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INSTALLATION, OPERATION, AND 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 Volume All

Remarks Electronic Copy– Certified

Distribution:

Rev. No.

By

Transmittal Date

1

MT

07 Jun 13

Hard Copy

Electronic

Customer Customer Approval:

1 Date:

Refer to Appendix 8—Revision Detail, for details of the revisions listed on this page.

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.

iv

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 Note as well that certain of the information in this manual may become outdated over time or may become unclear or appear inapplicable in whole or in part because of changes to the equipment by the owner or others, its state of repair, the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 other 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 If a situation arises that is not addressed in this manual or if any part of this manual has become outdated, is unclear, or appears inapplicable, and installation, operation, or maintenance personnel are uncertain how to proceed, contact FLSmidth without delay for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 situations 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, EXEMPLARY, 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 republished 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

v

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 separate 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) concerning the equipment. So there is no misunderstanding, FLSMIDTH DISCLAIMS ALL EXPRESS WARRANTIES AND ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE.

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.

vi

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 helping you solve your process problems. Accordingly, if FLSmidth can help in the operation of your flotation equipment, feel free to contact us at (801) 871-7000 or fax (801) 871-7001. Also, if you have any suggestions or comments 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 obligation 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 language other than English, THE NON-ENGLISH TRANSLATION IS PROVIDED ONLY AS A CONVENIENCE. FLSmidth shall not be liable for damages caused by errors in translation. The English 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

vii

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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

ix

Installation, Operation, and Maintenance Manual 59001675 1 General information 70011021

NOTE ! The present instruction manual is concerned with the situations which, according to the experience of FLSmidth, are the most likely to occur. An exhaustive 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 unable to handle, it is recommended that FLSmidth is contacted without undue delay for advice on appropriate action.

1 General information Definitions and abbreviations Authorized person

An authorized person is a skilled 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 dangers which, in case of non-observance, may cause fatal or serious injuries!

Attention! This sign is shown in the instruction manual where specific attention 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

2.1

Installation, Operation, and Maintenance Manual 59001675 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, Commissioning, 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

2.1

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 servicing 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 overhead 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 purposes 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

3.1

Installation, Operation, and Maintenance Manual 59001675 3 Equipment Description 70011021

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.

3.2

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 obtain 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 elsewhere 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 specifically 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

4.1

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 present. 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

4.2

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 environment to avoid tripping or stumbling on uneven surfaces or cords. This is especially acute on the top platform, 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 drawbridge 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 obstructions 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

4.3

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 platforms are provided with handrails, however it is recommended 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 directly 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 pressure 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, extreme 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 adequately 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 movement 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

4.4

Installation, Operation, and Maintenance Manual 59001675 4 Hazards and Safety Considerations 70011021

Cart Operation Hazards. Whenever cart is moved on the overhead runway or whenever the lift table is raised or lowered, all personnel must vacate the cart. Operation of the cart, using the remote hand pendant, must be undertaken 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 equipment and the implementation of appropriate handling, storage and disposal procedures.

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.

4.5

Installation, Operation, and Maintenance Manual 59001675 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 received. 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 disposition 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 these 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

5.1

Installation, Operation, and Maintenance Manual 59001675 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 because 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 storage location, under the runway beams and directly below 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 selected 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 position 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 sufficient clearances to allow the cart to pass through.

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.

6.1

Installation, Operation, and Maintenance Manual 59001675 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 specified 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 tightening 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

6.2

Installation, Operation, and Maintenance Manual 59001675 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 overhead 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 central 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

6.3

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

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.

6.4

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

A. Fit Trolleys to overhead runway beams A1.

Refer to Runway assembly drawing, parts list and Trolley Vendor Instruction 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 inwards 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

6.5

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

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.

6.6

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

B. Assemble top platform structure This will typically be shipped in two halves, with 2 additional transverse members 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 assembled with the Bottom platform, columns and diagonals and squared up.

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.

6.7

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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

6.8

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 assembly away from the assembly area.

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.

6.9

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 being 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 opening, 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 assembled with the Top platform, columns and diagonals.

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.

6.10

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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

6.11

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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

6.12

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 using 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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

6.13

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

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6.14

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 vertical.

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.

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6.15

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

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.

6.16

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 allow 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.

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6.17

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

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.

6.18

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 pilot

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!

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6.19

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

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.

6.20

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 accordingly. 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 corresponding lift table clevis connection points with a clevis pin and retaining ring at each.

L8.

If possible, run pump and bleed air out of cylinders per cylinder IOM instructions. Check lift table rises and lowers smoothly, with both cylinders extending at the same rate, and with the lift table remaining horizontal at all times.

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.

6.21

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 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

6.22

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 inner walkway thimble shaft by looping the cable around the thimble and securing with (2) wire rope clips as shown below.

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6.23

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021 M4.

Raise drawbridge up with inner walkway vertical (@90°) and weld on the stop to hinge fixed plate, so as to prevent it from being pulled into the cart structure and to allow it to always be lowered by gravity.

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6.24

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021 M5.

Fit "Raised" limit switch and adjust so it is activated by the striker just prior to the drawbridge hitting the stop @89° approximately. This will allow drawbridge can be lowered by gravity when winch unwinds.

M6.

Fit storage chain, so that the drawbridge is secured up, when it is in vertical storage position.

M7.

Fit Outer Walkway to the Inner Walkway and link mechanism

When cart is able to be moved into the discharge pocket: M8.

Raise and lower drawbridge with winch to verify unfolding mechanism works correctly and for the full drawbridge stroke. Verify cable does not interfere with structure and its fleet angle is per vendors IOM requirements.

M9.

If a (2) piece style walkway is provided, ensure that when drawbridge is fully lowered, and the (2) walkways are parallel, that the adjustable feet on the outer walkway are sitting equally on the foundation (adjust as necessary). Also check that the inner and outer walkways mating end faces lock up against one another, thereby preventing the draw bridge from lowering further and folding in on itself. This may require shims to be added.

