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NORDBERG HP100, HP200, HP300, HP400 AND HP500 CONE CRUSHERSInstruction manualIM-HPX00-CRUSHER-EN-00 (Translation of the original manual)

TECHNICAL INSTRUCTIONS NORDBERG CONE CRUSHERS HP100/200/300/400/500

FOREWORD

This user manual is designed to allow ownersand users of Metso products to familiarizethemselves with the use of their equipment.It contains important instructions for safe,optimal and economical use of the equipment.Follow these instructions to avert possiblehazards, cut repair costs and the number offailures, increase the equipment's reliabilityand prolong its service life.This manual should be completed with localsafety and environmental protectionregulations.A copy of this user manual should always beavailable near the equipment.In addition to this user manual and local safetyand environmental protection regulations, thegenerally accepted technical rules governingsafety in the workplace should be followed.This user manual must be read and used byanyone working on the equipment, amongother things during:Installation, start up, operation, applicationengineering, loading and unloading rawmaterials, working on site, environmentalprotection and safety departments, inspection,repairs, transportation, handling theequipment.There may also be optional pieces ofequipment that have separate user manuals.These manuals must be used by anyoneworking with the equipment.Due to constant development of the productsand improvement in their design, your newmachine may include changes that have notbeen included in this edition. However, eachedition is reviewed and revised if necessary, toupdate the changes in the latest editions.The description and specifications in thismanual were accurate when it was approvedfor publishing.

Metso reserves the right to discontinue itsmodels at any time, and change thespecifications or drawings, without notice orany obligation.Should you have any questions regarding themachine or this publication, please contactyour Metso sales representative to get thelatest available information.

CONTENTS

CONE CRUSHERS HPTABLE OF CONTENTS

Foreword - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section A

Safety general instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section B

Safety on the equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section C

Safety during maintenance and repairs - - - - - - - - - - - - - - - - - - - - - - - Section D

Safety- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 0

General information on the crusher - - - - - - - - - - - - - - - - - - - - - - - - - - Section 1

General information on installation - - - - - - - - - - - - - - - - - - - - - - - - - - Section 2

Instructions for use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 3

Regular maintenance and inspection - - - - - - - - - - - - - - - - - - - - - - - - - Section 4

Bowl, bowl liner and hopper assemblies- - - - - - - - - - - - - - - - - - - - - - - Section 5

Head, mantle and feeder cone assemblies- - - - - - - - - - - - - - - - - - - - - Section 6

Sleeve assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 7

Eccentric assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 8

Countershaft, countershaft housing and bullwheel assemblies - - - - - - - Section 9

Frame, adjusting ring and retaining cylinder assemblies - - - - - - - - - - Section 10

Lubrication system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 11

Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 12

Frequently asked questions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Section 13

1.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

1.2 - Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Section A

INTRODUCTION

Introduction SECTION A

1.1 General

This manual, together with specific instructionmanuals for individual equipment, has beenprepared by Metso Crushing and ScreeningBusiness Line to increase the knowledge andawareness of all persons involved in theoperation, supervision, service andmaintenance of crushing and screeningequipment with regard to safety andoperations. A copy of this manual must beprovided to and studied by each personentering the machine areas of the CrushingPlant, or otherwise involved in the operation ofthe Crushing Plant. It is the responsibility ofthe Owner to always keep this manual andother written instructions either in theCrushing Plant or its vicinity for Operatorreference.

Knowledge of the machines and the potentialhazards they present are essential to a safeworkplace. Knowledge of and compliancewith all state, provincial, and federal safetylaws, safety regulations, and Crushing Plantsafety procedures, warnings and instructionsalso are essential to a safe workplace. Failureto do so can result in serious injury or death.

When in doubt - don’t! Never bypassinstructions or procedures to save time. Neverplace foreign items, tools, rods, or any part ofyour body into an operating machine. Neverreach over, around or beyond safety devices.Never operate a machine if safety devices aremissing or disabled. Never replace an OEMsafety device with a non-OEM device.

Never service equipment until all potentiallymoving parts are secured and power has beenlocked out and tagged out to preventunexpected movement.

The Operator is responsible for using care andcommon sense at all times.

Remember, safety is everyone’s business. Youare responsible not only for your safety, but forthe safety of those around you.

