Mixcraft 1.00.11 serial key or number
Mixcraft 1.00.11 serial key or number
Chancador flsmidth
MAINTENANCE MANUAL
For
1525 mm x 2870 mm (60” X 113”)
Traylor® Type “NT”
Gyratory Crusher
Eccentric Maintenance Cart
Confidential and Proprietary
Property of FLSmidth
For Confidential Use Only
Not for Circulation, Distribution or
Reproduction
Without Prior Permission in Writing
Copyright 2011
All Rights Reserved.
Installation, Operation, and
Maintenance Manual
For
Bechtel/Xstrata Copper
Las Bambas
Apurimac Region, Peru
Purchase Order No.: 25635-220-POA-MFMS-00002
FLSmidth Order No.: 08-20366-720
Doc. No. 59001675
Installation, Operation, and Maintenance Manual
59001675
Revision and Distribution Record Sheet
Revision and Distribution Record Sheet
1,525-mm x 2,870-mm (60” x 113”) Crusher
Eccentric Maintenance Cart
Customer: Bechtel/Xstrata Copper
FLSM Contract No: 08-20366-720
Main Parts List No: 50049723
Manual Remarks Rev. By Transmittal
Volume No. Date
All Electronic Copy– Certified 1 MT 07 Jun 13
Distribution: Hard Copy Electronic
Customer 1
Customer Date:
Approval:
Refer to Appendix 8—Revision Detail, for details of the re-
visions listed on this page.
The information transmitted by this document is the proprietary and confidential property of FLSmidth iv
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
Caution
Caution: Read This Manual Carefully
This manual covers various procedures, recommendations and other matters concerning the
erection, operation, maintenance and repair of the Traylor® Type “NT” Gyratory Crusher. It is
not intended and, therefore, should not be understood to address all situations that may occur
during the erection, operation, maintenance and/or repair of the equipment. Note as well that
certain of the information in this manual may become outdated over time or may become un-
clear or appear inapplicable in whole or in part because of changes to the equipment by the
owner or others, its state of repair, the characteristics of the feed, site conditions, and/or oth-
er variables over which FLSmidth has no control. If a situation arises that is not addressed in
this manual or if any part of this manual has become outdated, is unclear, or appears inappli-
cable, and installation, operation, or maintenance personnel are uncertain how to proceed,
contact FLSmidth without delay for advice before proceeding with the affected work. FLSmidth
accepts no liability for any loss, damage or injury that may result from proceeding in such sit-
uations without FLSmidth’s prior notice and advice.
This equipment must be operated and maintained only by trained operators and maintenance
personnel who have been thoroughly trained and/or schooled with respect to applicable
OSHA/MSHA regulations, generally accepted industrial safety practices and, safety procedures
stated in this manual. In addition, appropriate lock out/tag out procedures and a plant-specific
safety plan must be followed in addition to procedures stated in this manual.
FLSMIDTH, ITS AGENTS, REPRESENTATIVES AND EMPLOYEES ARE NEITHER RESPONSIBLE
NOR LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEM-
PLARY, PUNITIVE, OR OTHER DAMAGES ARISING OUT OF OR RELATING IN ANY WAY TO THIS
MANUAL AND/OR CONTENT OR TRANSLATION OR INFORMATION CONTAINED WITHIN THE
MANUAL.
All contents within this manual, including, but not limited to text, logos and images are the
property of FLSmidth. No portion of the materials on these pages may be reprinted or repub-
lished in any form without the express written permission of FLSmidth.
BY USING THIS MANUAL YOU AGREE THAT YOU HAVE READ, UNDERSTAND AND
AGREE TO THE TERMS OF USE.
Reference may be made in this manual to international or
national standards, guides or other references. It is the
responsibility of the reader to obtain copies of and read all
such standards, guides and references in context with this
manual.
The information transmitted by this document is the proprietary and confidential property of FLSmidth v
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
No Warranty
No Warranty
This manual is not part of the contract under which the equipment was sold, nor is it a sepa-
rate contract for the supply of goods or services. Refer to the contract documents under which
the equipment was sold for information on any warranties that FLSmidth may have given and
for all other rights, duties and obligations that the parties may have regarding the equipment.
