FFE MINERALS USA INC.

GYRATORY CRUSHER
OPERATION AND MAINTENANCE TRAINING
 Ordering Parts
Parts lists and lists of recommended spare parts
are provided. In ordering parts from the factory,
be certain to specify the following on all orders
and related correspondence:
• Quantity
• Description
• Part Number
• Serial Number of Crusher
Important Contact Information
• Phone Number (610) 264-6900
• Fax Number (610) 264-6311
Component Names
1. Spider Cap
2. Spider Assembly
3. Top Shell Assembly
4. Middle Shell Assembly
5. Bottom Shell Assembly
6. Bottom Shell Liner and Shield
Assembly
7. Bottom Plate Assembly
8. Eccentric Assembly
9. Hydraulic Cylinder Assembly
10. Main Shaft Assembly
11. Concave Assembly
12. Counter Shaft Assembly
 Component Names
Spider Cap

2 3
1

1. Spider Cap – Dome Type

2. Spider Cap – Rock Box Type A
3. Spider Cap – Rock Box Type B
Component Names
Spider Assembly
1. Spider
2. Spider Shield
3. Taper Head Bolt Assembly
4. Spider Bushing Lubrication
Hose Assembly
5. Spider Bolt
6. Spider Bushing
7. Spider Seal
8. Epoxy Backing
Component Names
Spider Assembly
1. Spider Bolt
2. Washer
3. Spider Bolt Nut
4. Hex Head Cap
Screw
5. Lock Nut
A. Standard Nut
B. Tension Nut
 Component Names
Top Shell and Middle Shell (if applicable)

1. Top Shell
2. Epoxy Backing
3. Shell Bolt
Assembly
4. Top Shell Wearing
Plates
5. Top Shell Wearing
Plate Bolts
Component Names
Middle Shell
1. Middle Shell
2. Concave Support Ring
3. Shell Bolt Assembly
 Component Names
Bottom Shell Assembly

1 1. Bottom Shell
1
1 2. Outer Eccentric Bushing
1
3. Dust Seal Bonnet
4. Dust Seal Air Supply Line
5. Lubrication Oil Supply Line
1
 Component Names
Bottom Liner and Shield Assembly

1. Bottom Shell Rib Shields

2. Bottom Shell Rib Side Liners
3. Bottom Shell Gear Case Shields
4. Bottom Shell Hub Liners
 Component Names
Bottom Liner and Shield Assembly

1. Liner Mounting Disc Assembly

2. Bottom Shell Outer Wall Liner
3. Bottom Shell
Component Names
Main Shaft Assembly
1. Main Shaft
2. Dust Seal Ring
3. Dust Seal Retainer
4. Epoxy Backing
5. Eye Bolt
6. Main Shaft Sleeve
7. Head Nut
8. Filler Ring
9. Upper Mantle
10. Lower Mantle
11. Core
12. Split Ring Contact Oil Seal
13. Shaft Wearing Ring
Component Names
Eccentric Assembly

1. Eccentric
2. Inner Eccentric Bushing
3. Splash Plate
4. Bevel Gear
5. Key
Component Names
Bottom Plate Assembly

1. Bottom Plate
2. Eccentric Wearing
Ring
Component Names
Hydraulic Cylinder Assembly
1. Bottom Hydraulic Cylinder
2. Upper Piston Bushing
3. Lower Piston Bushing
4. Bottom Cover
5. Piston
6. Bottom Shield
7. Center Wearing Ring
8. Bottom Piston Wearing
Ring
9. Crane Homogenous
Rubber Wiper Ring
10. Crane Ever Seal Packing
Component Names
Counter Shaft Assembly
1. Shaft
2. Key
3. Shaft Bearings
4. Shaft Bearing RTD’s
5. Shaft Housing
6. Shaft Nut
7. Bushing
8. Seal Retainer Plate
9. Outer Seal Retainer
Plate
10. Oil Seal
11. Bevel Pinion
 Component Names
Counter Shaft Assembly

