Primary Gyratory Crusher Installation and Maintenance Manual
We provide a wide range of mills — including Raymond mill, trapezoidal mill, vertical mill, ultrafine mill, and ball mill, obtained ISO9001 international quality certification, EU CE certification, and Customs Union CU-TR certification. Suitable for processing minerals such as limestone, phosphate, quicklime, kaolin, talc, barite, bentonite, calcium carbonate, dolomite, coal, gypsum, clay, carbon black, slag, cement raw materials, cement clinker, and more.
The discharge range of these mills can be adjusted to meet specific processing needs, typically from 80-400 mesh, 600-3250 mesh, and can achieve the finest particle size of up to 6000 mesh(D50).
If you are looking for a reliable grinding solution to turn stone or minerals into fine powder, please feel free to contact our online customer service.
Introduction
Proper installation and diligent maintenance are the cornerstones of maximizing the operational lifespan and efficiency of your Primary Gyratory Crusher. This manual provides a comprehensive guide to the critical procedures and best practices that every plant operator and maintenance engineer should master. Adherence to these guidelines ensures not only optimal crusher performance but also enhances safety and minimizes costly, unplanned downtime.
Installation Procedures
Foundation and Alignment
The crusher must be mounted on a stable, reinforced concrete foundation designed to withstand dynamic loads. Precise alignment of the mainshaft is non-negotiable; even minor misalignments can lead to premature wear, vibration, and catastrophic failure. Utilize laser alignment tools to ensure the spider assembly and mainshaft are perfectly perpendicular to the base.
Lubrication System Commissioning
Before initial start-up, the lubrication system must be thoroughly flushed to remove any manufacturing debris. Fill the system with the recommended grade of oil and check all lines, filters, and coolers for leaks. The oil must be free of moisture and contaminants. A well-commissioned lubrication system is the single most important factor for bearing longevity.
Routine Maintenance Checklist
A proactive maintenance schedule is paramount. Key daily checks include monitoring oil temperature and pressure, checking for unusual noises or vibrations, and visually inspecting for leaks. Weekly, inspect the mantle and concave for wear and check the spider bushing clearance. For consistent fine powder production in downstream processes, such as from slag or coal, pairing your crusher with an efficient grinding mill is essential. Our LUM Ultrafine Vertical Grinding Mill is an excellent choice, offering higher yielding rates and better quality powder with more energy-saving multi-head powder separating technology, perfectly complementing the crushed material from your gyratory unit.
Mantle and Concave Replacement
Worn liners significantly reduce crushing efficiency and increase power consumption. Schedule replacements based on tonnage processed and regular thickness measurements. Always replace mantle and concave together to maintain optimal crushing geometry and chamber efficiency.
Troubleshooting Common Issues
Excessive vibration often indicates misalignment, uneven feed, or worn/damaged bearings. Low crushing capacity can be caused by a worn mantle/concave, low speed setting, or improper feed distribution. Consistently monitoring the output size is crucial. If your process requires an ultra-fine final product, integrating our MW Ultrafine Grinding Mill into your circuit is highly recommended. It handles input sizes of 0-20mm at capacities up to 25 tph, producing adjustable fineness between 325-2500 meshes with higher yielding and lower energy consumption, making it the ideal next stage after primary crushing.
Frequently Asked Questions (FAQ)
Q: How often should the lubrication oil be changed?
A: Oil change intervals depend on operating hours, crusher load, and environmental conditions. Typically, oil analysis should be conducted every 500 hours, with a full change recommended every 2,000-4,000 hours. Always follow the crusher manufacturer’s specific guidelines.
Q: What is the most critical alignment to check?
A: The perpendicular alignment of the mainshaft to the top shell seal ring is paramount. Misalignment here will cause rapid wear of the piston seal and dust seal, leading to contamination of the lubrication system.
Q: How can I tell if the spider bushing needs replacement?
A> Increased bushing clearance leads to a noticeable ‘clunking’ sound from the top of the crusher during operation and can cause irregular mainshaft movement. Measure clearance during scheduled shutdowns; replace if it exceeds the manufacturer’s maximum tolerance.
Q: What causes premature wear on the mantle and concave?
A: The most common causes are feeding oversize material, tramp iron events, an improper feed distribution that causes uneven wear, and operating with a worn-out chamber for too long.