Nothing in this manual states or otherwise provides any warranties (express or implied) con-
cerning the equipment. So there is no misunderstanding, FLSMIDTH DISCLAIMS ALL EXPRESS
WARRANTIES AND ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IM-
PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE.
The information transmitted by this document is the proprietary and confidential property of FLSmidth vi
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
Forward
Foreword
In keeping with the FLSmidth commitment to provide the latest technology and improvements
in its products, FLSmidth is also committed to providing the highest level of service and help-
ing you solve your process problems.
Accordingly, if FLSmidth can help in the operation of your flotation equipment, feel free to con-
tact us at (801) 871-7000 or fax (801) 871-7001. Also, if you have any suggestions or com-
ments that will help us serve you better, please forward them to us.
To ensure you receive the full benefits of proper installation, maintenance and operation of the
Dorr-Oliver flotation machines, we ask you to thoroughly read and familiarize yourself with the
instructions in this manual. Refer to the Table of Contents at the front of the manual.
The equipment, including the accessory equipment furnished but not built by FLSmidth, must
be stored, installed, operated, and maintained according to the manufacturer's instructions to
ensure warranty coverage.
The instructions in this manual are based on information available at the time of issue of this
manual. The right is reserved to make subsequent changes to the instructions without obliga-
tion to replace existing copies.
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 property
of FLSmidth and are confidential and may not be made public or copied.
FLSmidth will not furnish editable electronic copies of any data and/or drawings at any time.
FLSmidth accepts no liability whatsoever for unauthorized changes and/or alterations to the
data provided.
English is the governing language. When manuals are provided in both English and any lan-
guage other than English, THE NON-ENGLISH TRANSLATION IS PROVIDED ONLY AS A CON-
VENIENCE. FLSmidth shall not be liable for damages caused by errors in translation. The Eng-
lish translation will govern in case of minor discrepancies. In the event of major discrepancies,
notify your FLSmidth representative immediately. Refer to the contact list in this manual for
applicable addresses and telephone numbers.
The information transmitted by this document is the proprietary and confidential property of FLSmidth vii
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
TABLE OF CONTENTS
TABLE OF CONTENTS
1 General information ...................................................................................... 1.1
Definitions and abbreviations ............................................................................. 1.1
Legend ........................................................................................................... 1.1
2 Introduction.................................................................................................. 2.1
3 Equipment Description .................................................................................. 3.1
4 Hazards and Safety Considerations ............................................................... 4.1
Personal Protective Equipment ........................................................................... 4.1
Special tools for safe working environment .......................................................... 4.1
Site specific Hazards ......................................................................................... 4.1
5 Receipt and Storage Instructions .................................................................. 5.1
6 Installation ................................................................................................... 6.1
Advance Planning and Preparation ...................................................................... 6.1
Installation Sequence ....................................................................................... 6.3
7 Commissioning .............................................................................................. 7.1
Hydraulic System ............................................................................................. 7.1
Hydraulic Power Unit ...................................................................................... 7.1
Purge air from Cylinders. ................................................................................ 7.1
Extend the cylinders (Raise the Lift Table) ......................................................... 7.2
Retract the cylinders (Lower the Lift Table) ....................................................... 7.2
Hydraulic system Pressure relief Setpoints ........................................................ 7.3
Electrical System Inspection and Tests ................................................................ 7.5
General Tests................................................................................................ 7.5
Functional & Interlock Test of Equipment (Ensures Logic) .................................... 7.5
Performance Tests ............................................................................................ 7.6
Drawbridge................................................................................................... 7.6
Brake Mechanisms ......................................................................................... 7.6
Runway Tests ............................................................................................... 7.6
Lift Table Test ............................................................................................... 7.7
8 Operation ...................................................................................................... 8.1
Secure the work area ........................................................................................ 8.1
Prepare and Inspect Cart. .................................................................................. 8.1
Move cart into service position ........................................................................... 8.2
Preparing the crusher for disassembly ................................................................. 8.2
Raise the lift table up to Hydraulic cylinder........................................................... 8.3
Lower the Lift table with Hydraulic cylinder assembly ............................................ 8.3
