
SLC1
7 WEDGE SHIM RXL1010-0005-SLC1 RXL1010-0005- 8.0 EA A36 STL 5.2
SLC1
8 PLATE, LOCK RXL1010-0006-SLC1 RXL1010-0006- 8.0 EA ASTM A36 16
SLC1
9 RETAINER, BOLT RXL1010-0007-SLC1 RXL1010-0007- 8.0 EA A36 STL 16
SLC1
10 PIN, COTTER, EXTENDED RXL000-0030-004-SLC1 8.0 EA STL 0.0
PRONG 8mm X 80
11 MATERIAL, INSULATION, RXL000-0045-SLC1 1.0 EA UNFACED FI 11
THERMAL BATT BERGLASS
12 Heavy Duty Crusher Liner Epoxy RXL000-0385-SLC1 1000421140 1.0 EA 10.0
13 SHIM, WEDGE RXL1010-0008-SLC1 RXL1010-0008- 8.0 EA A36 STL 1.6
SLC1
14 SHIM, WEDGE RXL1010-0009-SLC1 RXL1010-0009- 8.0 EA A36 STL 3.2
SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
242 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 41)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 41 of 54

ASSY, BOWL STD XL1300 Use With RXL1100 Part No.: 648590-SLC1
Rev. No.: 3
XL1300 BOWL FOR USE WITH XL1100 Unit Weight: 22493 kg

Drawing No: 648590-SLC1 Parent Assembly Part No.: 1000873483

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

01 BOWL, STANDARD RXL1311-0001-SLC1 RXL1311-0001- 1.0 EA ASTM A148 G 19182

SLC1 RADE 80-50
02 CAP, ADJUSTMENT, RXL1011-0003-SLC1 RXL1011-0003- 1.0 EA ASTM A36 2303
STANDARD SLC1
03 RING, BOWL 648586-SLC1 648586-SLC1 1.0 EA A36 STL 902
04 RETAINER, WEDGE RXL1011-0006-SLC1 RXL1011-0006- 8.0 EA ASTM A36 64
SLC1
05 PLUG RXL1011-0007-SLC1 RXL1011-0007- 2.0 EA BLK NEOP, 40 0.4
SLC1 DURO
06 CAPSCR, HEX HEAD M20 x 120 RXL000-0006-015-SLC1 2.0 EA ZINC PLATED 0.6
LG, CL 8.8 STL
07 WASHER, LARGE RXL000-0124-013-SLC1 2.0 EA Steel 0.0
FLAT,FENDER, M20, DIN 9021
08 CAPSCR, HEX HEAD M20 X 80 RXL000-0006-011-SLC1 32.0 EA ZINC PLATED 6.4
LG STL
09 WASHER, LOCK M20 RXL000-0024-006-SLC1 32.0 EA TEMPERED S 0.3
PRING STL, ZI
NC PLATED
10 CAPSCR, HEX HEAD M30 x 90, RXL000-0008-005-SLC1 16.0 EA ZINC PLATED 8.0
CL 8.8 STL
11 WASHER, LOCK M30 RXL000-0024-008-SLC1 16.0 EA TEMPERED S 0.8
PRING STL, ZI
NC PLATED
12 PIN, THREADED, M36, CL 8.8 RXL000-0240-SLC1 8.0 EA ZINC PLATED 6.4
STL
13 ANTI-SEIZE, MOLY GRADE RXL000-0079-SLC1 1.0 EA 19
14 LOCTITE 243, 50ml, MED, BLUE RXL000-0044-013-SLC1 1.0 EA 0.1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 243

1000975960: Parts List/Bill of Materials (Sheet 42)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 42 of 54

Part No.: RXL1012-5001-SLC1

Assembly, Hopper, Standard Rev. No.: 3
Unit Weight: 3158 kg

Drawing No: RXL1012-5001-SLC1

Parent Assembly Part No.: 1000873483

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 HOPPER RXL1012-0001-SLC1 RXL1012-0001- 1.0 EA ASTM A36 3126

SLC1
2 SEAL, HOPPER, UPPER RXL1012-0002-SLC1 RXL1012-0002- 1.0 EA Black neoprene 21
SLC1 , 30-50 duro
3 SEAL, HOPPER, LOWER STD RXL1012-0004-SLC1 RXL1012-0004- 1.0 EA Black neoprene 11
SLC1 , 30-50 duro
4 ADHESIVE RXL000-0152-SLC1 RXL000-0152- 1.0 EA 0.1
SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
244 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 43)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 43 of 54

Part No.: RXL1017-5001-SLC1

TOOLS ASSEMBLY, XL1100 Rev. No.: 15
Unit Weight: 1227 kg

Drawing No: RXL1017-5001-SLC1

Parent Assembly Part No.: 1000873483

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 PLATE, HEAD LIFTING RXL1017-0001-SLC1 RXL1017-0001- 1.0 EA ASTM A36 162

SLC1
2 RING, ECCENTRIC LIFTING RXL1017-0002-SLC1 RXL1017-0002- 1.0 EA ASTM A36 213
SLC1
3 WRENCH, LOCKNUT RXL1017-0003-SLC1 RXL1017-0003- 1.0 EA 482
SLC1
4 PLATE, HEAD BALL LIFTING RXL1017-0012-SLC1 RXL1017-0012- 1.0 EA CRS 1018 BAR 8.5
SLC1
5 PIN, BOWL LIFTING RXL1017-0006-SLC1 RXL1017-0006- 2.0 EA AISI 1018 11
SLC1
6 TEMPLATE, THREAD 75 MM RXL1017-0008-SLC1 RXL1017-0008- 1.0 EA ASTM A36 0.7
PITCH SLC1
7 BLOCK, SAFETY RXL1017-0009-SLC1 RXL1017-0009- 4.0 EA ASTM A36 26
SLC1
8 STUD, LINE UP RXL1017-0010-SLC1 RXL1017-0010- 4.0 EA Steel, CL 8.8 7.6
SLC1
9 CHARGING ASSEMBLY RXL417-0003-SLC1 RXL417-0003 Re 1.0 EA 1.0
v A-SLC1
10 BOLT, RING M10 RXL000-0063-010-SLC1 4.0 EA Steel 0.2
11 BOLT, RING, DIN 580 M12 RXL000-0063-012-SLC1 2.0 EA DIN 580 0.2
12 BOLT, RING, DIN 580 M16 RXL000-0063-016-SLC1 4.0 EA DIN 580 0.5
13 BOLT, RING M20 RXL000-0063-020-SLC1 2.0 EA Steel 0.4
14 BOLT, RING, DIN 580 M24 RXL000-0063-024-SLC1 2.0 EA DIN 580 0.7
15 BOLT, RING M30 RXL000-0063-030-SLC1 2.0 EA Steel 1.5
16 BOLT, RING M36 RXL000-0063-036-SLC1 4.0 EA Steel 4.8
17 PLATE, HEAD TURNING RXL1017-0016-SLC1 RXL1017-0016- 2.0 EA AISI 1040 130
SLC1
18 CAPSCR, HEX HEAD, M36 X 140 RXL000-0175-008-SLC1 2.0 EA ZINC PLATED 0.0
STL, CL10.9
19 BOLT, RING, DIN 580 M100 RXL000-0063-100-SLC1 4.0 EA DIN 580 89
20 Flat Washer, M10 RXL000-0011-003-SLC1 2.0 EA ZINC PLATED 0.0
STL
21 Flat Washer, M12 RXL000-0011-004-SLC1 2.0 EA ZINC PLATED 0.0
STL
22 Flat Washer, M16 RXL000-0011-005-SLC1 4.0 EA ZINC PLATED 0.0
STL
23 Flat Washer, M20 RXL000-0011-006-SLC1 2.0 EA ZINC PLATED 0.0
STL
24 WASHER FLAT METRIC M24 RXL000-0011-007-SLC1 2.0 EA ZINC PLATED 0.0
STL
25 Flat Washer, M30, DIN 125 RXL000-0011-008-SLC1 4.0 EA ZINC PLATED 0.0
STL
26 Flat Washer, M36 RXL000-0011-009-SLC1 4.0 EA ZINC PLATED 0.0
STL
27 Metric Flat Washer M42 RXL000-0011-010-SLC1 39.0 EA ZINC PLATED 7.8
STL

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 245

1000975960: Parts List/Bill of Materials (Sheet 44)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 44 of 54
Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

28 ROD, THREADED, DIN 975 RXL000-0312-001-SLC1 2.0 EA Carbon Steel 0.5

M20x100mm, CL 10.9
29 ROD, THREADED, DIN 975 RXL000-0312-002-SLC1 1.0 EA Carbon Steel 0.4
M20X175MM, CL 10.9
30 NUT, LIFTING EYE, DIN 582, RXL000-0311-006-SLC1 3.0 EA 1051 CARBON 0.0
M20 STEEL
31 WASHER FLAT METRIC, DIN RXL000-0011-017-SLC1 4.0 EA ZINC PLATED 0.4
125, M100 STEEL
32 JACKSCREW, M36-X 240, ZINC RXL000-0211-SLC1 4.0 EA Steel 7.6
PLATED STL, CL10.9, DOG PT
33 JACKSCREW, M20MM X RXL000-0169-SLC1 4.0 EA Steel 2.0
200MM, ZINC PLATED STL,
CL10.9, DOG PT, FULL THRD
34 JACKSCREW, M42 X 240, ZINC RXL000-0212-SLC1 3.0 EA Steel 7.8
PLATED STL, CL10.9, DOG PT
35 CAPSCR, HEX HEAD M20 x 220 RXL000-0006-020-SLC1 2.0 EA Steel 1.1
LG, ZINC PLATED STL, CL8.8
36 CAPSCR, HEX HEAD M30 x 100 RXL000-0008-006-SLC1 7.0 EA ZINC PLATED 3.9
STL
37 CAPSCR, HEX HD, DIN 933 RXL000-0268-007-SLC1 4.0 EA Steel 2.6
M30 X 120, ZINC PLATED STL,
CL10.9
38 CAPSCR, HEX HEAD M30 x 150, RXL000-0008-011-SLC1 4.0 EA Steel 3.3
ZINC PLATED
39 RING, SWIVEL HOIST M36 RXL000-0176-SLC1 2.0 EA 4140 HIGH ST 31
RENGTH ALL
OY STL
40 RING, SWIVEL HOIST, M64 RXL000-0177-SLC1 1.0 EA 4140 HIGH ST 20
RENGTH ALL
OY STL

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
246 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 45)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 45 of 54

Part No.: RXL1020-5001-SLC1

ASSY, DECAL Rev. No.: 10
Unit Weight: 3.3 kg

Drawing No: RXL1020-5001-SLC1

Parent Assembly Part No.: 1000873483

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 NAMEPLATE, CONE CRUSHER 661752-SLC1 661752-SLC1 1.0 EA 302 SS 0.1

2 Safety instructions 1000162941 1000162941 1.0 EA Polyester 0.1
3 Danger plate, projectile hazard 1000162943 1000162943 8.0 EA Polyester 0.8
4 Rotation Arrow, Large XL1100 RXL1020-0006-SLC1 RXL1020-0006- 1.0 EA See Drawing 0.0
SLC1
5 Danger plate 1000162940 1000162940 8.0 EA Polyester 0.8
6 Notice plate 1000162945 1000162945 8.0 EA Polyester 0.8
7 SCREW, DRIVE 10 RXL000-0104-SLC1 RXL000-0104 re 4.0 EA 18-8 SS 0.0
v00-SLC1
8 DECAL, 1100 651774-SLC1 651774-SLC1 2.0 EA Polyester 0.2
9 DECAL, STRIPING, LARGE 651775-SLC1 651775-SLC1 1.0 EA See Drawing 0.1
10 DECAL, RAPTOR, LARGE 651776-SLC1 651776-SLC1 2.0 EA See Drawing 0.2
12 DECAL, FLSMIDTH, LARGE 651777-SLC1 651777-SLC1 2.0 EA See Drawing 0.2

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 247

1000975960: Parts List/Bill of Materials (Sheet 46)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 46 of 54

Part No.: 1000896918

Assembly, Foundation bolt Rev. No.: 1
Unit Weight: 1131 kg

Drawing No: 1000896918

Parent Assembly Part No.: 1000873483

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 Assembly, Sole plate 1000690716 1000690716 1.0 EA 601

2 Threaded Rod, M72 x 2600 Lg 1000896919 4.0 EA 332
3 Nut, hexagon, M72, 8 1000182896 16.0 EA Plain Carbon S 49
teel
4 Washer, A74, 300 HV 1000236953 4.0 EA Plain Carbon S 2.7
teel
5 Plate, 30mm x 400mm x 400mm 1000898101 1000898101 4.0 EA ASTM A36 146

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
248 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 47)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 47 of 54

Part No.: 1000690716

Assembly, Sole plate Rev. No.: 1
Unit Weight: 601 kg

Drawing No: 1000690716

Parent Assembly Part No.: 1000896918

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 Sole plate 1000400968 1000400968 4.0 EA ASTM A36 597

2 Screw, set, hexagon socket, ISO 1000000346 12.0 EA Plain Carbon S 1.3
4029, M20x50, 45 H, black oxide teel
finish
3 Bolt, eye, lifting, DIN 580, M16 1000024033 2.0 EA Plain Carbon S 0.6
teel
4 SHIM ROLL, .005" THICK ECT000-0187-SLC1 1.0 EA 0.8
5 SHIM ROLL, .010" THICK ECT000-0188-SLC1 1.0 EA 0.7

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 249

1000975960: Parts List/Bill of Materials (Sheet 48)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 48 of 54

Part No.: 1000896530

Rev. No.: 1
Assembly, drive, R1100 Unit Weight: 10148 kg

Parent Assembly Part No.: 1000873424

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 Motor, drive 1000908599 1000887044 1.0 EA 7500

2 Assy, Ø40", 8V, Crusher Sheave RXL1013-5001-SLC1 RXL1013-5001- 1.0 EA 979
SLC1
3 Ø28" 8V Motor Sheave Assembly RXL1013-5009-SLC1 RXL1013-5009- 1.0 EA 555
SLC1
4 V-belt, banded, 8V, 4 rib, 425 in 1000750426 4.0 EA 104
5 Belt Tensioner 1000896700 1000896700 1.0 EA 1000
6 Drive guard 1000896705 1000896705 1.0 EA 10

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
250 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 49)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 49 of 54

Part No.: RXL1013-5001-SLC1

Assy, Ø40", 8V, Crusher Sheave Rev. No.: 5
Unit Weight: 979 kg

Drawing No: RXL1013-5001-SLC1

Parent Assembly Part No.: 1000896530

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 SHEAVE, 40", 8V, 16 GROOVE RXL1013-0001-SLC1 1.0 EA Ductile iron 803

2 BUSHING, QD-S, 200MM BORE RXL1013-0004-SLC1 RXL1013-0004- 1.0 EA Ductile Iron 160
SLC1
3 KEY, 25MM X 45MM X 400MM RXL000-0239-006-SLC1 1.0 EA AISI 1144 3.5
4 SCREW, SET, CUP PT, 1.00-8 RXL000-0238-012-SLC1 1.0 EA BLK STL 0.1
5 CAPSCR, HEX HD, 1-1/4-7 X RXL000-0237-021-SLC1 5.0 EA STL, GR5 13
15-1/2
6 WASHER, LOCK 1-1/4 RXL000-0013-011-SLC1 5.0 EA TEMPERED S 0.3
PRING STL, Z
INC PLATED,
ANSI B27.1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 251

1000975960: Parts List/Bill of Materials (Sheet 50)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 50 of 54

Part No.: RXL1013-5009-SLC1

Ø28" 8V Motor Sheave Assembly Rev. No.: 5
Unit Weight: 555 kg

Drawing No: RXL1013-5009-SLC1

Parent Assembly Part No.: 1000896530

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 SHEAVE 28IN 8V 16 GROOVE RXL1013-0003-SLC1 RXL1013-0003- 1.0 EA Ductile Iron 468

MAA1
2 QD-W Bushing, Ø7.00" Bore, RXL1013-0009-SLC1 1.0 EA Ductile Iron 76
Raptor 1100
3 KEY, 1-3/4" X 1-1/2" x 11-3/8" LG RXL000-0239-004-SLC1 RXL000-0239 R 1.0 EA AISI 1144 3.8
ev L-SLC1
4 SET SCREW, STD SKT, CUP PT, RXL000-0238-010-SLC1 RXL000-0238 Re 1.0 EA BLACK-FINI 0.3
1.00-8 X 3" v 00-SLC1 SH
5 HEX HEAD CAPSCREW, 1 1/8-7 RXL000-0236-017-SLC1 RXL000-0236 Re 4.0 EA GR5 6.8
X 11 1/2" v 00-SLC1
6 WASHER, LOCK, 1 1/8" RXL000-0013-010-SLC1 RXL000-0013 R 4.0 EA SPRING STL, 0.2
EV B-SLC1 ZNC PL'D

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
252 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 51)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 51 of 54

Part No.: RXL1023-5004-SLC1

ASSY, COUNTERSHAFT BOX BLOWER Rev. No.: D
Unit Weight: 200 kg

Drawing No: RXL1023-5004 Rev C-SLC1

Parent Assembly Part No.: 1000873424

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 HOUSING, INLET RXL1023-0002-SLC1 RXL1023-0002- 1.0 EA NA 6.0

FILTER (OBSOLETE BY SLC1
MANUFACTURER. USE
1000388827 AS REPLACEMENT)
2 HOOD, INLET FILTER, W/ RXL1023-0003-SLC1 RXL1023-0003- 1.0 EA 41
CLAMP SLC1
3 FILTER, MOUNTING BAND RXL1023-0004-SLC1 RXL1023-0004- 2.0 EA 3.6
SLC1
4 BLOWER TURBO RXL1023-0017-SLC1 RXL1023-0017- 1.0 EA 100
MAA1
5 ADAPTOR, FILTER OUTLET RXL1023-0009-SLC1 RXL1023-0009- 1.0 EA CARBON STL 6.8
SLC1
6 ADAPTOR, COUNTERSHAFT RXL1023-0010-SLC1 RXL1023-0010- 1.0 EA CARBON STL 4.0
BOX SLC1
7 NIPPLE, DOUBLE ENDED KING RXL1023-0011-SLC1 RXL1023-0011- 1.0 EA 2.1
SLC1
8 ADAPTOR, BLOWER OUTLET RXL1023-0012-SLC1 RXL1023-0012- 1.0 EA A36 STL & CA 3.8
SLC1 RBON STL
9 CONNECTOR, FILTER OUTLET RXL1023-0013-SLC1 RXL1023-0013- 1.0 EA 0.0
SLC1
10 CLAMP, 6 IN RXL1023-0014-SLC1 RXL1023-0014- 1.0 EA 0.0
SLC1
11 CLAMP, 7 IN RXL1023-0015-SLC1 RXL1023-0015- 1.0 EA 0.0
SLC1
12 HOSE, AIR, REINFORCED RXL000-0244-007-SLC1 3.0 EA ALL FLOW EP 31
DM RBR, POL
Y-E YARN
13 CLAMP, HOSE, T-BOLT RXL000-0186-001-SLC1 6.0 EA 316SS 0.4
14 ADAPTOR, MALE PIPE RXL000-0190-SLC1 1.0 EA 0.0
15 CAPSCR, HEX HD, 3/4 X 1 1/4 RXL000-0021-002-SLC1 8.0 EA 3/4-10, GR5, Z 1.2
INC PLATED
STL
16 WASHER, LOCK 3/4 RXL000-0013-007-SLC1 8.0 EA TEMPERED S 0.2
PRING STEEL
17 NUT, HEX 3/4"-10 RXL000-0057-015-SLC1 8.0 EA B18.2.2, GR5, 0.5
ZINC PLATE
D STL
18 NIPPLE, 1.5IN X 3.00IN LG RXL000-0083-004-SLC1 RXL000-0083- 1.0 EA WELDED STL 0.0
SLC1 /GALV
19 TEE, 1.50-11.50 NPT RXL000-0112-008-SLC1 1.0 EA 0.0
20 ADAPTER, HOSE RXL000-0090-003-SLC1 1.0 EA STL 0.0
21 PLUG, PIPE, SQ HD .25-18 NPT RXL000-0098-002-SLC1 1.0 EA 0.0
22 CLEAR TUBE, 3/16" ID RXL000-0227-001-SLC1 1.0 EA Clear PVC Plas 0.0
tic/Polyurethan
e Rubber Blend
, 80A DURO
23 REDUCER,HEX,1.5" NPT X 0.25" RXL000-0226-SLC1 1.0 EA MALLEABLE 0.0
NPT,150 PSI IRON, GALV

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 253

1000975960: Parts List/Bill of Materials (Sheet 52)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 52 of 54
Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

24 MANOMETER FLEXIBLE TUBE RXL000-0225-SLC1 1.0 EA 0.0

RXLHDW

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
254 Appendix E Parts List/Bill of Materials

1000975960: Parts List/Bill of Materials (Sheet 53)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 53 of 54

HOUSING, INLET FILTER (OBSOLETE BY Part No.: RXL1023-0002-SLC1

Rev. No.: 5
MANUFACTURER. USE 1000388827 AS Unit Weight: 6.0 kg
REPLACEMENT)
Parent Assembly Part No.: RXL1023-5004-SLC1

Drawing No: RXL1023-0002-SLC1

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 ELEMENT, FILTER RXL1023-0005-SLC1 RXL1023-0005- 1.0 EA 6.0

SLC1
2 EJECTOR, DUST RXL1023-0007-SLC1 RXL1023-0007- 1.0 EA 0.0
SLC1
3 NUT, WING RXL1023-0006-SLC1 RXL1023-0006- 1.0 EA 0.0
SLC1

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix E Parts List/Bill of Materials 255

1000975960: Parts List/Bill of Materials (Sheet 54)

Crusher, Master, R1100
Part No. 1000873424 Rev 1
Page 54 of 54

Part No.: 1000896923

Assembly, Instrument Rev. No.: 1
Unit Weight: 12 kg

Drawing No: 1000896923

Parent Assembly Part No.: 1000873424

Total
Find
Description Part No. Document No. Qty. UOM Material Weight
No.
kg.

1 SENSOR, PROXIMITY RXL000-0292-SLC1 RXL000-0292- 1.0 EA 0.0

SLC1
2 Sensor, inductive, M12x1 1000726255 2.0 EA 0.1
3 Transmitter, temperature 1000134553 1.0 EA 0.2
4 TEMPERATURE SENSOR RXL405-0010-SLC1 RXL405-0010- 1.0 EA 0.0
SLC1
5 Accelerometer, 4-20mA 1000832312 4.0 EA 0.6
6 TRANSMITTER, PRESSURE, 670189-SLC1 670189-SLC1 1.0 EA 0.1
OIL, 150 psi
7 COVER RXL405-0014-SLC1 RXL405-0014- 1.0 EA Polyurethane 0.0
SLC1
8 CLAMP, MOUNTING RXL405-0015-SLC1 RXL405-0015- 1.0 EA 0.0
SLC1
9 ADAPTOR, MOUNTING RXL405-0011-SLC1 RXL405-0011- 1.0 EA 0.0
SLC1
10 CABLE, SENSOR RXL405-0013-SLC1 RXL405-0013- 1.0 EA 0.0
SLC1
11 CORD, PROXIMITY SENSOR RXL000-0293-SLC1 RXL000-0293- 1.0 EA 0.0
SLC1
12 Actuator and sensor cable, female 1000726548 2.0 EA 1.0
connector, M12 × 1
13 Signal converter, frequency to 1000617700 1.0 EA 0.2
analog,85 to 250 VAC
14 RECEPTACLE, FRONT MOUNT, 670183-SLC1 670183-SLC1 1.0 EA 0.0
MALE
15 PASTE, HEAT TRANSFER RXL000-0343-SLC1 RXL000-0343- 1.0 EA 0.0
SLC1
16 Sensor, level, ultrasonic, 25 m in 1000832302 1.0 EA 2.5
fluids / 15 m in solid, 1 in NPT ,
cable length: 20 m
17 BRACKET, SPEED SENSOR RXL1022-0001-SLC1 RXL1022-0001- 1.0 EA A36 STL 0.5
SLC1
18 SPACER, XL1100 RXL1022-0002-SLC1 RXL1022-0002- 1.0 EA STL 0.2
SLC1
19 ASSY, SPEED SENSOR TARGET, RXL922-0001-SLC1 RXL922-0001- 1.0 EA STL 0.7
XL600/XL900 SLC1
20 Bolt, hexagon head, ISO 4014, 1000005545 1.0 EA Plain Carbon S 0.4
M20x150, 8.8, electroplated teel
21 Alignment device, level sensor, 1000824675 1.0 EA 2.5
cavity
22 WASHER, LOCK M20 RXL000-0024-006-SLC1 1.0 EA TEMPERED S 0.0
PRING STL, ZI
NC PLATED
23 Transmitter, level, 2 x 0/4-20mA 1000832314 1.0 EA 3.0
HART
24 CORD, 5 PIN SHIELDED M12X1 681144-001-SLC1 681144-SLC1 1.0 EA 0.1
ADPATER RAPTOR 1100

Property of FLSmidth A/S. This document contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes
of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this document is
not permitted without the prior written permission of FLSmidth A/S.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
256 Appendix E Parts List/Bill of Materials

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
 257

Appendix F: Recommended
Spare Parts List
F.1 Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
258 Appendix F Recommended Spare Parts List

F.1 Recommended Spare Parts List

Tintaya
DESCRIPTION: RaptorConeCrusherSpares ProjectNo.9232515940
TAGNO.: ZͲϬϬϭ
MANUFACTURER: FLSmidth
MANUFACTURERMODELNO.: R1100
FLSMIDTHEQUIPMENTNO.: 1000873424
PRODUCTTYPOLOGY: RCC

Commissioning Operational Critical Total

Item FLSPartNumber Description U/M Notes
Qty. Qty. Qty. Qty.