Please read this manual carefully. Know itscontents. If you have any questions, contactyour Metso representative without delay foradvice. Keep in mind that there are differenttypes of risks, hazards and injury types (seeSection 2.3 «Typical risks in crushing plantworking environment»), which are related toeach other. Foresee and prevent such risks andhazards as well as resulting injuries and otherconsequences from occurring by all availablemeans. Never compromise when the questionis about safety!

Metso, as the machinery manufacturer andsupplier, regards safety as of the utmostimportance, and deems the following asessential prerequisites to the safe operation ofthe Crushing Plant:

– That the Owner makes available thismanual, before using the machinery, toeach person involved with theoperation, supervision, service, ormaintenance of the Crushing Plant.

– That compliance with and adherenceto this manual be mandated andsupervised by the Owner.

– That all personnel involved in theoperation, supervision, service, ormaintenance of the Crushing Plantbecome familiar with the contents ofthis manual prior to such involvement.

02/2005 METSO MINERALS SAFETY INSTRUCTIONS A-1

SECTION A - INTRODUCTION

– That every person involved in theoperation, supervision, service, ormaintenance of the Crushing Plant beproperly trained and have adequateprofessional skills as required for theperformance of the respective tasks.

– That all visitors to the Crushing Plantbe properly informed of applicablesafety precautions and risks, and thatsafety precautions be adequatelymaintained and in connection with anysuch visits, including, but not limitedto, adherence to this manual.

No changes shall be made in the operation ofthe machinery supplied by Metso or thecontents of this manual without expresswritten approval of Metso. All operation,service, maintenance, handling, modifications,or other use of Crushing Plant equipmentand/or systems is the responsibility of theOwner.

Metso shall not be liable for any injury, death,damage or cost caused by any act or omissionon the part of the Owner, Operator or otherpersonnel, agents, contractors, vendors, orothers. All applicable safety rules, regulations,standards, instructions, and procedures mustbe complied with; as must be those of thismanual as well as any other instructions,specifications, and recommendations byMetso.

This manual is based upon the safety laws,rules and regulations in effect on the datehereof. The owner and operator bear soleresponsibility for complying with anyamendments, additions or other changes tosafety law, rules or regulations arisingsubsequent to the date on which this manualwas drafted.

Although these instructions are intended to beas comprehensive as possible, there may behazards that cannot be anticipated, hazardsassociated with a particular work-site orhazards covered by special comany safetyprograms. The information may also notinclude all practices that must be observed,such as insurance requirements orgovernmental regulations.

If you have questions or concerns regardingsafety aspects of machinery supplied byMetso, contact us before using, operating,servicing or repairing the machinery.

1.2 Definitions

“Crushing Plant” means a combination orpart of various equipment, components,systems and parts for crushing and/orscreening of rock, minerals, recycling or othercrushable materials. For the purposes of thismanual, the Crushing Plant means alsostand-alone crushing or screening equipmentas applicable. Throughout this manual, wordssuch as “machine”, “machinery”, “equipment”and “crusher” are used interchangeably to referto the Crushing Plant and its component parts.

“Owner” means the entities or individualswho own or lease the Crushing Plant and/orthe entities or individuals who are in charge ofoperating and/or servicing the Crushing Plant.

“Operator” means the individuals who eitheroperate the Crushing Plant or perform actualmaintenance, service, repairs, supervision orany other activity on or for it.

“This manual” means, as applicable, thisgeneral safety instructions, together with anyspecific instructions for individual equipment,as amended from time to time, provided by oron behalf of Metso.

IMPORTANT !

Safe operation of the machine requiresalertness and safety-consciousness on thepart of all operating personnel. It should beoperated only by knowledgeable and trainedpersonnel.

A-2 METSO MINERALS SAFETY INSTRUCTIONS 02/2005

2.1 - Safe products and the crushingplant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

2.2 - Safety and you . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-22.2.1 - Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-32.2.2 - Safety Signs, Labels And Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-32.2.3 - Some General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-42.2.4 - Blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-52.2.5 - Portable Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-52.2.6 - Mobile Equipment Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

2.3 - Typical risks in crushing plantworking environment . . . . . . . . . . . . . . . . . B-62.3.1 - Typical hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-72.3.2 - Typical injury types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-18

2.4 - Personal protective equipmentand clothing . . . . . . . . . . . . . . . . . . . . . . B-20

Section B

GENERAL SAFETY INSTRUCTIONS

General safety instructions SECTION B

2.1 Safe products and thecrushingplant

All machines require human involvement.Like any other heavy machinery, a crushingplant has inherent dangers that must beidentified, understood and taken into accountin order to avoid accidents and injuries. Metso,as machinery manufacturer and supplier, iscommitted to promoting safety at the crushingplant by providing safety devices and features,and by providing training, services, manualsand instructions.