Move cart into storage position........................................................................... 8.4
The information transmitted by this document is the proprietary and confidential property of FLSmidth viii
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
TABLE OF CONTENTS
Remove Hydraulic cylinder assembly. .................................................................. 8.5
Move cart back into service position .................................................................... 8.6
Raise the lift table up to Bottom Plate ................................................................. 8.6
Lower the Lift table with Bottom plate and Eccentric assemblies. ............................. 8.6
Move cart into storage position........................................................................... 8.6
Remove Bottom plate and Eccentric assemblies .................................................... 8.7
Shutdown and Store cart ................................................................................... 8.7
Crusher re-assembly......................................................................................... 8.7
Emergency lowering of lift table ......................................................................... 8.7
9 Maintenance ................................................................................................. 9.1
Hydraulic system ............................................................................................. 9.1
Fixed table and cylinders ................................................................................... 9.1
Trolleys .......................................................................................................... 9.1
Drawbridge ..................................................................................................... 9.1
General Inspection ........................................................................................... 9.1
Run systems.................................................................................................... 9.1
10 TROUBLE SHOOTING ................................................................................. 10.1
List of appendices
Appendix 1 - Runway Beam Installation & Alignment Tolerances
Appendix 2 - Structural (Inch) Fastener Tightening
Appendix 3 - Metric Fastener Tightening
Appendix 4 - Test Weights, Gauging Templates & Clearance
Appendix 5 - Hydraulic No Load Test
Appendix 6 - Hydraulic 50% Load Test
Appendix 7 - Hydraulic 100% Load Test
Appendix 8 – Revision Detail
Appendix 9 – Lubrication Schedule
Appendix 10 – Parts List
Appendix 11 - Drawings
The information transmitted by this document is the proprietary and confidential property of FLSmidth ix
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
1 General information 70011021
NOTE !
The present instruction manual is concerned with the situations which, ac-
cording to the experience of FLSmidth, are the most likely to occur. An ex-
haustive enumeration of all conceivable situations, which may occur during
manufacture, installation, operation and maintenance of the equipment,
cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not
foreseen in the instruction manual, and which the operator is/or feels un-
able to handle, it is recommended that FLSmidth is contacted without undue
delay for advice on appropriate action.
1 General information
Definitions and abbreviations
Authorized An authorized person is a skilled person,
person who is qualified and who by the responsible
manager is entrusted with certain tasks.
Skilled person A person, who after an education as a
craftsman, is capable of doing skilled work.
SDS Safety Data Sheet (In US known as MSDS)
MSDS Material safety data sheet
N/A Not applicable.
OM Operation and maintenance.
Legend
Mandatory!
This symbol appears in the instruction manual to indicate dan-
gers which, in case of non-observance, may cause fatal or seri-
ous injuries!
Attention!
This sign is shown in the instruction manual where specific atten-
tion and caution is needed to avoid damage to or destruction of
the equipment and/or parts of the installation.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 2.1
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
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2 Introduction 70011021
2 Introduction
This manual is intended to define the specific standards, technical specifications and
procedures that must be applied for the safe and trouble free Installation, Commis-
sioning, Operation and Maintenance of an FLS gyratory crusher eccentric maintenance
cart.
This is achieved through:
• Detailed Product description
• Hazard Identification and Safety considerations
• Step by Step erection, commissioning and operation procedures.
• Maintenance procedures
This manual is to be used in conjunction with the Gyratory crusher IOM manual and
all relevant safety and work procedures contained within this document must also be
read and followed.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 2.1
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
3 Equipment Description 70011021
3 Equipment Description
This Eccentric Maintenance Cart is a tool specifically designed to facilitate the servic-
ing of an FLS Traylor gyratory crusher in a more convenient and safe manner.
The cart structure is suspended on motorized, wheeled trolleys that run on 2 over-
head runway beams that allow movement into and out of the crusher discharge
chamber.
The structure includes service platforms which allow workers and their tools to gain
safe access to the underside region of the crusher for maintenance or inspection pur-
poses and is designed to transport the hydraulic cylinder and eccentric assemblies out
of the crusher to an external access area.
In order to raise and lower the above mentioned assemblies into and out of the
crusher, some carts are fitted with hydraulic lifting equipment, whereas some use the
overhead crusher service crane.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 3.1
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
3 Equipment Description 70011021
The information transmitted by this document is the proprietary and confidential property of FLSmidth 3.2
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
4 Hazards and Safety Considerations 70011021
4 Hazards and Safety Considerations
Note: This section is to be used to supplement all existing site safety procedures and
regulations. These existing site procedures and regulations must be adhered to at all
times.