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6.25

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

N. Assemble Brake Assemblies N1. Refer to the Brake assembly drawing and parts list. N2.

Assemble both Right and Left end assemblies.

N3.

The brake should both be adjusted so that the vertical stroke of the brake pins are sufficient to: • When raised, engage with the mating bushings (that are welded to the underside of the runway beam) by at least 25mm depth. • When lowered, disengage and clear the bushing undersides by at least 15mm. The brake pin stroke adjustment can be made by loosening the Hinge arm set screws and rotating them about the connecting rod.

N4.

Adjust limit switches so that they are activated, when the pin is raised up into the bushing in the "locked" position.

N5.

Final adjustments will be required when the brakes are commissioned. See next section

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6.26

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

O. Assemble Electrical Panels & Loose Components O1. Before commencing, refer to the Parts List and : • General electrical assembly drawing. • Electrical panel layout drawing. • Festoon Assembly drawing. O2.

Assemble the power panel, relay panel, circuit breaker, transformer, horn and light, and hand pendant per the General electrical assembly drawing.

O3.

If the cart was not supplied with factory pre-wired interconnecting wiring, then some components such as beacon/horn, receptacles and lighting hardware will be designed and supplied by the installer.

O4.

The main electrical panels are mounted off (3) bolt-on horizontal members, and the transformer is mounted off the corner column as shown below.

O5.

Assemble Festoon per the festoon assembly drawing. The Festoon track must be mounted to the foundation level to the Runway beam flange.

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.

6.27

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021 O6.

O7.

The festoons are connected to the cart upper deck by a telescopic Tow arm and Clevis assembly. The Tow arm can be adjusted in length depending on the height of the Festoon tracks. The tow arm is connected to the leading Tow trolley of both Festoons via a horizontal threaded rod / clevis arrangement.

Once the festoons are connected to the Tow arm assembly, move cart forwards and back to verify that the cart motion will smoothly pull open and push back the Festoon trolleys along the track.

P. Install Interconnecting Electrical Wiring P1.

Refer to the Electrical System Interconnection Diagrams provided in the IOM manual.

P2.

If the interconnecting wiring was factory installed, then it will need to be connected per the shop match marking & labels and the Electrical System Interconnection Diagrams provided later in the IOM manual. Below are the instructions for reconnecting the shop wiring :1. Each panel box has mounting brackets welded to the structural beams. 2. The panel boxes are different sizes and will only fit in one location. 3. There are short conduit runs between the panels for interconnections. 4. Each conduit is marked with a label at the ends describing the purpose or location

5. 6. 7. 8. 9.

Note: labels were masked over before final paint and may need masking removed Unions are used where needed to allow for shipping in sections. Unistrut is welded to the structure to support conduits All wiring is labelled at each end and terminate at corresponding terminals Extra Unistrut clips and seal tight connectors were included in the shipment Wiring for each conduit is bundled together in the panel or with the trolleys

P3.

If the interconnecting wiring was not factory installed, then the erector will be required to design, supply and install all interconnecting wiring between all electrical components located on the eccentric cart including but not limited to: • Wiring, Conduit, Boxes & Fittings. • Hardware & brackets necessary to mount all components.

P4.

Positions of electrical components are as shown in the General Electrical Assembly.

P5.

All required connections are shown in the Electrical System Interconnection Diagrams.

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6.28

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021 P6.

As a minimum requirement, all electrical wiring and systems shall built in accordance with the National Electric Code (NFPA 70). Additional local specifications & codes, shall also be adhered to.

P7.

All Wiring, Conduit, Fittings, Junction boxes & Panels must be built to NEMA 4 / IP65.

P8.

All Conductors shall be enclosed in RMC, IMC or LFMC conduits. Individual runs of LFMC shall not exceed six feet in length.

P9.

Electrical Line Routing is to be designed by the installer. All conduit and cable is to be retained inside the cart structure external envelope for protection.

P10.

All Circuits and controls and interlocks must be fully tested during the Eccentric cart commissioning test (See later)

P11.

During assembly testing, Cart Structure must be adequately grounded.

Q. Assemble Lift Table Guard Q1. Refer to Lift table guard assembly drawing and parts list. Q2.

Assemble the (4) vertical columns between the Top and Bottom decks, do not torque bolts.

Q3.

Mount the (4) guard side panels to the vertical columns.

Q4.

Fit the (8) access doors to the guard sides. Verify doors open and close correctly.

Q5.

Each pair of Doors should be padlocked closed to prevent unauthorized access into this hazardous area. Padlocks are to be supplied by others.

Q6.

Torque all bolts.

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6.29

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

R. Assemble Hand Rail Assembly R1.

Refer to Hand Rail General assembly drawing and parts list.

R2.

Fit access ladder to Top Platform.

R3.

Assemble Top Platform handrails. Each post is telescopic thereby allowing the hand rails to be lowered prior to the cart been moved avoiding potential interferences the foundation. Fit lower support posts to upper deck. Drop in handrails over the support posts. Raise up into extended position and secure each post with the bolts provided (2 per post). Fit Corner pieces and bolt to the main panels to form a continuous handrail on both the outer and inner sides of the walkway. Verify Raised and Lowered handrail height matches General Assembly drawing.

R4.

Assemble Bottom Platform handrails.

R5.

Fit Side access gate and latch. While latch is in the closed position, verify that the gate remains closed when a force of 90 kg (200 lbf) is applied to it from either direction.

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.

6.30

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

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.

6.31

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

S. Loose Runway Components S1. Refer to the runway components assembly drawing and parts list.

S2.

Weld Stopper Bushings to underside of runway beam.

The cart brake pins engage with the bushing, thereby mechanically locking the cart on the runway when the cart is in either the storage or service position. Additionally when in the service position and when the pin is engaged with the bushing, the cart is dead centered under the crusher. 2 pairs of bushings are provided and are to be welded to the underside of the runway beam flanges to align with the brake pin when the cart is in either:

S2.1

Storage position (outside crusher chamber under overhead floor access openings). Move cart to storage position. It is suggested that at this point the runway and foundation must allow 400mm additional cart movement away from crusher to allow for cart to coast down to rest. Weld (2) bushings to the underside of the Runway beam flange as described in S2.3.