2.2 Safety and you

Safety is everyone's responsibility; safety isyour responsibility.

Safety is the concern of all personnel. Withyour actions, you participate in establishing thesafety of the working environment.

Metso products are designed and constructedwith safety in mind. The machines incorporatehigh quality safety features used.

To assure safe operation, all personnel must bealert when operating or working on or aroundthe machine. Be aware of real and potentialhazards. Only properly trained personnelshould operate, supervise, maintain, or servicethe machine.

Personnel must carefully study all aspects ofthe specific machine, including :

– operating instructions

– service, diagnostic and maintenanceinstructions

– automated features and motions of themachine

– specific safety features andinstructions

GENERAL SAFETY INSTRUCTIONS FOR A CRUSHING PLANTOR PLANT ENVIRONMENT

IMPORTANT !• If unsure of any procedure, check the

operation manuals and/or contact yoursupervisor before proceeding.

• Follow all lockout and safety proceduresbefore entering the machine.

• Be constantly aware of the location ofeach worker on or around the machine.

• Observe all safety instructions.

• Do not remove or disable any guard,safety device, sign or warning.

02/2005 CONSIGNES DE SÉCURITÉ METSO MINERALS B-2

SECTION B - GENERAL SAFETY INSTRUCTIONS

2.2.1 Objective

The objective of these instructions is tominimize risks and to avoid or preventaccidents and injuries. Accidents are oftencaused by carelessness or disregard ofimportant instructions.

Knowledge of the machine operation andcontinuous safety training are necessary for asafe working environment.

Safety can be summarized in three mainthemes :

– MACHINE KNOWLEDGE

– SAFE OPERATION ANDMAINTENANCE

– GOOD HOUSEKEEPING

2.2.2 Safety Signs, Labels AndSymbols

The following symbol is used in this manualand on the machine to call attention toinstructions, which will help prevent machinerelated injuries.

When you see this symbol on your machine orin this manual, be alert to the potential forpersonal injury.

Figure 2-1 Alert symbol

This manual uses the alert symbol, with wordssuch as DANGER, WARNING or CAUTION,to alert you and other Crushing Plant personnelof actions or conditions that pose a potentialsafety hazard, with an attending risk ofpersonal injury (including death) or propertydamage. The machine also disgaps safetysigns, labels and tags at appropriate points toshow safety risks that may exist.

Figure 2-2 Danger, Warning, Caution Signs And Their Meaning

Sign Description

DANGERImmediate hazards or unsafepractices that will result insevere personal injury or death.

WARNINGHazards or unsafe practices thatcould result in severe personalinjury or death

CAUTIONHazards or unsafe practices thatcould result in minor personalinjury or equipment damage

DANGER

CAUTION

WARNING

B-3 CONSIGNES DE SÉCURITÉ METSO MINERALS 02/2005


2.2.3 Some General Safety Instructions

1. Do not remove, cover or disable anyinstalled safety devices, guards, warningsigns or tags. They are attached toequipment to warn personnel of possibledanger and prevent injury. Use OEMreplacements in the event any safetydevices, warning signs or tags becomedamaged or unreadable. Observe allinstructions. Keep warnings signs andtags clean, visible and readable(Warning signs are listed and theirlocations described in the machinesafety instructions).

2. Make sure that all required walkways,handrails, barriers, safety devices, andguards are in place before starting themachine. Do not use non-OEMwalkways, handrails, barriers, safetydevices or guards, when such items areavailable from OEM.

3. Keep the machine itself and the areaaround the machine clean and clear ofobstructions. Be aware of dust, smoke orfog, which may obscure your vision.

4. Wipe up any substance, such as spilledoil, grease, water or ice, which maycause a person to slip or fall. Goodhousekeeping practices prevent injuries.Be a good housekeeper. Keep themachine environment and walkwaysclean and free from oil, grease, rags,cables, chains, buckets, rocks and otherobstructions. Keep loose parts in atoolbox or return them there promptly.