Before undertaking any work on or using the eccentric cart in any way, it is essential
that all workers are fully aware of all potential hazards that are present so that all
necessary precautions, safety procedures and personal protective equipment can be
taken and used so as to ensure a safe and accident free working environment.
Before commencing any work, notify Control room and Site management so as to ob-
tain all required permissions and permits.
Personal Protective Equipment
It is recommended that all personnel working on the maintenance cart (in addition
to any other PPE required by the site) wear as a minimum:
• Head Protection
• Eye Protection
• Protective footwear
• Hearing protection
• Respirator (Dust protection)
• Harness with double lanyards
• Stout Gloves
Special tools for safe working environment
Although the cart bottom platform is provided with overhead lights, additional
Portable lights (by others) will be required on the top platform and maybe else-
where in the crusher discharge pocket.
All power tools and cords used must be fit for service and protected by GFCI's
(Ground Fault Circuit Interrupters).
Site specific Hazards
Every site has its own set of specific hazards; however some possible hazards spe-
cifically associated with the eccentric maintenance cart are listed below:
Crusher and Auxiliary equipment motors must be locked out.
Before commencing work, all persons on the cart must
have their personal locks on crusher main drive and
discharge chamber apron feeder motor starters thereby
preventing accidental start up.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 4.1
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
4 Hazards and Safety Considerations 70011021
Falling Rocks & dirt from overhead crusher dump pocket.
The dump pocket must be thoroughly cleaned out to
eliminate the risk of rock accidentally falling down
through the crusher. The crusher rim must be swept
clear of all dirt. Additionally any build of material inside
the crusher (e.g. spider cap, spider arm shields, dust
bonnet or bottom shell arm liners) must be removed.
Ideally a protective shield will be installed around the
rim of the crusher, or completely over the crusher
opening. Protective headgear & eyeglasses must be
worn at all times.
Haul Trucks accidental discharge into the dump pocket.
Physically block off truck access to the truck dump area
and cordon off with tape / flags. Notify Control room so
that they can:
• Stop all truck haulage
• Ensure that truck dump permission light is
locked to "Red"
Opening Discharge chamber Bulk Head Doors. Before opening
the doors, verify that the discharge chamber has been
adequately emptied and that there is no large pile of
material leaning against the doors that could cause
burst through, rapidly engulfing anyone in the vicinity.
Confined Space. If the chamber is classified as a confined space
by plant and local regulations, all necessary precautions
must be taken.
Nuclear Level instruments. Before entering the chamber, verify
that there are no nuclear level instrument hazards pre-
sent.
Dust Clouds inside chamber. It is likely that there will be high
levels of dust inside the discharge pocket. Respirators
must be worn at all times inside dusty environments.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 4.2
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
4 Hazards and Safety Considerations 70011021
Reduced Visibility inside chamber. The lack of light combined
with possible dust clouds will result in reduced visibility
and so portable lighting systems must be employed.
Such lighting systems can cause shadows and blind
spots. Care must be taken at all times in such an envi-
ronment to avoid tripping or stumbling on uneven sur-
faces or cords. This is especially acute on the top plat-
form, where a combination of low headroom, presence
of cords for portable lighting and workers' tools in a
confined area combine to create high risks for tripping
or stumbling.
Fall hazard inside Discharge chamber. If the chamber has
been emptied, there could be a large drop just inside
the access door. It is recommended that all workers
who enter the doors without using the eccentric cart
drawbridge walkway (for example to clean the material
way from the door area before cart is moved in) is tied
off.
Collapse of material inside chamber. Be sure to make sure
that there are no unstable piles of material in chamber
that may collapse, causing engulfment. Do not walk on
material stockpile in the chamber as it possible that due
to bridged material condition, a rat hole could open up
causing engulfment. Instead the eccentric cart draw-
bridge must be used at all times, which will connect the
cart with the access door, thereby avoiding this risk.
