FLSmidth 1300 x 1800 TSU Gyratory Crusher Installation, Operation and Maintenance Manual

Description

FLSmidth 1300 x 1800 TSU Gyratory Crusher – Complete Installation, Operation and Maintenance Manual

This FLSmidth 1300 x 1800 Top Service Ultra Duty (TSU) Gyratory Crusher Installation, Operation and Maintenance Manual is the full IOM documentation package issued for the Ravenswood Gold Mine project under document number 9232510974, dated September 2021. It covers every phase of the crusher’s service life – from foundation preparation and component assembly, through commissioning, ore crushing operations, scheduled preventive maintenance, major component replacement, and field troubleshooting. Written by FLSmidth engineers for the 1300 x 1800 TSU specifically, it is the primary field reference for the crusher, its lubrication system, hydraulic adjustment system, spider lubrication system, drive arrangement and control interlocks.

File Details

• Manual type: Installation, Operation, and Maintenance Manual (IOM)
• Equipment: FLSmidth Gyratory Crusher 1300 x 1800 Top Service Ultra Duty (TSU)
• Document number: 9232510974 / 10007027431
• Project: Ravenswood Gold Mine
• Revision date: September 2021
• Language: English
• Page count: 366 pages
• File format: PDF
• Drive motor rating: 450 kW
• Feed opening: 1300 mm (51 in)
• Maximum mantle diameter: 1800 mm (71 in)

Chapters Covered

• Chapter 1 – Safety: hazard signal indicators, mandatory action and prohibition symbols, warning symbols, safe working practices, operator responsibilities, unauthorized modifications, lockout/tagout energy isolation, fire extinguishers, emergency procedures, equipment safety signs and labels, protective devices (emergency stop switches, safety trip wire, interlocks, guards), equipment-specific risks, slip/trip/fall hazards, pressurized hydraulics and lubrication, lifting and moving heavy components, flying or falling objects, confined spaces, respiratory concerns, high noise levels, crusher control system interlocks, tool safety, general risks and hazards, hazardous chemicals and materials
• Chapter 2 – Introduction: using the manual, installation and start-up services, shipment and receiving, parts and repair orders, warranty conditions, accessory equipment manufacturer information, FLSmidth offices
• Chapter 3 – Storage: long-term storage, maintaining warranty, storing OEM components, outdoor storage, covered or indoor storage, equipment support, preventing corrosion (shop primer paints, protective finishes, machined surfaces), storing elastomer components, storing fiberglass reinforced plastic components, storing equipment after operation, storing methods, environmental precautions
• Chapter 4 – Equipment Overview: crusher body, spider assembly, concaves and mantles, eccentric, mainshaft wear ring
• Chapter 5 – Installation: installation considerations, bolt torque values, interference fit components (heating and cooling methods), receipt of material, foundation preparation, hydraulic support and cylinder installation, bottom shell installation and grouting, bottom shell liners, eccentric installation, countershaft assembly, dust bonnet and gear guard, shells installation, concave installation, spider and mainshaft installation, lip seals, top shell wear and seal plates, mantle position indicator, lubrication and hydraulic installation, drive motor and couplings, torque limiting coupler, drive guard, countershaft low speed switch, dust seal blower, rock breaker, post-installation inspection, final mechanical inspection and commissioning
• Chapter 6 – Operation: start-up from complete shutdown, standby shutdown, emergency shutdown and power failure, shutdown operations, ore receiving and crushing inspections, adjusting the crusher open-side setting, clearing the crusher, clearing tramp material jam, rock breaker use
• Chapter 7 – Maintenance: component replacement, running and shutdown mechanical inspections, major mechanical preventive maintenance, electrical and instrument preventive maintenance, manganese steel growth and trimming of concaves and mantles, stator insulation resistance measurement, dust bonnet replacement, spider replacement, mainshaft replacement, mantle replacement, core replacement, eccentric replacement, hydraulic piston replacement, hydraulic cylinder replacement, countershaft assembly maintenance, concaves replacement, extension shaft maintenance
• Chapter 8 – Troubleshooting: general crusher troubleshooting, mainshaft and eccentric assembly troubleshooting, lubrication system troubleshooting, drive system troubleshooting, concave troubleshooting, liner troubleshooting, troubleshooting process variables
• Appendix A – Lubrication: lubrication schedule, oil and grease selection, crusher hydraulic and lubrication systems, spider lubrication system, mainshaft dust seal and countershaft triple seal, drive safety coupling bearings, oil and grease quantity, oil contamination, oil viscosity, oil sampling
• Appendix B – Pre-Installation Inspection: component-by-component inspection form
• Appendix C – Commissioning: commissioning overview, sequence flow chart, pre-operational testing, pre-commissioning mechanical and electrical inspection, instrumentation, no-load commissioning, 50% feed load commissioning, full load commissioning
• Appendix D – Maintenance Schedule: daily, weekly, monthly, annual and major mechanical checklists; weekly, monthly and annual electrical checklists; quarterly instrument checklist
• Appendix E – Parts List / Bill of Materials: assembly-by-assembly parts lists with part numbers, drawings, materials and weights
• Appendix F – Recommended Spare Parts List: start-up and commissioning spares, second-year operational spares, capital and insurance spares
• Appendix G – Functional Specification (Document 1000656041): lubrication system interlocks and controls, spider lubrication system, hydraulic system, mantle solenoids, mantle position calibration, dust seal fan, countershaft speed, main drive interlocks, crusher feed permission
• Appendix H – Drawing Package: crusher general assembly, foundation load and clearance requirements, foundation bolt assembly, mainshaft/spider/shell handling drawings, spider assembly, top shell assembly, top shell seal assembly, middle shell assembly, bottom shell assembly, bottom shell liner assembly, dust bonnet assembly, eccentric assembly, hydraulic cylinder assembly, mainshaft assembly, concave assembly, concave installation and removal rings, bonnet cover, countershaft assembly, lube and hydraulic schematic, spider lubrication GA, countershaft extension assembly, drive guard assembly, dust seal assembly, mantle position indicator assembly, hydraulic jack assembly, mantle relief valve and accumulator, blower assembly schematic, gear and pinion assembly field installation, erection and maintenance data, acceptable epoxy grouts, instrument list, electrical load list, control and instrumentation diagram, interconnection drawing, lubrication unit electrical schematic, block diagram, I/O list
• Appendix I – Final Mechanical Inspection: field sign-off checklist