5. Keep clothing and all parts of the bodyaway from nip points and rotating ormoving equipment. Be especially alertto avoid contact with parts that moveintermittently.

6. Know the weight limitations of liftingdevices and their loads. Never detach alifting device from a load until the loadis stable and secured from unintendedmovement.

7. Do not climb or stand on equipmentother than in areas, which are designedfor that purpose. Do not overreach.

8. Emergency-Stop buttons should betested on a regular schedule for properoperation, as should electrical interlocksand related limit switches. Safetydefects should be repaired prior tocontinuing operation, and thereaftertested and certified for appropriateoperation by skilled personnel.

9. Personal protective equipment andsafety uniforms, safety shoes, helmets,safety glasses, heavy gloves, earprotection devices etc. should be used atall times. Safety shoes should be used byall personnel entering into the CrushingPlant. Persons with loose clothing, neckties, necklaces, unprotected long beardor long hair should not go near themachine. Wrist watches and rings can bedangerous.Rings should be removed orcovered with tape. Keep your pocketsfree of loose objects.

10.Keep all non-operating and non-trainedpersonnel clear of the Crushing Plant atall times. Injury or death may result ifthis is not done.

11.The equipment at the control panelshould be handled with care. Do notplace objects on the keyboard, colordisgap or other equipment. Allequipment can fail if put in contact withliquids, or excessive heat or excessivehumidity. Allow good air flow aroundthe equipment at all times. Keepmagnets away from computercomponents, particularly hard drivesand PLC cabinets.

12.A knowledgeable and properly trainedOperator familiar with this manual,safety requirements, and automaticoperation of the machine should bestationed at the controls whenever themachine is operating.



13.Do not consume any alcoholicbeverages or other intoxicants beforecoming to work or while on the job. Donot operate the Crushing Plant aftertaking any medicines, tranquilizers orother drugs, which can impair thesenses.

14.Familiarize yourself with the safetysigns on the Crushing Plant. Neverremove or damage any safety signs,nameplates or other safety relatedwarnings, symbols or components.Replace them as necessary with OEMequipment.

15.Do not paint over safety signs, nameplates or warnings.

2.2.4 Blasting

The use of the Crusher Plant’s radio controldevice is strictly forbidden during blastingoperations, as it may cause a prematureexplosion. Move the mobile Crushing Plant farenough away from dangerous area whenblasting. Do not store or transport explosiveson mobile crushing plant or screening plants.

2.2.5 Portable Plants

If the Crushing Plant includes of portableequipment (i.e. crushing and screeningequipment mounted on trailers), trailer footingor cribbing is extremely important for safeoperation. Your machine must be on as solidand level footing as possible. If the ground isnot naturally level, it must be leveled so thatthe unit will operate safely and effectively. Theground must support the weight of entire unitand keep it from sinking or shifting. Use heavytimber mats as needed. Trailers must be raisedso that trailer wheels do not touch the ground.

Place jacks at each corner of the trailer or asnear the corner as possible and to othersuggested support points at mid-frame. Allcorner jacks must be at an equal distance fromeach end. Adjust each jack until theunsupported portion of the trailer beams stopsvibrating or until vibrations are reduced to aminimum. Lock jacks and adjustable supportlegs mechanically with locking pins whenapplicable.

Periodically recheck trailer footing forstability.

2.2.6 Mobile Equipment Transportation

Use only appropriate transportation and liftingequipment with adequate capacity. Provide asupervisor to direct lifting operations. Followall disassembly and assembly instructionscarefully. Disconnect all external powersupplies before moving any part of theequipment.Transport or hoist components andhandle any parts in accordance with theinstructions and advice provided. Fasten thelifting equipment only to the points meant forlifting.

WARNING

Only qualified and properly trainedoperators and servicemen shouldoperate or service the machine.Everyone else should stay clear ofthe machine when it is operating, orunder service or maintenance!



Use only proper means of transport withadequate transporting capacity. Fasten the loadcarefully. For lifting use only the fasteningsshown in instructions. Secure all componentparts of the equipment immediately afterloading to avoid any accidental shifting.Attach required warning signs to the load.

