7.

2 CRUSHER ERECTION AND MAINTENANCE DATA - FLSMIDTH

Contract number 08-20366-910
Project Name XTRATA - Los Bombas
CRUSHER SIZE 60" x 113" TRAYLOR TYPE "NT" inches mm
Crusher Setting 8.00 203
HORSEPOWER 1000HP / 750KW Eccentric Throw 1.75 44
Motor RPM 506
PREPARED BY MAT Counter Shaft RPM 506
APPROVED BY JON Mantle Gyrations per minute 125
Capacity (tons per hour) 8267 7500 metric tons
Crusher Rotation - facing Counter Shaft CLOCKWISE

BOLT TORQUE ( with lubricated threads)

THE FOLLOWING COMPONENTS ARE CONSIDERED CRITICAL, AND AS SUCH THEIR BOLT/ NUT TORQUE VALUES SHOULD BE VERIFIED AFTER
INSTALLATION. FOR ALL OTHER COMPONENT TORQUE VALUES, PLEASE REFER TO THE BOLT TORQUE SECTION OF THE CRUSHER IOM MANUAL IN

Spider Bushing Bolts mm ft. lbs. Nm

item number 01.02.01.07 Dia 36 torque 1,024 1,389

Spider Shield Nuts mm ft. lbs. Nm

item number 01.02.02.15 Dia 48 torque 2,464 3,341

Spider Super Nut Bolts mm ft. lbs. Nm (Only applicable to super nut type Spider Nuts)
item number 01.02.03.01 Dia 24 torque 295 400

Spider Hydraulic Nuts lbs kN (Only applicable to hydraulic type Spider Nuts)
item number N/A pre load N/A N/A

Top Shell Wearing Plate Nuts mm ft. lbs. Nm

item number 01.03.02.01 Dia 24 torque 295 400

Shell Bolt Nuts mm ft. lbs. Nm

item number 01.03.02.05 Dia 100 torque 24,373 33,050
item number 01.04.01.09

Bottom & Middle Shell Liner Nuts mm ft. lbs. Nm

item number 01.04.01.19 Dia 24 torque 295 400
item number 01.06.03.07

Dust Bonnet to Bottom Shell Bolts mm ft. lbs. Nm

item number 01.05.01.11 Dia 36 torque 1,024 1,389

Bottom Plate to Bottom Shell Nuts mm ft. lbs. Nm

item number 01.05.02.11 Dia 56 torque 8,715 11,817

Hydraulic Bottom to Bottom Shell Nuts mm ft. lbs. Nm

item number 01.05.02.11 Dia 56 torque 8,715 11,817

Gear to Eccentric Bolts mm ft. lbs. Nm

item number 01.08.02.01 Dia 30 torque 1,289 1,748

Inner Eccentric Bushing Bolts mm ft. lbs. Nm

item number 01.08.01.15 Dia 24 torque 295 400
item number 01.08.01.17

Bottom Cover to Hydraulic Bottom Nuts mm ft. lbs. Nm

item number 01.09.02.17 Dia 56 torque 8,715 11,817

Mainshaft Sleeve Bolts mm ft. lbs. Nm

item number 01.10.02.07 Dia 48 torque 5,420 7,350

Dust Seal Retainer Bolts mm ft. lbs. Nm

item number 01.10.02.15 Dia 30 torque 586 795

Counter Shaft Housing Bolts mm ft. lbs. Nm

item number 01.12.01.19 Dia 48 torque 2,464 3,341

ISSUE DATE 27 Sep 12

PAGE 1 of 3
MADE FROM MASTER Master V11.0

FL SMIDTH DOCUMENT NO. 70020685 VER. 1

Print Date 9/27/2012 page 1 of 3

 7.2 CRUSHER ERECTION AND MAINTENANCE DATA - FLSMIDTH
Contract number 08-20366-910
Project Name XTRATA - Los Bombas

WEAR REPLACEMENT CRITERIA

Crushing Surfaces
Replace the crushing surfaces when the product size can not be maintained, or when the usual capacity can not
be maintained, or when there is a pronounced and consistant increase in the crusher operating horsepower, or when there is
a pronounced concave area worn into the lower row of concaves, or when there is a pronounced concave area worn into the
lower mantle, or when there are cracked or split parts.

Protective Surfaces
Replace the spider arm shields, spider cap, top shell wearing plates, bottom shell outer wall liners, bottom shell rib and counter shaft
housing shields and liners when these components are about to wear through, or when there are cracked or split parts.