Moving Cart Hazards. The moving cart could potentially crush or
pinch someone, so to warn other personnel in the area,
a flashing beacon and siren will automatically operate
before the cart moves. However the operator must also
continually check that no other workers or any obstruc-
tions are in its intended path. Care must be taken
when the cart enters the discharge pocket that the
doors are opened up adequately and that material level
is low enough to offer sufficient clearance. Additionally
while the cart is moving, the operator must continually
check that the festoons are operating correctly and do
not become snagged.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 4.3
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
4 Hazards and Safety Considerations 70011021
Hazard from falling objects from upper levels. As soon
as one enters the discharge chamber, there is a risk of falling
objects from upper levels including loose deposits from the
crusher or dump hopper, or from people working overhead
and so protective head gear must be worn at all times. Try to
minimize working time in high risk areas.
Fall hazard into discharge chamber. The Top and Bottom plat-
forms are provided with handrails, however it is rec-
ommended that when climbing up access ladder and
whilst on the Top Platform, workers must be "tied off"
at all times.
Pinch / Crush hazard under lift table. As lift table is lowered
down, all operators must vacate the cart structure so as
to avoid crush / pinch hazard. Additionally a lift table
guard is provided to prevent workers from standing di-
rectly underneath when the lift table is raised, in case
of sudden failure of lift mechanism. All guard doors
should be kept locked closed at all times until they need
to be opened to access the payload.
High pressure Hydraulic oil leaks. If the cart is supplied with a
hydraulic power pack, there is potential for a high pres-
sure oil leak. Eye protection must be worn at all times.
Low Head clearance above Top Platform. When working on
Top platform, there may be a reduced head clearance
on the underside of the overhead foundation. Head
protection must be worn at all times.
Burning / Hot work. When performing hot work of any sort, ex-
treme caution must be taken to protect the cart and
avoid damage to its electrical or hydraulic systems due
to scorching, burning or starting a fire. Additionally
when on lower platform, always be mindful of overhead
hot work been carried out.
Electrocution hazards from welding or accidental wiring
damage. Ensure cart and runway beams are ade-
quately grounded at all times. Additionally all electrical
equipment and tools should be protected by GFCI's
(Ground Fault Circuit Interrupters). Be careful when
laying out electrical leads that they do pass through wet
areas or are likely to be damaged in any way by move-
ment of the cart or other activities such as burning or
welding.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 4.4
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
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4 Hazards and Safety Considerations 70011021
Cart Operation Hazards. Whenever cart is moved on the over-
head runway or whenever the lift table is raised or low-
ered, all personnel must vacate the cart. Operation of
the cart, using the remote hand pendant, must be un-
dertaken with operator off the cart and standing on the
foundation.
Oil Hazards. When the assemblies are removed from the crusher,
personnel will be exposed to the crusher lubrication and
hydraulic oils and any additives that they may contain.
Refer to the oil MSDS sheets for any hazards specific to
the oil and precautions that need to be taken.
Additionally used crusher oil will include particles of metals including Lead, Tin,
Zinc, Iron and Copper, so precautions must be taken to prevent oil ingestion or
absorption by personnel through the use of suitable personal protective equip-
ment and the implementation of appropriate handling, storage and disposal
procedures.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 4.5
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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5 Receipt and Storage Instructions 70011021
5 Receipt and Storage Instructions
Check and verify that all parts and pieces listed on the Cart Parts List have been re-
ceived. For this purpose refer to both the Packing List and Parts list.
All Components must be visually checked for possible damages occurred during the
transportation or improper handling. Any damage must be reported to FLS for dispo-
sition before erection commences.
Until the cart is erected, the cart components MUST be stored in a dry environment
until they are needed. At this time all protective materials such as waterproof paper,
wood, and rust preventive coatings must be inspected and repaired or replaced if the-
se items have been damaged.
It is essential that all electrical components be stored indoors in a temperature not
less than 40°F (5°C). This includes:-
• Electric Winch
• Hydraulic Power Unit and Reservoir
• Motorised Trolleys
• Electrical Panels & Junction Boxes
• Instruments, lights and receptacles
• Festoon cables
• Any items with pre-wired conduit / cabling
The information transmitted by this document is the proprietary and confidential property of FLSmidth 5.1
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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6 Installation 70011021
6 Installation
Advance Planning and Preparation
Before assembling the equipment, following aspects should be considered:
Prior to erecting the cart, the installation contractor is required to
determine the location of assembly. This is critical be-
cause the fully assembled cart or its sub assemblies
may not fit through all openings into its service area.