When moving your trailer, check bridgesbefore crossing. Make sure they will supportthe weight of the machine. Check clearancesunder bridges, for overhead lines or anyoverhead obstruction. Never travel with nearcapacity loads. Check local laws, especially onweight limitations. When travelling on thehighway make sure all headlights, clearancelights and tail lights are on, as applicable. Useproper traffic warning flags and signs.

Remove all shipping brackets beforere-starting the Crushing Plant. Carefullyassemble all of the parts previouslydisassembled. Perform any start up inaccordance with the instruction manual.

After the system is running, check all gaugesand instruments to see that they are workingcorrectly. Check that all controls functionnormally and properly. Listen for unusualnoises. Shut system down immediately if anycomponent of the system does not operatenormally.

2.3 Typical risks in crushingplantworking environment

Even though every Metso machine is designedwith many safety features, it is impossible todesign out all safety risks. There are potentialhazards, that must be recognized and avoided.Noise levels may interfere with normaldiscussion when the machine is operating. Bytheir nature, Crushing Plant and auxiliaryequipment can create dust. Crushing itself andsome other machine processes maymomentarily obstruct the view of somemachine parts. In general, high levels ofrespirable silica and other dust in the air mayexpose Operator to health risks for lungdisease depending upon the length and amountof exposure and type of material beingcrushed. In addition, there are some risks orhazards which cannot be completely guardedor avoided because of interference withmachine operations. Accordingly, working onthe Crushing Plant requires constant alertnessby all personnel in the area. Accidents happenunexpectedly. Below are some typical hazardsand types of accidents that everyone workingat, on or around the Crushing Plant should beaware of.

Typical Hazards :

– nips, gaps, and pinch points

– poor housekeeping

– elevated or narrow working areas

– lifting and shifting heavy loads

– cranes and mobile cranes

– sharp edges

– high-pressure hydraulic equipment



– electrical equipment

– automatic functions and unexpectedstart-ups

– toxic and corroding agents

– machine inertia

– hot surfaces and fires

– zinc

– conveyor belts

– dust

– noise and vibration

– improper work methods

– rotating equipment and movingcomponents

– ejection of material from the crusher

– falling material from conveyors, andfrom loading, unloading and feedingoperations

– crushing cavity

These typical hazards are discussed more fullyin section 2.3.1 «Typical hazards» of thischapter. Be aware of these hazards. Allpersonnel working on or around the machineshould be properly trained in avoiding thesehazards.

Typical Injury Types :

– crushing

– slipping, tripping and bumping

– falling

– cutting

– entanglement

– burns and electrical shocks

– respitary organ illnesses

– asphyxiation

2.3.1 Typical hazards

Nips, Gaps, and Pinch Points

An ingoing nip is formed by drive devicessuch as belt and pulley, chain and sprocket orgears. Similarly, a pinch point may be formedby rotating or moving equipment.

Poor Housekeeping

Promote good housekeeping. Keep machineenvironment, walkways, platforms etc. cleanand dry and free of debris. Oily or wet machineenvironment, walkways, platforms, steps andhand rails are slippery. In cold weather, watchout for ice and snow. Wet spots, especially nearelectrical equipment, are dangerous. Returntools to their proper place after use. Even thenextreme caution should be used. Followestablished Crushing Plant safety procedures.Clean slippery deposits from walkways,ladders and floors. Tidiness provides a saferworking environment by preventing or helpingreduce tripping, slipping, fire hazards andelectrical shocks.

DANGER

Nips and gaps are serious hazards ina Crushing Plant. They are usuallyguarded by nip guards, railings, orlocation. In all cases, extreme caremust be taken to avoid nips, gaps,and pinch points or serious injury oreven death may occur.



Elevated or Narrow Working Location

Crushing Plants are tall structures. Thewalkways and platforms, designed to be usedduring machine operation, are furnished withrailings to help prevent falling.

When working on an elevated surface beaware of machine movements and otheractivities in the area. Do not run on thewalkways. Do not reach over or beyondwalkway railings while the machine isrunning. Do not stand on railings or toe plates.

There may be narrow access routes formaintenance purposes. Do not use these routeswhile the machine is operating.

Do not enter any close quarters within theCrushing Plant when the machine is operating.