MAINFRAMEASSEMBLY
1 RXL1001Ͳ0013ͲSLC1 MAINFRAMEPIN 1 – 1 2 EA
2 RXL1301Ͳ0010ͲSLC1 LOWERTHRUSTBEARING – – 1 1 EA
3 RXL1001Ͳ0016ͲSLC1 LOWER"U"SEAL 1 – 1 2 EA
4 RXL000Ͳ0062ͲSLC1 ADHESIVE 1 – 1 2 EA
5 RXL1001Ͳ0020ͲSLC1 ARMGUARD – 2 – 2 EA
6 RXL1001Ͳ0021ͲSLC1 BOXͲARMGUARD – 1 – 1 EA
7 RXL1301Ͳ0003ͲSLC1 MAINFRAMELINERS – 1 – 1 EA
8 RXL1001Ͳ0015ͲSLC1 MAINFRAMESEATLINER – – 1 1 EA

ADJUSTMENTRINGASSEMBLY
9 RXL1002Ͳ0044ͲSLC1 MAINFRAMEPINBUSHING – – 1 1 EA
10 1000687266 CLAMPINGCYLINDERASSEMBLY – – 1 1 EA
11 1000735684 CLAMPINGCYLINDERSEALSREPAIRKIT 1 – 1 2 EA

TRAMPRELEASEASSEMBLY
12 1000687267 TRAMPRELEASECYLINDERASSY – – 1 1 EA
13 1000736051 CYLINDERREPAIRKIT 1 – 1 2 EA
14 RXL1003Ͳ0037ͲSLC1 BLADDERANDSTEMASSEMBLY 1 – 1 2 EA

COUNTERSHAFTASSEMBLY
15 RXL1004Ͳ0005ͲSLC1 OILFLINGER – – 1 1 EA
16 RXL1004Ͳ0003ͲSLC1 COUNTERSHAFTBUSHING – – 2 2 EA

ECCENTRICASSEMBLY
17 RXL1006Ͳ0004ͲSLC1 ECCENTRICBUSHING – – 1 1 EA
18 RXL1006Ͳ0001ͲSLC1 UPPERTHRUSTBEARING – – 1 1 EA
19 RXL1006Ͳ0006ͲSLC1 UPPER"U"SEAL 1 – 1 2 EA
20 RXL1006Ͳ0005ͲSLC1 LOWER"T"SEAL 1 – 1 2 EA
21 RXL000Ͳ0062ͲSLC1 ADHESIVE 1 – 1 2 EA

SOCKETASSEMBLY
22 RXL1007Ͳ0006ͲSLC1 SOCKETLINER – – 1 1 EA

HEADASSEMBLY
23 RXL1008Ͳ0033ͲSLC1 HEADBUSHINGͲLOWER – – 1 1 EA
24 RXL1008Ͳ0032ͲSLC1 LOWERHEADBUSHINGRING – – 1 1 EA
25 RXL1008Ͳ0002ͲSLC1 UPPER"T"SEAL 1 – 1 2 EA
26 RXL000Ͳ0062ͲSLC1 ADHESIVE 1 – 1 2 EA
27 RXL1008Ͳ0004ͲSLC1 HEADBUSHINGͲUPPER – – 1 1 EA

FEEDPLATEASSEMBLY
28 RXL1009Ͳ0004ͲSLC1 LOCKINGNUT – 1 – 1 EA
29 RXL1009Ͳ0003ͲSLC1 FEEDPLATE – 1 – 1 EA

COUNTERSHAFTBOXBLOWER
30 1000388828 FILTERELEMENT,PRIMARY 3 12 – 15 EA

INSTRUMENTATION
31 RXL1001Ͳ0040ͲSLC1 RTDSENSORͲMAINFRAME(QTY2) 1 – 1 2 EA

CRUSHEROILPIPING
32 670189ͲSLC1 TRANSMITTER,PRESSURE 1 – 1 2 EA
33 1000134553 TEMPERATURESENSOR,TRANSMITTER 1 – 1 2 EA
34 RXL405Ͳ0013 SENSORCABLE 1 – 1 2 EA

AIRCOOLERASSEMBLY
35 1000744729 Fan – 1 – 1 EA
36 1000958316 Hose,3/2.5in,25bar – 2 – 2 EA
37 1000644676 Valve,pressurerelief,5bar – 1 – 1 EA

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix F Recommended Spare Parts List 259

Recommended Spare Parts List (Sheet 2)

Commissioning Operational Critical Total
Item FLSPartNumber Description U/M Notes
Qty. Qty. Qty. Qty.

38 1000625783 Thermometer,biͲmetal – 1 – 1 EA
39 1000396481 TEMPERATURESENSOR – 1 – 1 EA
40 1000744731 Cable – 1 – 1 EA

LUBRICATIONPACKAGE
41 1000396481 TEMPERATURESENSOR – 1 – 1 EA
42 1000745799 Switch,level,length820mm – 1 – 1 EA
43 1000618179 Breather,air,2150l/min 1 4 – 5 EA
44 1000957899 OͲring,OR56.74X3.53NBR70 – 4 – 4 EA
45 1000640556 Indicator,visual,oillevel – 1 – 1 EA
46 1000625783 Thermometer,biͲmetal – 1 – 1 EA
47 1000624859 Transmitter,temperature,Ͳ50to150deg.C – 1 – 1 EA
48 1000396358 BUTTERFLYVALVE,DN125,SAE5in. – 1 – 1 EA
49 1000958762 Sensor,inductive,NPN,M12x1,sensingrange4mm – 2 – 2 EA
50 1000958324 OͲring,OR110.72X3.53NBR90 – 2 – 2 EA
51 1000958764 Mount,captive,rubber,load170kg – 4 – 4 EA
52 1000958359 Hub,pumpͲmotorGGͲA48/60Ͳ38H7L=56 – 2 – 2 EA
53 1000958362 Hub,pumpͲmotorGGͲA48/60ͲUB60L=65 – 2 – 2 EA
54 1000958370 Spider 2 4 – 6 EA
55 1000798503 Valve,relief,pressure – 1 – 1 EA
56 1000396476 PRESSURETRANSMITTER,4Ͳ20MAOUTPUT – 2 – 2 EA
57 1000428674 Manometer,1/4"BSP,0Ͳ25Bar – 2 – 2 EA
58 1000744720 Filterelement 8 32 – 40 EA

HYDRAULICPOWERUNITASSEMBLY
59 1000618179 Breather,air,2150l/min 1 4 – 5 EA
60 1000744738 Levelguage,Oil – 1 – 1 EA
61 1000798578 Switch,level,length500mm – 1 – 1 EA
62 1000625783 Thermometer,biͲmetal – 1 – 1 EA
63 1000624859 Transmitter,temperature,Ͳ50to150deg.C – 1 – 1 EA
64 1000744723 VibrationIsolator – 4 – 4 EA
65 1000958762 Sensor,inductive,NPN,M12x1,sensingrange4mm – 1 – 1 EA
66 1000744731 Cable – 1 – 1 EA
67 1000958389 Hub,pumpͲmotorA55/70ͲUBL=65 – 1 – 1 EA
68 1000958395 Spider 1 2 – 3 EA
69 1000958397 Hub,pumpͲmotorA55/70ͲN5L=44 – 1 – 1 EA
70 1000958403 Valve,relief,210bar – 1 – 1 EA
71 1000958407 Insert,valve,NG25 – 1 – 1 EA
72 1000622469 Transmitter,pressure 1 1 – 2 EA
73 1000624769 Gauge,pressure,1/4in – 2 – 2 EA
74 1000958411 Valve,check,NG16 – 1 – 1 EA
75 1000958412 Insert,valve,NG16 – 1 – 1 EA
76 1000958414 Element,filter 1 4 – 5 EA
77 1000958417 Accesory,lter – 1 – 1 EA
78 1000958427 Valve,check – 1 – 1 EA
79 1000958440 Valve,flowcontrol – 1 – 1 EA
80 1000755959 Valve,relief,210bar – 1 – 1 EA
81 1000746327 Pressureswitch – 1 – 1 EA
82 1000624716 Valve,needle,1/4in – 1 – 1 EA
83 1000746328 CartridgeValve – 1 – 1 EA
84 1000627895 Gauge,pressure,G1/4B – 1 – 1 EA
85 1000958478 Plug,solenoid – 4 – 4 EA

LINERASSEMBLIES
86 RXL1010ͲB004ͲSLC1 BOWLLINER – 5 – 5 EA
87 RXL1010ͲM001ͲSLC1 MANTLE – 5 – 5 EA
88 RXL1010Ͳ0004ͲSLC1 TORCHRING – 5 – 5 EA

MAJORASSEMBLIESͲCAPITALSPARES
One(1)HeadAssembly,includingthefollowingitems:
Head,HeadBall,LowerHeadBushing,UpperTͲSeal,
Standard/ShortHeadMantle,TorchRing,Epoxybacking
89 677553ͲSLC1 – – 1 1 EA
material,FeedPlateAssembly(LockingBolt&FeedPlate),
MiscellaneousHardware,andLabortoInstallHeadBall,
Seal,Mantle,andFeedPlateAssembly
One(1)BowlAssembly,includingthefollowingitems:
Bowl,AdjustmentCap,BowlRing,Epoxybackingmaterial,
90 648590ͲSLC1 Wedges,WedgeBolts,Standard/ShortHeadBowlLiner, – – 1 1 EA
MiscellaneousHardware,andLabortoInstallBowlLiner
andAdjustmentCap

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
260 Appendix F Recommended Spare Parts List

Recommended Spare Parts List (Sheet 3)

Commissioning Operational Critical Total
Item FLSPartNumber Description U/M Notes
Qty. Qty. Qty. Qty.

One(1)EccentricAssemblywithGear,Counterweight&
91 677551ͲSLC1 – – 1 1 EA
Guard
92 677548ͲSLC1 One(1)CounteweightSubͲAssemblywithGuard – – 1 1 EA
One(1)CountershaftBoxAssemblyCompletewithShaft,
93 RXL1004Ͳ5003 – – 1 1 EA
BushingsandPinion

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
 261

Appendix G: Functional
Specification
G.1 1000899112: Functional Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
262 Appendix G Functional Specification

G.1 1000899112: Functional Specification

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Functional Specification
Raptor® 1100 Cone Crusher

Antapaccay - Tintaya

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix G Functional Specification 263

1000899112: Functional Specification (Sheet 2)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Table of Contents
1. Revision History.....................................................................................................................................................3
2. Abbreviations and Definitions ................................................................................................................................4
2.1 Abbreviations and Definitions....................................................................................................................................... 4
2.2 Cross-reference Documentation................................................................................................................................... 4
2.3 Introduction .................................................................................................................................................................. 4
2.4 Motor Controls.............................................................................................................................................................. 5
2.5 Emergency Stop ............................................................................................................................................................ 5
2.6 Start Warning................................................................................................................................................................ 5
2.7 Control Modes .............................................................................................................................................................. 5
2.8 Interlocking ................................................................................................................................................................... 5
2.9 Automatic Start............................................................................................................................................................. 6
2.10 Analog Instruments..................................................................................................................................................... 6
2.11 Calculations................................................................................................................................................................. 6

3. Lubrication System ................................................................................................................................................7

3.1 LS Interlocks and Sequence Table............................................................................................................................... 11
3.2 LS Alarms Table ........................................................................................................................................................... 12
3.3 LS Calculations Table................................................................................................................................................... 12
3.4 LS Setpoints Table ....................................................................................................................................................... 12
4. Hydraulic System .................................................................................................................................................14
4.1 HS Interlocks and Sequence Table .............................................................................................................................. 18
4.2 HS Pressurize Sequence Table .................................................................................................................................... 18
4.3 HS Alarms Table .......................................................................................................................................................... 18
4.4 HS Setpoints Table ...................................................................................................................................................... 18
5. Crusher& Main Drive ...........................................................................................................................................20
5.1 CR Factors, Variables and Formulas............................................................................................................................ 24
5.2 CR Interlocks and Sequence Table .............................................................................................................................. 24
5.3 CR Alarms Table .......................................................................................................................................................... 25
5.4 CR Setpoints Table ...................................................................................................................................................... 25
5.5 CR Functions................................................................................................................................................................ 25
5.5.1 Tooth Counting Process....................................................................................................................................... 25
2

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
264 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 3)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

5.5.1.1 Tooth Counting Process Sequence Table....................................................................................................... 26

5.5.2 Metal to Metal Calibration .................................................................................................................................. 28
5.5.2.1 Metal to Metal Calibration Sequence Table .................................................................................................. 28
5.5.3 Bowl Creep........................................................................................................................................................... 30
6. Feed & Discharge Integration ...............................................................................................................................32
6.1 FD Interlocks Table...................................................................................................................................................... 34
6.2 FD Alarms Table .......................................................................................................................................................... 34
6.3 FD Setpoints Table ...................................................................................................................................................... 35

1. Revision History
Revision Summary of changes Author Revision date

1 Initial Release JGamez 22-May-2023

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix G Functional Specification 265

1000899112: Functional Specification (Sheet 4)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

2. Abbreviations & Definitions

2.1 Abbreviations, Definitions
Term Definition
AL_OK Alarm OK
ALR Alarm
ASTR Automatic Start
CALC Calculation
CMD Command
DN Done
H1 Alarm Limit High
H2 Alarm Limit High High
H3 Alarm Limit High High High
INT Interlock
L1 Alarm Limit Low
L2 Alarm Limit Low Low
L3 Alarm Limit Low Low Low
LIM_H1 Limit High 1 (Auxiliary contact)
LIM_L1 Limit Low 1 (Auxiliary contact)
SEQ Sequence
STP Stop

2.2 Cross-reference Documentation

S.no Description Document No.

1 Control and Instrumentation Diagram 1000892011

2 Electrical Load List

3 Instrument List

2.3 Introduction
The purpose of this document is to specify the equipment protection and basic operating
requirements of the cone crusher control system. The target audience of this document
is a competent control system engineer with experience developing control systems for
industrial machinery and a basic understanding of the operation of the cone crusher.
The scope of this document does not include the detailed design of the program
architecture and operator interface. This document is intended to be used in conjunction
with the machine’s P&ID, Instrument List and I/O List. The I/O List contains the value
for all warning, alarm and control settings for instruments. All warning, alarm, and
control points required by the I/O List shall be included in the program. Signals that are
used for warning and alarming only (not interlocking or control) are not discussed in this
document.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
266 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 5)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

2.4 Motor Controls

This document assumes that a motor protection scheme that includes the monitoring of
the motor starter signals (Ready, Run, Fault) exists in the cone crusher control system.
The control system shall provide the operator with status feedback of the motor control
interface. Control system treatment of the motor starter signals is not further described
in this document.
2.5 Emergency Stop
This document assumes that an emergency stop circuit fulfilling all local requirements is
included with the motor control circuits. When an emergency stop has been initiated by
an operator, all power contactors are opened and the power supply to all control system
outputs is removed. The control system shall provide the operator with status feedback
and the ability to perform any required reset. Control system treatment of the
emergency stop signals is not further described in this document.
2.6 Start Warning
This document assumes that a start warning scheme that includes visual and/or audible
warning signals for local personnel is in place at the crusher. A start warning should
sound for the crusher main drive. A start warning is not required when crusher auxiliary
subsystem motors (lubrication, spider lubrication and hydraulic) are started. This
includes moving the mantle as personnel cannot be in the area of the moving mantle.
Control system treatment of the start warning signals is not further described in this
document.

2.7 Control Modes

This document considers two modes of operation for the crusher, Automatic and Manual.
Automatic mode is defined as the operation of one or more units as functional groups, in
sequential operations or based on instrument feedback. Manual mode is the operation
of individual units by the operator with no consideration for automated control based on
functional groups, sequential operations or instrument feedback.

Local control is only considered for functions where local control buttons are provided by
FLSmidth. Local start stop stations for motors are considered part of the motor control
scheme and are not further described in this document

2.8 Interlocking
Interlocking for each unit or function is presented in an interlock table containing all the
interlocks for that item. Each interlock is identified with a unique index, a description
identifying the logical conditions required to make the interlock TRUE and a Type and
Mode identify when an interlock is enabled. All enabled interlocks must be TRUE for the
unit to operate.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix G Functional Specification 267

1000899112: Functional Specification (Sheet 6)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

2.9 Automatic Start

Auto Starting for each unit or function is presented in a control table containing all the
starting and stopping conditions for that item. Each condition is identified with a unique
index, a description identifying the logical conditions and the associated control action.
Control loops are also presented in control tables with the P&ID identifier, description,
the process variable and the control variable.

2.10 Analog Instruments

The alarm and control points associated with each analog instrument are referenced in
alarm tables on each section. The numeric setpoints associated with each of these
alarm and control points can be found on the I/O List and in the setpoints table of each
section. Unless stated otherwise, each analog alarm shall have a 1 second debounce
timer

2.11 Calculations
This section specifies the equations for calculated values identified on the PID.

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
268 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 7)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

3. Lubrication System (LS)

LS Oil Reservoir Heaters (HE-001, HE-002, HE-003, HE-004)
Four oil immersion heaters (HE-001, HE-002, HE-003, HE-004) located in the Lube Oil
Reservoir (TK-001) maintain the oil temperature within the operation range. The four
heaters will control the temperature based on the tank oil temperature (TE-003). With
the Start when (TCL-003) is activated and Stop when (TCH-003) is activated. See the
Interlocks Sequence Table and Setpoint Table in this section for details regarding the
ON-OFF cycle of the heaters.

LS Pumps (PU-002, PU-003)

Two lubrication pumps (PU-002 & PU-003) are provided with the Crusher. One of the
pumps is to operate while the other is in standby. See the Interlocks and Sequence
Table in this section for details on the operation of those pumps.

Heat Exchanger Fan (FN-006 & FN-007)

The lubrication system has a heat exchanger fan to reduce the lube oil temperature (TE-
002) of the lubrication oil drain of the crusher. See Interlocks and Sequence Tables in
this section for details on the operation of this fan.

Dust Seal Fan (BL-001)

The Dust seal fan is required to keep a positive pressure inside the crusher and prevent
dust from entering through the seals. The fan is started at the same time as the lube oil
pump (PU-002 & PU-003). See Interlocks and Sequence Table in this section for details
on the operation of this fan.
[ALR_LS01] An alarm is setup as a warning when the fan trips.

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Appendix G Functional Specification 269

1000899112: Functional Specification (Sheet 8)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

LS Oil Reservoir Level Indication (LI-003)

A level transmitter is provided as part of the lubrication oil reservoir (TK-001).
[ALR_LS02] Signal from this level transmitter is wired to the control system for
monitoring and alarming purposes. See Alarms Table in this section for details.

Differential Pressure Calculation (PDY-006)

A differential pressure Calculation is performed across the filter pressure transmitters
PI-006B and PI-006A in the lubrication skid to help its operation and maintenance, to
inform when the filter is clog and needs to be cleaned up. See Calculations Table on this
section for details.
[ALR_LS03] Signal from this switch is programmed in the control system
to alarm when filter is clogged. See Alarms Table in this section for details.

Drain Oil Temperature Indication (LU TI-002)

A temperature element and indicating transmitter is provided as part of
the lubrication oil circuit.
[ALR_LS04] Signal from this temperature transmitter is wired to the control system for
monitoring and alarming. See Alarms Table in this section for details.

Differential Drain Oil Temperature Calculation (TDY-004)

[CALC_LS02] A calculation of the differential temperature between the lubrication oil
supply and drain is displayed to help the system operation. See Calculations Table on
this section for details.
[ALR_LS05] Signal from this soft calculation is programmed in the control system to be
displayed as a warning and
[ALR_LS06] is also programmed in the control system to be displayed as an alarm. See
Alarms and Setpoints Table in this section for details.

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270 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 9)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

LS Oil Reservoir Temperature Indication (TI-003)

A temperature element and indicating transmitter is provided as part of
the lubrication oil reservoir (TK-001). This temperature indication has a set of software
control limits LIM_L1 (TCL-003) to turn on automatically heaters 1, 2, 3, and 4 (HE-001,
HE-002, HE-003, HE-004), and LIM_H1 (TCH-003) to turn off automatically heaters 1,
2, 3 and 4 (HE-001, HE-002, HE-003, HE-004).
[ALR_LS07] Signal from this temperature transmitter is wired to the control system as a
warning. See Alarms Table in this section for details.

LS Supply Oil Temperature Indication (TI-004)

A temperature element and indicating transmitter is provided as part of
the lubrication system to monitor the oil supply.
[ALR_LS08] Signal from this temperature transmitter is wired to the control system as a
warning. See Alarms Table in this section for details.

Differential Eccentric Bushing Temperature Calculation (TDY-002)

[CALC_LS03] A calculation of the temperature between the lubrication system drain oil
and the eccentric bushing is displayed to help the system operation. See Calculations
Table on this section and Interlocks & Sequence Table in CR and FD sections for details.

Pump 1 Suction Valve Open Position Indication (ZAO-004)

A position switch is provided at the suction of the pump 1 to confirm when the valve is
open. The pump 1 can only operate when the suction valve is open. See Interlocks and
Sequence Tables in this section for details on this operation.

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Appendix G Functional Specification 271

1000899112: Functional Specification (Sheet 10)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Pump 2 Suction Valve Open Position Indication (ZAO-006)

A position switch is provided at the suction of the pump 2 to confirm when the valve is
open. The pump 2 can only operate when the suction valve is open. See Interlocks and
Sequence Tables in this section for details on this operation.

Pump 1 Discharge Valve Open Position Indication (ZAO-005)

A position switch is provided at the discharge of the pump 1 to confirm when the valve
is open. The pump 1 can only operate when the discharge valve is open. See Interlocks
and Sequence Tables in this section for details on this operation.

Pump 2 Discharge Valve Open Position Indication (ZAO-007)

A position switch is provided at the discharge of the pump 2 to confirm when the valve
is open. The pump 2 can only operate when the discharge valve is open. See Interlocks
and Sequence Tables in this section for details on this operation.

Lubrication Remote I/O Panel E-stop Push Button Indication (LU HI-001)
A push button is located in the lubrication remote I/O panel to indicate to
the operator when an e-stop event is present. Each panel provided by
FLSmidth has an e-stop push button and all of them are part of a
consolidated e-stop circuit.

LS Factors
Parameter Tag
Lube Min Run Time Elapsed G02OSP01

10

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272 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 11)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Normal Startup

*Interlocks in equipment need to be satisfied to enable startup sequence.

**Shutdown sequence shall be opposite to startup sequence, initiated by operator
command and will be enabled if all STP interlocks are satisfied.

3.1 LS Interlocks and Sequence Table

Index Equipment Tag Condition Delay Interlock Type Description
[INT01_HE-001, HE-002, HE- HE-001, HE-002,
003, HE-004] HE-003, HE-004 X45_OK 5 INT Crusher-CONTROL SYSTEM Network Communication OK
[INT02_HE-001, HE-002, HE- HE-001, HE-002,
003, HE-004] HE-003, HE-004 > LI-003 _L1 INT Lube Reservoir Oil > L1
[INT03_HE-001, HE-002, HE- HE-001, HE-002,
003, HE-004] HE-003, HE-004 < TI-003 _H2 INT Lube Oil Res Temperature < H2
[ASTR__HE-001, HE-002, HE-001, HE-002,
HE-003, HE-004_ON] HE-003, HE-004 TI-003 _LIM_L1 ASTR Immersion Heaters 1, 2, 3, and 4 ON (TCL-003)
[ASTR__HE-001, HE-002, HE-001, HE-002,
HE-003, HE-004_OFF] HE-003, HE-004 TI-003 _LIM_H1 ASTR Immersion Heaters 1, 2, 3, and 4 OFF (TCH-003)

[INT01_PU-002] PU-002 X45_OK 5 INT Crusher-CONTROL SYSTEM Network Communication OK

[INT02_PU-002] PU-002 > LI-003 _L3 INT Lube Reservoir Oil Level > L3

[INT03_PU-002] PU-002 >CR PI-001 _L3 CR PI-001 _L3_Delay INT Lube Oil Supply Pressure > L3

[INT04_PU-002] PU-002 > TI-003_L3 INT Lube Oil Res Temperature > L3

[SEQ01_PU-002] PU-002 > TI-003_L2 SEQ Lube Oil Reservoir Temperature > L2

[SEQ02_PU-002] PU-002 PU-002_SEL SEQ Lube Pump 1 Selected

[SEQ03_PU-002] PU-002 PU-003_NOT_RUN SEQ Lube Pump 2 Not Running

CRC-001-
[STP01_PU-002] PU-002 CRC-001-M01 _STOP M01_STOP_Delay STP Crusher off for 2 minutes

[INT01_PU-003] PU-003 X45_OK 5 INT Crusher-CONTROL SYSTEM Network Communication OK

[INT02_PU-003] PU-003 > LI-003_L3 INT Lube Reservoir Oil Level > L3

[INT03_ PU-003] PU-003 >CRC PI-001_L3 LS PI-001 _L3_Delay INT Lube Oil Supply Pressure > L3

11

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Appendix G Functional Specification 273

1000899112: Functional Specification (Sheet 12)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Index Equipment Tag Condition Delay Interlock Type Description

[INT04_ PU-003] PU-003 > TI-003_L3 INT Lube Oil Res Temperature > L3 (In PLC)

SEQ01_PU-003] PU-003 > TI-003_L2 SEQ Lube Oil Reservoir Temperature > L2

[SEQ02_PU-003] PU-003 PU-003_SEL SEQ Lube Pump 2 Selected

[SEQ03_PU-003] PU-003 PU-002_NOT_RUN SEQ Lube Pump 1 Not Running

CRC-001-
[STP01_PU-003] PU-003 CRC-001-M01_STOP M01_STOP_Delay STP Crusher off for 2 minutes

[INT01_FN-006, FN-007] FN-006 & FN-007 X45_OK 5 INT Crusher-CONTROL SYSTEM Network Communication OK

[SEQT01_FN-006, FN-007] FN-006 & FN-007 PU-002_RUN SEQ Lube Pump 1 Running, Pump 2 Standby

[SEQ02_FN-006, FN-007] FN-006 & FN-007 PU-003_RUN SEQ Lube Pump 2 Running, Pump 1 Standby

[ASTR_FN-006_ON] FN-006 LU TI-002_LIM_H1 ASTR Air Cooler 1 ON

[ASTR_FN-006_OFF] FN-006 LU TI-002_LIM_L1 ASTR Air Cooler 1 OFF

[ASTR_FN-007_ON] FN-007 LU TI-002_LIM_H2 ASTR Air Cooler 2 ON

[ASTR_FN-007_OFF] FN-007 LU TI-002_LIM_L2 ASTR Air Cooler 2 OFF

[INT01_BL-001] BL-001 X45_OK 5 INT Crusher-CONTROL SYSTEM Network Communication OK

*Refer to Setpoint Table in this section to find delay value using the code in the delay column of this table.