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6.32

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

S3.

S2.2

Service position (centered under crusher). Move cart to service position so it is centered approximately under crusher. Slowly raise lift table up with crusher bottom plate on it until the bottom plate is within 100mm of the (3) crusher guide pins that project down from the bottom shell gear case flange. The bottom plate is drilled with (3) extra mating holes on the Bolt Circle that the guide pins will locate into. From the Top platform, look at the guide pin/hole alignment and move cart in or out accordingly till they align. Finish raising the bottom plate fully up to the bottom shell flange and verify it is aligned. Weld (2) bushings to the underside of the Runway beam flange as described in S2.3.

S2.3

Tack Weld Stopper Bushings to underside of runway beam above each brake pin. Before permanently welding, verify that: • Both brake pins are centered with bushing and when the pin is raised, are engaged by at least 25mm. Adjust brake stroke if necessary per section N2. • With the brake pin lowered, the trolley must pass over the bushing without interference.

Weld travel limit cam plates to runway beam.

S3.1

Verify that the (2) travel limit switches are installed on the (2) leading trolleys as described in A2

The purpose of these cam plates is to activate the travel limit switches and cut out the trolley motors causing the cart to stop moving. They must be welded to the runway beam webs so that: • They are at correct height on the web to strike and fully push back the limit switch arm. • They are at the correct travel position along the length of the beam as described below. • All limit switches MUST be located 400mm prior to the end of runway bumper stop location (see S4) and any possible foundation interference (to allow the moving cart to coast down to a stop).

S3.2

Outward Travel (To Service position under crusher)

The cart may be required to have the outward limit switch trip out the cart so that the lift table is centered exactly underneath the crusher CL so that no travel adjustments are subsequently required to align the cart under the crusher. In this case the outward cam plate must be positioned to activate the outward limit switch just prior to the cart becoming centered under the crusher so as to take into account the coasting distance while it coasts down to a stop. Is it recommended that this coasting distance is set for when the cart is travelling in a low

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6.33

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021 speed mode so as to improve likelihood that the cart stops correctly centered under crusher.

Alternatively for other service reasons, the cart may be required to travel beyond the crusher CL. This is classified as "overtravel" on the assembly drawing and is limited (by Festoon length Capacity) to the specific amount listed on the drawing and also the ability of the lowered drawbridge to reach the foundation. Therefore with the cart CL aligned with the crusher CL, the outward travel cam plate must be located beyond the outward travel limit switch arm by a distance equal to the desired "overtravel". In this case the cart will have to be manually centered under the crusher to allow the brake pins to be locked into the bushing.

S3.3

Return Travel (To Storage position)

The Return cam plate must be positioned to trip the return limit switch when the cart reaches its storage position. S4.

Weld travel stops to runway beam.

The travel stops physically limit the cart travel at the runway ends before it interferes with the foundation or other obstacles. At each travel extremity, weld (4) stops to the runway beam webs so that: • They are at correct height on the web to interfere with the trolley bumpers. • Each beam's web has stops on both sides. • The (4) stops interfere with the (4) trolley bumpers simultaneously. • MUST be located exactly 400mm after the travel limit switch has been activated. • MUST be located prior to the cart interfering with foundation or any obstruction.

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6.34

Installation, Operation, and Maintenance Manual 59001675 6 Installation 70011021

T. Fit warning signs T1.

Fit the (2) entrance warning signs adjacent to the (2) cart entrances. One is mounted on the column to the right of the drawbridge walkway opening. The other is mounted on the column to the left of the side door entrance.

T2.

Fit the (2) Lift Table Guard warning signs to the lift table guard, (1) each side, in between the (4) access doors.

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6.35

Installation, Operation, and Maintenance Manual 59001675 7 Commissioning 70011021

7 Commissioning Hydraulic System Assemble hydraulic system and connect up all hoses as previously described in section 1 "Installation".

Hydraulic Power Unit The power unit is factory pre-set and tested and only minor adjustments may be necessary. Follow the commissioning and adjustment procedures described in the HPU IOM manual. Before start up, prepare power unit per the instructions in the HPU IOM manual. This includes: • Filling and Checking oil level. • Turning on Heaters. • Verifying valves are in correct position. Start the hydraulic pump motor as described in "Operation" section 0. • Verify motor is rotating Anti-clockwise. • While running in standby mode, verify pressure developed is as indicated in HPU IOM manual.

Purge air from Cylinders. Refer to cylinder instructions in the separate vendor IOM. Raise the Lift table up 25mm (1") (as described in section 1 "Operation") so as to start filling the hoses and cylinders with oil. Turn hydraulic pump off. Most of the air in the system should be trapped inside the small cylinder plungers and should be bled out on both cylinders. Lower the cylinders and repeat until no more air can be bled out.

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7.1

Installation, Operation, and Maintenance Manual 59001675 7 Commissioning 70011021

Extend the cylinders (Raise the Lift Table) Restart the Hydraulic pump and continue to extend the cylinders Verify that the cylinders extend upwards at the same rate and that the lift table rises smoothly. Check for leaks in lines & fittings If the lift table "judders" upwards, then there are several possibilities: • There may be air remaining in the system ( lower table and repeat step 0) • Guides may not be squared correctly (take measurements & adjust their alignment accordingly) • Guides may need to be "run" in to remove rust and scale deposits (Cycle cylinders & lift table) • High Friction between guides (Lubricate the guides with a small amount of Light oil.) If lift table ascent is smooth, continue until the cylinders are fully extended. Using a tape measure, verify that the total vertical stroke equals the cylinder drawing rated stroke. Check that just prior to the end of the third stage, that the lift table striker plate activates the 75% raised limit switch.

Retract the cylinders (Lower the Lift Table) The cylinders are single acting and rely on the weight of the lift table and payload to squeeze the oil out of them allowing them to retract.