Spider Bushing 01.02.01.05

inches mm
Replace the spider bushing when a feeler gauge greater than 0.107 2.71 can be inserted between the
main shaft (or main shaft sleeve) and the spider bushing at the bottom of the spider bushing

Inner Eccentric Bushing 01.08.01.09 inches mm

Replace the inner eccentric bushing when the inside diameter of the inner eccentric bushing is greater than 42.252 1073.21

Outer Eccentric Bushing 01.05.01.05 inches mm

Replace the outer eccentric bushing when the inside diameter of the outer eccentric bushing is greater than 54.324 1379.83

Eccentric Wearing Ring 01.07.01.05 inches mm

Replace the eccentric wearing ring when the thickness of the eccentric wearing ring is less than 1.938 49.23

Main Shaft Wearing Ring 01.10.02.21 inches mm

Replace the main shaft wearing ring when the thickness of the main shaft wearing ring when measured at the center is less than 3.331 84.61

Center Wearing Ring 01.09.03.09 inches mm

Replace the center wearing ring when the thickness of the center wearing ring when measured at the center is less than 2.649 67.28

Bottom Piston Wearing Ring 01.09.03.07 inches mm

Replace the bottom piston wearing ring when the thickness of the bottom piston wearing ring is less than 2.453 62.31

Upper and Lower Piston Bushings 01.09.01.15 & 17 inches mm

Replace the upper and lower piston bushings when the inside diameter of the upper and/or lower piston bushings are greater than 38.020 965.70

Dust Seal Ring 1.10.02.11 inches mm

Replace the dust seal ring when the inside diameter of the dust seal is greater than 56.545 1436.25
or the thickness of the dust seal ring is less than 2.326 59.08

Dust Seal Ring Lower (Nylon) N/A

Replace dust seal ring when less than 0.5mm clearance exists between bolt head and dust seal ring lower surface

Dust Seal Packing N/A

Replace dust seal packing if continuous contact around dust seal bonnet does not exist

Dust Seal Bonnet 01.05.01.07 inches mm

Replace the dust seal bonnet when the inside diameter of the dust seal bonnet is greater than 54.054 1372.97
or the outside diameter of the dust seal bonnett is less than 56.444 1433.67

Main Shaft Contact Seal 01.10.03.09 inches mm

Replace the main shaft contact seal when the outside diameter of the main shaft contact seal is less than 53.946 1370.23

Main Shaft Sleeve (or Spider Journal) 01.10.03.05

Replace the main shaft sleeve or repair the main shaft spider journal area when inches mm
the outside diameter of the main shaft sleeve or spider journal area is less than 30.899 784.83

Main Shaft Inner Eccentric Bushing Journal 01.10.01.03

Repair the main shaft inner eccentric bushing journal area when the inches mm
diameter of the main shaft inner eccentric bushing journal area is less than 41.748 1060.40

Eccentric 01.08.01.03 inches mm

Replace the eccentric when the outer diameter of the eccentric is less than 53.676 1363.37
or when the outside diameter of the eccentric is oval to an amount greater than 0.071 1.81
as determined by measuring diameter of the eccentric at two places 90 degrees from each other and subtracting the smallest
measurement from the largest measurement

ISSUE DATE 27 Sep 12

PAGE 2 of 3
MADE FROM MASTER Master V11.0

FL SMIDTH DOCUMENT NO. 70020685 VER. 1

Print Date 9/27/2012 page 2 of 3

 7.2 CRUSHER ERECTION AND MAINTENANCE DATA - FLSMIDTH
Contract number 08-20366-910
Project Name XTRATA - Los Bombas

GEAR SET BACKLASH

inches mm
minimum maximum minimum maximum
Required "transverse" Backlash @ heal of tooth face 0.091 0.102 2.30 2.59
inches mm
Pinion Pitch radius @ heal of tooth face 10.782 273.85 (measure "transvere" backlash at this radius)

a) Using Gaskets
Change of "transverse" Backlash per gasket inches mm
.031" [0.787mm] gasket at Counter Shaft 0.005 0.13 (with 15% compression allowance of gasket material)
.062" [1.574mm] gasket at Counter Shaft 0.010 0.26 (with 15% compression allowance of gasket material)

.031" [0.787mm] gasket at Bottom Plate 0.021 0.53 (with 15% compression allowance of gasket material)
.062" [1.574mm] gasket at Bottom Plate 0.042 1.06 (with 15% compression allowance of gasket material)

b) Rotating Countershaft Housing

Rotation Direction Countershaft Rotation Change in "Transverse" Backlash

Degrees inches mm

-10 0.081 2.06

-------------------------->

-9 0.073 1.86
Anti-Clockwise Rotation

-8 0.065 1.65
-7 0.057 1.45
-6 0.049 1.24
-5 0.041 1.03
-4 0.033 0.83
-3 0.024 0.62
-2 0.016 0.41
-1 0.008 0.21
Housing Arrow Vertical 0 0.000 0.00
<-------------------------
Clockwise Rotation

1 -0.008 -0.21
2 -0.016 -0.41
3 -0.024 -0.62
4 -0.033 -0.83
5 -0.041 -1.03
6 -0.049 -1.24
7 -0.057 -1.45
8 -0.065 -1.65
9 -0.073 -1.86
10 -0.081 -2.06

ISSUE DATE 27 Sep 12

PAGE 3 of 3
MADE FROM MASTER Master V11.0

FL SMIDTH DOCUMENT NO. 70020685 VER. 1

Print Date 9/27/2012 page 3 of 3