3.2 LS Alarms Table

Alarm
Index Signal Tag Delay (s) Alarm Description
ID
[ALR_LS01] BL-001 Run Countershaft Box Blower Not Running Alarm

[ALR_LS02] LI-003 H1 LS Oil Reservoir Level Indication Warning

[ALR_LS03] PDY-006 OK LS Differential Pressure Switch Clogged Filter Alarm

[ALR_LS04] LU TI-002 H1 LS Drain Oil Temperature Warning

[ALR_LS05] TDY-004 H1 LS Differential Drain Oil Temperature Calculation Warning

[ALR_LS06] TDY-004 H2 LS Differential Drain Oil Temperature Calculation Alarm

[ALR_LS07] TI-003 H1 LS Oil Reservoir Temperature Warning

[ALR_LS08] TI-004 L1 LS Supply Oil Temperature Low Warning

3.3 LS Calculations Table

Index Signal Tag Equation Description
[CALC_LS02] TDY-004 TDY-004=(TI-002) – (TI-004) LS Differential Drain Oil Temperature Calculation
Differential Eccentric Bushing Temperature Calculation. (Eccentric Oil Temperature) – (Oil
[CALC_LS03] TDY-002 TDY-002=(CRC TI-002) – (LU TI-002)
Drain Temperature)
[CALC_LS04] PDY-006 PDY=(PI-006B) – (PI-006A) LS Filter Pressure Differential Calculation

3.4 LS Setpoints Table

Alarm/Control Delay
Instrument Instrument Description Function R1100 Units
Limits (s)
G02OSP01 DN Lube Min Run Time Elapsed Timer 120 S

LI-003 H1 LS Oil Reservoir Level Indication Alarm 90 %

LI-003 L1 LS Oil Reservoir Level Indication Feed Interlock 50 %

LI-003 L3 LS Oil Reservoir Level Indication LS Pump Interlock 10 % 60

CRC PI-001 L3 LS Oil Supply Line Pressure Indication LS Pumps Interlock 35 kpa 5

PDY-006 A_OK LS Differential Pressure Switch Clogged Filter Alarm 241 kpa

12

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274 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 13)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Alarm/Control Delay
Instrument Instrument Description Function R1100 Units
Limits (s)
LU TI-002 H1 LS Drain Oil Temperature Indication Crusher Interlock 55 C 60

LU TI-002 LIM_H1 LS Drain Oil Temperature Indication Air Cooler 1 Auto-ON 43 C

LU TI-002 LIM_L1 LS Drain Oil Temperature Indication Air Cooler 1 Auto-OFF 38 C

LU TI-002 LIM_H2 LS Drain Oil Temperature Indication Air Cooler 2 Auto-ON 46 C

LU TI-002 LIM_L2 LS Drain Oil Temperature Indication Air Cooler 2 Auto-OFF 40 C

TDY-004 H2 LS Differential Drain Oil Temperature Calculation Alarm 17 C 600

TDY-004 H1 LS Differential Drain Oil Temperature Calculation Warning 17 C

TI-003 H2 LS Oil Reservoir Temperature Indication LS Heaters Interlock 42 C

TI-003 H1 LS Oil Reservoir Temperature Indication Alarm 35 C

TI-003 L2 LS Oil Reservoir Temperature Indication LS Pumps Sequence 34 C

TI-003 L3 LS Oil Reservoir Temperature Indication LS Pumps Interlock 15 C

TI-003 LIM_H1 LS Oil Reservoir Temperature Indication LS Heaters Auto-OFF 35 C

TI-003 LIM_L1 LS Oil Reservoir Temperature Indication LS Heaters Auto -ON 30 C

TI-004 L1 LS Supply Oil Temperature Indication Warning 20 C

13

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Appendix G Functional Specification 275

1000899112: Functional Specification (Sheet 14)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

4. HS System (HS)

HS Oil Pump (PU-001 & PU-002)

Two HS pump with Single motor is provided with the crusher HS system.
See Interlocks and Sequence Table and Setpoint Table in this section for details on the
operation of this pump.

HS System Return Oil Solenoid (YC-001)

The HS is provided with a solenoid valve to maintain the pressurization of the system.
See Pressurize Sequence Table in this section for details on the operation of this valve.

High Flow Solenoid Valve (YC-002)

The HS is provided with a solenoid valve to enable high speed when bowl open/close
adjustment is to be performed, allowing high oil flow to reduce the time of this
operation. See Pressurize Sequence Table in this section for details on the operation of
this valve.

Bowl Close Valve (YC-003)

The HS is provided with a solenoid valve to allow the close bowl function. See Pressurize
Sequence Table in this section for details on the operation of this valve.

Bowl Open Valve (YC-004)

The HS is provided with a solenoid valve to allow the open bowl function. See Pressurize
Sequence Table in this section for details on the operation of this valve.

Clamp Pressurization Valve (YC-005)

The HS has a solenoid valve to maintain the desired clamping pressure to keep the
crusher bowl down at the desired CSS so is ready to receive material and crush it. See

14

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276 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 15)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Pressurize Sequence Table and Alarms Table in this section for details on the operation
of this valve.

Clamp Dump Valve (YC-006)

The HS is provided with a solenoid valve to release the clamping pressure when an open
or close adjustment of the bowl is to be performed. See Pressurize Sequence Table in
this section for details on the operation of this valve.

HS Clearing Solenoid Valve (YC-008)

The HS is provided with a solenoid valve to allow the crusher chamber to evacuate any
material by lifting the crusher when the main motor is off. See Pressurize Sequence
Table in this section for details on the operation of this valve.

Tramp Pressurization Valve (YC-009)

The HS has a solenoid valve to maintain the desired tramping pressure. See
Pressurize Sequence Table and Alarms Table in this section for details on the
operation of this valve.

HS Oil Reservoir Level Indication (LI-002)

A level transmitter is provided as part of the HS oil reservoir.
[ALR_HS01] Signal from this level transmitter is wired to the control system as a
warning. See Alarms Table in this section for details.

HS Oil System Filter Differential Pressure Switch (PDAH-001)

A pressure switch is provided to the HS to monitor the functionality of the filter and
display alarm when the filter is clogged to indicate maintenance is needed.
[ALR_HS02] Signal from this switch is taken to the control system as an alarm. See
Alarms Table in this section for details.

15

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Appendix G Functional Specification 277

1000899112: Functional Specification (Sheet 16)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

HS Clamping Pressure (HU PI-001)

A pressure transmitter is provided in the HS to measure clamping pressure.
[ALR_HS03] Signal from this pressure transmitter is wired to the control system to help
controlling the clamping pressure. See Alarms Table and Setpoints Table in this section
for details.

HS Tramp Pressure Indication (HU PI-002)

A pressure transmitter is provided in the HS to measure tramping pressure.
[ALR_HS04] Signal from this pressure transmitter is wired to the DCS to help
controlling the tramping pressure. See Alarms Table and Setpoints Table in this
section for details.

HS Oil System Pressure Indication (PI-003)

A pressure transmitter is provided in the HS to monitor the system pressure.
[ALR_HS05] Signal from this pressure transmitter is wired to the control system to
help monitoring the system pressure. See Alarms Table and Setpoints Table in this
section for details.

Bowl Drive Pressure Switch (PAH-001)

A pressure switch located in the HS to signal when the bowl liner and mantle touches
and resets the CSS to zero when the calibration function is performed. See the
Functions Table on this section for details.

HS Oil Reservoir Temperature Indication (TI-001)

A temperature element and indicating transmitter is provided as part of the HS oil
reservoir (CRC-001K). See Interlocks and Sequence Table and Setpoint Table in this
section and FD section for details.

16

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278 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 17)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Pump 1 and 2 Suction Valve Open Position Indication (ZAO-012, ZAO-013)

A position switch is provided at the suction of the pump 1 and 2 to confirm when the
valve is open. The hydraulic pumps can only operate when its suction valve is open. See
Interlocks and Sequence Tables in this section for details on this operation.

Hydraulic Remote I/O Panel E-stop Push Button Indication (HU HI-001)
A push button is located at the hydraulic remote I/O panel to indicate to
the operator when an e-stop event is present. Each panel provided by
FLSmidth has an e-stop push button and all of them are part of a
consolidated e-stop circuit.

Normal Startup

*Interlocks in equipment need to be satisfied to enable startup sequence.

**Shutdown sequence shall be opposite to startup sequence, initiated by operator
command and will be enabled if all STP interlocks are satisfied.

17

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Appendix G Functional Specification 279

1000899112: Functional Specification (Sheet 18)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

4.1 HS Interlocks and Sequence Table

Equipment Interlock
Index Tag Condition Delay Type Description
[INT01_PU-001 & PU-002] PU-001 & PU-002 X45_OK 5 INT Crusher-CONTROL SYSTEM Network Communication OK

[INT02_PU-001 & PU-002] PU-001 & PU-002 X42_OK INT Not Continuous Pressurization

[INT03_PU-001 & PU-002] PU-001 & PU-002 > LI-002_L3 INT HS Oil Reservoir Level > L3

[INT04_PU-001 & PU-002] PU-001 & PU-002 < TI-001_H3 INT HS Oil Reservoir Temperature < H3
[ASTR_PU-001 & PU-
002_ON] PU-001 & PU-002 HU PI-001_LIM_L1 ASTR Clamp Circuit Auto Re-pressurize ON
[ASTR_PU-001 & PU-
002_OFF] PU-001 & PU-002 HU PI-001_LIM_H1 ASTR Clamp Circuit Auto Re-pressurize OFF
[ASTR_PU-001 & PU-
002_ON] PU-001 & PU-002 PI-002_LIM_L1 ASTR Tramp Circuit Auto Re-pressurize ON
[ASTR_PU-001 & PU-
002_OFF] PU-001 & PU-002 PI-002_LIM_H1 ASTR Tramp Circuit Auto Re-pressurize OFF
*Refer to Setpoint Table in this section to find delay value using the code in the delay column of this table.

4.2 HS Pressurize Sequence Table

Condition HS PU-001 &

(Automatic) Sequence YC-001 YC-002 YC-003 YC-004 YC-005 YC-006 YC-009 YC-08 PU-002
ASTR_PU-001 Clamp
& PU-002_ON Pressurize X 0 0 0 X 0 0 0 X
ASTR_PU-001 Tramp
& PU-002_ON Pressurize X 0 0 0 0 0 X 0 X
Clearing X 0 0 0 0 0 0 X X
Bowl Open X 0 0 X 0 X 0 0 X
Bowl Open
High Speed X X 0 X 0 X 0 0 X
Bowl Close X 0 X 0 0 X 0 0 X
Bowl Close
High Speed X X X 0 0 X 0 0 X
*Metal to
Metal
Calibration X
System Idle 0 0 0 0 0 0 0 0 0
*X=Open or Run, 0=Closed or Stop
**See System Idle @ Table 5.2 HS Pressurize Table

4.3 HS Alarms Table

Index Signal Tag Alarm ID Delay (s) Alarm Description
[ALR_HS01] LI-002 L1 HS Oil Level Low Warning

[ALR_HS02] PDSH-001 AL_OK HS Oil Filter Differential Pressure Switch High Alarm

[ALR_HS03] HU PI-001 L1 HS Low Clamping Pressure Warning

[ALR_HS04] PI-002 L1 HS Low Tramping Pressure Warning

[ALR_HS05] PI-003 H2 HS System Pressure Warning

G05ALPU-001 & PU- AL_OK 900 System Idle Alarm OK*

002

4.4 HS Setpoints Table

Alarm/Control
Tag Instrument Description Function R1100 Units Delay (s)
Limits
LI-002 H1 HS Oil Reservoir Level Indication Warning 90 %

LI-002 L3 HS Oil Reservoir Level Indication HS Pump Interlock 15 % 60

PAH-001 AL_OK HS Bowl Drive Pressure Switch Automation 8.6 MPa 3

HS Oil Filter Differential Pressure Switch
PDAH-001 AL_OK High Automation 8.6 MPa 3

18

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280 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 19)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Alarm/Control
Tag Instrument Description Function R1100 Units Delay (s)
Limits
HU PI-001 L1 HS Clamping Pressure Warning 17.9 MPa

HU PI-001 L2 HS Clamping Pressure Indication Feed Interlock 17.9 MPa 180

HU PI-001 L3 HS Clamping Pressure Indication Feed Interlock 16.5 MPa 5

HU PI-001 Lim_H1 HS Clamping Pressure Indication HS Pump Auto-OFF 19.3 MPa

HU PI-001 Lim_L1 HS Clamping Pressure Indication HS Pump Auto-ON 17.9 MPa

PI-002 L1 HS Tramp Pressure Indication Warning 11 MPa 60

PI-002 L2 HS Tramp Pressure Indication Feed Sequence 11 MPa 300

PI-002 L3 HS Tramp Pressure Indication Feed Interlock 9.6 MPa 5

PI-002 Lim_H1 HS Tramp Pressure Indication HS Pump Auto-OFF 12.4 MPa

PI-002 Lim_L1 HS Tramp Pressure Indication HS Pump Auto-ON 11 MPa

PI-003 H2 HS System Pressure Indication Warning 25 MPa

TI-001 H3 HS Oil Reservoir Temperature Indication HS Pump Interlock 65 C

TI-001 H2 HS Oil Reservoir Temperature Indication Feed Sequence 63 C

19

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Appendix G Functional Specification 281

1000899112: Functional Specification (Sheet 20)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

5. Crusher & Main Drive (CR)

Main Drive Motor Space Heater (HE-005)
The main drive motor is provided with a space heater (HE-005) to keep the motor warm
and moisture free during shutdown of the main drive.
See Interlocks and Sequence Table and Setpoint Table in this section for details on the
ON-OFF cycle of this heater.

Main Drive Motor (CRC-001-M01)

The Crusher is driven by an electric motor. The lubrication pumps (PU-001 & PU-002)
must always run prior to starting and that the main drive motor is running.
See Interlocks and Sequence Table and Setpoint Table in this section for details on the
main drive motor operation.

Oil Supply Flow Indication (FI-001)

The crusher is equipped with a flow transmitter to monitor the oil supply flow coming
into the crusher (CRC-001). See Interlocks and Sequence Table and Setpoint Table in
this section for details.

Cavity Level Indication (LI-001)

The crusher is equipped with a lever transmitter to monitor and control the feed level in
the crushing chamber (CRC-001). See Interlocks and Sequence Table and Setpoint
Table in FD section for details.

System Pressure Indication (CRC PI-001)

The crusher is equipped with a pressure transmitter to monitor the oil supply pressure of
the crusher (CRC-001). See Interlocks and Sequence Table and Setpoint Table in this
section for details.

20

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282 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 21)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Crusher Sheave Speed Indication (SI-003)

A proximity switch mounted in the countershaft box assembly to monitor the speed of
the crusher sheave.
[ALR_CR01] Signal from this proximity is wired to a frequency transducer located in the
PLC panel to help monitoring the crusher sheave speed.
See Alarms Table and Setpoints Table in this section for details. See Interlocks and
Sequence Table and Setpoint Table in CR and FD sections for details.

Eccentric Bushing Temperature Indication (CRC TI-002)

A temperature element and indicating transmitter is provided as part of
the crusher instrumentation to monitor the bushing temperature. See Interlocks and
Sequence Table and Setpoint Table in FD and this section for details.

Countershaft Temperature Indication (TI-005)

A temperature element and indicating transmitter is mounted in the countershaft box to
monitor countershaft bushing temperature. See Interlocks and Sequence Table and
Setpoint Table in FD and this section for details.

DE Motor Bearing Temperature Indication (TI-007)

A temperature element and indicating transmitter is mounted in the control system to
monitor the drive end motor bearing temperature. See Interlocks and Sequence Table
and Setpoint Table in this section for details.

NDE Motor Bearing Temperature Indication (TI-009)

A temperature element and indicating transmitter is mounted in the control system to
monitor the non-drive end motor bearing temperature. See Interlocks and Sequence
Table and Setpoint Table in this section for details.
Motor Winding Temperature Indication (TI-010, TI-011, TI-012)

21

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Appendix G Functional Specification 283

1000899112: Functional Specification (Sheet 22)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Three temperature elements and indicating transmitter are mounted in the control
system to monitor the motor winding temperature. See Interlocks and Sequence Table
and Setpoint Table in this section for details.

Ring Vibration 1 Indication (VI-001)

A vibration sensor and indicating transmitter is provided with the crusher to monitor ring
vibration. See Interlocks and Sequence Table and Setpoint Table in FD section for
details.

Ring Vibration 2 Indication (VI-002)

A vibration sensor and indicating transmitter is provided with the crusher to monitor ring
vibration. See Interlocks and Sequence Table and Setpoint Table in FD section for
details.

Ring Vibration 3 Indication (VI-003)

A vibration sensor and indicating transmitter is provided with the crusher to monitor ring
vibration. See Interlocks and Sequence Table and Setpoint Table in FD section for
details.

Ring Vibration 4 Indication (VI-004)

A vibration sensor and indicating transmitter is provided with the crusher to monitor ring
vibration. See Interlocks and Sequence Table and Setpoint Table in FD section for
details.

Alarm Horn and Dump Light (XC-101, YC-101)

A tower light and buzzer is located in the control system to alarm horn and to indicate
when the crusher cannot receive feed.

22

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284 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 23)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Adjustment Drive Switch (ZS-001, ZS-002)

Proximity switches are provided in the bowl drive to detect movement of the pinion
tooth and count to adjust the bowl creep. See Functions Section for details on this
process.

Control Panel E-stop Push Button Indication (CR-BB HI-001)

A push button is located at the main control panel to indicate to the
operator when an e-stop event is present. Each panel provided by
FLSmidth has an e-stop push button and all of them are part of a
consolidated e-stop circuit.

Control Panel Surge Suppressor Indication (HI-002)

An input is provided in the main control panel to indicate to the operator
that the surge suppressor of the panel is not faulted.

Control Panel Safety Relay 1 and Relay 2 Indication (HI-003, HI-004)

Two safety relays are provided in the main control panel to de-energize
digital outputs on the crusher remote I/O panels and customer MCC. Those
relays are open when an estop event is present.

Crusher Remote I/O Panel E-stop Push Button Indication (CR-IOB HI-001)
A push button is located at the crusher remote I/O panel to indicate to the
operator when an e-stop event is present. Each panel provided by
FLSmidth has an e-stop push button and all of them are part of a
consolidated e-stop circuit.

23

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Appendix G Functional Specification 285

1000899112: Functional Specification (Sheet 24)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

5.1 CR Factors, Variables & Formulas

Description Tag Value
Crusher-CONTROL SYSTEM X45_OK
Network Communication OK Communication OK1=OK, Communication Alarm =0
Not Continuous Pressurization X42_OK Not Continuous Press = 1, Continuous Press = 0
Crusher CSS (Setpoint) G03OSP07 X mm
Max CSS Allowed* G03OSP13 20 mm
Min CSS Allowed* G03OSP14 12 mm
mm of CSS/gear tooth Tooth_Ratio 0.23 mm
Calibration Command Calib_CMD 1 = Start / 0 = Stop
Count up Cnt_Up G03OSP07 + Tooth_Ratio
Count Down Cnt_Down G03OSP07 - Tooth_Ratio
Bowl Creep Alarm ZI1X41 Bowl Creep Alarm_OK = 1, Bowl Creep Alarm = 0
*Applicable for short head fine liner profile.

5.2 CR Interlocks and Sequence Table

Equipment
Index Tag Condition Delay Interlock Type Description
[INT01_HE-005] HE-005 X45_OK 5 INT Crusher-CONTROL SYSTEM Network Communication OK
CRC-001-M01
[ASTR_ HE-005 _ON] HE-005 ASTR Main Drive Motor Heater ON
_NOT_RUN
[ASTR_ HE-005 _OFF] HE-005 CRC-001-M01 _RUN ASTR Main Drive Motor Heater OFF

[INT01_CRC-001-M01] CRC-001-M01 X45_OK 5 INT Crusher-CONTROL SYSTEM Network Communication OK

G05ALPU-001 & PU-
[INT02_CRC-001-M01] CRC-001-M01 INT System Idle Alarm OK
002_OK
[INT03_CRC-001-M01] CRC-001-M01 Calib_CMD=0 INT Calibration Not Active

[INT04_CRC-001-M01] CRC-001-M01 > SI-003_L3 INT Crusher Speed > L3

[INT05_CRC-001-M01] CRC-001-M01 G03OSP07>G03OSP14 INT Crusher CSS > Min Allowable

[INT06_CRC-001-M01] CRC-001-M01 G03OSP07<G03OSP13 INT Crusher CSS < Max Allowable

[INT07_CRC-001-M01] CRC-001-M01 < TI-005_H3 INT C-Shaft Bushing Temperature < H3

[INT08_CRC-001-M01] CRC-001-M01 < CRC TI-002_H2 INT Crusher Eccentric Oil Temperature < H2

[INT09_CRC-001-M01] CRC-001-M01 < CRC TI-002_H3 INT Crusher Eccentric Oil Temperature < H3

[INT10_CRC-001-M01] CRC-001-M01 < TDY-002_H2 INT Differential Eccentric Bushing Temperature < H2

[INT11_CRC-001-M01] CRC-001-M01 <TDY-002_H3 INT Differential Eccentric Bushing Temperature < H3

[INT12_CRC-001-M01] CRC-001-M01 > LI-002_L2 INT HS Oil Reservoir Level > L2

[INT13_CRC-001-M01] CRC-001-M01 G02OSP01=DN INT Lube Min Run Time Elapsed

[INT14_CRC-001-M01] CRC-001-M01 < LU TI-002_H3 INT Lube Oil Drain Temperature < H3

[INT15_CRC-001-M01] CRC-001-M01 TE-002X41_OK INT Lube Oil Drain Temperature OK

[INT16_CRC-001-M01] CRC-001-M01 > LI-003_L2 INT Lube Oil Reservoir Level > L2

[INT17_CRC-001-M01] CRC-001-M01 > CRC PI-002_L2 INT Lube Oil Supply Pressure > L2

[SEQ01_CRC-001-M01] CRC-001-M01 M19_RUN SEQ Discharge Conveyor Running

[SEQ02_CRC-001-M01] CRC-001-M01 > LI-003_L1 SEQ Lube Oil Reservoir Level > L1

[SEQ03_CRC-001-M01] CRC-001-M01 > CRC PI-002_LIM_H1 SEQ Lube Oil Supply Pressure > Lim_H1

24

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286 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 25)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

5.3 CR Alarms Table

Signal
Index Equipment/Instrument Tag Alarm ID Delay (s) Alarm Description
ALR_CR01 SI-003 L1 ZI-003_L1_Delay Crusher Speed Warning

ALR_CR02 ZI1X41 OK Bowl Creep Alarm

5.4 CR Setpoints Table

Alarm/Control Delay
Tag Instrument Description Function R1100 Units
Limits (s)
LI-001 H2 Cavity Level Indication Feed Interlock 80 %

LI-002 L1 HS Oil Reservoir Level Indication Feed Interlock 47 %

LI-002 L2 HS Oil Reservoir Level Indication Crusher Interlock 37 % 5

CRC PI-001 LIM_H1 LS Oil Supply Line Pressure Indication Crusher Sequence 137 kpa

CRC PI-001 H1 LS Oil Supply Line Pressure Indication Interlock 117 kpa

CRC PI-001 L1 LS Oil Supply Line Pressure Indication Crusher Interlock 90 kpa

CRC PI-001 L2 LS Oil Supply Line Pressure Indication Crusher Interlock 75 kpa

SI-003 L1 Crusher Sheave Speed Indication Warning 95 % 3

SI-003 L3 Crusher Sheave Speed Indication Crusher Interlock 95 % 18

LU TI-002 H3 LS Drain Oil Temperature Indication Crusher Interlock 60 C

LU TI-002 H2 LS Drain Oil Temperature Indication Feed Interlock 57 C

LI-003 L1 LS Oil Reservoir Level Indication Crusher Interlock 50 %

LI-003 L2 LS Oil Reservoir Level Indication Crusher Interlock 40 % 5

TI-005 H3 C-Shaft Temperature Crusher Interlock 59 C

CRC TI-002 H3 Eccentric Bushing Temperature Indication Crusher Interlock 90 C 5

CRC TI-002 H2 Eccentric Bushing Temperature Indication Crusher Interlock 75 C 180

CRC TI-002 H1 Eccentric Bushing Temperature Indication Feed Interlock 75 C

Differential Eccentric Bushing Temperature
TDY-002 H3 Calculation Crusher Interlock 55 C
Differential Eccentric Bushing Temperature
TDY-002 H2 Calculation Crusher Interlock 30 C 60
Differential Eccentric Bushing Temperature
TDY-002 H1 Calculation Feed Interlock 24 C

5.5 CR Functions
5.5.1 Tooth Counting Process
The tooth counting process is a process of proximity switches detecting the tip of the
pinion tooth. Two proximity switches are slightly skewed to detect rotation and count.
Depending on direction, the first proximity switch detects direction. The second
proximity switch counts the teeth. When both proximity switches are off, the process is
reset. This method will allow partial contact at the beginning of an adjustment or bowl
creep.

25

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Appendix G Functional Specification 287

1000899112: Functional Specification (Sheet 26)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

5.5.1.1 Tooth Counting Process Sequence Table

Sequence Step ZS-001 ZS-002 Prox1 Count Dir Prox2 Count Dir

Crusher Setting Count Direction Up X 0 0 X

Count Up = +1 0 X 0 X

Crusher Setting Count Direction Down 0 X X 0

Count Down = -1 X 0 X 0

Reset Crusher Setting Count Directions 0 0 0 0

X= Activated / 0=Deactivated

26

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288 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 27)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

27

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Appendix G Functional Specification 289

1000899112: Functional Specification (Sheet 28)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

5.5.2 Metal to Metal Calibration

The Calibration procedure is called metal-to-metal. This method uses contact between
the liner and the mantle to zero the CSS, then the bowl opens to the CSS Setpoint,
allowing the system to account for liner wear. A pressure switch is used to measure the
HS pressure. The auto control closes the bowl with the lube running while the crusher
drive motor is off.
Upon contact, the pressure increases to approximately 1250 psi [8,618 kPa] and stops
the bowl from closing. The CSS is set to zero. The bowl opens to the last registered
CSS using tooth count.