Restart the Hydraulic pump and Lower the Lift table (as described in section 1 "Operation") so that oil is drained back to tank and the cylinders retract.

Verify that the cylinders retract at the same rate and that the lift table lowers smoothly. Note the rate of descent will reduce as each cylinder stage closes, due to the area of the piston getting larger. The rate of descent will be very slow when there is no payload and may take several minutes.

Warning! The rate of descent can be adjusted via the Down flow control valve, however it must only be adjusted when the cart is loaded (see load performance test later), so as to avoid the payload from coming down too quickly causing the lift table to impact the lower deck.

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7.2

Installation, Operation, and Maintenance Manual 59001675 7 Commissioning 70011021

Hydraulic system Pressure relief Setpoints The Low and High pressure Modes limit the amount of pressure supplied to the cylinders and therefore the resulting loads induced on the cart.

Therefore before any load tests are undertaken, it is extremely important that all the pressure relief set points are verified to avoid overloading the hydraulic system or the cart & runway structures. System Safety Relief Valve Verify the max hydraulic system pressure setting is 13,800Kpa (2,000 psi). This is the system relief valve set point and can be determined by reading pump discharge pressure when: • Running the pump in "standby" mode (without raise or lower solenoid energized) • The Lift Table 75% Up Limit switch is activated (either manually or by elevating lift table) • Turn safety relief valve CW all the way in. • Temporarily set the pump pressure compensator CW to 2,000 psi by reading the pump pressure gauge. • Turn safety relief valve CCW slowly, while watching the pressure gauge. Stop turning the screw as soon as gauge starts to drop below 2,000 psi. • The safety relief valve is now set at approximately 2,000 psi. Tighten the locknut on the valve’s adjustment screw. • Reset pump pressure compensator back to previous set point as described in 7.1.5.3. Low Pressure Mode (Cylinder stages 1,2,3) Verify the Low Pressure Set point. This is the low pressure relief valve set point and can be determined by reading pump discharge pressure when: • Running the pump in "standby" mode (without raise or lower solenoid energized) • With the cylinders fully retracted (lowered) Check it equals that specified in the HPU IOM manual and if necessary, adjust relief valve per IOM instructions.

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7.3

Installation, Operation, and Maintenance Manual 59001675 7 Commissioning 70011021 High Pressure Mode (Cylinder stage 4) Verify the High Pressure Set point. This is the pump pressure compensator set point and can be determined by reading pump discharge pressure when: • Running the pump in "standby" mode (without raise or lower solenoid energized) • The Lift Table 75% Up Limit switch is activated (either manually or by elevating lift table) Check it equals that specified in the HPU IOM manual and if necessary, adjust pump pressure compensator per IOM instructions.

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.

7.4

Installation, Operation, and Maintenance Manual 59001675 7 Commissioning 70011021

Electrical System Inspection and Tests WARNING!! Before cart system is energized, ensure cart structure is adequately grounded!!

General Tests • •

Verify Lighting Verify Outlets / Circuit Breakers / etc are functioning.

Functional & Interlock Test of Equipment (Ensures Logic) Beacon Light: • Key operated selector switch – Check Beacon comes on and stays on while in “On” position. Phase Reversal Relay:

Siren:

•

Ensure correct phase order to energize Phase Reversal Relay before continuing

• • •

Verify Siren sounds when trolley motors energized Verify Siren sounds when winch motor energized Verify Siren sounds when hydraulic pump energized (applicable to hydraulic units only ) Verify Siren sounds when hydraulic motion occurs (applicable to hydraulic units only )

•

Note that the Siren will not sound again until one minute passes without any commanded motion Trolleys: • • • • • • •

Verify Trolley direction / Wheel rotation for both “Out” / “In” Switch selection. Verify Trolley Speed for the “Slow” / ”Fast” Switch selection in both “Out” / “In” Directions. Verify “In” limit switch cuts out trolley motors energized in the “In” direction. Verify “Out” limit switch cuts out trolley motors energized in the “Out” direction. Verify that trolleys won’t run when lift table not fully lowered. Verify that trolleys won’t run when either brake pin is in the locked up position. Verify that trolleys won’t run when drawbridge is not fully up.

Drawbridge: • Verify that Winch operates correctly in for both “Up” and “Down” switch selection. • Verify that Drawbridge Up Limit Switch Cuts out the Winch “Up” Operation.

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7.5

Installation, Operation, and Maintenance Manual 59001675 7 Commissioning 70011021 Hydraulic Unit (applicable to hydraulic units only): • Verify the Raise Solenoid won’t energise if either brake pin is not in the locked “Up” position. • Verify that hydraulic movement switch “Raise” = Lift table rises • Verify that hydraulic movement switch “Off” = Lift table Held in last position. • Verify that hydraulic movement switch “Lower” = Lift table Drops • Verify that Cylinder 75% Extended limit switch closes the Low Pressure relief valve when “Raise” is energized.

Performance Tests Drawbridge • • • •

Verify self lowering action by gravity. While fully lowered, add 500 Kg Load midway along walkway span and verify deflection is less than 6mm (1/4"). Raise and Lower (6) times. Adjust limit switch to be activated to cut out winch just prior to drawbridge stop.

Brake Mechanisms Verify Mechanisms gives required Vertical Stroke of Brake Pin – adjust as necessary as per section N3

Runway Tests Unloaded Clearance & Gauging Check • With cart unloaded, run cart over full length of runway forwards and backwards. • Over the entire travel length (limit stop to limit stop) check that cart clears all adjacent equipment, foundations and openings by at least 150mm. • Check Trolley Wheel and runway beam flange overlap every 3 meters, by incremental cart movements. • Verify Festoon extends and retracts in a smooth fashion and cables do not snag. • At travel extremities verify travel limit switches trip out cart and that travel limit stops are placed 400mm beyond limit switches with no obstruction between them.