1. Countershaft Extension
2. Crusher Coupling
3. Countershaft Extension Coupling
SCHEDULED MAINTENANCE
• Do not over tighten the tension bolts.
A torque wrench must be used.
• Spider nuts are a main item!
SCHEDULED MAINTENANCE
OIL
• Keep record of oil temperature in and
out of the crusher.
• Inspect contents of screen in reservoir.
• The maximum allowable return oil
temperature is 140F (60C).
• Check filter condition (differential
pressure).
SCHEDULED MAINTENANCE
MAIN SHAFT
• Check main shaft rotation.
• Check counter shaft movement.
• Check spider movement.
SCHEDULED MAINTENANCE
OTHER ITEMS
• Check sounds. (unusual, hollow,
metallic, gear or coupling noise)
• Check hydraulic system.
• Check dust seal blower filter.
DISASSEMBLY SEQUENCE
SPIDER REMOVAL
• Spider Cap
• Lubrication Line
• Arm Shields
• Spider Bolts
• Jack Spider loose
Component Names
Spider Assembly
1. Spider
2. Spider Shield
3. Taper Head Bolt Assembly
4. Spider Bushing Lubrication
Hose Assembly
5. Spider Bolt
6. Spider Bushing
7. Spider Seal
8. Epoxy Backing
DISASSEMBLY SEQUENCE
MAIN SHAFT REMOVAL
• Lift shaft out with crane – making sure
that shaft is lifted out vertically.
Component Names
Main Shaft Assembly
1. Main Shaft
2. Dust Seal Ring
3. Dust Seal Retainer
4. Epoxy Backing
5. Eye Bolt
6. Main Shaft Sleeve
7. Head Nut
8. Filter Ring
9. Upper Mantle
10. Lower Mantle
11. Core
12. Split Ring Contact Oil Seal
13. Shaft Wearing Ring
DISASSEMBLY SEQUENCE
COUNTER SHAFT REMOVAL
• Remove guard assembly.
• Remove counter shaft extension.
• Remove mounting bolts.
• Used jacking screw to push assembly
out.
• Lift assembly clear.
DISASSEMBLY SEQUENCE
HYDRAULIC ASSEMBLY REMOVAL
• Lower main shaft to bottom.
• Remove protection around pipes and hoses.
• Remove hydraulic, lube oil return and lube line.
• Remove mantle position indicator.
• Support weight of assembly with cart.
• Remove fasteners.
• Lower assembly.
DISASSEMBLY SEQUENCE
ECCENTRIC ASSEMBLY REMOVAL
• Keep assembly level.
• Watch for cable hanging up on liners.
 INSPECTION OF BUSHINGS
NOTE: For accurate determination of wear of bushing,
FFE Minerals should be contacted for designed clearances
within your crusher.
“Rule of Thumb” Clearance Guidelines
• Spider Bushing - Shaft journal diameter in inches
multiplied by .001”.
• Inner Eccentric Bushing - Main shaft journal in inches
multiplied by .004”.
• Piston Bushings - Piston diameter in inches multiplied
by .0005”.
 WHEN IS A BUSHING WORN OUT?
Spider Bushing
Maximum Tolerance: Initial clearance plus 100%
Inspection for Wear:
• Remove spider gear seal.
• Remove spider cap.
• Jack main shaft to one side from top of main shaft.
• Measure clearance between bushing and main shaft
at bottom of bushing – NOT THE TOP!
Inspection for Damage such as:
• Abrasion
• Cracks
• Burned
 WHEN IS A BUSHING WORN OUT?
Inner Eccentric Bushing
Inspection for Wear:
• Measure clearance for wear.

Inspection for Damage such as:

• Burned
• Cracking
• Broken
 WHEN IS A BUSHING WORN OUT?
Outer Eccentric Bushing
Inspection for Wear:
• Measure bushing inside diameter for wear.
• Wear can be determined by feeler gauge or dial
indicator.
Inspection for Damage such as:
• Burned
• Cracking
• Broken
 LUBRICATION FLOW
THROUGH THE CRUSHER
• From sump tank via pump
• Through a filter
• Through a cooler (not in all cases)
• To the flow meters at each enter point
 COUNTER SHAFT ASSEMBLY

• Oil for the counter shaft bearings enters above the

assembly.
• Usually approximately 5 gallons per minute.
Component Names
Counter Shaft Assembly
 OUTER ECCENTRIC BUSHING

• Oil usually fed at the rear of the crusher.

• Lubricates the outer eccentric bushing.
• After, the bushing oil then lubricates the pinion
and eccentric gears.
Outer Eccentric Bushing
 CRUSHER BOTTOM

• Enters Crusher Bottom

• Lubricates wearing rings
• Lubricates inner eccentric bushing
• Lubricates pinion and eccentric gears
Component Names
 HYDRAULIC SYSTEM

• Tank
• Pump
• Filter
• Control Valves
• Accumulator
• Vickers Valve
• Steel Braided Hose
• Air in System
Assembling Crusher
 Outer Eccentric Bushing
Insert Outer
Eccentric Bushing
Install Eccentric
Hydraulic Assembly
Main Shaft Assembly
Check Gear Back Lash
• Connect all lubrication lines
• Install protection
• Install Mantle Position Indicator
• Bleed air from hydraulic system.
Concaves
 Mantel Liners

• Gap between Upper and Lower Liners

• Difference between Zinc and Epoxy
Backing
• Tightening of nut
• Pins are welded to nut
 A number of upgrades maybe available
for your crusher.
Contact FFE Minerals for further information.
Telephone (610) 264-6900
Fax (610) 264-6311