5.5.2.1 Metal to Metal Calibration Sequence Table

CSS SP = CSS Calib_CMD
Sequence PU-001 &
Actual YC-001 YC-002 YC-003 YC-004 YC-006 PAH-001
Step PU-002

Calibration 0 X 0 0 0 0 0 0 0
Bowl Close 0 X X 0 X 0 X 0 X
Bowl Close
High Speed
0 X X X X 0 X 0 X
Bowl Close
Stop
0 X X X X 0 X X X
Bowl Open 0 X X 0 0 X X X X
Bowl Open
High Speed
0 X X X 0 X X 0 X
Calibration
Done
X X X X 0 X X 0 X
X= Activated/Open, 0=Deactivated/Close
(*) Feed Stopped before metal to metal calibration.
(**) Crusher Stopped before metal to metal calibration.

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290 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 29)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

29

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Appendix G Functional Specification 291

1000899112: Functional Specification (Sheet 30)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

5.5.3 Bowl Creep

If the bowl assembly turns two or more teeth in either direction during operation
(defined by existence of full clamp pressure, 2400 psi (16,550 kPa)), a “Bowl Creep
Alarm” notification should be displayed and feed to the crusher should be stopped.

30

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292 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 31)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Normal Startup

*Interlocks in equipment need to be satisfied to enable startup sequence.

**Shutdown sequence shall be opposite to startup sequence, initiated by operator
command and will be enabled if all STP interlocks are satisfied.

31

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Appendix G Functional Specification 293

1000899112: Functional Specification (Sheet 32)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

6. Feed and Discharge Integration (FD)

Discharge Conveyor (M19) Optional, Not included in FLS Supply

The discharge conveyor typically is not part of the crusher equipment provided by
FLSmidth. This section is for integration purposes.
The interlocks on this equipment are to be defined by client. It must run prior the
crusher main motor and the feed start. If the discharge conveyor stops, the main motor
and the vibration feeder will stop immediately.

Vibrating Feeder (M20) By FLS

The vibrating feeder is part of the crusher equipment provided by FLSmidth.
See Interlocks and Sequence Table in this section for details.
Vibration Feeder is controlled directly by FLS Crusher PLC.

MCC Remote I/O Panel E-stop Push Button Indication (MCC HI-001)
A push button is located at the MCC remote I/O panel to indicate to the
operator when an e-stop event is present. This panel is not provided by
FLSmidth but the system has reserved terminals to interconnect this e-stop
push button with the consolidated e-stop circuit.

32

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294 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 33)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

Start

No
No
Crusher Drive Vibrating Feeder
Running = 1 Running M20 =1 Yes

Yes Crusher Drive

Yes Running = 1
Shut Down
Feed
No
No

Timer = 2 Min
General
Alarm

Yes
Yes
Vibrating
Feeder RESET
M20 = 0

No

33

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Appendix G Functional Specification 295

1000899112: Functional Specification (Sheet 34)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

6.1 FD Interlocks Table

Equipment Interlock
Index Condition Delay Index
Tag Type
INT01_M20 M20 X45_OK 5 INT
Crusher-CONTROL SYSTEM Network Communication OK
INT02_M20 M20 M19_RUN INT Discharge Conveyor Running

INT03_M20 M20 CRC-001-M01_RUN INT Crusher Motor Running

INT04_M20 M20 CALLIBRATION_SEL INT Calibration Not Active

G03OSP07 <
INT05_M20 M20 INT Crusher CSS > Min Allowable
G03OSP14
G03OSP07 <
INT06_M20 M20 INT Crusher CSS < Max Allowable
G03OSP13
INT07_M20 M20 < TI-005_H2 INT C-Shaft Bushing Temperature < H2

INT08_M20 M20 > SI-003_L2 INT Crusher Speed > L2

INT09_M20 M20 < VI-001_H2 INT Crusher Vibration Indication 1 < H2

INT10_M20 M20 < VI-002_H2 INT Crusher Vibration Indication 2 < H2

INT11_M20 M20 < VI-003_H2 INT Crusher Vibration Indication 3 < H2

INT12_M20 M20 < VI-004_H2 INT Crusher Vibration Indication 4 < H2

INT13_M20 M20 > LI-001_H2 Int Crusher Cavity Level < H2

INT14_M20 M20 ZI1X41_OK INT Bowl Creep Alarm OK

INT15_M20 M20 < CRC TI-002_H1 INT Crusher Ecc Bushing Oil Temperature < H1

INT16_M20 M20 < TDY-002_H1 INT Ecc Bushing Oil Diff Temperature < H1

INT17_M20 M20 > LI-002_L1 INT HS Oil Tank Level > L1

INT18_M20 M20 < TI-001_H3 INT HS Oil Tank Temperature < H3

INT19_M20 M20 > HU PI-001_L2 INT HS Clamping Pressure > L2

INT20_M20 M20 > HU PI-001_L3 INT HS Clamping Pressure > L3

INT21_M20 M20 > PI-002_L2 INT HS Tramp Release Pressure > L2

INT22_M20 M20 > PI-002_L3 INT HS Tramp Release Pressure > L3

INT23_M20 M20 < LU TI-002_H2 INT Lube Oil Drain Temperature < H2

INT24_M20 M20 TE-002X41_OK INT Lube Oil Drain Temperature OK

INT25_M20 M20 > LI-003_L1 INT Lube Oil Tank Level > L1

INT26_M20 M20 > PI-002_L1 INT Lube Oil Supply Pressure > L1

INT27_M20 M20 < TDY-004_H2 INT Lube Oil Diff Temperature < H2
CRC-001-M01_RUN
INT28_M20 M20 SEQ Crusher Motor Running for 2 min
>= 120
SEQ01_M20 M20 < TI-001_H2 SEQ HS Oil Reservoir Temperature < H2

SEQ02_M20 M20 < TI-005_H1 SEQ C-Shaft Bushing Temperature < H1

6.2 FD Alarms Table

Index Signal Tag Alarm ID Delay (s) Alarm Description
[ALR_FD01] VI-001 H1 3 FD Vibration 1 Indication High Warning

[ALR_FD02] VI-001 H1 3 FD Vibration 2 Indication High Warning

[ALR_FD03] VI-001 H1 3 FD Vibration 3 Indication High Warning

[ALR_FD04] VI-001 H1 3 FD Vibration 4 Indication High Warning

34

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296 Appendix G Functional Specification

1000899112: Functional Specification (Sheet 35)

Functional Specification
Document No. 1000899112
Project No. 9232515940
Raptor 1100 Cone Crusher

6.3 FD Setpoints Table

Alarm/Control Delay
Tag Instrument Description Function R1100 Units
Limits (s)
TI-005 H2 C-Shaft Temperature Feed Interlock 54 C

TI-005 H1 C-Shaft Temperature Feed Sequence 49 C

SI-003 L2 Crusher Sheave Speed Indication Feed Interlock 95 % 10

VI-001 H2 Crusher Vibration Indication 1 Feed Interlock 8 mm/s 10

VI-001 H1 Crusher Vibration Indication 1 Feed Interlock 6 mm/s 3

VI-002 H2 Crusher Vibration Indication 2 Feed Interlock 8 mm/s 10

VI-002 H1 Crusher Vibration Indication 2 Feed Interlock 6 mm/s 3

VI-003 H2 Crusher Vibration Indication 3 Feed Interlock 8 mm/s 10

VI-003 H1 Crusher Vibration Indication 3 Feed Interlock 6 mm/s 3

VI-004 H2 Crusher Vibration Indication 4 Feed Interlock 8 mm/s 10

VI-004 H1 Crusher Vibration Indication 4 Feed Interlock 6 mm/s 3

35

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 297

Appendix H: Drawing
Package
H.1 1000855444: General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
H.2 1000896918: Foundation Bolt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
H.3 647092: Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
H.4 RXL1301-5000: Main Frame Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
H.5 1000687903: Adjustment Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
H.6 1000920546: Split Tramp Release Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
H.7 RXL1004-5003: Countershaft Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
H.8 677551: Eccentric Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
H.9 677550: Eccentric Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
H.10 677548: Counterweight Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
H.11 RXL1007-5005: Socket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
H.12 RXL1007-5004: Socket Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
H.13 677553: Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
H.14 RXL1008-5002: Head Stub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
H.15 RXL1316-5000: Adjustment Mechanism Assembly . . . . . . . . . . . . . . . . . . . . . . . . 321
H.16 RXL1016-5002: Adjustment Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
H.17 RXL1016-5003: Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
H.18 RXL1016-5007: Pinion Shield Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
H.19 RXL1005-5006: Oil Piping Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
H.20 RXL1009-5002: Feed Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
H.21 RXL1010-5003: Liner Assembly, Standard Head Fine . . . . . . . . . . . . . . . . . . . . . 328
H.22 648590: Bowl Assembly, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
H.23 RXL1012-5001: Hopper Assembly, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
H.24 RXL1017-5001: Tools Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
H.25 RXL1020-5001: Decal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
H.26 1000690716: Sole Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
H.27 RXL1013-5001: Crusher Sheave Assembly, Ø40, 8V . . . . . . . . . . . . . . . . . . . . . . 336
H.28 RXL1013-5009: Motor Sheave Assembly, Ø28, 8V . . . . . . . . . . . . . . . . . . . . . . . .337
H.29 RXL1023-5004: Countershaft Box Blower Assembly . . . . . . . . . . . . . . . . . . . . . 338
H.30 1000896923: Instrument Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
H.31 1000855586: Air Seal Blower General Arrangement . . . . . . . . . . . . . . . . . . . . . 342

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
298 Appendix H Drawing Package

H.32 1000894264: Electrical Load List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343

H.33 1000894004: Instrument List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
H.34 1000892011: Control and Instrumentation Diagram . . . . . . . . . . . . . . . . . . . . . . . 351
H.35 1000855581: Lubrication Unit General Arrangement . . . . . . . . . . . . . . . . . . . . . 358
H.36 1000855590: Lubrication Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
H.37 1000855583: Heat Exchanger General Arrangement . . . . . . . . . . . . . . . . . . . . 360
H.38 1000855555: Hydraulic Power Unit General Arrangement . . . . . . . . . . . . . . . . . 361
H.39 1000855588: Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
H.40 1000911692: Interconnection Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
H.41 1000890158: Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370
H.42 1000924365: Network Signal List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
H.43 1000907855: PLC Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379
H.44 1000907858: Machine RIO Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
H.45 1000907856: Lube RIO Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433
H.46 1000907857: HPU RIO Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
H.47 1000887465: Control System Design Datasheet . . . . . . . . . . . . . . . . . . . . . . . . .479

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

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9232515940 — 1000912341 1
Appendix H Drawing Package
 ITEM WEIGHT
NO. PART NUMBER QTY PART NAME EACH (KG)

9 1 661752 1 Nameplate, Crusher -

10 2 1000162941 1 Safety Instructions -

10 3 1000162943 8 Danger Plate-Projectile -

4 RXL1020-0006 1 Rotation Arrow, Large -

10 5 1000162940 8 Danger Plate-Crushing -

10 9 6 1000162945 8 Notice Plate -
7 RXL000-0104 4 Drive Screw #10 -

9 8 651774 2 Decal, 1100 -

9 9 651775 A/R Decal, Striping, Large -

9 10 651776 2 Decal, Raptor, Large -

LEFT-SIDE VIEW FRONT VIEW
11

9 12 651777 2 Decal, FLSmidth, Large -

12 9 10 8 9 See note 4
9 13

9 14

9 15

9 16
Appendix H Drawing Package

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

C:\smarteam\651775.jpg C:\smarteam\651777.jpg
C:\smarteam\651775.jpg C:\smarteam\651775.jpgC:\smarteam\651775.jpg C:\smarteam\651775.jpg C:\smarteam\651776.jpg C:\smarteam\651774.jpg
C:\smarteam\651775.jpg
C:\smarteam\651775.jpg C:\smarteam\651775.jpg

6
5
8-Places, equally
spaced around
adjustment ring 5
6
DANGER DANGER DANGER DANGER DANGER DANGER
Crushing Hazard NOTICE Crushing Hazard NOTICE Crushing Hazard NOTICE Crushing Hazard NOTICE Crushing Hazard NOTICE Crushing Hazard NOTICE
Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release
the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting
crusher. Crusher. crusher. Crusher. crusher. Crusher. crusher. Crusher. crusher. Crusher. crusher. Crusher.
Keep hands and feet clear. Keep hands and feet clear. Keep hands and feet clear. Keep hands and feet clear. Keep hands and feet clear. Keep hands and feet clear.
For replacement Notice Plate order For replacement Notice Plate order For replacement Notice Plate order For replacement Notice Plate order For replacement Notice Plate order For replacement Notice Plate order
For replacement Danger Plate FLSmidth Part Number 1000162945 For replacement Danger Plate FLSmidth Part Number 1000162945 For replacement Danger Plate FLSmidth Part Number 1000162945 For replacement Danger Plate FLSmidth Part Number 1000162945 For replacement Danger Plate FLSmidth Part Number 1000162945 For replacement Danger Plate FLSmidth Part Number 1000162945
order FLSmidth Part Number order FLSmidth Part Number order FLSmidth Part Number order FLSmidth Part Number order FLSmidth Part Number order FLSmidth Part Number
1000162940 1000162940 1000162940 1000162940 1000162940 1000162940

4
DANGER DANGER DANGER DANGER DANGER
Projectile Hazard Projectile Hazard Projec
Projectile Hazard Projectile Hazard Projectile Hazard
Avoid serious injuries and property damage . Avoid serious injuries and property damage. Avoid se
Remove safety blocks before pressurizing tramp release cylinders Remove safety blocks before pressurizing tramp release cylinders Remove s Avoid serious injuries and property damage. Avoid serious injuries and property damage. Avoid serious injuries and property damage .
Remove safety blocks before pressurizing tramp release cylinders Remove safety blocks before pressurizing tramp release cylinders Remove safety blocks before pressurizing tramp release cylinders
For replacement Danger Plate order
FLSmidth Part Number 1000162943 For replacement Danger Plate order For replacement Danger Plate order
FLSmidth Part Number 1000162943 FLSmidth Part Number 1000162943 For replacement Danger Plate order For replacement Danger Plate order For replacement Danger Plate order
FLSmidth Part Number 1000162943 FLSmidth Part Number 1000162943 FLSmidth Part Number 1000162943

RAPTOR CONE CRUSHER

MODEL NO. SERIAL N0.

CUSTOMER P.O. NO.

RAPTOR 1100 TAG NO.

For Parts and Services, please visit www.flsmidth.com

SAFETY
INSTRUCTIONS
1. Read all instructions in the

ROTA
instruction manual before Crusher
start up and before performing any
maintenance or repair work.

2. Removal of tramp iron lodged in the

Crusher cavity is extremely
dangerous. Follow Crusher clearing
instructions in the manual.

3. A platform should be installed

around the Crusher level with the top
of the adjustment ring providing a
safe and convenient working area.
DO NOT attach the platform to the
Crusher.

4. Lock out electrical devices before

performing maintenance or repair
work.

5. Replace guards before operating.

6. Use extreme caution around

hydraulic hoses.

7. Do not lean on or touch crusher

while it is operating.

8. Do not look into Crusher cavity while

it is operating.
For replacement Safety Instructions
Plate order FLSmidth Part Number
1000162941

3/13/24
8 x, space as
9 necessary around
3 3
Main Frame while
maintaning visibilty
See note 1 7 1 2

Notes:

1. Requires Ø4.1 (#20) x 10 deep hole to install.

H.25 RXL1020-5001: Decal Assembly

2. Thoroughly clean surface before applying nameplates in area of crusher as shown.

3. Stamp crusher model and serial number on crusher nameplate (Item 1).

4. Cut striping decal (Item 9) to length as required. Ref: 10.7 m lg.

5. Parts with decals must be painted prior to decal application.

9 6.

11

10 MRN JWIN 15-Dec-21 Item nos 2,3,5,6 updated

9 JWG MJE 20-Dec-12 ECN: 54201 Removed Items 13-16; Changed Items 8 to 10 and 12.

8 TER JKD 20-Feb-12 ECN:48473 Paint, Items 13 thru 15, changed to "epoxy"

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
®
All dimensions are in
millimeters ©

All weights are in

Kilograms
333

9232515940 — 1000912341 1
 334

RIGHT-SIDE VIEW BACK VIEW

12 9 See note 4 10 8 9

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

5

C:\smarteam\651775.jpg C:\smarteam\651777.jpg
C:\smarteam\651775.jpg C:\smarteam\651775.jpgC:\smarteam\651775.jpg C:\smarteam\651775.jpg C:\smarteam\651776.jpg C:\smarteam\651774.jpg
C:\smarteam\651775.jpg
C:\smarteam\651775.jpg C:\smarteam\651775.jpg

6 5

DANGER DANGER DANGER DANGER DANGER DANGER

Crushing Hazard NOTICE Crushing Hazard NOTICE Crushing Hazard NOTICE Crushing Hazard NOTICE Crushing Hazard NOTICE Crushing Hazard NOTICE
Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release Do not place hands or feet in the space between To avoid damage to Crusher, Tramp Release
the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting the adjustment ring and main frame when clearing the circuit must be at proper operating pressure before starting
crusher. Crusher. crusher. Crusher. crusher. Crusher. crusher. Crusher. crusher. Crusher. crusher. Crusher.
Keep hands and feet clear. Keep hands and feet clear. Keep hands and feet clear. Keep hands and feet clear. Keep hands and feet clear. Keep hands and feet clear.
For replacement Notice Plate order For replacement Notice Plate order For replacement Notice Plate order For replacement Notice Plate order For replacement Notice Plate order For replacement Notice Plate order
For replacement Danger Plate FLSmidth Part Number 1000162945 For replacement Danger Plate FLSmidth Part Number 1000162945 For replacement Danger Plate FLSmidth Part Number 1000162945 For replacement Danger Plat e FLSmidth Part Number 1000162945 For replacement Danger Plat e FLSmidth Part Number 1000162945 For replacement Danger Plat e FLSmidth Part Number 1000162945
order FLSmidth Part Number order FLSmidth Part Number order FLSmidth Part Number order FLSmidth Part Number order FLSmidth Part Number order FLSmidth Part Number
1000162940 1000162940 1000162940 1000162940 1000162940 1000162940

3/13/24
ANGER DANGER DANGER DANGER DANGER DANGER
Projectile Hazard Projectile Hazard Projectile Hazard
zard Projectile Hazard Projectile Hazard Avoid serious injuries and property damage . Avoid serious injuries and property damage. Avoid serious injuries and property damage.
Remove safety blocks before pressurizing tramp release cylinders Remove safety blocks before pressurizing tramp release cylinders Remove safety blocks before pressurizing tramp release cylinders
es and property damage. Avoid serious injuries and property damage. Avoid serious injuries and property damage.
efore pressurizing tramp release cylinders Remove safety blocks before pressurizing tramp release cylinders Remove safety blocks before pressurizing tramp release cylinders
For replacement Danger Plate order For replacement Danger Plate order For replacement Danger Plate order
FLSmidth Part Number 1000162943 FLSmidth Part Number 1000162943 FLSmidth Part Number 1000162943

For replacement Danger Plate order For replacement Danger Plate order
FLSmidth Part Number 1000162943 FLSmidth Part Number 1000162943

TION
3 3
RXL1020-5001: Decal Assembly (Sheet 2)

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
®

9232515940 — 1000912341 1
Appendix H Drawing Package
                          

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9232515940 — 1000912341 1
335
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Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

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RXL1013-5001: Crusher Sheave Assembly, Ø40, 8V

9232515940 — 1000912341 1
Appendix H Drawing Package
  ) /  @ = A . &  ) /  @ = A . &   ) /  @
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Appendix H Drawing Package

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9232515940 — 1000912341 1
337
338 Appendix H Drawing Package

H.29 RXL1023-5004: Countershaft Box Blower

Assembly

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix H Drawing Package 339

H.30 1000896923: Instrument Assembly

©
D-D
D

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
340 Appendix H Drawing Package

1000896923: Instrument Assembly (Sheet 2)

®
Others

©
FLSmidth
See Note 5

Field Sensor Junction Box

Section B-B

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix H Drawing Package 341

1000896923: Instrument Assembly (Sheet 3)

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
342 Appendix H Drawing Package

H.31 1000855586: Air Seal Blower General Arrangement

©
N1

Certified Final

Secondary Tintaya Plant

09-Nov-2023

Jeremiah Winebrenner
5

Antapaccay

9232515940
Yauri, Peru
-
-
CUSTOMER ORDER NUMBER
4

CONSULTING ENGINEER
EQUIPMENT NUMBER

PROJECT LOCATION
FLS ORDER NUMBER
13-Jan-2023
PROJECT
CLIENT

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
 Translation of the original

Electrical Load List

Antapaccay
Tintaya
Raptor 1100 Cone Crusher

Project number: 9232515940

Document Type : Motor and Drive

Appendix H Drawing Package

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

Reference Documents:

S.No Document Number Description Rev Date

1 1000892011 Control And Instrumention Diagram 1 19-Apr-23

3/13/24
H.32 1000894264: Electrical Load List

Doc: 1000894264
Rev: 1
1 3-May-23 VPU TWILK JGAMEZ Preliminary issue
Rev Date Created By Checked By Approved By Description

Property of FLSmidth A/S. This drawing contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
drawing is not permitted without the prior written permission of FLSmidth A/S.
343

9232515940 — 1000912341 1
 344

Electrical Load List

Doc: 1000894264 Rev: 1
Page 2 of 3

MOTOR VOLTAGES ABBREVIATIONS FOR MOTOR TYPE COLUMN:

Medium Voltage (3 Phase) SCHB = HV Squirrel Cage, Foot Mounted Motor

SCHF = HV Squirrel Cage, Flange Mounted Motor
4160V , 60 Hz for MV Motors SCLB = LV Squirrel Cage, Foot Mounted Motor
SCLF = LV Squirrel Cage, Flange Mounted Motor
Low Voltage (3 Phase) SRHB = HV Slip Ring, In-Direct Air-Cooled Motor
SRHC = HV Slip Ring, Direct Air-Cooled Motor
600V , 60 Hz for LV Motors SRHW = HV Slip Ring, Water Cooled Motor
VSCHB = Variable HV Squirrel Cage, Foot Mounted Motor

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

Control and Instrumentation (1 Phase) VSCLB = Variable LV Squirrel Cage, Foot Mounted Motor
VSCLF = Variable LV Squirrel Cage, Flange Mounted Motor
120V, 60 Hz For Single Phase

ABBREVIATIONS FOR STARTER TYPE COLUMN: GENERAL ABBREVIATIONS:

CB = Circuit Breaker A/C = Air Conditioning

FVC = Full Voltages Contactor AM = Ammeter
FVLC = Full Voltage Lighting Contactor AT = Auto Transformer
FVNR = Full Voltage Non Reversing Starter BDT = Breakdown Torque

3/13/24
FVR = Full Voltage Reversing Starter CB = Circuit Breaker
RVNR = Reduced Voltage Non Reversing Starter CH = Constant HP
2S2W = 2 Speed 2 Winding CT = Constant Torque
2S1W = 2 Speed 1 Winding EM = Electromagnetic
AFD = Adjustable Frequency Drive GM = Gear Motor
SS = Soft Starter H = Hydraulic Drive
HST = High Starting Torque
HE = Heater (Space Heater, Lube Heater, Etc.)
FCB = Low Voltage Circuit Breaker
RS = Reactor Start
STB = Standby
T/R = Transformer Rectifier
T/S = Transfer Switch
1000894264: Electrical Load List (Sheet 2)

VT = Variable Torque
TEFC = Totally Enclosed, Fan Cooled

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth. This drawing contains confidential and proprietary information of FLSmidth A/S
and may only be used for the limited purposes of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this drawing is not permitted without the prior written permission of FLSmidth A/S.

9232515940 — 1000912341 1
Appendix H Drawing Package
 Electrical Load List

Doc: 1000894264 Rev: 1

Page 3 of 3

OPERATING SPEED DUTY/STANDBY/

EQUIPMENT TAG POWER RATING LOAD VOLTAGE FREQUENCY
REV P&ID MOTOR TAG NUMBER EQUIPMENT DESCRIPTION MOTOR TYPE STARTER TYPE NO OF POLES RANGE INTERMITTENT POWER SOURCE REMARKS
NUMBER (KW) (V) (Hz)
(RPM) LOAD

1 1000892011, Sh.03 CRC-001 BL-001-M01 Cone Crusher Blower FVNR 1.5 kW SCLB 460 60 2 3000 Duty -

1 1000892011, Sh.03 CRC-001 CRC-001-M01 Cone Crusher Main Drive FVNR 746 kW SS 4160 60 6 1200 Duty -

1 1000892011, Sh.03 CRC-001 HE-005 Cone Crusher Motor Heater FCV 0.3 kW - 230 60 - - Duty -

1 1000892011, Sh.03 LU-001 PU-002-M01 Cone Crusher Lubrication Pump Motor - Primary FVNR 37 kW SCLF 460 60 6 1450 Duty -

1 1000892011, Sh.03 LU-001 PU-003-M01 Cone Crusher Lubrication Pump Motor - Stand by FVNR 37 kW SCLF 460 60 6 1450 Duty -

1 1000892011, Sh.03 LU-001 HE-001 Cone Crusher Reservoir Heater - 1 Lube Oil Section FCV 4.8 kW - 460 60 - - Duty -

1 1000892011, Sh.03 LU-001 HE-002 Cone Crusher Reservoir Heater - 2 Lube Oil Section FCV 4.8 kW - 460 60 - - Duty -
Appendix H Drawing Package

1 1000892011, Sh.04 LU-001 HE-003 Cone Crusher Reservoir Heater - 3 Oil Return Section FCV 3.2 kW - 460 60 - - Duty -

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

1 1000892011, Sh.04 LU-001 HE-004 Cone Crusher Reservoir Heater - 4 Oil Return Section FCV 3.2 kW - 460 60 - - Duty -

1 1000892011, Sh.05 LU-001 FN-006-M01 Cone Crusher Heat exchanger Fan-1 Motor FVNR 11 kW SCLF 460 60 8 980 Duty -

1 1000892011, Sh.05 LU-001 FN-007-M01 Cone Crusher Heat exchanger Fan-2 Motor FVNR 11 kW SCLF 460 60 8 980 Duty -

1 1000892011, Sh.06 HU-001 PU-001-M01 Cone Crusher Hydraulic Pumps 1 and 2 Motor FVNR 37 kW SCLF 460 60 6 1450 Duty -

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth. This drawing contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes of evaluating proposals
or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this drawing is not permitted without the prior written permission of FLSmidth A/S.