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7.6

Installation, Operation, and Maintenance Manual 59001675 7 Commissioning 70011021

50% Load Tests • Position ½ Test weight (Ref Appendix 4) on Lift table • Move cart along total runway length in increments so that at each point the cart (or trolleys) is midway along an unsupported length of runway beam (in between supports). At each point, record for each trolley: -Runway beam deflection* -Runway Beam Span (Ref Dim L Appendix 1)** -Verify all (4) trolleys are sharing load -Check Trolley Wheel and runway beam flange overlap 100% Load Tests • Position Test weight (Ref Appendix 4) on Lift table • Move cart along total runway length in increments so that at each point the cart (or trolleys) is midway along an unsupported length of runway beam (in between supports). At each point, record for each trolley: -Runway beam deflection* -Runway Beam Span (Ref Dim L Appendix 1)** -Verify all (4) trolleys are sharing load -Check Trolley Wheel and runway beam flange overlap

* Report to plant structural engineer for approval ** Check is within Appendix 1 Limits

Lift Table Test Non–Hydraulic Units • Undertake a “Dry Run” of unloaded Lift Table with Cardboard Template added (Ref Appendix 4) • Using an overhead crane lift the lift table up the cart rated vertical travel. Note do not go higher than rated travel as there are no stops and lift table will disengage guides. • Verify and record clearances between moving Lift table / Guides / Template & Fixed structure. • Check smoothness of guides in both Up and down direction. • Verify that lift table drops by gravity by slowly lowering crane cable. • Make adjustments / lubricate as necessary • Fully Raise and lower (6) times • Add Test Load Weight (Ref Appendix 4) with CG centrally offset by 75mm. • Fully Raise and Lower, always observing guides & structure for excessive deflections. • Repeat the run with the CG rotated in (4) locations (Every 90°). 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.

7.7

Installation, Operation, and Maintenance Manual 59001675 7 Commissioning 70011021 Hydraulically Operated Units

No Load Tests • • • • • • • • • • • • •

Undertake a “Dry Run” of unloaded Lift Table with Cardboard Template added (Ref Appendix 4) Energize pump and Raise Lift Table Verify and record clearances between moving Lift table / Guides / Template & Fixed structure Record Line pressure & time for each cylinder stage up and down (Ref Appendix 5) Verify that cylinders extend at same rate and smoothly Verify Final Lift Table height raised equals the full cylinder stroke Hold for 5 minutes Verify height unchanged (Up or Down) Lower Lift Table - Adjust flow control as necessary Repeat (5) times Check reservoir oil temperature after the (6) successive lifts - must remain below 70°C (158°F) Fully Raise up Lift Table (unloaded) and de-energize power panel. Connect up hand pump and manually lower the lift table. Record time taken. Inspect guides, lift table & cart structure before proceeding with Load testing.

50% Load Tests •

•

• • • • • •

With Cardboard Template Still fitted, ½ Test weight (Ref Appendix 4) shall be positioned with CG offset positioned in line with the (2) cylinders to give max unequal loading on cylinders. Lift table shall be supported by service crane during load tests, with the cable slack being retrieved as the lift table rises and paid out as the lift table drops. Energize pump and Raise Lift Table Verify and record clearances between moving Lift table / Guides / Template & Fixed structure Record Line pressure & time for each cylinder stage up and down (Ref Appendix 6) Verify that cylinders extend at same rate and smoothly Verify Final Lift Table height raised equals the full cylinder stroke Hold for 5 minutes. Verify height unchanged (Up or Down)

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.

7.8

Installation, Operation, and Maintenance Manual 59001675 7 Commissioning 70011021 • • • • •

Lower Lift Table - Adjust flow control as necessary if too rapid a descent * Repeat (5) more times Check reservoir oil temperature after the (6) successive lifts - must remain below 70°C (158°F) Observe structure for excessive deflections while under load. Inspect guides, lift table & cart structure before proceeding with 100% Load test.

100% Load Tests • • • • • •

Repeat section 0 but with 100% Test weight (Ref Appendix 4) Record Line pressure & time for each cylinder stage up and down (Ref Appendix 7) Relief valve may need to be adjusted during testing in order to lift the 100% test weight. Fully Raise up Lift Table (loaded) and de-energise power panel. Connect up hand pump and manually lower the lift table. Record time taken. Raise Lift Table, turn pump off, measure height and repeat after 1 hour to check for leakage. * If flow control adjusted during Load test, Unloaded Descent test to be repeated.

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.

7.9

Installation, Operation, and Maintenance Manual 59001675 8 Operation 70011021

8 Operation Secure the work area Prior to commencing work, the following steps must be taken to make the crusher discharge chamber safe: • •

•

• •

Notify Control room and Site management so as to obtain all required permissions and permits. 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 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. 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 and ensure that truck dump permission light is locked to "Red".

Prepare and Inspect Cart. For hydraulically operated models only: Check hydraulic oil reservoir oil level and turn on cart power with key operated switch on the hand pendant so that oil heater is turned on at least 2 hours before use. Carefully Open bulkhead doors and verify that path is clear of obstacles for the cart to travel to service position. This may require removal of piping, instruments, electrical lines, shielding of runway beams etc. Clean off any ore deposits on the beams to prevent trolleys from losing traction. Inspect condition of runway beam flanges inside crusher discharge chamber. Look for signs of erosion and verify that: •

Lower flange thickness is same as that outside the discharge pocket.

•

Lower flange width is same as that outside the discharge pocket.

Any reduction in beam flange thickness or width could mean that the structural integrity of the beams has been compromised. Report to FLS for disposition. 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.

8.1

Installation, Operation, and Maintenance Manual 59001675 8 Operation 70011021

Turn on cart power with key operated switch on the hand pendant. Unchain drawbridge so it can be lowered later and check it remains fully raised Move cart into service position No personnel should be on the cart while it is being moved.