It is recommended that the cart is assembled in its intended stor-
age location, under the runway beams and directly be-
low the Crusher Service Crane floor access openings.
The assembly area floor should be clean and flat.
Check that all the parts and pieces are in the area that was select-
ed to assemble the equipment. Pieces that will need
lowering into the structure, such as hydraulic unit, fixed
table, lift table and guides, it is suggested are stored in
overhead levels, so that they can be dropped into posi-
tion later using the overhead crane and floor access
openings.
Verify that all necessary drawings and technical specifications that
describe the assembly process included in the manual
are available.
Confirm that all foundation structures, beams and profiles are in
accordance with the assembly drawing requirements
and offer sufficient clearances. Verify that the door
opening into the crusher discharge pocket offers suffi-
cient clearances to allow the cart to pass through.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.1
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
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6 Installation 70011021
Verify the Runway beams are made from the correct structural
steel section and are set at the correct gauge specified
by the Cart Foundation drawing and that the beams' are
level, straight and parallel to within the tolerances spec-
ified in Appendix 1.
Verify by plumbing that the Runway beams are centered below the
overhead crusher bottom shell hub bore ±3mm (1/8").
This is Critical to the successful operation of the cart.
Cart assembly will require both welding and bolt assembly.
For all Structural (English) bolts refer to Appendix 2 for bolt tight-
ening instructions.
For all Metric bolts, refer to Appendix 3 for bolt tightening torques.
Refer to sub assembly drawings for site welding details.
The Maintenance cart will be shipped in several pre-assembled
pieces. Sequence of assembly is important and should
be planned in advance so that all necessary tools and
resources are available.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.2
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
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6 Installation 70011021
Installation Sequence
FLS recommends the following order of assembly. This sequence
assumes that the cart is to be assembled in its storage
area under the runway beams and directly under the
overhead access opening, so that the service crane can
be used for lifting.
When assembling components, look for shop match marks that
may indicate correct item locations and orientations.
As the Cart is erected, it should be continually verified that as new
parts are added, that they are centered below the over-
head crusher bottom shell hub bore so that by the time
the lift table is added, its support rings are centered
within ±3mm (1/8"). Critical items to be verified cen-
tral include Runway Beams, Guides & Lift table Rings. It
is recommended that a custom fixture with a plumb bob
or laser be installed on the crusher hub bore to ensure
that the cart centrality can be easily and repeatedly
checked.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.3
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.4
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
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6 Installation 70011021
A. Fit Trolleys to overhead runway beams
A1. Refer to Runway assembly drawing, parts list and Trolley Vendor In-
struction manual.
A2. Fit the (2) travel limit switches to the trolley frame sides.
A3. Fit the (4) trolleys to overhead runway. Ensure trolleys are oriented so
that their Drive Motors are inside the runway beams and pointing in-
wards to one another.
A4. Adjust Kingpin spacers to correctly position trolley wheel on runway
flange per vendor instructions.
A5. In order to allow the trolleys to temporarily run on the runway without
power during erection, it is suggested that the motor, gearbox & pinion
assembly are temporarily pulled off the trolley side plate so as to allow
them to be disconnected from trolley wheels. This would be achieved by
unbolting the (4) gearbox to side plate mounting screws. The assembly
could be :
• Pulled back 35mm via the use of temporary, longer 4 mounting
screws (note Inch UNC ).
• Pulled back 35mm, remove bolts and securely tie up to the side
plate with wire or other means.
• Removed completely and store until they are ready to be wired
up the power panel.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.5
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.6
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
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6 Installation 70011021
B. Assemble top platform structure
This will typically be shipped in two halves, with 2 additional transverse mem-
bers and will eventually require welding after being bolted together with rest of
the framework. See Top Platform Assembly drawing for weld details.
B1. Refer to Top Platform Assembly drawing and parts list.
B2. It is suggested that this item is assembled under the runway beams
and crane access opening, to aid subsequent lifting and assembly.
B3. On a level flat surface, loosely bolt together the 2 halves using the
supplied connection plates, 2 transverse cross members and hardware.