3/13/24
1000894264: Electrical Load List (Sheet 3)

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
9232515940 — 1000912341 1
345
 346

Translation of the original

Instrument List

Antapaccay
Tintaya
Raptor 1100 Cone Crusher

Project number: 9232515940

Document Type: Control and instrumentation

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

Reference Documents:

S.No Document Number Description Rev Date

1 1000892011 Control And Instrumention Diagram 1 19-Apr-23

3/13/24
H.33 1000894004: Instrument List

Doc: 1000894004
Rev: 1
1 3-May-23 VPU TWILK JGAMEZ Preliminary issue
Rev Date Created By Checked By Approved By Description

Property of FLSmidth A/S. This drawing contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication,
modification, or other use of this drawing is not permitted without the prior written permission of FLSmidth A/S.

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
9232515940 — 1000912341 1
Appendix H Drawing Package
 Control and instrumentation
Doc: 1000894004
Rev: 1

Equipment Instrument Tag Equipment Code Device / Eng I/O Range Range Alarm Alarm Alarm Alarm Alarm FLS
Ver C&ID Number Subsystem Measured Variable Manufacturer Model Number Comments
Number Number Description Signal Units Type Min Max Setpoint HH H L LL Supply
BI8U-EM18WD-AP6X-
1 1000892011, Sh.03 CRC-001 ZS-001 Cone Crusher Adjustment Drive Position Switch mm 0 8 Yes Turck H1141

1 1000892011, Sh.03 CRC-001 ZI-001 Cone Crusher Adjustment Drive Position Indication mm DI
BI8U-EM18WD-AP6X-
1 1000892011, Sh.03 CRC-001 ZS-002 Cone Crusher Adjustment Drive Position Switch mm 0 8 Yes Turck H1141

1 1000892011, Sh.03 CRC-001 ZI-002 Cone Crusher Adjustment Drive Position Indication mm DI

1 1000892011, Sh.03 CRC-001 TE-005 Cone Crusher Counter Shaft Box Bushing Temperature Element Deg C -40 90 Yes IFM Efector TS5089

1 1000892011, Sh.03 CRC-001 TIT-005 Cone Crusher Counter Shaft Box Bushing Temperature Transmitter Deg C -40 300 Yes IFM Efector TR2432

1 1000892011, Sh.03 CRC-001 TI-005 Cone Crusher Counter Shaft Box Bushing Temperature Indication Deg C AI
Ni30U-EM30WD-AN6X- This signal is converted to
1 1000892011, Sh.03 CRC-001 ZS-003 Cone Crusher Counter Shaft Speed Speed Switch mm 0 30 Yes Turck H1141 frequency to calculate
Frequency Transducer that
1 1000892011, Sh.03 CRC-001 SI-003 Cone Crusher Counter Shaft Speed Speed Indication mm DI converts position signals to
8F5B80-
1 1000892011, Sh.03 CRC-001 FIT-001 Cone Crusher Oil Supply Line Flow Transmitter Lpm 0 41904 Yes Endress and Hauser GAEBAEAAFBAB3ASAABSA
Appendix H Drawing Package

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

1 1000892011, Sh.03 CRC-001 FI-001 Cone Crusher Oil Supply Line Flow Indication Lpm AI

1 1000892011, Sh.03 CRC-001 PIT-001 Cone Crusher Oil Supply Line Pressure Transmitter PSI 1.5 10150 Yes E&H PMP71-UAC1PK1GAAAA

1 1000892011, Sh.03 CRC-001 PI-001 Cone Crusher Oil Supply Line Pressure Indication PSI AI

1 1000892011, Sh.03 CRC-001 LT-001 Cone Crusher Cavity Level Transmitter m 0 15 Yes Endress and Hauser FDU93-FN4A

1 1000892011, Sh.03 CRC-001 LI-001 Cone Crusher Cavity Level Indication m AI Endress and Hauser FMU90-L11CA232AA1A
A-Px-2-25-1-1-5.00-Z420-
1 1000892011, Sh.03 CRC-001 TE-002 Cone Crusher Eccentric Bushing Temperature Element Deg C -130 650 Yes C-Temp SPL

1 1000892011, Sh.03 CRC-001 TT-002 Cone Crusher Eccentric Bushing Temperature Transmitter mA 4 20 Yes Redlion IRMA2003

1 1000892011, Sh.03 CRC-001 TI-002 Cone Crusher Eccentric Bushing Temperature Indication Deg C AI

1 1000892011, Sh.03 CRC-001 VT-001 Cone Crusher Ring Vibration 1 Vibration Transmitter mm/Sec 0 50 Yes Hansford Sensors HS-4200505002

1 1000892011, Sh.03 CRC-001 VI-001 Cone Crusher Ring Vibration 1 Vibration Indication mm/Sec AI

1 1000892011, Sh.03 CRC-001 VT-002 Cone Crusher Ring Vibration 2 Vibration Transmitter mm/Sec 0 50 Yes Hansford Sensors HS-4200505002

1 1000892011, Sh.03 CRC-001 VI-002 Cone Crusher Ring Vibration 2 Vibration Indication mm/Sec AI

1 1000892011, Sh.03 CRC-001 VT-003 Cone Crusher Ring Vibration 3 Vibration Transmitter mm/Sec 0 50 Yes Hansford Sensors HS-4200505002

1 1000892011, Sh.03 CRC-001 VI-003 Cone Crusher Ring Vibration 3 Vibration Indication mm/Sec AI

3/13/24
1 1000892011, Sh.03 CRC-001 VT-004 Cone Crusher Ring Vibration 4 Vibration Transmitter mm/Sec 0 50 Yes Hansford Sensors HS-4200505002

1 1000892011, Sh.03 CRC-001 VI-004 Cone Crusher Ring Vibration 4 Vibration Indication mm/Sec AI
Start/Stop
1 1000892011, Sh.03 CRC-001 YC-101 Cone Crusher Dump Light Command DO
Start/Stop
1 1000892011, Sh.03 CRC-001 XC-101 Cone Crusher Alarm Horn Command DO
Start/Stop
1 1000892011, Sh.03 CRC-001 BL-001-M01-C31 Cone Crusher Blower Motor Signal Command DO NO

1 1000892011, Sh.03 CRC-001 BL-001-M01-X11 Cone Crusher Blower Motor Signal Remote Mode DI NO

1 1000892011, Sh.03 CRC-001 BL-001-M01-X21 Cone Crusher Blower Motor Signal Accident DI NO

1 1000892011, Sh.03 CRC-001 BL-001-M01-X31 Cone Crusher Blower Motor Signal In Operation DI NO
1000894004: Instrument List (Sheet 2)

1 1000892011, Sh.03 CR-BB-001 HS-001 Cone Crusher Blue Box Emergency Stop Hand Switch Push Button Yes A-B 800T-FRXTS00X

1 1000892011, Sh.03 CR-BB-001 HI-001 Cone Crusher Blue Box Emergency Stop Hand Switch Indication DI
Surge
1 1000892011, Sh.03 CR-BB-001 HS-002 Cone Crusher Blue Box Surge Suppressor Hand Switch Suppressor

1 1000892011, Sh.03 CR-BB-001 HI-002 Cone Crusher Blue Box Surge Suppressor Hand Switch Indication DI

1 1000892011, Sh.03 CR-BB-001 HI-003 Cone Crusher Blue Box Emergency Stop Relay 1 Relay Indication DI Installed in Panel

1 1000892011, Sh.03 CR-BB-001 HI-004 Cone Crusher Blue Box Emergency Stop Relay 2 Relay Indication DI Installed in Panel
Cone Crusher Remote
1 1000892011, Sh.03 CR-IOB-001 HS-001 IO Box Emergency Stop Hand Switch Push Button Yes A-B 800T-FRXTS00X
Cone Crusher Remote
1 1000892011, Sh.03 CR-IOB-001 HI-001 IO Box Emergency Stop Hand Switch Indication DI

1 1000892011, Sh.04 CRC-001 TE-006 Main Drive Main Motor Bearing (DE) Spare Temperature Element Deg C 0 150 Yes Part of Motor

1 1000892011, Sh.04 CRC-001 TE-007 Main Drive Main Motor Bearing (DE) Temperature Element Deg C 0 150 Yes Part of Motor

1 1000892011, Sh.04 CRC-001 TI-007 Main Drive Main Motor Bearing (DE) Temperature Indication Deg C RI

1 1000892011, Sh.04 CRC-001 TE-008 Main Drive Main Motor Bearing (NDE) Spare Temperature Element Deg C 0 150 Yes Part of Motor

1 1000892011, Sh.04 CRC-001 TE-009 Main Drive Main Motor Bearing (NDE) Temperature Element Deg C 0 150 Yes Part of Motor

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
1 1000892011, Sh.04 CRC-001 TI-009 Main Drive Main Motor Bearing (NDE) Temperature Indication Deg C RI

1 1000892011, Sh.04 CRC-001 TE-010 Main Drive Main Motor Winding 1 Temperature Element Deg C 0 150 Yes Part of Motor

1 1000892011, Sh.04 CRC-001 TI-010 Main Drive Main Motor Winding 1 Temperature Indication Deg C RI
347

9232515940 — 1000912341 1
 348

Control and instrumentation

Doc: 1000894004
Rev: 1

Equipment Instrument Tag Equipment Code Device / Eng I/O Range Range Alarm Alarm Alarm Alarm Alarm FLS
Ver C&ID Number Subsystem Measured Variable Manufacturer Model Number Comments
Number Number Description Signal Units Type Min Max Setpoint HH H L LL Supply

1 1000892011, Sh.04 CRC-001 TE-011 Main Drive Main Motor Winding 2 Temperature Element Deg C 0 150 Yes Part of Motor

1 1000892011, Sh.04 CRC-001 TI-011 Main Drive Main Motor Winding 2 Temperature Indication Deg C RI

1 1000892011, Sh.04 CRC-001 TE-012 Main Drive Main Motor Winding 3 Temperature Element Deg C 0 150 Yes Part of Motor

1 1000892011, Sh.04 CRC-001 TI-012 Main Drive Main Motor Winding 3 Temperature Indication Deg C RI

1 1000892011, Sh.04 CRC-001 TE-013 Main Drive Main Motor Winding Spare Temperature Element Deg C 0 150 Yes Part of Motor

1 1000892011, Sh.04 CRC-001 TE-014 Main Drive Main Motor Winding Spare Temperature Element Deg C 0 150 Yes Part of Motor

1 1000892011, Sh.04 CRC-001 TE-015 Main Drive Main Motor Winding Spare Temperature Element Deg C 0 150 Yes Part of Motor
Start/Stop
1 1000892011, Sh.04 CRC-001 M01-C31 Main Drive MV Cell Motor Signal Command DO NO Part of starter panel

1 1000892011, Sh.04 CRC-001 M01-X41 Main Drive MV Cell Motor Signal Accident DI NO Part of starter panel

1 1000892011, Sh.04 CRC-001 M01-X51 Main Drive MV Cell Motor Signal Included DI NO Part of starter panel

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

1 1000892011, Sh.04 CRC-001 M01-X31 Main Drive MV Cell Motor Signal In Operation DI NO Part of starter panel

1 1000892011, Sh.04 CRC-001 M01-I01 Main Drive MV Cell Motor Signal Current A AI NO Part of starter panel

1 1000892011, Sh.04 CRC-001 M01-J01 Main Drive MV Cell Motor Signal Power Kw AI NO Part of starter panel
Start/Stop
1 1000892011, Sh.04 CRC-001 HE-005-C31 Main Drive Space Heater Motor Signal Command DO NO

1 1000892011, Sh.04 CRC-001 HE-005-X31 Main Drive Space Heater Motor Signal In Operation DI NO

1 1000892011, Sh.04 CR-MCC-001 HS-001 MCC Remote IO Box Emergency Stop Hand Switch Push Button Yes A-B 800T-FRXTS00X

1 1000892011, Sh.04 CR-MCC-001 HI-001 MCC Remote IO Box Emergency Stop Hand Switch Indication DI

1 1000892011, Sh.05 LU-001 LT-003 Lube Oil System Lubrication System Oil Reservoir Tank Level Transmitter mm 785 25 Yes Bühler Technology NT 63-KN-MS-M12 /820

1 1000892011, Sh.05 LU-001 LI-003 Lube Oil System Lubrication System Oil Reservoir Tank Level Indication mm AI 785 25
Manometer Ø63mm, 0/25
1 1000892011, Sh.05 LU-001 PG-006 Lube Oil System Lubrication System Pump Outlet Pressure Gauge kPa 0 360 Yes Afriso BAR+PSI, 1/4" BSP

1 1000892011, Sh.05 LU-001 PT-006A Lube Oil System Lubrication System Filter Inlet Pressure Transmitter kPa 0 2500 Yes IFM Electronics PT5403

1 1000892011, Sh.05 LU-001 PI-006A Lube Oil System Lubrication System Filter Inlet Pressure Indication kPa AI 0 2500

1 1000892011, Sh.05 LU-001 PT-006B Lube Oil System Lubrication System Filter Outlet Pressure Transmitter kPa 0 2500 Yes IFM Electronics PT5403

1 1000892011, Sh.05 LU-001 PI-006B Lube Oil System Lubrication System Filter Outlet Pressure Indication kPa AI 0 2500

3/13/24
Manometer Ø63mm, 0/25
1 1000892011, Sh.05 LU-001 PG-007 Lube Oil System Lubrication System Filter Outlet Pressure Gauge kPa 0 360 Yes Afriso BAR+PSI, 1/4" BSP

1 1000892011, Sh.05 LU-001 TG-007 Lube Oil System Lubrication System Cooler Inlet Temperature Gauge Deg C 0 120 Yes Baumer (Saniflow) TB 63/212.122/20T

1 1000892011, Sh.05 LU-001 PRV-002 Lube Oil System Cooling Fan Return Line Pressure Relief Valve kPa 200 500 Yes Kracht SPVF80A2F1A05

1 1000892011, Sh.05 LU-001 TG-008 Lube Oil System Lubrication System Heat Exchanger Outlet Line Temperature Gauge Deg C 0 120 Yes Baumer (Saniflow) TB 63/212.122/20T
Temperature Element with
1 1000892011, Sh.05 LU-001 TE-004 Lube Oil System Lubrication System Heat Exchanger Outlet Line Temperature Element Deg C -50 150 Yes IFM TA2415 Transmitter

1 1000892011, Sh.05 LU-001 TT-004 Lube Oil System Lubrication System Heat Exchanger Outlet Line Temperature Transmitter Deg C -50 150 Yes IFM TA2415

1 1000892011, Sh.05 LU-001 TI-004 Lube Oil System Lubrication System Heat Exchanger Outlet Line Temperature Indication Deg C AI
Temperature Element with
1 1000892011, Sh.05 LU-001 TE-002 Lube Oil System Crusher Return line Temperature Element Deg C -50 150 Yes IFM TA2415 Transmitter
1000894004: Instrument List (Sheet 3)

1 1000892011, Sh.05 LU-001 TT-002 Lube Oil System Crusher Return line Temperature Transmitter Deg C -50 150 Yes IFM TA2415

1 1000892011, Sh.05 LU-001 TI-002 Lube Oil System Crusher Return line Temperature Indication Deg C AI
Temperature Element with
1 1000892011, Sh.05 LU-001 TE-003 Lube Oil System Lubrication System Oil Reservoir Tank Temperature Element Deg C -50 150 Yes IFM TA2447 Transmitter

1 1000892011, Sh.05 LU-001 TT-003 Lube Oil System Lubrication System Oil Reservoir Tank Temperature Transmitter Deg C -50 150 Yes IFM TA2447

1 1000892011, Sh.05 LU-001 TI-003 Lube Oil System Lubrication System Oil Reservoir Tank Temperature Indication Deg C AI

1 1000892011, Sh.05 LU-001 TG-003 Lube Oil System Lubrication System Oil Reservoir Tank Temperature Gauge Deg C 0 120 Yes Baumer (HNC) TB 63/212.122/20T

1 1000892011, Sh.05 LU-001 LG-003 Lube Oil System Lubrication System Oil Reservoir Tank Level Gauge Yes MP Filtri LVU0600UA10P01

1 1000892011, Sh.05 LU-001 ZSO-004 Lube Oil System Lubrication System Pump 1 Suction Position Switch mm 0 4 Yes IFM IFS 242

1 1000892011, Sh.05 LU-001 ZAO-004 Lube Oil System Lubrication System Pump 1 Suction Position Alarm DI

1 1000892011, Sh.05 LU-001 ZSO-006 Lube Oil System Lubrication System Pump 2 Suction Position Switch mm 0 4 Yes IFM IFS 242

1 1000892011, Sh.05 LU-001 ZAO-006 Lube Oil System Lubrication System Pump 2 Suction Position Alarm DI

1 1000892011, Sh.05 LU-001 ZSO-005 Lube Oil System Lubrication System Pump 1 Discharge Position Switch mm 0 4 Yes IFM IFS 242

1 1000892011, Sh.05 LU-001 ZAO-005 Lube Oil System Lubrication System Pump 1 Discharge Position Alarm DI

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
1 1000892011, Sh.05 LU-001 ZSO-007 Lube Oil System Lubrication System Pump 2 Discharge Position Switch mm 0 4 Yes IFM IFS 242

1 1000892011, Sh.05 LU-001 ZAO-007 Lube Oil System Lubrication System Pump 2 Discharge Position Alarm DI

1 1000892011, Sh.05 LU-001 PRV-005A Lube Oil System Lubrication System Pump 1 Return Pressure Relief Valve kPa 300 2500 1500 Yes Kracht DV B 80 F2F 1J A

9232515940 — 1000912341 1
Appendix H Drawing Package
 Control and instrumentation
Doc: 1000894004
Rev: 1

Equipment Instrument Tag Equipment Code Device / Eng I/O Range Range Alarm Alarm Alarm Alarm Alarm FLS
Ver C&ID Number Subsystem Measured Variable Manufacturer Model Number Comments
Number Number Description Signal Units Type Min Max Setpoint HH H L LL Supply

1 1000892011, Sh.05 LU-001 PRV-005B Lube Oil System Lubrication System Pump 2 Return Pressure Relief Valve kPa 300 2500 1500 Yes Kracht DV B 80 F2F 1J A
Start/Stop
1 1000892011, Sh.05 LU-001 PU-002-M01-C31 Lube Oil System Lube Oil Pump 1 Motor Signal Command DO NO

1 1000892011, Sh.05 LU-001 PU-002-M01-X11 Lube Oil System Lube Oil Pump 1 Motor Signal Remote Mode DI NO

1 1000892011, Sh.05 LU-001 PU-002-M01-X21 Lube Oil System Lube Oil Pump 1 Motor Signal Accident DI NO

1 1000892011, Sh.05 LU-001 PU-002-M01-X31 Lube Oil System Lube Oil Pump 1 Motor Signal In Operation DI NO
Start/Stop
1 1000892011, Sh.05 LU-001 PU-003-M01-C31 Lube Oil System Lube Oil Pump 2 Motor Signal Command DO NO

1 1000892011, Sh.05 LU-001 PU-003-M01-X11 Lube Oil System Lube Oil Pump 2 Motor Signal Remote Mode DI NO

1 1000892011, Sh.05 LU-001 PU-003-M01-X21 Lube Oil System Lube Oil Pump 2 Motor Signal Accident DI NO

1 1000892011, Sh.05 LU-001 PU-003-M01-X31 Lube Oil System Lube Oil Pump 2 Motor Signal In Operation DI NO
Start/Stop
1 1000892011, Sh.05 LU-001 HE-001-C31 Lube Oil System Heater 1 Motor Signal Command DO NO
Appendix H Drawing Package

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

1 1000892011, Sh.05 LU-001 HE-001-X31 Lube Oil System Heater 1 Motor Signal In Operation DI NO
Start/Stop
1 1000892011, Sh.05 LU-001 HE-002-C31 Lube Oil System Heater 2 Motor Signal Command DO NO

1 1000892011, Sh.05 LU-001 HE-002-X31 Lube Oil System Heater 2 Motor Signal In Operation DI NO
Start/Stop
1 1000892011, Sh.05 LU-001 HE-003-C31 Lube Oil System Heater 3 Motor Signal Command DO NO

1 1000892011, Sh.05 LU-001 HE-003-X31 Lube Oil System Heater 3 Motor Signal In Operation DI NO
Start/Stop
1 1000892011, Sh.05 LU-001 HE-004-C31 Lube Oil System Heater 4 Motor Signal Command DO NO

1 1000892011, Sh.05 LU-001 HE-004-X31 Lube Oil System Heater 4 Motor Signal In Operation DI NO
Start/Stop
1 1000892011, Sh.05 LU-001 FN-006-M01-C31 Lube Oil System Heat Exchanger Fan 1 Motor Signal Command DO NO

1 1000892011, Sh.05 LU-001 FN-006-M01-X11 Lube Oil System Heat Exchanger Fan 1 Motor Signal Remote Mode DI NO

1 1000892011, Sh.05 LU-001 FN-006-M01-X21 Lube Oil System Heat Exchanger Fan 1 Motor Signal Accident DI NO

1 1000892011, Sh.05 LU-001 FN-006-M01-X31 Lube Oil System Heat Exchanger Fan 1 Motor Signal In Operation DI NO
Speed
1 1000892011, Sh.05 LU-001 FN-006-M01-S31 Lube Oil System Heat Exchanger Fan 1 Motor Signal Command AO NO
Start/Stop
1 1000892011, Sh.05 LU-001 FN-007-M01-C31 Lube Oil System Heat Exchanger Fan 2 Motor Signal Command DO NO

1 1000892011, Sh.05 LU-001 FN-007-M01-X11 Lube Oil System Heat Exchanger Fan 2 Motor Signal Remote Mode DI NO

3/13/24
1 1000892011, Sh.05 LU-001 FN-007-M01-X21 Lube Oil System Heat Exchanger Fan 2 Motor Signal Accident DI NO

1 1000892011, Sh.05 LU-001 FN-007-M01-X31 Lube Oil System Heat Exchanger Fan 2 Motor Signal In Operation DI NO
Speed
1 1000892011, Sh.05 LU-001 FN-007-M01-S31 Lube Oil System Heat Exchanger Fan 2 Motor Signal Command AO NO
See PMC Parts List for Part
1 1000892011, Sh.05 LU-001 CV-007 Lube Oil System Check Valve Check Valve Yes ARI Details
See PMC Parts List for Part
1 1000892011, Sh.05 LU-001 CV-008 Lube Oil System Check Valve Check Valve Yes ARI Details
Lubrication System
1 1000892011, Sh.05 LU-IOB-001 HS-001 Remote IO Box Emergency Stop Hand Switch Push Button Yes A-B 800T-FRXTS00X
Lubrication System
1 1000892011, Sh.05 LU-IOB-001 HI-001 Remote IO Box Emergency Stop Hand Switch Indication DI
Start/Stop
1 1000892011, Sh.06 HU-001 PU-001-M01-C31 Hydraulic Oil System Oil Pump 1 and 2 Motor Signal Command DO NO
1000894004: Instrument List (Sheet 4)

1 1000892011, Sh.06 HU-001 PU-001-M01-X11 Hydraulic Oil System Oil Pump 1 and 2 Motor Signal Remote Mode DI NO

1 1000892011, Sh.06 HU-001 PU-001-M01-X21 Hydraulic Oil System Oil Pump 1 and 2 Motor Signal Accident DI NO

1 1000892011, Sh.06 HU-001 PU-001-M01-X31 Hydraulic Oil System Oil Pump 1 and 2 Motor Signal In Operation DI NO
See PMC Parts List for Part
1 1000892011, Sh.06 HU-001 LG-001 Hydraulic Oil System Oil Reservoir Tank Level Gauge mm Yes PMC Q YWZ-350T Details

1 1000892011, Sh.06 HU-001 LT-002 Hydraulic Oil System Oil Reservoir Tank Level Level Transmitter mm 465 25 Yes Bühler Technology NT 63-KN-MS-M12 /500

1 1000892011, Sh.06 HU-001 LI-002 Hydraulic Oil System Oil Reservoir Tank Level Level Indication mm DI

1 1000892011, Sh.06 HU-001 ZSO-013 Hydraulic Oil System Pump 1 Suction Valve Position Switch mm DI 0 4 Yes IFM IFS 242

1 1000892011, Sh.06 HU-001 ZAO-013 Hydraulic Oil System Pump 1 Suction Valve Position Alarm

1 1000892011, Sh.06 HU-001 ZSO-012 Hydraulic Oil System Pump 2 Suction Valve Position Switch mm DI 0 4 Yes IFM IFS 242

1 1000892011, Sh.06 HU-001 ZAO-012 Hydraulic Oil System Pump 2 Suction Valve Position Alarm
Temperature Element with
1 1000892011, Sh.06 HU-001 TE-001 Hydraulic Oil System Oil Reservoir Tank Temperature Element Deg C -50 150 Yes IFM TA2447 Transmitter

1 1000892011, Sh.06 HU-001 TT-001 Hydraulic Oil System Oil Reservoir Tank Temperature Transmitter Deg C -50 150 Yes IFM TA2447

1 1000892011, Sh.06 HU-001 TI-001 Hydraulic Oil System Oil Reservoir Tank Temperature Indication Deg C AI

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
1 1000892011, Sh.06 HU-001 PRV-001 Hydraulic Oil System Pressure Valve Pressure Relief Valve PSI 145 3046 3046 Yes Atos LIMHA-2/210-EX 24DC 50

1 1000892011, Sh.06 HU-001 SV-001 Hydraulic Oil System Pressure Valve Solenoid Valve kPa 0 42000 Yes Atos SC LI-25312 30

1 1000892011, Sh.06 HU-001 YC-001 Hydraulic Oil System Pressure Valve Solenoid Command DO

9232515940 — 1000912341 1
349
 350

Control and instrumentation

Doc: 1000894004
Rev: 1

Equipment Instrument Tag Equipment Code Device / Eng I/O Range Range Alarm Alarm Alarm Alarm Alarm FLS
Ver C&ID Number Subsystem Measured Variable Manufacturer Model Number Comments
Number Number Description Signal Units Type Min Max Setpoint HH H L LL Supply

1 1000892011, Sh.06 HU-001 SV-002 Hydraulic Oil System High Flow Valve Solenoid Valve kPa 0 42000 Yes Atos SC LI-25312 30

1 1000892011, Sh.06 HU-001 YC-002 Hydraulic Oil System High Flow Valve Solenoid Command DO

1 1000892011, Sh.06 HU-001 PRV-002 Hydraulic Oil System Outlet Relief Valve Pressure Relief Valve PSI 145 3046 1276 Yes Atos LIMHA-2/210-EX 24DC 50

1 1000892011, Sh.06 HU-001 PT-003 Hydraulic Oil System Hydraulic System Outlet Pressure Transmitter PSI 0 3625 Yes IFM Electronics PT5401

1 1000892011, Sh.06 HU-001 PI-003 Hydraulic Oil System Hydraulic System Outlet Pressure Indication PSI AI

1 1000892011, Sh.06 HU-001 PG-005 Hydraulic Oil System Outlet PG Pressure Gauge PSI 0 3625 Yes Afriso 85122701S
Range Max is the pressure
1 1000892011, Sh.06 HU-001 PDSH-001 Hydraulic Oil System Outlet Filter Pressure Differential Switch Hi PSI 0 72 Yes MP Filtri DLE50HF50P01 setting.