Verify following interlocks are satisfied: • • •

Lift table is fully down Drawbridge is fully up Both Brakes pins are fully lowered

Turn on cart power with "Control Power" key operated switch on the hand pendant to mid-position. Move cart into crusher discharge chamber pocket via the hand pendant "Trolley move" switch in the "In" position until cart outward travel limit switch automatically stops the cart. The cart can be moved either "Fast" or "Slow" via the "trolley Speed" selector switch on the hand pendant. While cart is moving, constantly check that no personnel or obstructions are in the way and that the festoons cables are operating normally and don’t get snagged. The last few feet should be undertaken at "Slow" speed so as to allow cart and brake pins to be centered up. Once in service position under the crusher, and it has come to rest, lower the drawbridge down to access the cart by hand pendant "Bridge Winch" switch in the "Down" position. Lock the brake pins into the bushings, thereby locking and centering the cart in service position. Preparing the crusher for disassembly Refer to the crusher IOM manual instructions prior to starting work on crusher disassembly. Drain oil from lube and hydraulic systems and remove all connecting lines to the crusher hydraulic cylinder assembly. This should include: •

Inner eccentric lube oil connection hose

•

Hydraulic oil connection hose

•

Lube oil Drain connection hose

Disconnect and remove any level switches or transmitters from under the hydraulic cylinder.

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.

8.2

Installation, Operation, and Maintenance Manual 59001675 8 Operation 70011021

Disconnect the cable from MPI level transmitter. Remove the lock nuts and loosen the main nuts that secure the hydraulic cylinder to crusher. Raise the lift table up to Hydraulic cylinder. No personnel should be on the cart during lifting/lowering operations.

For Hydraulically operated models: •

Turn the hand pendant "Control Power" key switch fully over to start the pump.

•

Set the "Hydraulic move" button on the hand pendant to "Up" to elevate the lift table.

•

Carefully observe lift table as it rises and as soon as its inner ring reaches the hydraulic cylinder or is observed to stop moving, release the "Up" button to avoid overloading the structure.

For Non-Hydraulically operated models, the crusher service crane must be used: •

Position the crusher service crane centered exactly over the crusher. This is very important to avoid putting side loads on the guides and deflecting lift table out of position.

•

Lower (4) lifting cables down through the crushing chamber and connect (1) of them to each of the lift table corners. The use of a spreader beam may be required to equally distribute loading.

•

Slowly raise the lift table up until the lift table's inner ring is supporting the hydraulic cylinder.

Verify that the ring is correctly engaged with the hydraulic cylinder bottom cover. The ring should locate inside (3) lugs welded to the hydraulic cylinder bottom cover or inside the flange bolt circle. Note there should be a notch in the ring and a lug on the bottom cover that need to mate to ensure correct orientation. Remove the remaining nuts that secure the hydraulic cylinder assembly to the crusher. Lower the Lift table with Hydraulic cylinder assembly No personnel should be on the cart during lifting/lowering operations.

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.

8.3

Installation, Operation, and Maintenance Manual 59001675 8 Operation 70011021

For Hydraulically operated models: •

Turn the hand pendant "Control Power" key switch fully over to start the pump.

•

Set the "Hydraulic move" button on the hand pendant to "Down" to lower the lift table.

For Non-Hydraulically operated models (using the crusher service crane): •

Slowly lower the lift table up until the lift table is fully down on the bottom platform.

•

Be careful to avoid impacting it heavily as it comes to rest on the bottom platform.

Move cart into storage position. No personnel should be on the cart while it is being moved.

Unlock brake pins and raise the drawbridge via the hand pendant "Bridge Winch" switch in the "Up" position. Move cart out of crusher chamber via the hand pendant "Trolley move" switch in the "Out" position until cart Return travel limit switch automatically stops the cart. The cart can be moved either "Fast" or "Slow" via the "trolley Speed" selector switch on the hand pendant. While cart is moving, constantly check that no personnel or obstructions are in the way and that the festoons cables are operating normally and don’t get snagged. The last few feet should be undertaken at "Slow" speed so as to allow cart and brake pins to be centered up. Once in storage position and it has come to rest, access the cart via the side door. Lock the brake pins into the bushings, thereby locking and centering the cart in storage position.

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.

8.4

Installation, Operation, and Maintenance Manual 59001675 8 Operation 70011021

Remove Hydraulic cylinder assembly. The assemblies will be removed via the overhead service crane and openings in the upper floors. Center up the overhead service crane above the cart and lower the lifting cables. Open the lift table guard upper doors and connect the lifting cables to the hydraulic assembly upper flange. Lift assembly out and transfer to the storage/work area. The Hydraulic cylinder assembly should be stored on a steel ring similar to that on the lift table or on wooden cribbing so as to avoid damage to cover plate bolts or MPI Cap plate when set down.

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.

8.5

Installation, Operation, and Maintenance Manual 59001675 8 Operation 70011021

Move cart back into service position Repeat section 0

Raise the lift table up to Bottom Plate Raise up lift table as described in 0 and 0 until the lift table's outer ring is supporting the bottom plate. Verify that the lift table locating pins/lugs are correctly engaged with the bottom plate.

Remove the nuts that secure the bottom plate to the bottom shell and record how many bottom plate gaskets have been used to set mounting distance. Lower the Lift table with Bottom plate and Eccentric assemblies. Repeat section 0

Move cart into storage position. Repeat section 0

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.

8.6

Installation, Operation, and Maintenance Manual 59001675 8 Operation 70011021

Remove Bottom plate and Eccentric assemblies This should be undertaken in 2 steps with the eccentric assembly lifted separately to the bottom plate assembly. The assemblies will be removed via the overhead service crane and openings in the upper floors. Open the lift table guard upper doors and fit the FLS supplied Swivel hoist rings to the top of the eccentric as per the eccentric assembly drawing. Torque their bolts to the correct torque per the eccentric assembly drawing. Center up the overhead service crane above the cart and connect up the cables to hoist rings. Slowly lift assembly up and transfer to the storage/work area. The Eccentric assembly should be stored on wooden cribbing so as to avoid damage to its underside when set down. Remove Bottom plate and eccentric wear ring. These (2) items are loosely pinned together with dowels and so must remain upright at all times when undergoing lifting. Shutdown and Store cart Turn off cart power with "Control Power" key operated switch on the hand pendant turned to "Off" position. Check all lift table guards are closed and locked. Verify brake pin are in up "locked" position. Chain up Drawbridge. Crusher re-assembly Re-assembly of the crusher is the reverse sequence of events described previously 0 thru 0 with a few differences:

Verify the amount of gaskets on the bottom plate is equal to the amount originally on the bottom plate when removed. When lifting assemblies back up to the crusher, the flange of the hydraulic cylinder or bottom plate should be carefully observed to ensure that it is correctly aligned with the 3 guide rods sticking down from the crusher bottom shell. Emergency lowering of lift table In case of a pump or power failure, whilst the lift table is raised, this unit is equipped with a hand pump.