B4. Verify squareness and flatness of assembly and Torque.
Attention! Do not Weld halves together until the upper platform has been as-
sembled with the Bottom platform, columns and diagonals and squared up.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.7
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
C. Assemble top platform grating
The Grating is supplied as pre-cut loose pieces.
C1. Refer to Grating assembly drawing and parts list.
C2. Fit grating to Top Platform structure.
C3. Once grating is fitted, do NOT yet tack weld down to structure until
Later (after the 2 structure halves are welded together later on).
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.8
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
D. Assemble top platform to overhead trolleys
D1. Position the 4 trolleys in the approximate overhead locations.
D2. Using the overhead service crane, lift the top platform up to the trolleys
and loosely bolt them together.
Attention! Hand tighten only! Do not Torque bolts until the upper
platform has been assembled with the bottom platform, columns and
diagonals later.
D3. Before proceeding with Bottom platform assembly, roll top platform as-
sembly away from the assembly area.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.9
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
E. Assemble bottom platform
This will typically arrive in two pieces and will eventually require welding after be-
ing bolted together with rest of the basic framework. See Lower Platform Assembly
drawing for weld details.
E1. Refer to Bottom Platform Assembly drawing and parts list.
E2. On a level flat surface under the runway beams and crane access open-
ing, loosely bolt together the 2 halves using the supplied connection
plates and hardware.
E3. Verify squareness and flatness of assembly and torque bolts.
Attention! Do not weld halves together until the lower platform has been as-
sembled with the Top platform, columns and diagonals.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.10
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
F. Assemble bottom platform grating
Grating is supplied as pre-cut loose pieces.
F1. Refer to Grating assembly drawing and parts list.
F2. Assemble grating to Bottom Platform prior to installing support columns
because grating will be difficult to maneuver if it is done afterwards.
F3. Once grating is fitted, do NOT yet tack weld down to structure until
Later (after the 2 structure halves are welded together).
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.11
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
G. Assemble Vertical Support Columns and Cross Bracing To
Bottom Frame.
G1. Refer to Support Column assembly drawing and parts list.
G2. Loosely bolt down the columns. Note each column is different, so verify
columns are in correct positions.
G3. Assemble cross bracing and hand tighten all hardware. Attention! Do
not torque until later.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.12
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
H. Assemble Lower and Upper Platforms
H1. Position Top platform and Trolleys above the Bottom platform.
H2. Lift Bottom platform & support columns with overhead service crane.
H3. Loosely bolt together the tops of the columns to the upper platform us-
ing the supplied hardware.
H4. Once all connecting hardware is in position, hand tighten.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.13
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.14
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
I. Verify structure Squareness and Weld
I1. Check the 2 platforms are Level and the support columns are all verti-
cal.
I2. Verify Squareness of the complete cubic structure by taking:
• 2 diagonal corner measurements across each cube face
(6 positions typical)
• 2 diagonal corner measurements inside opposite corners
(2 positions typical)
I3. Verify that the overhead Crusher bottom shell Bore is centered above
the cart center ±2mm.
I4. Once structure is verified as square and centered, Torque all fasteners
and re-check steps I1 through I3.
I5. Re-inspect (4) trolleys and check:
• Level - That each trolley has each wheel sitting correctly on the
beam flange. If necessary shim trolleys to adjust wheel vertical
runway beam contact and adjust Kingpin spacers to move
wheels in and out to/from runway beam to ensure equal load
distribution between the (4) trolleys.
• Gauge - Matches the Runway Beam gauge
• Parallel - To the Runway beam
I6. Weld Top & Bottom platform halves together - See platform assembly
drawings for weld details.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.15
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.16
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
J. Install Fixed Table & Cylinder Assembly
J1. Refer to fixed table assembly drawing and parts list.
J2. Install Fixed table and bolt to Bottom platform. Verify table beam
flanges are level in both X and Z direction.
J3. Bolt pillowblocks down onto fixed table. Hand tighten hardware. Verify
with laser that bores of opposite pairs are installed concentric and all
(4) are parallel with one another. Shim if required.
J4. Match mark one pillowblock of each pair and temporarily remove to al-
low assembly of the (2) telescoping cylinders.