1 1000892011, Sh.06 HU-001 PDAH-001 Hydraulic Oil System Outlet Filter Pressure Differential Alarm Hi PSI
Manometer Ø63mm, 0/250
1 1000892011, Sh.06 HU-001 PG-001 Hydraulic Oil System Clamp Pressure Pressure Gauge PSI 0 3625 Yes Afriso BAR+PSI, 1/4" BAG
Manometer Ø63mm, 0/250
1 1000892011, Sh.06 HU-001 PG-002 Hydraulic Oil System Tramp Release Pressure Gauge PSI 0 3625 Yes Afriso BAR+PSI, 1/4" BAG
Range Max is the Max

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

1 1000892011, Sh.06 HU-001 SV-003 Hydraulic Oil System Bowl Close Valve Solenoid Valve PSI 0 5075 Yes Atos DPHE-2713DL9-X 24DC 40 pressure the Valve can

1 1000892011, Sh.06 HU-001 YC-003 Hydraulic Oil System Bowl Close Valve Solenoid Command DO

1 1000892011, Sh.06 HU-001 SV-004 Hydraulic Oil System Bowl Open Valve Solenoid Valve 0 5075 Yes Atos DPHE-2713DL9-X 24DC 40

1 1000892011, Sh.06 HU-001 YC-004 Hydraulic Oil System Bowl Open Valve Solenoid Command DO

1 1000892011, Sh.06 HU-001 PG-003 Hydraulic Oil System Bowl Drive Pressure Gauge PSI 0 3625 Yes Afriso 85122701S

1 1000892011, Sh.06 HU-001 PSH-001 Hydraulic Oil System Bowl Drive Over Pressure Pressure Switch Hi PSI 0 1450 Yes IFM Efector PK6532

1 1000892011, Sh.06 HU-001 PAH-001 Hydraulic Oil System Bowl Drive Over Pressure Pressure Alarm Hi PSI DI

1 1000892011, Sh.06 HU-001 PT-001 Hydraulic Oil System Crusher Clamping Cylinder Pressure Transmitter PSI 0 3625 Yes IFM PT5401

1 1000892011, Sh.06 HU-001 PI-001 Hydraulic Oil System Crusher Clamping Cylinder Pressure Indication AI

1 1000892011, Sh.06 HU-001 SV-005 Hydraulic Oil System Clamp Pressure Valve Solenoid Valve PSI 0 5075 Yes Atos DLEH-2C-X24DC

1 1000892011, Sh.06 HU-001 YC-005 Hydraulic Oil System Clamp Pressure Valve Solenoid Command DO
CART ARE-
1 1000892011, Sh.06 HU-001 PRV-003 Hydraulic Oil System Clamp pressure Pressure Relief Valve PSI 363 6092 3046 Yes Atos 15/420/PED/210 52

1 1000892011, Sh.06 HU-001 PRV-004 Hydraulic Oil System Accumulator Oil/gas Pressure Relief Valve PSI 363 6092 2103 Yes Atos CART ARE-15/420/52

1 1000892011, Sh.06 HU-001 SV-006 Hydraulic Oil System Clamp Dump Valve Solenoid Valve PSI 0 5075 Yes Atos DLEH-2C-X24DC

3/13/24
1 1000892011, Sh.06 HU-001 YC-006 Hydraulic Oil System Clamp Dump Valve Solenoid Command DO

1 1000892011, Sh.06 HU-001 FC-001 Hydraulic Oil System Clearing Jack Flow Flow Control Valve Lpm 0 160 Yes Atos KQ-013 53

1 1000892011, Sh.06 HU-001 SV-008 Hydraulic Oil System Clearing Valve Solenoid Valve PSI 0 5075 Yes Atos DKE-1713-X 24DC 20

1 1000892011, Sh.06 HU-001 YC-008 Hydraulic Oil System Clearing Valve Solenoid Command DO

1 1000892011, Sh.06 HU-001 SV-009 Hydraulic Oil System Tramp Pressurize Valve Solenoid Valve 0 5075 Yes Atos DKE-1713-X 24DC 20

1 1000892011, Sh.06 HU-001 YC-009 Hydraulic Oil System Tramp Pressurize Valve Solenoid Command DO

1 1000892011, Sh.06 HU-001 PT-002 Hydraulic Oil System Accumulator Oil/gas Pressure Transmitter PSI 0 3625 Yes IFM Electronics PT5401

1 1000892011, Sh.06 HU-001 PI-002 Hydraulic Oil System Accumulator Oil/gas Pressure Indication PSI AI
1000894004: Instrument List (Sheet 5)

1 1000892011, Sh.06 HU-001 TG-001 Hydraulic Oil System Oil Reservoir Tank Temperature Gauge Deg C 0 120 Yes Baumer (HNC) TB 63/212.122/20T
LIDA-1 50 & SC LI-16 32 1
1 1000892011, Sh.06 HU-001 CV-001 Hydraulic Oil System Check Valve Check Valve PSI 4.35 Yes Atos 40
LIDA-1 50 & SC LI-16 32 1
1 1000892011, Sh.06 HU-001 CV-002 Hydraulic Oil System Check Valve Check Valve PSI 4.35 Yes Atos 40

1 1000892011, Sh.06 HU-001 CV-003 Hydraulic Oil System Check Valve Check Valve PSI 0 4565 Yes Atos KR-013/2 35
Hydraulic System
1 1000892011, Sh.06 HU-IOB-001 HS-001 Remote IO Box Emergency Stop Hand Switch Push Button Yes A-B 800T-FRXTS00X
Hydraulic System
1 1000892011, Sh.06 HU-IOB-001 HI-001 Remote IO Box Emergency Stop Hand Switch Indication DI

Property of FLSmidth A/S. This drawing contains confidential and proprietary information of FLSmidth A/S and may only be used for the limited purposes of evaluating proposals or installing, operating or maintaining FLSmidth equipment. Disclosure, duplication, modification, or other use of this drawing is not permitted without the prior written
permission of FLSmidth A/S.

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
9232515940 — 1000912341 1
Appendix H Drawing Package
Appendix H Drawing Package 351

H.34 1000892011: Control and Instrumentation

Diagram

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
352 Appendix H Drawing Package

1000892011: C&ID (Sheet 2)

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
 MOTOR CONTROL DETAIL TYPE MOTOR CONTROL DETAIL TYPE MOTOR CONTROL DETAIL TYPE MOTOR CONTROL DETAIL TYPE
MT - 1 MT - 2 MT - 3 MT - 4
DIRECT ONLINE ( DOL ) LOW VOLTAGE ( LV ) VARIABLE FREQUENCY DRIVE ( VFD ) LOW VOLTAGE ( LV ) DIRECT ONLINE ( DOL ) MEDIUM VOLTAGE ( MV ) VARIABLE FREQUENCY DRIVE ( VFD ) MEDIUM VOLTAGE ( MV )

J01
POWER
J01 * XYZ
POWER
* XYZ I01
CURRENT
I01 * XYZ
CURRENT
S01 * XYZ S01
SPEED SPEED
C71 OVER LOAD ** * EQUIPMENT NUMBER * XYZ C71 * EQUIPMENT NUMBER * XYZ
OVER LOAD **
* EQUIPMENT NUMBER * XYZ ** REQUIRED ON ALL MOTORS C71 * EQUIPMENT NUMBER * XYZ ** REQUIRED ON ALL MOTORS C71
OVER LOAD ** OVER LOAD **
** REQUIRED ON ALL MOTORS C41 LARGER THAN 37 KW * XYZ ** REQUIRED ON ALL MOTORS C41 LARGER THAN 37 KW * XYZ
MOTOR READY MOTOR READY
LARGER THAN 37 KW * XYZ C41 LARGER THAN 37 KW * XYZ C41
MOTOR READY MOTOR READY
C61 * XYZ C61 * XYZ
RUNNING 1 RUNNING 1
* XYZ C31 C32 COMMAND 1 * XYZ C31 C32 COMMAND 1
C31 * XYZ * XYZ COMMAND 2 C31 * XYZ * XYZ COMMAND 2
COMMAND 1 COMMAND 1
* XYZ C61 * XYZ C61
RUNNING 1 RUNNING 1
* XYZ * XYZ
C62 C62
RUNNING 2 RUNNING 2
* XYZ * XYZ
MCC MCC

MPR OR HARDWIRE MPR OR HARDWIRE

MCC MCC

VFD OR HARDWIRE VFD OR HARDWIRE

MT - 1 TE MT - 3 TE
M M
Appendix H Drawing Package

MOTOR DOL LV * MOTOR DOL MV *

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

MT - 2 TE MT - 4 TE
MOTOR VFD LV M * MOTOR VFD MV M *

MOTOR CONTROL DETAIL TYPE MOTOR CONTROL DETAIL TYPE

MOTOR CONTROL DETAIL TYPE MOTOR CONTROL DETAIL TYPE
MT - 5 MT - 6
MT - 7 MT - 8
REVERSING MOTOR ( REV ) LOW VOLTAGE ( LV ) REVERSING MOTOR ( REV )MEDIUM VOLTAGE ( MV )
HEATER OR MISCELLANEOUS LOW VOLTAGE ( LV ) MOTOR VALVE LOW VOLTAGE ( LV )

J01
* EQUIPMENT NUMBER * EQUIPMENT NUMBER POWER
* XYZ
** REQUIRED ON ALL MOTORS * EQUIPMENT NUMBER * EQUIPMENT NUMBER
** REQUIRED ON ALL MOTORS I01
LARGER THAN 37 KW CURRENT
LARGER THAN 37 KW * XYZ
1000892011: C&ID (Sheet 3)

C71 OVER LOAD ** C71 OVER LOAD **

* XYZ * XYZ
C41 MOTOR READY C41 MOTOR READY
* XYZ * XYZ

3/13/24
C31 C32 COMMAND 1 NO OVERLOAD C31 C32 COMMAND 1
C61 RUNNING 1
* XYZ * XYZ COMMAND 2 PROTECTION REQUIRED * XYZ * XYZ COMMAND 2
* XYZ
C61 C62 RUNNING 1 C61 C62 RUNNING 1
C31 COMMAND 1
* XYZ * XYZ RUNNING 2 * XYZ * XYZ RUNNING 2
* XYZ

MCC MCC

MPR OR HARDWIRE MPR OR HARDWIRE

MT - 5 TE MT - 8 TE
REV MOTOR LV M * ON / OFF VALVE LV M *
MT - 7 HTR
OR
HTR OR MISC LV MISC

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
®

©
353

9232515940 — 1000912341 1
354 Appendix H Drawing Package

1000892011: C&ID (Sheet 4)

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix H Drawing Package 355

1000892011: C&ID (Sheet 5)

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
356 Appendix H Drawing Package

1000892011: C&ID (Sheet 6)

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Appendix H Drawing Package 357

1000892011: C&ID (Sheet 7)

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED. 3/13/24 9232515940 — 1000912341 1

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
 358

Nozzle/Connection Schedule
No Size Type Description

N1 8" Pipe ANSI 150# Oil Return Line (from crusher)

N2 3" Pipe SAE CODE 61 Oil Supply Line

Skid Weight, Lube Unit

Skid without lube oil (kg) 2935
Skid with lube oil (kg) 6250

Design Data, Lube Unit

Ambient Temperature, Design Maximum, °C 25°
Ambient Temperature, Design Minimum, °C -10°
Altitude, Installed (masl) 4100

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

Arrangement

3/13/24
H.35 1000855581: Lubrication Unit General

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
EQUIPMENT NUMBER
PROJECT Secondary Tintaya Plant
CLIENT Antapaccay
CONSULTING ENGINEER - ®
CUSTOMER ORDER NUMBER - ©
FLS ORDER NUMBER 9232515940
PROJECT LOCATION Yauri, Peru
13-Jan-2023 Jeremiah Winebrenner

9232515940 — 1000912341 1
Appendix H Drawing Package
 Material Handling
Component List Component List
FLS Tag # Description Specification FLS Tag # Description Specification
TG-007 Temperature Gauge 0-120 GR TK-001 Tank 3700 Liter
See note 3 TG-008 Temperature Gauge 0-120 GR 13 Ball Valve 1" BSP, 32 Bar
See note 3 MA101 Coupling G 1/4" 14 Ball Valve 1" BSP, 32 Bar
See note 3 MA102 Coupling G 1/4" 15 Ball Valve 1" BSP, 32 Bar
See note 3 TE-004 Temperature Element -50 to 150° C, M12 18 Compensator 5", K16S
BL-001 Blower - 20 Bell Housing RV450
VT-004 VT-003 VT-002 VT-001 LT-001 See note 3
DM1 Damper - 32 Needle Valve In-line, 1/4 "
ZS-001 See note 3
F Filter, air 10 micron 32.1 Gauge Valve 90 Degree, 1/4 "
BL-001-M01 Motor, blower 247W, 460 VAC, 3 ph, 60 Hz 40 Ball Valve DN80, PN16
ZS-002 See note 3
CRC-001-M01 Motor, main drive 820 kW, 575 V, 1800 RPM, 60 Hz 49.1 Hose Air flush
PIT-001 Pressure transducer, eccentric 4-20 mA analog 49.2 Hose Air flush
TT-002 Temperature transducer, eccentric 4-20 mA analog 49.3 Orifice M10
DM1 BL-001 BL-001-M01 TIT-005 Temperature transducer, countershaft box 4-20 mA analog 16 Butterfly flange Valve AF-125, 5"
F
Hydraulic Schematic
VT-001 Vibration transducer 4-20 mA analog 17 Butterfly flange Valve AF-125, 5"
See note 1
1000855588 Air hose, 4" Air from VT-002 Vibration transducer 4-20 mA analog 25 Ball Valve DN80, PN16
Air hose, 4" Atmosphere
VT-003 Vibration transducer 4-20 mA analog 26 Ball Valve DN80, PN16
VT-004 Vibration transducer 4-20 mA analog 27A Coupling G 1/4"
ZS-001 Proximity switch, adjust 1 Digital 27B Coupling G 1/4"
TIT-005 See note 3 ZS-002 Proximity switch, adjust 2 Digital 28 Hose 3", 25 Bar
ZS-003 Proximity switch, countershaft Digital 29 Hose 3", 25 Bar
M
LT-001 Level transmitter, cavity 4-20 mA HART 43.1 Ball Valve 1/2" BSP, 32 Bar
Appendix H Drawing Package

V-Belt

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

100 Termination Box N/A 43.2 Ball Valve 1/2" BSP, 32 Bar
CRC-001-M01
SR1 Filternet See PMC Parts List BR2 Breather 3 micron, visual
43.3 Ball Valve 3/4" CV-007 Check Valve DN80, PN40
ZS-003 See note 3
43.4 Ball Valve 3/4" CV-008 Check Valve DN80, PN40
114 Skid Tray - F1 Filter Pressure line
F2 Filter Pressure line
Material Handling F3 Filter Pressure line
PIT-001
F4 Filter Pressure line
HE-001 Immersion Heater 4.8 kW
TT-002 See note 3 HE-002 Immersion Heater 4.8 kW
HE-003 Immersion Heater 3.2 kW
HE-004 Immersion Heater 3.2 kW
Notes:
LG-003 Level Gauge Oil Level
1. See 1000855444, General Arrangement Cone Crusher, for hydraulic connection points.
2. PIT-001 supplied by FLSmidth. Piping and remote mounting by Others. LT-003 Level Transmitter NT 63
3. Refer to drawing "Machine RIO Panel, 1000907858" and "Interconnection Drawing, PU-002-M01 Motor Later
See note 3 1000911692" for wiring details. Machine RIO Panel supplied by FLSmidth. PU-003-M01 Motor Later
8'', See general arrangement, cone crusher 4. TT-002 is shown connected to the drain pipe, but the actual wire lead runs from the inside
1000855444 for drain line installation requirements PU-002 Gear Pump 25 Bar
of the crusher and comes out of the drain pipe.
PU-003 Gear Pump 25 Bar
5. Signal wires continue to Lubrication I/O Panel located on the Lube Unit skid. Refer to
FLSmidth drawing, 1000907856. PG-006 Pressure Gauge 1/4" BSP
6. Pos. 21 consists of pos. 21.1, 21.2, and 21.3 in PMC's parts list. See PMC's parts list for PG-007 Pressure Gauge 1/4" BSP

3/13/24
instrument details. PT-006A Pressure Transmitter 0-25 Bar, M12
7. Pos. 48 consists of pos. 48.1 and 48.2 in PMC's parts list. See PMC's parts list for instrument PT-006B Pressure Transmitter 0-25 Bar, M12
details.
PRV-005A Pressure relief Valve DV Type
PRV-005B Pressure relief Valve DV Type
Temperature Gauge 0-120 GR

CRUSHER RETURN
TG-003

<---8" ANSI 150 INLET

See note 5 TE-002 Temperature Element -50 to 150° C, M12
32
TG-008 TE-004
I TE-003 Temperature Element -50 to 150° C, M12
I TE-002 MA102 T
T
I BR2 3" TO CRUSHER ---> ZSO-004 Position Switch 30V DC, M12
TK-001 LT-003 L
3" SAE 61 OUTLET 3"
# 10
SR1 ZSO-005 Position Switch 30V DC, M12

--> COOLER UNIT

HE-004

3" SAE 61 OUTLET

T PRV-005B T PRV-005A 100 LG-003 HE-002 118 118
TG-003 ZSO-006 Position Switch 30V DC, M12
Vol: 3700 /2850 L oil HE-001 Heaters not installed G2" socket plugged 117 117
HE-003
15 bar 15 bar ZSO-007 Position Switch 30V DC, M12
ZSO-006 T ZSO-004
10
P P 13 opt. off-line 14 I 15
filter return 27A 17 TE-003 16 HEX1 Air Cooler HMC 160-6
FN-006-MO1 FN-007-MO1
50 HP opt. off-line filter intake HEX2 Air Cooler HMC 160-6
3" 18 1780 rpm 18 119 119
3"
S PU-003-M01 PU-002 S HEX1 HEX2 FN-006-M01 Motor Later
PU-003 15 HP 1175 rpm 15 HP 1175 rpm
PRV-002 FN-007-M01 Motor
27B PU-002-M01 Later
50 HP TG-007
CV-007 118 117 117 117 Hose 3", 25 Bar
43.1 3 bar
622 CC/Rev P 20 21 622 CC/Rev P 20 21 1780 rpm ---> FROM LUBE UNIT 118
29 28 3" SAE 61 INLET 140 DN80, PN16
49.3 120 120 118 Ball Valve
PG-007 49.3 MA101

25 mic 49.1 25 mic

49.1 119 Ball Valve 1/2" BSP, 32 Bar
48 48 PG-006 120 Ball Valve 3/4"
32 32.1 ZSO-007 25 ZSO-005
H.36 1000855590: Lubrication Schematic

26
PRV-002 Pressure relief Valve 3", 2-5 Bar
F3 F1 40
3"

F4 F2 I
P
49.3 49.3 PT-006A
49.2 49.2
P 25 mic 25 mic
I
PT-006B 48 48

CV-008 43.2
43.3 43.4

By FLSmidth
By Others

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
EQUIPMENT NUMBER
PROJECT Secondary Tintaya Plant
CLIENT Antapaccay
CONSULTING ENGINEER - ®
CUSTOMER ORDER NUMBER - ©
FLS ORDER NUMBER 9232515940
PROJECT LOCATION Yauri, Peru
13-Jan-2023 Jeremiah Winebrenner

9232515940 — 1000912341 1
359
 360

Nozzle/Connection Schedule
No Size Type Description

N1 3" Pipe Flange SAE Code 61 Inlet, From Lube System

H.37
N2 3" Pipe Flange SAE Code 61 Outlet, To Cone Crusher

Skid Weight, Heat Exchanger

Skid without lube oil (kg) 1420
Skid with lube oil (kg) xxxx

Design Data
Ambient Temperature, Design Maximum, °C 25°
Ambient Temperature, Design Minimum, °C -10°
Altitude, Installed (masl) 4100

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

Arrangement

3/13/24
1000855583: Heat Exchanger General

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
EQUIPMENT NUMBER
PROJECT Secondary Tintaya Plant
CLIENT Antapaccay
CONSULTING ENGINEER - ®
CUSTOMER ORDER NUMBER - ©
FLS ORDER NUMBER 9232515940
PROJECT LOCATION Yauri, Peru
13-Jan-2023 Jeremiah Winebrenner

9232515940 — 1000912341 1
Appendix H Drawing Package
 Nozzle/Connection Schedule
No Size Type Description

N1 JIC #16, male Hydraulic Motor Close (HMC)

N2 JIC#16, male Hydraulic Motor Open (HMO)
N3 JIC #6, male Hydraulic Motor Brake (MB)
N4 JIC #20, male Tramp Release Cylinder Circuit (TR)
N5 JIC #12, male Clearing Cylinder Circuit (CLR)
N6 JIC #6, male Clamping Cylinder Circuit (CMP)

Skid Weight, Hydraulic Power Unit

Skid without hydraulic oil (kg) 1619
Skid with hydraulic oil (kg) 1850

Design Data
Appendix H Drawing Package

Ambient Temperature, Design Maximum, °C 25°

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

Ambient Temperature, Design Minimum, °C -10°
Altitude, Installed (masl) 4100
Arrangement

3/13/24
FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
H.38 1000855555: Hydraulic Power Unit General

EQUIPMENT NUMBER
PROJECT Secondary Tintaya Plant
CLIENT Antapaccay
CONSULTING ENGINEER - ®
CUSTOMER ORDER NUMBER - ©
FLS ORDER NUMBER 9232515940
PROJECT LOCATION Yauri, Peru
13-Jan-2023 Jeremiah Winebrenner

9232515940 — 1000912341 1
361
 362

Clamping
Bowl adjust cylinders (16) Release cylinders (16) Component List
motors (4) AC2-AC5 (four accumulators
mounted on crusher) FLS Tag # Description Specification
SH1 Shuttle valve -
SV-001 Solenoid valve 1, system pressure 115 V coil
SV-002 Solenoid valve 2, high flow 115 V coil
SV-003 Solenoid valve 3, bowl close 115 V coil
SV-004 Solenoid valve 4, bowl open 115 V coil
SV-004+003 PSH-001 PG-003 SV-008
Tramp Clamp
50 bar a b
dump dump SV-005 Solenoid valve 5, clamp pressurize 115 V coil
35 bar
SV-009
P YC-008A B YC-009T PG-002 PG-001
AB MA4 SV-006 Solenoid valve 6, clamp dump 115 V coil

1-1/4"G
1-1/4"G
12x1,5
a b SV-008 Solenoid valve 8, clearing 115 V coil
1/2"G CV-003
YC-004 PT YC-003 PSH-001 92 91
AC1 SV-009 Solenoid valve 9, tramp pressure 115 V coil
P A B T

HMC
HMO
PT-001 PT-002

MB
I 70 bar I
P P TT-001 Temperature transducer, tank 4-20 mA analog
SH1
SV-005 SV-006 MA5 FC-001 12x2,0
MV2 MV1
1/2"G 3/8"G 3/4"G 3/4"G
3/4"G A B 3/8"G
P T

YC-005 YC-006 CMP AC1 PG-001 145 bar CLR TR PG-002

PT-001 1 MA3
Ø 1,2 PRV-004 PT-002 MA3
Ø 1,4 Panel
O1 PRV-003 MA2 MA2 mount
O2 2 1
210 bar T 3/8"G
2 12x2,0

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

38x3,0

11/2"G
F1out 10 mic PDSH-001
F1in 11/2"G
F1
38x3,0

A A A
A CV-002 PRV-001 PRV-002 CV-001 PG-005
B B B B
PG-005
25 25 16
16
PU-001 MA1 PU-002 43
X Ts X Y Tr X Y X

PT-003
1-1/4"G 1-1/4"G 11/4"G 1"G
AP 210 bar AP 88 bar

CV2.1 CV1.1 PT-003

MA1 P
I

P T P T
YC-001A B YC-002A B
SV-001 a SV-002 a

35x2,5 35x2,5

3/13/24
PG T
1 BR1

30x2
I
1"G 1"G L LT-002
1 LG-001
TK-002 100 TG-001

25x2
vol: 1050 / 725 L oil I TT-001
T
12 13 5
10
ZSO-012 ZSO-013
31 32
S S 50 HP
72 lpm 149 lpm 1780 rpm

Notes:
PU-002 PU-001 21 20
PU-001-M01
1. Any time a pressure exceeding 1100 psi is sensed on PT-003, SV-002 must be
33 34 de-engergized.
2. Pos. 21 consists of pos. 21.1, 21.2, and 21.3 in PMC's parts list. See PMC's parts list for
H.39 1000855588: Hydraulic Schematic

instrument details.
15 15

Solenoid Function Table Skid-mounted hydraulic unit

Operation SV-001 SV-002 SV-003 SV-004 SV-005 SV-006 SV-008 SV-009

Pressurize clamp cylinders
Open bowl adjust, no-load
Open bowl

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Close bowl adjust, no-load
Close bowl
EQUIPMENT NUMBER
Clearing cylinder, raise PROJECT Secondary Tintaya Plant
CLIENT Antapaccay
Set tramp release system CONSULTING ENGINEER - ®
CUSTOMER ORDER NUMBER - ©
Bowl removal, high speed FLS ORDER NUMBER 9232515940
Bowl install, high speed PROJECT LOCATION Yauri, Peru
13-Jan-2023 Jeremiah Winebrenner