To use the hand pump, the isolation ball valve must be in the closed position. This will allow pressure to build in the

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.

8.7

Installation, Operation, and Maintenance Manual 59001675 8 Operation 70011021

pilot lines and pilot open the counterbalance valves and allow the cylinders to retract. The hand pump hoses will need to be connected to ports C15 (suction) and C16 (pilot pressure). This will allow the hand pump to draw oil from the tank and pressurize the pilot lines that go to the counterbalance valves. Once the pilot lines have been pressurized, the counterbalance valves will open and let the cylinders retract. To stop the cylinders at any time during their descent, open the hand pump unloading valve (part of the hand pump). This will relieve the pilot pressure to tank. To restart the lowering, close the hand pump unloading valve and use the hand pump to build up the pilot pressure again. Once the cylinders have fully retracted, be sure to open the hand pump isolation ball valve. This will allow the counterbalance valves to function normally once the problem is repaired or power is restored.

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.

8.8

Installation, Operation, and Maintenance Manual 59001675 9 Maintenance 70011021

9 Maintenance Hydraulic system •

The hydraulic oil should be sampled every 6 months to determine the quality of the oil. If any sample is found to have abnormal levels of contamination (dirt or water), the hydraulic oil should be replaced and the oil reservoir interior cleaned before new filtered oil is added.

•

The electric motor should be greased every 250 hours of operation.

•

The hydraulic oil filter should be replaced every 6 months and/or when major maintenance is preformed.

•

The reservoir breathers should be replaced every 6 months.

Fixed table and cylinders • •

Before use : Grease Fixed table pillow block nipples (4 locations). Before use : Grease cylinder plunger end clevis nipples (2 locations).

Trolleys • •

Before use: Grease Trolley hangar/kingpin nipples (4 locations). Refer to Trolley IOM for further maintenance requirements.

Drawbridge •

Before use: lubricate all links and hinges on folding mechanism.

General Inspection • • • •

Check all handrails are present and is in good condition. Check lift table guard is in position and is in good condition. Look at general structure condition, check for damage or rust. Check for loose bolts. Check that all lights are functioning.

Run systems Run all systems and devices every 6 months. This should include:

• • •

Run hydraulic pump and fully extend cylinders up and down 5 times. Move cart backwards and forwards 3 feet using motorised trolleys. Lower drawbridge as far down as possible.

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.

9.1

Installation, Operation, and Maintenance Manual 59001675 10 TROUBLE SHOOTING 70011021

10 TROUBLE SHOOTING 10.1

Trolleys won't move

*Check brake pins are fully released * Check drawbridge fully raised * Check lift table fully down

10.2

Trolleys turning, but cart stuck

* Check rail for dirt causing loss of traction * Check trolleys are all level and in contact with rail * Check rails are straight, parallel and gauge is correct

10.3

Drawbridge wont lower with winch on

* May need to be pulled off Top Dead center to start

10.4

Control Panel does not work

*Relays could be frozen if low ambient temperature

10.5

Pump won’t run

*Check oil temperature and level. * Check brake pins are fully up in locked position

10.6

Pump stops mid cycle

* Check oil level.

10.7

Pump runs, but cylinder 4th stage stuck

* Check Lift table 75% Up limit switch activated

10.8

Lift Table Rises in judders

* Guides not square and parallel. Check guide alignment * Air in system. Bleed out air. * Guides coated in rust or mill scale. Run in by cycling. * Friction high. Add small amount of light oil.

10.9

Lift table gets stuck coming down

* Need to open up descent control bleed valve.

10.10

Lift table won't stay up with payload

* check leakage from cylinder seals & counterbalance valve * Remove and clean counterbalance valves

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.

10.1

Installation, Operation, and Maintenance Manual 59001675 Appendix 1 70011021

Appendix 1 - Runway Beam Installation & Alignment Tolerances.

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.

Installation, Operation, and Maintenance Manual 59001675 Appendix 2 70011021

Appendix 2 - Structural (Inch) Fastener Tightening

All structural (Inch) fasteners are to be tightened using the 2 steps below to ensure that the bolts are adequately pre-tensioned. It is recommended that joints are not fully pre-tensioned until the complete cart structure has been assembled and checked for squareness. Step 1 - Snug tighten All bolt holes shall be aligned to permit insertion of the bolts without undue damage to the threads. Bolts shall be placed in the holes with washers positioned as called out in the erection drawings and nuts threaded on to complete the assembly. Compacting the joint to the Snug tight condition shall progress systematically from the most rigid part of the joint. The Snug tightened condition is the tightness attained with a few impacts of an impact wrench or the full effort of an iron worker using an ordinary hand wrench. More than 1 cycle through the bolt pattern may be required to achieve the snug tightened joint. Step 2 - Pre-tension Once all fasteners have been snug tightened, the nut or head rotation specified in below shall be applied to all fastener assemblies in the joint, progressing systematically from the most rigid part of the joint in a manner that will minimize relaxation of previously pretensioned bolts. The part not turned by the wrench shall be prevented from rotating during this operation.