What this 1300 x 1800 TSU gyratory crusher manual gives a maintenance team is the full sequence of procedures and reference data behind every major component on the machine. The installation chapter walks through cold-fitting interference components with dry ice or liquid nitrogen, hot-pouring epoxy backing around concaves and mantles, setting gear backlash with a dial indicator and shim stack, and grouting the bottom shell onto the foundation to the correct level. The operation chapter explains how to calculate the open-side setting from the closed-side measurement and throw, how to raise and lower the mantle using the hydraulic adjustment system, and how to clear a tramp material jam with a thermal lance without entering the crushing cavity. The maintenance chapter documents the removal and installation of the eccentric bushings, hydraulic piston and cylinder, countershaft assembly, spider bushing and mainshaft sleeve, along with the torque values and fit tolerances each procedure requires. Throughout, the manual preserves the exact technical figures – bolt torque tables, hydraulic pressures up to 69 bar (1000 psi), accumulator pre-charge to 2068 kPa (300 psi), lubricant fill quantities (681 L hydraulic, 4921 L lubrication), oil viscosity at ISO VG 320, and temperature limits for epoxy pours and bearing heating – that keep the machine inside its design envelope.

Why This Manual Matters for Owners and Maintenance Crews

The 1300 x 1800 TSU is a heavy, high-value primary crusher with individual components weighing tens of tonnes and stored hydraulic energy that can injure or kill if released carelessly. Working on one of these machines without the exact procedures and torque values for its model risks damaging shell flanges, eccentric bushings, mainshaft threads, dust seals and hydraulic pistons, or producing a crushing setting that overloads the drive motor. This IOM manual removes the guesswork: it tells a fitter which bolts to torque and to what value, which components need heating or cooling for an interference fit, how long to flush the lubrication circuits, how to calibrate the mantle position indicator, how to measure gear backlash at four eccentric positions, and how to diagnose the most common fault conditions from a dedicated troubleshooting chapter with cause and corrective-action tables.

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Instant PDF Delivery of the FLSmidth Gyratory Crusher 1300 x 1800 IOM Manual

This FLSmidth 1300 x 1800 TSU gyratory crusher installation, operation and maintenance manual is delivered as an instant PDF download – no shipping and no waiting. Open it on any laptop, tablet or smartphone in the workshop or site office, print the checklists, data sheets and drawing extracts you need for a specific job, and keep a full digital copy on hand for maintenance planning, operator training and spare parts identification. Whether you are commissioning a new 1300 x 1800 TSU, planning a mantle and concave change-out, setting up a lubrication and hydraulic maintenance schedule, or chasing down an unusual noise or a lost open-side setting, this manual puts the FLSmidth engineering documentation for the machine at your fingertips.