9232515940 — 1000912341 1
Appendix H Drawing Package
 Component List Component List
FLS Tag # Description Specification FLS Tag # Description Specification
TK-002 Reservoir - PRV-003 Pressure Relief Valve 210 Bar
10 Ball Valve 3/4" PRV-004 Pressure Relief Valve 210 Bar
12 Ball Valve DN 50, PN25 SH1 Cartridge Valve -
13 Ball Valve DN 40, PN25 SV-001 Solenoid Valve NG 25
15 Ball Valve 1/2" BSP YC-001 Solenoid Command -
20 Bell Housing RV450 SV-002 Solenoid Valve NG 25
31 Hose DN32 YC-002 Solenoid Command -
32 Hose DN51 SV-003 Solenoid Valve 24V DC
33 Hose - YC-003 Solenoid Command -
34 Hose - SV-004 Solenoid Valve 24V DC
43 Needle Valve - YC-004 Solenoid Command -
91 Needle Valve - SV-005 Solenoid Valve 24V DC
92 Needle Valve - YC-005 Solenoid Command -
AC1 Accumulator 5 Liter, 360 Bar SV-006 Solenoid Valve 24V DC
BR1 Breather 3 micron YC-006 Solenoid Command -
Check Valve
Appendix H Drawing Package

CV-001 NG 16 SV-008 Solenoid Valve 24V DC

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

CV1.1 Check Valve Insert NG 16 YC-008 Solenoid Command -
CV-002 Check Valve NG 16 SV-009 Solenoid Valve 24V DC
CV2.1 Check Valve Insert NG 16 YC-009 Solenoid Command -
CV-003 Check Valve NG 10 TG-001 Temperature Gauge 0-120 GR
FC-001 Flow Control Valve NG 10 TE-001 Temperature Element 0-150° C
F1 Filter NG400 ZSO-013 Position Switch M12 x 60
PDSH-001 Pressure Differential Switch HI - ZSO-012 Position Switch M12 x 60
LG-001 Level Gauge -
LT-002 Level Transmitter M12/500
MA1 Coupling G 1/4"
MA2 Coupling G 1/4"
MA3 Coupling G 1/4"
MA4 Coupling G 1/4"
MA5 Coupling G 1/4"
PU-001-M01 Motor 50 hp, 1780 rpm

3/13/24
MV1 Shut-Offf Valve -
MV2 Shut-Offf Valve -
O1 Orifice Plug M6
O2 Orifice Plug M6
PU-001 Pump Duplex Gear
PU-002 Pump Duplex Gear
PG T Pressure Gauge 0-250 Bar
PG-001 Pressure Gauge 0-250 Bar
PG-002 Pressure Gauge 0-250 Bar
PG-003 Pressure Gauge 0-250 Bar
PG-005 Pressure Gauge 0-250 Bar
PSH-001 Pressure Switch HI 5-100 Bar
PT-001 Pressure Transmitter 0-250 Bar
PT-002 Pressure Transmitter 0-250 Bar
PT-003 Pressure Transmitter 0-250 Bar
PRV-001 Pressure Relief Valve NG 25
1000855588: Hydraulic Schematic (Sheet 2)

PRV-002 Pressure Relief Valve NG 25

100 Termination Box -

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
®

©
363

9232515940 — 1000912341 1
 364

LEGEND :-

BY FLS
FIELD INSTRUMENTS CR-IOB-001 Note 2
BY CLIENT
CRC-001 Note 2 MACHINE RIO PANEL ETHERNET
WH WH PLUG / RECEPTACLE
VT-001 + VT001-I1 X42/1:26
BK BK
CONE CRUSHER RING VIBRATION TRANSMITTER 1 -
X42/1:27
SHLD NOTE:
X42/1:30 1. CONVERTED TO SPEED VIA FREQUENCY TRANSDUCER THAT IS MOUNTED IN MACHINE RIO
WH WH PANEL (SEE 1000907858 SHEET 1=05/5 FOR DETAILS).
VT-002 + VT002-I1 X42/1:31
BK 2. SEE TAGGING REGISTER (1000611870) TO DISTINGUISH TAGS BETWEEN INDIVIDUAL
CONE CRUSHER RING VIBRATION TRANSMITTER 2 - BK
X42/1:32 CRUSHERS.
SHLD 3. THE E-STOP PUSH BUTTONS ARE WIRED IN SERIES WITH THE E-STOP RELAY
X42/1:35 IN THE CONTROL PANEL CABINET. IT IS THEN WIRED FROM THE CRUSHER
WH WH CONTROL PANEL CABINET TO DCS FOR INTERLOCK
VT-003 + VT003-I1 X42/1:36
BK 4. REFERENCE DOCUMENTS:-
CONE CRUSHER RING VIBRATION TRANSMITTER 3 - BK
X42/1:37 CRUSHER PLC CONTROL PANEL : 1000907855
SHLD MACHINE RIO PANEL: 1000907858
X42/1:40 LUBE RIO PANEL: 1000907856

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

WH WH HYDRAULIC RIO PANEL: 1000907857
VT-004 + VT004-I1 X42/2:1
BK BK
CONE CRUSHER RING VIBRATION TRANSMITTER 4 -
X42/2:2
SHLD
Note 1 X42/2:5SHLD
ZS-003 + BU BU
ZS003-C1 X61/1:12
COUNTER SHAFT SPEED - BK
BK
BN X61/1:11
OUT
BN
X61/1:10
BK BK BK BK
COUNTER SHAFT BOX BUSHING + TE005-I1 + TIT005-I1 X42/1:1
TEMPERATURE ELEMENT+TRANSMIITER TE-005 WH TIT-005 WH
WH - WH
- X42/1:2
SHLD
X42/1:5
BK BK BK BK
ECCENTRIC BUSHING + TE002-I1 + TT002-I1 X42/1:21
TEMPERATURE ELEMENT+TRANSMIITER WH WH TT-002 WH
TE-002 - - WH
RD X42/1:22

3/13/24
RD
SHLD
X42/1:25
BN BK
PIT-001 + PIT001-I1 X42/1:11
WH WH
OIL SUPPLY LINE PRESSURE TRANSMITTER -
X42/1:12
SHLD
X42/1:15
YE YE BK BK
CAVITY LEVEL 9 LE001-I1 9 5(+) LIT001-I1 X42/1:17
LE-001 BK BK 10 4(-) WH
SENSOR 10 WH
11 RD RD X42/1:18
11
LIT-001 SHLD
X42/1:20
FMU90
BK BK
1 LIT001-P1 X01/1:F06
2 WH
GRN 120V AC SUPPLY WH
3 X01/1:N
GRN
X01/1:PE
ZS-001 + 1 BN BN
ZS001-C1 X61/1:4
ADJUSTMENT DRIVE SWITCH-1 3 BU
- BU
BK X61/1:6
OUT 4
H.40 1000911692: Interconnection Drawing

BK
X61/1:5
ZS-002 + 1 BN BN
ZS002-C1 X61/1:7
ADJUSTMENT DRIVE SWITCH-1 3 BU
- BU
BK X61/1:9
OUT 4
BK
X61/1:8

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
®
CONTINUED TO SHEET 2
©

9232515940 — 1000912341 1
Appendix H Drawing Package
 LEGEND :-
CR-IOB-001 Note 2 BY FLS
MACHINE RIO PANEL BY CLIENT
FIELD INSTRUMENTS CONTINUED FROM SHEET 1 ETHERNET
CRC-001 Note 2
PLUG / RECEPTACLE

BK BK
OIL SUPPLY LINE FLOW TRANSMITTER 26+ FIT001-I1 X42/1:7
27- WH
WH NOTE:
FIT-001 X42/1:8 1. CONVERTED TO SPEED VIA FREQUENCY TRANSDUCER THAT IS MOUNTED IN MACHINE RIO
BK FIT001-P1
P WH PANEL (SEE 1000907858 SHEET 1=05/5 FOR DETAILS).
N X42/1:10
GRN 120V AC SUPPLY 2. SEE TAGGING REGISTER (1000611870) TO DISTINGUISH TAGS BETWEEN INDIVIDUAL
PE BK CRUSHERS.
X01/1:F07
WH 3. THE E-STOP PUSH BUTTONS ARE WIRED IN SERIES WITH THE E-STOP RELAY
X01/1:N IN THE CONTROL PANEL CABINET. IT IS THEN WIRED FROM THE CRUSHER
GRN CONTROL PANEL CABINET TO DCS FOR INTERLOCK
X01/1:PE
4. REFERENCE DOCUMENTS:-
BK BK CRUSHER PLC CONTROL PANEL : 1000907855
YA-101 + YA101-C1 K101:11
DUMP LIGHT WH WH MACHINE RIO PANEL: 1000907858
-
X74/1:1 LUBE RIO PANEL: 1000907856
BK BK HYDRAULIC RIO PANEL: 1000907857
XA-101 + XA101-C1 K102:11
Appendix H Drawing Package

WH

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

ALARM - WH
X74/1:2

CONTINUED TO SHEET 6

FIELD INSTRUMENTS LU-IOB-001 Note 1

LU-001 Note 1 LUBRICATION RIO PANEL
1 BK BK
TT-003 + TT003-I1 X42/1:26
2 WH WH
LUBRICATION SYSTEM OIL RESERVOIR TANK TEMERATURE - X42/1:27
SHLD
X42/1:30
1 BN BN
PT-006A + PT006A-I1 X42/1:6
2 WH WH
LUBRICATION SYSTEM FILTER INLET PRESSURE - X42/1:7

3/13/24
SHLD
X42/1:10SHLD
1 BN BN
PT-006B + PT006B-I1 X42/1:11
2 WH WH
LUBRICATION SYSTEM FILTER OUTLET PRESSURE - X42/1:12
SHLD
X42/1:15SHLD
1 BK BK
TT-002 + TT002-I1 X42/1:21
2 WH WH
CRUSHER RETURN LINE TEMERATURE - X42/1:22
SHLD
X42/1:25
1 BK BK
LT-003 + LT003-I1 X42/1:1
4 WH WH
LUBRICATION SYSTEM OIL RESERVOIR TANK LEVEL TRANSMITTER - X42/1:2
SHLD
X42/1:5
ZSO-004 + 1 BN BN
ZSO004-I1 X61/1:4
LUBRICATION SYSTEM PUMP 1 SUCTION POSITION SWITCH OUT 4 BU BU
BK X61/1:5
- 3
BK
X61/1:6
ZSO-005 + 1 BN BN
ZSO005-I1 X61/1:10
LUBRICATION SYSTEM PUMP 1 DISCHARGE POSITION SWITCH OUT 4 BU BU
BK X61/1:11
- 3
BK
1000911692: Interconnection Drawing (Sheet 2)

X61/1:12

CONTINUED TO SHEET 3

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
®

9232515940 — 1000912341 1
365
 366

LEGEND :-
LU-IOB-001 Note 1
BY FLS
FIELD INSTRUMENTS LUBRICATION RIO PANEL BY CLIENT
CONTINUED FROM SHEET 2
LU-001 Note 1 ETHERNET
PLUG / RECEPTACLE
1 BK BK
TT-003 + TT003-I1 X42/1:26
2 WH WH
LUBRICATION SYSTEM OIL RESERVOIR TANK TEMERATURE - X42/1:27 NOTE:
SHLD 1. CONVERTED TO SPEED VIA FREQUENCY TRANSDUCER THAT IS MOUNTED IN MACHINE RIO
X42/1:30 PANEL (SEE 1000907858 SHEET 1=05/5 FOR DETAILS).
1 BN BN 2. SEE TAGGING REGISTER (1000611870) TO DISTINGUISH TAGS BETWEEN INDIVIDUAL
PT-006A + PT006A-I1 X42/1:6
2 WH CRUSHERS.
LUBRICATION SYSTEM FILTER INLET PRESSURE - WH
X42/1:7 3. THE E-STOP PUSH BUTTONS ARE WIRED IN SERIES WITH THE E-STOP RELAY
SHLD IN THE CONTROL PANEL CABINET. IT IS THEN WIRED FROM THE CRUSHER
X42/1:10SHLD CONTROL PANEL CABINET TO DCS FOR INTERLOCK
1 BN BN 4. REFERENCE DOCUMENTS:-
PT-006B + PT006B-I1 X42/1:11
2 WH CRUSHER PLC CONTROL PANEL : 1000907855
LUBRICATION SYSTEM FILTER OUTLET PRESSURE - WH MACHINE RIO PANEL: 1000907858

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

X42/1:12
LUBE RIO PANEL: 1000907856
SHLD
X42/1:15SHLD HYDRAULIC RIO PANEL: 1000907857
1 BK BK
TT-002 + TT002-I1 X42/1:21
2 WH WH
CRUSHER RETURN LINE TEMERATURE - X42/1:22
SHLD
X42/1:25
1 BK BK
LT-003 + LT003-I1 X42/1:1
4 WH WH
LUBRICATION SYSTEM OIL RESERVOIR TANK LEVEL TRANSMITTER - X42/1:2
SHLD
X42/1:5
ZSO-004 + 1 BN BN
ZSO004-I1 X61/1:4
LUBRICATION SYSTEM PUMP 1 SUCTION POSITION SWITCH OUT 4 BU BU
BK X61/1:5
- 3
BK
X61/1:6

3/13/24
ZSO-005 + 1 BN BN
ZSO005-I1 X61/1:10
LUBRICATION SYSTEM PUMP 1 DISCHARGE POSITION SWITCH OUT 4 BU BU
BK X61/1:11
- 3
BK
X61/1:12
ZSO-006 + 1 BN BN
ZSO006-I1 X61/1:7
LUBRICATION SYSTEM PUMP 2 SUCTION POSITION SWITCH OUT 4 BU BU
BK X61/1:8
- 3
BK
X61/1:9
ZSO-007 + 1 BN BN
ZSO007-I1 X61/1:13
LUBRICATION SYSTEM PUMP 2 DISCHARGE POSITION SWITCH OUT 4 BU BU
BK X61/1:14
- 3
BK
X61/1:15
1 BK BK
TT-004 + TT004-I1 X42/1:16
2 WH WH
HEAT EXCHANGER OUTLET TEMPERATURE -
X42/1:17
SHLD
X42/1:20
1000911692: Interconnection Drawing (Sheet 3)

CONTINUED TO SHEET 6

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
®

9232515940 — 1000912341 1
Appendix H Drawing Package
 LEGEND :-

BY FLS
FIELD INSTRUMENTS Note 1 HU-IOB-001 Note 1 BY CLIENT
HYDRULIC CONTROL PANEL ETHERNET
HU-001
1 BK BK PLUG / RECEPTACLE
TT-001 + TT001-I1 X42/1:1
2 WH WH
HYDRAULIC SYSTEM OIL RESERVOIR TANK TEMERATURE - X42/1:2
SHLD NOTE:
X42/1:5 1. CONVERTED TO SPEED VIA FREQUENCY TRANSDUCER THAT IS MOUNTED IN MACHINE RIO
1 BK BK PANEL (SEE 1000907858 SHEET 1=05/5 FOR DETAILS).
LT-002 + LT002-I1 X42/1:21
4 WH 2. SEE TAGGING REGISTER (1000611870) TO DISTINGUISH TAGS BETWEEN INDIVIDUAL
HYDRAULIC SYSTEM OIL RESERVOIR TANK LEVEL TRANSMITTER - WH CRUSHERS.
X42/1:22
3. THE E-STOP PUSH BUTTONS ARE WIRED IN SERIES WITH THE E-STOP RELAY
SHLD
X42/1:25 IN THE CONTROL PANEL CABINET. IT IS THEN WIRED FROM THE CRUSHER
1 BN BN CONTROL PANEL CABINET TO DCS FOR INTERLOCK
PT-003 + PT003-I1 X42/1:6 4. REFERENCE DOCUMENTS:-
2 WH WH
HYDRAULIC SYSTEM OUTLET PRESSURE - X42/1:7 CRUSHER PLC CONTROL PANEL : 1000907855
Appendix H Drawing Package

MACHINE RIO PANEL: 1000907858

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

SHLD
X42/1:10 LUBE RIO PANEL: 1000907856
1 BN BN HYDRAULIC RIO PANEL: 1000907857
PT-001 + PT001-I1 X42/1:11
2 WH WH
- X42/1:12
HYDRAULIC SYSTEM ON CRUSHER CLAMPING CYLINDER PRESSURE SHLD
X42/1:15
1 BN BN
PT-002 + PT002-I1 X42/1:17
2 WH WH
HYDRAULIC SYSTEM ON ACCUMULATOR OIL/GAS PRESSURE - X42/1:18
SHLD
X42/1:20
1 BN BK
PSH-001 L+ PSH001-I1 X61/1:13
BOWL DRIVE PRESSURE SWITCH HIGH 2 BU
NC WH
4 WH X61/1:14
NO BK
3 BK X61/1:15
L-
BK BK

3/13/24
PDSH-001 C PDSH001-I1 X61/1:16
NO WH
HYDRAULIC SYSTEM OUTLET FILTER PRESSURE WH
X61/1:17
ZSO-013 + 1 BN BN
ZSO013-I1 X61/1:7
HYDRAULIC SYSTEM PUMP 1 SUCTION VALVE POSITION SWITCH OUT 4 BU BU
BK X61/1:8
- 3
BK
X61/1:9
ZSO-012 + 1 BN BN
ZSO012-I1 X61/1:10
HYDRAULIC SYSTEM PUMP 2 SUCTION VALVE POSITION SWITCH OUT 4 BU BU
BK X61/1:11
- 3
BK
X61/1:12

+ BK
HYDRAULIC SYSTEM PRESSURE VALVE SV-001 WH
SV001-C1 K101-14
- WH
X74/1-1
BK BK
HYDRAULIC SYSTEM HIGH FLOW + SV002-C1 K102-14
VALVE SV-002 WH
- WH
X74/1-2
BK BK
HYDRAULIC SYSTEM BOWL CLOSE + SV003-C1 K103-14
VALVE SV-003 WH
- WH
X74/1-3
1000911692: Interconnection Drawing (Sheet 4)

BK BK
HYDRAULIC SYSTEM BOWL OPEN + SV004-C1 K104-14
SV-004 WH
VALVE - WH
X74/1-4

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
CONTINUED TO SHEET 4
®

9232515940 — 1000912341 1
367
 368

Note 1 HU-IOB-001 Note 1 LEGEND :-

FIELD INSTRUMENTS
HU-001 HYDRULIC CONTROL PANEL BY FLS
CONTINUED FROM SHEET 4 BY CLIENT
ETHERNET
PLUG / RECEPTACLE

NOTE:
BK BK 1. CONVERTED TO SPEED VIA FREQUENCY TRANSDUCER THAT IS MOUNTED IN MACHINE RIO
HYDRAULIC SYSTEM CLAMP + SV005-C1 K105-14
SV-005 WH PANEL (SEE 1000907858 SHEET 1=05/5 FOR DETAILS).
PRESSURE VALVE - WH
X74/1-5 2. SEE TAGGING REGISTER (1000611870) TO DISTINGUISH TAGS BETWEEN INDIVIDUAL
CRUSHERS.
BK BK
HYDRAULIC SYSTEM CLAMP DUMP + SV006-C1 K106-14 3. THE E-STOP PUSH BUTTONS ARE WIRED IN SERIES WITH THE E-STOP RELAY
SV-006 WH
VALVE - WH IN THE CONTROL PANEL CABINET. IT IS THEN WIRED FROM THE CRUSHER
X74/1-6 CONTROL PANEL CABINET TO DCS FOR INTERLOCK
BK BK 4. REFERENCE DOCUMENTS:-
HYDRAULIC SYSTEM CLEARING VALVE + SV008-C1 K107-14
SV-008 WH CRUSHER PLC CONTROL PANEL : 1000907855
- WH
MACHINE RIO PANEL: 1000907858

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

X74/1-7
BK LUBE RIO PANEL: 1000907856
HYDRAULIC SYSTEM TRAMP + BK SV009-C1
SV-009 K108-14 HYDRAULIC RIO PANEL: 1000907857
PRESSURIZED VALVE - WH
WH
X74/1-8

CONTINUED TO SHEET 6

3/13/24
1000911692: Interconnection Drawing (Sheet 5)

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
®

9232515940 — 1000912341 1
Appendix H Drawing Package
 LEGEND :-
CONTINUED FROM
BY FLS
SHEET 3
BY CLIENT
ETHERNET
PLC CONTROL PANEL
LU-IOB-001
CR-BB-001 PLUG / RECEPTACLE
LUBRICATION RIO PANEL
LUIOB001-T1
COMMUNICATION CABLE - ETHERNET I/P
NOTE:
1C 1C 1. CONVERTED TO SPEED VIA FREQUENCY TRANSDUCER THAT IS MOUNTED IN MACHINE RIO
X90/1-1 LUIOB001-C1 X90/1-1 PANEL (SEE 1000907858 SHEET 1=05/5 FOR DETAILS).
6CX1.5 Sq.mm,Cu, PVC
2C 2C 2. SEE TAGGING REGISTER (1000611870) TO DISTINGUISH TAGS BETWEEN INDIVIDUAL
FL001-HSS-XXX X90/1-2 X90/1-2
CRUSHERS.
EMERGENCY STOP 3C 3C 3. THE E-STOP PUSH BUTTONS ARE WIRED IN SERIES WITH THE E-STOP RELAY
X90/1-3 X91/1-1
4C 4C IN THE CONTROL PANEL CABINET. IT IS THEN WIRED FROM THE CRUSHER
X90/1-4 X91/1-2 CONTROL PANEL CABINET TO DCS FOR INTERLOCK
5C 5C 4. REFERENCE DOCUMENTS:-
X90/1-9 X90/1-15
K01- ESTOP CRUSHER PLC CONTROL PANEL : 1000907855
RELAY STATUS 6C 6C MACHINE RIO PANEL: 1000907858
X90/1-10 X90/1-16
LUBE RIO PANEL: 1000907856
120V AC INCOMING HYDRAULIC RIO PANEL: 1000907857
POWER SUPPLY POWER DISTRIBUTION BLOCK
1C 1C
X00/1-L U20-1 LUIOB001-P1 U20-1 F09-L
3C X 2.5 Sq.mm,Cu, PVC
2C 2C
X00/1-N U20-2 U20-2 X01/2-N
Appendix H Drawing Package

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

GND GND
X00/1-PE U20-3 U20-3 X01/2-PE

LUIOB001-T2
CONTINUED FROM COMMUNICATION CABLE - ETHERNET I/P
SHEET 5

HU-IOB-001
HYDRULIC CONTROL PANEL

1C 1C
X90/1-1 HUIOB001-C1 X90/1-3
6CX1.5 Sq.mm,Cu, PVC
2C 2C
FL001-HSS-XXX X90/1-2 X90/1-4
EMERGENCY STOP 3C 3C
X90/1-3 X91/1-3
4C 4C
X90/1-4 X91/1-4
5C 5C
X90/1-9 X90/1-17
K01- ESTOP
RELAY STATUS 6C 6C

3/13/24
X90/1-10 X90/1-18

120V AC INCOMING
POWER DISTRIBUTION BLOCK
POWER SUPPLY
1C 1C
X00/1-L U20-1 HUIOB001-P1 U21-1 F10-L
3C X 2.5 Sq.mm,Cu, PVC
2C 2C
X00/1-N U20-2 U21-2 X01/2-N
GND GND CRB-001-T01
X00/1-PE U20-3 U21-3 X01/2-PE
COMMUNICATION CABLE - ETHERNET I/P
BY CLIENT

DCS
(BY CLIENT)

CONTINUED FROM HUIOB001-T1

COMMUNICATION CABLE - ETHERNET I/P X90/1-21 DCS-C01
SHEET 2 E-STOP
RELAY STATUS X90/1-22 (BY CLIENT)

CR-IOB-001
MACHINE RIO PANEL
CRIOB001-T1
COMMUNICATION CABLE - ETHERNET I/P

1C 1C
X90/1-1 CRIOB001-C1 X90/1-5
6CX1.5 Sq.mm,Cu, PVC
2C 2C
FL001-HSS-XXX X90/1-2 X90/1-6
EMERGENCY STOP 3C 3C
X90/1-3 X91/1-5
4C 4C
X90/1-4 X91/1-6
5C 5C
1000911692: Interconnection Drawing (Sheet 6)

X90/1-9 X90/1-19
K01- ESTOP
RELAY STATUS 6C 6C
X90/1-10 X90/1-20

120V AC INCOMING
POWER DISTRIBUTION BLOCK
POWER SUPPLY
1C 1C
X00/1-L U20-1 CRIOB001-P1 U22-1 F11-L

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
3C X 2.5 Sq.mm,Cu, PVC
2C 2C
X00/1-N U20-2 U22-2 X01/2-N
GND GND
X00/1-PE U20-3 U22-3 X01/2-PE

9232515940 — 1000912341 1
369
 LEGEND
370

PEBBLE CRUSHER TYPICAL BLOCK DIAGRAM ELECTRICAL ROOM SUPPLIED BY FLS AND WIRED BY FLS
OR
CONTROL ROOM SUPPLIED BY FLS AND WIRED BY CLIENT
FIELD INSTRUMENTS
H.41
SUPPLIED BY CLIENT WIRED BY CLIENT (HARDWIRE)

SUPPLIED BY CLIENT WIRED BY CLIENT(HIGHWAY COMMUNICATION)

PEBBLE CRUSHER NO.1 120VAC UPS

PLC I/O COMMUNICATION
HYDRAULIC OIL RIO BOX POWER SUPPLY
(BY CLIENT) INSTRUMENT(S)
PROFIBUS
HPU INSTRUMENTS
POWER SUPPLY
E-STOP
E

Mounted on Skid by FLS

PEBBLE CRUSHER NO.1 PLC I/O COMMUNICATION

LUBE OIL RIO BOX

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

PROFIBUS
LUBE INSTRUMENTS
POWER SUPPLY
E-STOP
E

Mounted on Skid by FLS

PEBBLE CRUSHER NO.1

PLC I/O COMMUNICATION PEBBLE CRUSHER NO.1
MACHINE RIO BOX
CONTROL PANEL
PROFIBUS (PLC+HMI ) PLC I/O COMMUNICATION
CRUSHER INSTRUMENTS
E-STOP CLIENT CONTROL
POWER SUPPLY MODBUS TCP/IP NETWORK
E
E-STOP
E