Table A2. Nut Rotation from Snug Tight Condition for Turn-of-Nut Pre tensioning Bolt Lengthc

a,b

Disposition of outer faces of Bolted parts. Both faces normal to Bolt axis

One face normal to bolt axis, other sloped not more than 1:20d

Both faces sloped not more than 1:20d from normal to bolt axisd

Not more than 4db

1/3 turn

1/2 turn

2/3 turn

More than 4db, but not more than 8db

1/2 turn

2/3 turn

5/6 turn

More than 8db, but not more than 12db

2/3 turn

5/6 turn

1 turn

a

Nut rotation is relative to bolt regardless of the element ( nut or bolt) being turned. For required nut rotations of 1/2 turn or less, the tolerance is ±30 degrees; For required nut rotations of 2/3 turn and more, the tolerance is ±45°. b

Applicable only to joints with in which all material in the grip is steel.

c

When the bolt length exceeds 12db, the required nut rotation shall be determined by actual testing in a suitable tension calibrator that simulates the conditions of solidly fitting steel.

d

Beveled washer not used.

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.

Installation, Operation, and Maintenance Manual 59001675 Appendix 3 70011021

Appendix 3 - Metric Fastener Tightening

All metric fasteners are to be tightened using Torque wench.

All metric fasteners specified in the parts list or marked as grade 8.8 are to be torqued per column 1.

Al other metric fasteners are to be torqued per column 2.

Table A3. Metric Fastener Torque chart. Column 1.

Column 2.

Grade 8.8

General

M

Nm

Lbf - Ft

Nm

Lbf - Ft

5

7

9

2

3

6

12

16

4

5

8

29

39

9

12

10

58

79

19

26

12

102

138

33

45

16

253

343

86

117

20

509

690

160

217

24

879

1,192

270

366

30

1,748

2,370

540

732

36

3,056

4,144

950

1,288

42

4,894

6,636

1,500

2,034

48

7,350

9,967

2,300

3,119

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.

Installation, Operation, and Maintenance Manual 59001675 Appendix 4 70011021

Appendix 4 - Test Weights, Gauging Templates & Clearance

Table A4 - Test Weights, Gauging Templates & Clearance

Crusher Size

Mass Kg

1100x1750 NT / 1300x1750NT /

Gauging Template*

CG Offset mm

Outside Diameter

Inside Diameter

mm

mm

10,145

75mm

2,170

54x77 UD / 60x89 NT

15,600

75mm

2,411

60x113 NT/ 60x113 UD

22,900

75mm

2,700

/ 54x77 NT / 1600x2000 NT

Min Clearance recorded Between Gauging Template & Fixed Structure :

*Gauging Template to be made from Corrugated Cardboard and to be mounted concentrically over the lift table outer ring

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.

= Lift Table Outer Ring OD

Test Load

Installation, Operation, and Maintenance Manual 59001675 Appendix 5 70011021

Appendix 5 - Hydraulic No Load Test

Table A5 – Hydraulic No Load Test (With final flow control adjustments) Low Pressure Mode (Low Relief Valve setpoint): High Pressure Mode (Pump Pressure compensator setpoint): Cylinder

Cumulative

Pressure

Stage

Time

@Cylinder

@Pump

[Min-secs]

[psi]

[psi]

UP-STROKE

Down

0

1 2 3 4

DOWN-STROKE

Up Up

0

4 3 2 1 Down

Manual Lowering Time :

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.

Installation, Operation, and Maintenance Manual 59001675 Appendix 6 70011021

Appendix 6 - Hydraulic 50% Load Test

Table A6 - Hydraulic 50% Load Test (With final flow control adjustments) Test Load : Low Pressure Mode (Low Relief Valve setpoint): High Pressure Mode (Pump Pressure compensator setpoint): Cylinder

Cumulative

Pressure

Stage

Time

@Cylinder

@Pump

[Min-secs]

[psi]

[psi]

Down

0

DOWN-STROKE

UP-STROKE

1 2 3 4 Up Up

0

4 3 2 1 Down

Manual Lowering Time :

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.

Installation, Operation, and Maintenance Manual 59001675 Appendix 7 70011021

Appendix 7 - Hydraulic 100% Load Test

Table A7 - Hydraulic 100% Load Test (With final flow control adjustments) Test Load : Low Pressure Mode (Low Relief Valve setpoint): High Pressure Mode (Pump Pressure compensator setpoint): Cylinder

Cumulative

Pressure

Stage

Time

@Cylinder

@Pump

[Min-secs]

[psi]

[psi]

Down

0

DOWN-STROKE

UP-STROKE

1 2 3 4 Up Up

0

4 3 2 1 Down

Manual Lowering Time :

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.

Installation, Operation, and Maintenance Manual 59001675 Appendix 8

Appendix 8—Revision Detail Detailed Revision List Revision

Section

Document

Description

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.

Installation, Operation, and Maintenance Manual 59001675 Appendix 9

Appendix 9 – Lubrication Schedule

CUSTOMER: See Eccentric Cart Manual Cover Sheet

DATE: 01/16/2012

FLS CONTRACT NO: See Eccentric Cart Manual Cover Sheet EQUIP. NUMBER(S): See Manual

VENDOR: Varies DOCUMENT No.: 70018175 version 1

* ECCENTRIC MAINTENANCE CART * COMPONENT(S) NO. OF COMPONENTS

Eccentric Maintenance Cart HPU

Hydraulic Cylinders

Kingpin on Trolleys

Pillow Block on Cylinders

1

2

4

4

LUBRICANT

LUBRICANT #1

Hydraulic Oil

Lithium - Sodium Grease

LUBRICANT #2

N/A

Sodium Calcium Grease

LUBRICANT #3

N/A

N/A

ISO VG 46 Mineral Base, Anti Wear

NLGI #1

CUSTOMER PREFERENCE

N/A

N/A

INITIAL FILL QUANTITY *

416 Liters

As required

FREQUENCY

Check prior to use afer any period of storage

Grease prior to use after any period of storage

QUANTITY *

As needed to fill tank

Grease until grease is purged from the contact area.

FREQUENCY

Yearly or if tank becomes contaminated above allowable

N/A

QUANTITY *

Full Change (416 Liters)

N/A

832 Liters