J5. Install cylinders with the hydraulic connections facing inwards to the
cart center and refit pillowblocks.
J6. Verify center to centre distance and heights of the (2) cylinder end
clevis holes.
J7. Torque all hardware.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.17
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.18
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
K. Install Hydraulic System
K1. Bolt a counterbalance valve to each hydraulic cylinder flanged inlet
connection.
K2. Lower in the (2) hydraulic skid halves and bolt down to the structure.
K3. Connect up the hoses per the hydraulic schematic to make the following
connections:
(1) Reservoir to pump inlet.
(1) Relief Valve to Reservoir
(2) Raise Line - Pump pressure supply to the Cylinder
(2) Lower Line - Pump pressure supply to the counterbalance valves pi-
lot
K4. Fill reservoir with Oil.
Attention! The hydraulic power pack should not be used to extend the
cylinders until the lift table and guides are installed!
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.19
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.20
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
L. Install guides and Lift Table
L1. Refer to the Lift table & Guide assembly drawing and parts list.
L2. Fit (4) middle guides to main structure. If match marked, install ac-
cordingly. Hand tighten only. Verify guides are vertical and parallel.
Check center to center position matches the lift table.
L3. Lower Lift table down from above onto the (4) outer guides. The Lift
table must be orientated correctly so that the (2) "IN" arrows painted
on the lift table legs point towards the Crusher. Verify its rings are
centered below the overhead bottom shell Hub bore ±2mm.
L4. Add shims as necessary to adjust guides.
L5. Drop in from above, the (4) inner guides.
L6. Using the overhead crane, verify that the lift table raises up and down
smoothly.
L7. Torque all hardware and connect the (2) Cylinder plungers to the corre-
sponding lift table clevis connection points with a clevis pin and retain-
ing ring at each.
L8. If possible, run pump and bleed air out of cylinders per cylinder IOM in-
structions. Check lift table rises and lowers smoothly, with both cylin-
ders extending at the same rate, and with the lift table remaining hori-
zontal at all times.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.21
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
L9. Fit "Table Down" limit switch to middle guide base and adjust so that
the lift table, as it is lowered, has its striker plate fully activate the
switch about 10mm above the lift table fully "DOWN" position.
L10. Fit "Table 75% Up" limit switch to top platform and adjust so that the
lift table, as it is raised, has its striker plate fully activate the switch
about 50mm prior to the commencement of the final 4th cylinder stage.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 6.22
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Installation, Operation, and Maintenance Manual
59001675
6 Installation 70011021
M. Assemble Walkway Draw Bridge
It should be noted that the drawbridge link mechanism will interfere with the
floor when drawbridge is lowered and so the links should be installed last with
the drawbridge raised.
M1. Refer to the walkway assembly drawing and parts list.
M2. Fit Inner Walkway to Main Structure.
M3. Fit Winch to underside of top platform, add cable and connect to the in-
ner walkway thimble shaft by looping the cable around the thimble and
Steam *32 process appears in task manager, not really running steam.
hey there,
for a good while now i've been occasionally seeing a spike in my CPU usage, when i opened the performance monitor, it showed that "Xboxstat" is the process that's causes the extra load, after googling, it's a legit process but it's only used to run the Xbox controller for windows and should not under any circumstances hog 25% of my cpu load! (i have i5 3570k quad core process Running @4.4 GHz!)
lately this spike started happening again, but this time the process shows up as "Steam" in the performance monitor, and sure, i do have it installed, but it's not running at the time, and i didn't even set it to run when windows start!
the problem now is p[retty much identical to this thread:
"http://www.bleepingcomputer.com/forums/t/562628/steam-32-process-appears-in-task-manager/"
a while back now, my PC was infected with a VBS script that turns every thing into shortcuts on any removable driver, the original script was on my C partition and it was not detected by any antivirus at all! i had to track it down and remove it manually, but i found a program called USBfix that's supposed to remove this particular script,
http://www.en.usbfix.net/
well, it worked, i guess..but i have already removed the original script manually like i said, and this program looks a bit dodgy too, so i thought i would state this as past history of infection, maybe it's related..
went ahead and did a FRST scan, i killed the process manually now, if you want a scan while it's still running i can always reboot and do a new scan when it shows up, let me know what you guys think..
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