3/13/24
Field Mounted by Customer
1000890158: Block Diagram

Field Mounted by Customer

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
®

9232515940 — 1000912341 1
Appendix H Drawing Package
 Appendix H Drawing Package

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

Network Signal List
Cone Crusher

3/13/24
H.42 1000924365: Network Signal List

Contract No.: 9232515940 Release Purpose: Designation: Document ID: Rev.: Language:
Customer: Antapaccay Draft / Certified Title: Project Location 1000924365 2.0 English
Dept.: Project Name: Tintaya Created By: Approved By: Network Signal List Document Class: DCC: Date of Issue: Rev. Date: Chapter:

The information transmitted by this document is the propriatary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written
JMH-US ARI-US Cone Crusher 3/11/2024 3/11/2024 0

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
371

9232515940 — 1000912341 1
 372

Date of Issue:
MCS Remote Control Interface 1000924365 ver: 2.0 11-Mar-2024
Panel Tag: Panel Type: Network Type: PCS #: MCS #: PCS IP Address: MCS IP Address: Approved By:
111CR101A01 Cone Crusher Ethernet IP JMH-US/ARI-US
From: Process Control System To: Machine Control System
Digital signals:
Holding Register Signal Tag Code Name Range Description Type
4000.0 _111CR001K31 Crusher Watchdog Pulse, 1 second ON, 1 second OFF BOOL
4000.1 _111CRC001C39 Local Permission 0 = Remote, 1 = Local BOOL
4000.2 _111CRC001_ALMRST Alarm Reset from PCS Momentary 1 = Reset BOOL
4000.3 _111CRC001M19RET Downstream Equipment Running 1 = Equipment Running BOOL
4000.4 _111CRC001G04_START Start Auxilliaries Command Momentary 1 = Start BOOL

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

4000.5 _111CRC001G04_STOP Stop Auxilliaries Command 0 = Stop, 1 = Not Stop BOOL
4000.6 _111LU001G01_START Heating Group Start Momentary 1 = Start BOOL
4000.7 _111LU001G01_STOP Heating Group Stop 0 = Stop, 1 = Not Stop BOOL
4000.8 _111LU001G02_START Lubrication Group Start Momentary 1 = Start BOOL
4000.9 _111LU001G02_STOP Lubrication Group Stop 0 = Stop, 1 = Not Stop BOOL
4000.10 _111HU001G03_START Hydraulic Group Start Momentary 1 = Start BOOL
4000.11 _111HU001G03_STOP Hydraulic Group Stop 0 = Stop, 1 = Not Stop BOOL
4000.12 _111CRC001G05_START Main Drive Group Start Momentary 1 = Start BOOL
4000.13 _111CRC001G05_STOP Main Drive Group Stop 0 = Stop, 1 = Not Stop BOOL
4000.14 _111CRC001G06_START Crusher Feed Group Start Momentary 1 = Start BOOL
4000.15 _111CRC001G06_STOP Crusher Feed Group Stop 0 = Stop, 1 = Not Stop BOOL
4001.0 _111CR001_PCS_START Crusher Start Command from DCS Momentary 1 = Start BOOL
4001.1 _111CR001_PCS_STOP Crusher Stop Command from DCS 0 = Stop, 1 = Not Stop BOOL
4001.2 _111HE0001RET Lube Oil Heater Running 1 = Running BOOL

3/13/24
4001.3 _111HE0005RET Main Drive Motor Heater Running 1 = Running BOOL
4001.4 _111BL001M01RET Countershaft Blower Running 1 = Running BOOL
4001.5 _111BL001M01FLT Countershaft Blower Fault 0=Fault, 1 = OK BOOL
4001.6 _111PU02M01RET Lube Oil Pump 1 Running 1 = Running BOOL
4001.7 _111PU02M01FLT Lube Oil Pump 1 Fault 0=Fault, 1 = OK BOOL
4001.8 _111PU03M01RET Lube Oil Pump 2 Running 1 = Running BOOL
4001.9 _111PU03M01FLT Lube Oil Pump 2 Fault 0=Fault, 1 = OK BOOL
4001.10 _111FN006M01RET Heat Exch. Fan 1 Running 1 = Running BOOL
4001.11 _111FN006M01FLT Heat Exch. Fan 1 Fault 0=Fault, 1 = OK BOOL
4001.12 _111FN007M01RET Heat Exch. Fan 2 Running 1 = Running BOOL
4001.13 _111FN007M01FLT Heat Exch. Fan 2 Fault 0=Fault, 1 = OK BOOL
4001.14 _111PU001M01RET Hyd. Oil Pump 1 Running 1 = Running BOOL
4001.15 _111PU001M01FLT Hyd. Oil Pump 1 Fault 0=Fault, 1 = OK BOOL
4002.0 _111CRC001M01RDY Main Drive Motor Ready 1 = Ready BOOL
1000924365: Network Signal List (Sheet 2)

4002.1 _111CRC001M01RET Main Drive Motor Running 1 = Running BOOL

4002.2 _111CRC001M01FLT Main Drive Motor Fault 0=Fault, 1 = OK BOOL
4002.3 _111CRC001M20RET Feeder Motor Running 1 = Running BOOL
4002.4 _111CRC001M20FLT Feeder Motor Fault 0=Fault, 1 = OK BOOL
4002.5 _111HU001G03S11_PCS Adjust CSS Now Momentary 1 = Make CSS Adjustment BOOL
4002.6 _111HU001G03S12_PCS Cancel CSS Adjustment Momentary 1 = Cancel CSS Adjustment BOOL
4002.7 _111CR001G06S01_PCS Cavity Level PID Auto Mode 1 = Auto, 0 = Manual BOOL
4002.8 Spare BOOL
4002.9 Spare BOOL

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
4002.10 Spare BOOL

page 8.10

9232515940 — 1000912341 1
Appendix H Drawing Package
 Date of Issue:
MCS Remote Control Interface 1000924365 ver: 2.0 11-Mar-2024
Panel Tag: Panel Type: Network Type: PCS #: MCS #: PCS IP Address: MCS IP Address: Approved By:
111CR101A01 Cone Crusher Ethernet IP JMH-US/ARI-US
4002.11 Spare BOOL
4002.12 Spare BOOL
4002.13 Spare BOOL
4002.14 Spare BOOL
4002.15 Spare BOOL
4003.0 Spare BOOL
4003.1 Spare BOOL
4003.2 Spare BOOL
Appendix H Drawing Package

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

4003.3 Spare BOOL
4003.4 Spare BOOL
4003.5 Spare BOOL
4003.6 Spare BOOL
4003.7 Spare BOOL
4003.8 Spare BOOL
4003.9 Spare BOOL
4003.10 Spare BOOL
4003.11 Spare BOOL
4003.12 Spare BOOL
4003.13 Spare BOOL
4003.14 Spare BOOL
4003.15 Spare BOOL
BOOL

3/13/24
1000924365: Network Signal List (Sheet 3)

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
page 8.11
373

9232515940 — 1000912341 1
 374

Date of Issue:
MCS Remote Control Interface 1000924365 ver: 2.0 11-Mar-2024
Panel Tag: Panel Type: Network Type: PCS #: MCS #: PCS IP Address: MCS IP Address: Approved By:
111CR101A01 Cone Crusher Ethernet IP JMH-US/ARI-US
From: Process Control System To: Machine Control System
Real signals:
Address Signal Tag Code Name Range Description Type
4004 _111CRC001F01 Crusher Throughput 0-15,000 t/hr WORD
4005 _111CRC001M01J01 Main Drive Motor Power 0 - 1800 kw Value is Multipied by 10 WORD
4006 _111CRC001M01I01 Main Drive Motor Current 0-750 A Value is Multipied by 10 WORD
4007 _111HU001G03OSP08_PCS Close Side Setting Setpoint 0 - 200 mm Value is Multipied by 10 WORD
4008 _111CR001I01S11 Feeder Cavity Level Speed Setpoint 0 - 100 % Value is Multipied by 10 WORD

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

4009 _111CRC001M01TI009 Crusher Motor, Temp NDE Value is Multipied by 10 WORD
4010 _111CRC001M01TI007 Crusher Motor, Temp DE Value is Multipied by 10 WORD
4011 _111CRC001M01TI17 Crusher Motor Winding Temp. Highest Value is Multipied by 10 WORD
4012 _111CRC001M01TI010 Crusher Motor Winding Temp. 1 Value is Multipied by 10 WORD
4013 _111CRC001M01TI011 Crusher Motor Winding Temp. 2 Value is Multipied by 10 WORD
4014 _111CRC001M01TI012 Crusher Motor Winding Temp. 3 Value is Multipied by 10 WORD
4015 Spare WORD
4016 Spare WORD
4017 Spare WORD
4018 Spare WORD
4019 Spare WORD

3/13/24
1000924365: Network Signal List (Sheet 4)

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
page 8.12

9232515940 — 1000912341 1
Appendix H Drawing Package
 Date of Issue:
MCS Remote Control Interface 1000924365 ver: 2.0 11-Mar-2024
Panel Tag: Panel Type: Network Type: PCS #: MCS #: PCS IP Address: MCS IP Address: Approved By:
111CR101A01 Cone Crusher Ethernet IP JMH-US/ARI-US
From: Machine Control System To: Process Control System
Digital signals:
Address Signal Tag Code Name Range Description Type
4020.0 _111CRC001K81 Crusher Watchdog Pulse, 1 second ON, 1 second OFF BOOL
4020.1 _111CRC001_RSTREQ Alarm Reset Required 1 = Required, 0 = Not Required BOOL
4020.2 _111CRC001Y01C31_DB.OUT Crusher Start Warning 1 = ON, 0 = OFF BOOL
4020.3 _111CRC001G04_DB.RDY_START Auxilliaries Ready 1 = Ready, 0 = Not Ready BOOL
4020.4 _111CRC001G04_DB.GSTR Auxilliaries Starting 1 = Starting, 0 = Not Starting BOOL
Appendix H Drawing Package

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

4020.5 _111CRC001G04_DB.GRUN Auxilliaries Running 1 = Running, 0 = Not Running BOOL
4020.6 _111LU001G01_DB.RDY_START Heating Group Ready 1 = Ready, 0 = Not Ready BOOL
4020.7 _111LU001G01_DB.GSTR Heating Group Starting 1 = Starting, 0 = Not Starting BOOL
4020.8 _111LU001G01_DB.GRUN Heating Group Running 1 = Running, 0 = Not Running BOOL
4020.9 _111LU001G02_DB.RDY_START Lubrication Group Ready 1 = Ready, 0 = Not Ready BOOL
4020.10 _111LU001G02_DB.GSTR Lubrication Group Starting 1 = Starting, 0 = Not Starting BOOL
4020.11 _111LU001G02_DB.GRUN Lubrication Group Running 1 = Running, 0 = Not Running BOOL
4020.12 _111HU001G03_DB.RDY_START Hydraulic Group Ready 1 = Ready, 0 = Not Ready BOOL
4020.13 _111HU001G03_DB.GSTR Hydraulic Group Starting 1 = Starting, 0 = Not Starting BOOL
4020.14 _111HU001G03_DB.GRUN Hydraulic Group Running 1 = Running, 0 = Not Running BOOL
4020.15 _111CRC001G05_DB.RDY_START Main Drive Group Ready 1 = Ready, 0 = Not Ready BOOL
4020.16 _111CRC001G05_DB.GSTR Main Drive Group Starting 1 = Starting, 0 = Not Starting BOOL
4021.0 _111CRC001G05_DB.GRUN Main Drive Group Running 1 = Running, 0 = Not Running BOOL
4021.1 _111CRC001G06_DB.RDY_START Crusher Feed Group Ready 1 = Ready, 0 = Not Ready BOOL

3/13/24
4021.2 _111CRC001G06_DB.GSTR Crusher Feed Group Starting 1 = Starting, 0 = Not Starting BOOL
4021.3 _111CRC001G06_DB.GRUN Crusher Feed Group Running 1 = Running, 0 = Not Running BOOL
4021.4 _111HE0001CMD Lube Oil Heater 1 Cmd. 1 = Run, 0 = Stop BOOL
4021.5 _111BL001M01CMD Countershaft Blower Run Cmd 1 = Run, 0 = Stop BOOL
4021.6 _111PU02M01CMD Lube Oil Pump 1 Cmd. 1 = Run, 0 = Stop BOOL
4021.7 _111PU03M01CMD Lube Oil Pump 2 Cmd. 1 = Run, 0 = Stop BOOL
4021.8 _111FN006M01CMD Heat Exch. Fan 1 Cmd. 1 = Run, 0 = Stop BOOL
4021.9 _111FN007M01CMD Heat Exch. Fan 2 Cmd. 1 = Run, 0 = Stop BOOL
4021.10 _111PU001M01CMD Hyd. Oil Pump 1 Cmd. 1 = Run, 0 = Stop BOOL
4021.11 _111CRC001M01CMD Main Drive Motor Run Cmd 1 = Run, 0 = Stop BOOL
4021.12 _111HE005CMD Main Drive Heater Cmd. 1 = Run, 0 = Stop BOOL
4021.13 Spare BOOL
4021.14 Spare BOOL
4021.15 Spare BOOL
1000924365: Network Signal List (Sheet 5)

4021.16 Spare BOOL

4022 Spare BOOL
4023 Spare BOOL

From: Machine Control System To: Process Control System

Real signals:
Address Signal Tag Code Name Range Description Type
4024 _111CR001I01S21 Feeder Speed Setpoint 0 - 100 % Value is Multipied by 10 WORD
4025 _111HU001G03OSP07 Crusher Close Side Setting 0 - 200 mm Value is Multipied by 10 WORD

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
4026 _111LU120G02OSP01 Lube Prestart Run Timer 0 - 600 s WORD

page 8.13

9232515940 — 1000912341 1
375
 376

Date of Issue:
MCS Display Data 1000924365 ver: 2.0 11-Mar-2024
Panel Tag: Panel Type: Network Type: PCS #: MCS #: PCS IP Address: MCS IP Address: Approved By:
111CR101A01 Cone Crusher Ethernet IP 0 0 0 JMH-US/ARI-US

From: Machine Control System To: Process Control System

Digital signals:
Address Signal Tag Code Name Range Description Type
4031.0 _111CR001HI002_DB.OK Surge Suppressor OK Display Only, 0 = Alarm, 1 = OK BOOL
4031.1 _111CR001HI001_DB.OK E-Stop PB OK Display Only, 0 = Alarm, 1 = OK BOOL
4031.2 _111CR001HI003_DB.OK E-Stop Relay OK Display Only, 0 = Alarm, 1 = OK BOOL
4031.3 _111LU001HI001_DB.OK Lube Panel E-Stop OK Display Only, 0 = Alarm, 1 = OK BOOL

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

4031.4 _111HU001HI001_DB.OK Lube Panel E-Stop OK Display Only, 0 = Alarm, 1 = OK BOOL
4031.5 _111CR001HI004_DB.OK Machine Panel E-Stop OK Display Only, 0 = Alarm, 1 = OK BOOL
4031.6 _111LU001ZAO004_DB.OK Pump 1 Suction Valve Open Display Only, 0 = Alarm, 1 = OK BOOL
4031.7 _111LU001ZAO006_DB.OK Pump 2 Suction Valve Open Display Only, 0 = Alarm, 1 = OK BOOL
4031.8 _111LU001ZAO005_DB.OK Pump 1 Discharge Valve Open Display Only, 0 = Alarm, 1 = OK BOOL
4031.9 _111LU001ZAO007_DB.OK Pump 2 Discharge Valve Open Display Only, 0 = Alarm, 1 = OK BOOL
4031.10 _111HU001ZAO013_DB.OK Pump 1 Suction Valve Open Display Only, 0 = Alarm, 1 = OK BOOL
4031.11 _111HU001ZAO012_DB.OK Pump 2 Suction Valve Open Display Only, 0 = Alarm, 1 = OK BOOL
4031.12 _111LU001TI003_DB.AL_L2 Lube Tank Oil Temperature AL2 Display Only, 0 = Alarm, 1 = OK BOOL
4031.13 _111LU001LI003_DB.AL_L1 Lube Tank Oil Level AL1 Display Only, 0 = Alarm, 1 = OK BOOL
4031.14 _111LU001PDY006_DB.AL_H1 Lube Filter Bank 1 Differential Pressure AH1 Display Only, 0 = Alarm, 1 = OK BOOL
4031.15 _111LU001PDY006_DB.AL_H2 Lube Filter Bank 1 Differential Pressure AH2 Display Only, 0 = Alarm, 1 = OK BOOL
4032.0 _111LU001TI002_DB.AL_H2 Lube Return Oil Temperature AH1 Display Only, 0 = Alarm, 1 = OK BOOL
4032.1 _111LU001TI002_DB.AL_H3 Lube Return Oil Temperature AH2 Display Only, 0 = Alarm, 1 = OK BOOL

3/13/24
4032.2 _111LU001PI001_DB.AL_L1 Lube Supply Oil Pressure AL1 Display Only, 0 = Alarm, 1 = OK BOOL
4032.3 _111LU001PI001_DB.AL_L2 Lube Supply Oil Pressure AL2 Display Only, 0 = Alarm, 1 = OK BOOL
4032.4 _111LU001TDY004_DB.AL_H2 Lube Oil Differential Temperature AH2 Display Only, 0 = Alarm, 1 = OK BOOL
4032.5 _111CR001TI002_DB.AL_H1 Crusher Eccentric Oil Temperature AH1 Display Only, 0 = Alarm, 1 = OK BOOL
4032.6 _111CR001TI002_DB.AL_H2 Crusher Eccentric Oil Temperature AH2 Display Only, 0 = Alarm, 1 = OK BOOL
4032.7 _111CR001TI005_DB.AL_H2 Crusher Countershaft Temperature AH2 Display Only, 0 = Alarm, 1 = OK BOOL
4032.8 _111LU001FI001_DB.AL_L1 Eccentric Lube Supply Oil Flow AL1 Display Only, 0 = Closed, 1 = Open BOOL
4032.9 _111LU001FI001_DB.AL_L2 Eccentric Lube Supply Oil Flow AL2 Display Only, 0 = Alarm, 1 = OK BOOL
4032.10 _111LU001FI001_DB.AL_L3 Eccentric Lube Supply Oil Flow AL3 Display Only, 0 = Alarm, 1 = OK BOOL
4032.11 _111HU001LI002_DB.AL_L1 Hydraulic Reservoir Oil Level AL1 Display Only, 0 = Alarm, 1 = OK BOOL
4032.12 _111HU001LI002_DB.AL_L2 Hydraulic Reservoir Oil Level AL2 Display Only, 0 = Alarm, 1 = OK BOOL
4032.13 _111HU001LI002_DB.AL_H2 Hydraulic Reservoir Oil Level AH2 Display Only, 0 = Alarm, 1 = OK BOOL
1000924365: Network Signal List (Sheet 6)

4032.14 _111HU001TI001_DB.AL_H2 Hydraulic Reservoir Oil Temperature AH2 Display Only, 0 = Alarm, 1 = OK BOOL
4032.15 _111HU001TI001_DB.AL_H3 Hydraulic Reservoir Oil Temperature AH3 Display Only, 0 = Alarm, 1 = OK BOOL
4033.0 _111HU001PI001_DB.AL_L2 Hydraulic Clamping Pressure AL2 Display Only, 0 = Alarm, 1 = OK BOOL
4033.1 _111HU001PI002_DB.AL_L2 Hydraulic Tramp Release Pressure AL2 Display Only, 0 = Alarm, 1 = OK BOOL
4033.2 _111HU001I01X41_DB.OK Hydraulic System Excessive Pressurization Display Only, 0 = Alarm, 1 = OK BOOL
4033.3 _111HU110I01X42_DB.OK Hydraulic System Continuous Pressurization Display Only, 0 = Alarm, 1 = OK BOOL
4033.4 _111CR001VI001_DB.AL_H2 Crusher Ring Vibration 1 AH2 Display Only, 0 = Alarm, 1 = OK BOOL
4033.5 _111CR001VI001_DB.AL_H3 Crusher Ring Vibration 1 AH3 Display Only, 0 = Alarm, 1 = OK BOOL
4033.6 _111CR001VI002_DB.AL_H2 Crusher Ring Vibration 2 AH2 Display Only, 0 = Alarm, 1 = OK BOOL

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
page 8.50

9232515940 — 1000912341 1
Appendix H Drawing Package
 Date of Issue:
MCS Display Data 1000924365 ver: 2.0 11-Mar-2024
Panel Tag: Panel Type: Network Type: PCS #: MCS #: PCS IP Address: MCS IP Address: Approved By:
111CR101A01 Cone Crusher Ethernet IP 0 0 0 JMH-US/ARI-US
4033.7 _111CR001VI002_DB.AL_H3 Crusher Ring Vibration 2 AH3 Display Only, 0 = Alarm, 1 = OK BOOL
4033.8 _111CR001VI003_DB.AL_H2 Crusher Ring Vibration 3 AH2 Display Only, 0 = Alarm, 1 = OK BOOL
4033.9 _111CR001VI003_DB.AL_H3 Crusher Ring Vibration 3 AH3 Display Only, 0 = Alarm, 1 = OK BOOL
4033.10 _111CR001VI004_DB.AL_H2 Crusher Ring Vibration 4 AH2 Display Only, 0 = Alarm, 1 = OK BOOL
4033.11 _111CR001VI004_DB.AL_H3 Crusher Ring Vibration 4 AH3 Display Only, 0 = Alarm, 1 = OK BOOL
4033.12 _111CR001VT1Y41_DB.OK Crusher Ring Ring Bounce AH Display Only, 0 = Alarm, 1 = OK BOOL
4033.13 _111CR001LI001_DB.AL_H2 Crusher Cavity Level AH2 Display Only, 0 = Alarm, 1 = OK BOOL
Appendix H Drawing Package

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

4033.14 _111CR001SI003_DB.AL_L1 Crusher Speed AL1 Display Only, 0 = Alarm, 1 = OK BOOL
4033.15 _111CR001SI003_DB.AL_L2 Crusher Speed AL2 Display Only, 0 = Alarm, 1 = OK BOOL
4034.0 _111CR001SI003_DB.AL_L3 Crusher Speed AL3 Display Only, 0 = Alarm, 1 = OK BOOL
4034.1 Spare BOOL
4034.2 Spare BOOL
4034.3 Spare BOOL
4034.4 Spare BOOL
4034.5 Spare BOOL
4034.6 Spare BOOL
4034.7 Spare BOOL
4034.8 Spare BOOL
4034.9 Spare BOOL
4034.10 Spare BOOL
4034.11 Spare BOOL

3/13/24
4034.12 Spare BOOL
4034.13 Spare BOOL
4034.14 Spare BOOL
4034.15 Spare BOOL

From: Machine Control System To: Process Control System

Real signals:
Address Signal Tag Code Name Range Description Type
4036 _111LU001TI003_DB.PV_SCAL Lube Tank Oil Temperature -40 - 300 °C Display Only WORD
4037 _111LU001LI003_DB.PV_SCAL Lube Tank Oil Level 0 - 100% Display Only WORD
4038 _111LU001TI002_DB.PV_SCAL Lube Return Oil Temperature -40 - 300 °C Display Only WORD
1000924365: Network Signal List (Sheet 7)

4039 _111LU001PI001_DB.PV_SCAL Lube Supply Oil Pressure 0 - 10 bar Display Only WORD
4040 _111LU001TI004_DB.PV_SCAL Heat Exchanger Outlet Oil Temperature -40 - 300 °C Display Only WORD
4041 _111LU001TDY004_DB.PV_SCAL Lube Oil Differential Temperature -40 - 300 °C Display Only WORD
4042 _111CR001TI005_DB.PV_SCAL Eccentric Oil Temperature -40 - 300 °C Display Only WORD
4043 _111LU001FI001_DB.PV_SCAL Eccentric Lube Supply Oil Flow 0 - 1100 L/min Display Only WORD
4044 _111HU001TI001_DB.PV_SCAL Hydraulic Reservoir Oil Temperature -40 - 300 °C Display Only WORD
4045 _111HU001LI002_DB.PV_SCAL Hydraulic Reservoir Oil Level 0 - 100% Display Only WORD
4046 _111HU001PI003_DB.PV_SCAL Hydraulic Supply Pressure 0 - 207 bar Display Only WORD
4047 _111HU001PI002_DB.PV_SCAL Hydraulic Tramp Release Pressure 0 - 207 bar Display Only WORD

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
page 8.51
377

9232515940 — 1000912341 1
 378

Date of Issue:
MCS Display Data 1000924365 ver: 2.0 11-Mar-2024
Panel Tag: Panel Type: Network Type: PCS #: MCS #: PCS IP Address: MCS IP Address: Approved By:
111CR101A01 Cone Crusher Ethernet IP 0 0 0 JMH-US/ARI-US
4048 _111HU001PI001_DB.PV_SCAL Hydraulic Clamping Pressure 0 - 207 bar Display Only WORD
4049 _111CR001SI003_DB.PV_SCAL Crusher Speed 0 - 1000 RPM Display Only WORD
4050 _111CR001VI001_DB.PV_SCAL Crusher Ring Vibration 1 0 - 81 mm/s Display Only WORD
4051 _111CR001VI002_DB.PV_SCAL Crusher Ring Vibration 2 0 - 81 mm/s Display Only WORD
4052 _111CR001VI003_DB.PV_SCAL Crusher Ring Vibration 3 0 - 81 mm/s Display Only WORD
4053 _111CR001VI004_DB.PV_SCAL Crusher Ring Vibration 4 0 - 81 mm/s Display Only WORD
4054 _111CR001LI001_DB.PV_SCAL Crusher Cavity Level 0 - 100% Display Only WORD

Copyright © 2024 FLSmidth. ALL RIGHTS RESERVED.

4055 _111CR001TI002_DB.PV_SCAL Eccentric Bushing Temp -40 - 300 °C Display Only WORD
4056 Spare WORD
4057 Spare WORD
4058 Spare WORD

3/13/24
1000924365: Network Signal List (Sheet 8)

FLSmidth is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
page 8.52

9232515940 — 1000912341 1
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1000907858: Machine RIO Panel (Sheet 23)

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1000907858: Machine RIO Panel (Sheet 24)

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