Lifting And Shifting Heavy Loads

• Cranes

Crushing Plants, like any other type ofmechanical equipment, require regularperiodic maintenance. One of the most flagrantCrushing Plant safety violations is the use ofinadequate and unsafe lifting equipment.Although a Crushing Plant is a finely tuned

piece of equipment, the internal parts of aCrushing Plant should be assembled anddisassembled with crane facilities that have thecapability of gently and slowly lifting andlowering the various parts that make up aCrushing Plant.

Do not use chain hoists (chain blocks) toassemble or disassemble a Crushing Plant.These lifting devices lack the stability androbustness required in lifting and positioningheavy components.

Do not use impact hammer boom or any otherequipment which are not designed for lifting,for assembly or disassembly purposes.

Affix the load securely to its destination.Never detach a lifting device from a load untilthe load is stable and secured from unintendedmovement.

When it comes to safety, don't compromise!

IMPORTANT !

When using a crane, always operate withinthe rated capacity of the crane. The safe ratedcapacity includes weight of hook, block andany materials handling devices such ascables, slings, spreader bars, etc. Subtract theweight of all these items from the ratedcapacity to find the true weight of the loadthat can be handled safely. Always followthe crane manufacturer's operational andsafety instructions.

IMPORTANT !

The weight indicated in machine plates tellsthe weight of standard configuration. Inmany cases the actual weight may differgreatly from that indicated in machine platedue to, e.g., options or ancillary equipment.Always verify the weight of the object youare lifting before attempting to lift it.



• Mobile cranes

Safe ratings are based on operating the craneon firm, level ground; outriggers must beproperly extended and/or lowered wheneverrequired. Avoid fast swings, hoists or suddenbraking; these can cause overloads. Do nothandle large, heavy loads in strong winds.When moving your crane, check bridgesbefore crossing, make sure they will supportthe total weight in question. Check clearancesunder bridges for overhead electrical lines andany overhead obstruction. Be sure your hitcheris clear before starting lift. Make sure the loadis securely attached.

Take the following precautions when liftingheavy loads :

– Follow all established Crushing Plantprocedures.

– Follow all instructions and safetyprocedures recommended by the cranemanufacturer.

– Plan the lifting and maintenanceprocedures in advance. Read andunderstand specific instructions forproper use of lifting equipment priorto using (e.g instructions of themachine, lifting device and localregulations).

– Clean the working environmentbeforehand to prevent slipping andtripping hazards.

– Make sure that the crane and otherlifting devices such as chains andslings have sufficient capacity and arein good working order.

– Do not attempt to ride or sit on movingloads.

– Be sure that crane operators, riggersand other personnel have beenproperly trained.

– Rig the load firmly to prevent anyunintened movement and assure stableand accurate positioning.

– Make sure nobody is below or on thepath of the load and that the transferroutes are clear and proper protectiveclothing and gear are used.

Sharp Edges

Sharp edges may occur on any metalstructures. Equipment damage may uncover orproduce unexpected sharp edges. Sharp edgesmay inflict deep and serious cuts. Wearprotective gloves when handling materials,parts, etc. with sharp edges. Repair or guarddetected sharp edges immediately.

High-pressure Equipment - Hydraulic orAir

High pressure oil can be dangerous. Relieve allpressure before opening or removing anyhydraulic or air pressure lines, valves, fittings,etc. Do not touch pressurized componentssince the pressure from a pin hole leak is sostrong that it can easily penetrate the skin or

IMPORTANT !

When using a mobile crane, always operatewithin the rated capacity of the machine toavoid buckling the boom or tipping.



eyes. Always exercise caution when handlinghydraulic devices.

Regularly check the condition of hoses, pipes,valves and various connections. Replace themas necessary.

Before starting any maintenance work, stop allhydraulic pumps, lock out pump motors, anddepressurize the system, bringing allcomponents to a zero energy status. Rememberto also depressurize the accumulators throughthe bleed valve for each accumulator. Do notdisconnect any hoses until the actuator hasbeen brought to a zero energy status andproperly secured.

Bleed the hydraulic system regularly toremove entrapped air that may interfere withnormal expected machine operation or cause ahazard during maintenance.

Electrical Equipment

Be especially cautious when working with ornear electrical equipment. An electric shockcan be fatal. Crushing Plant electrical outletsmust be grounded and have ground faultinterruption protection. Tools plugged into theoutlets must be double insulated. Never exposeelectrical equipment to mechanical damage orhumidity. Protect all electrical equipment fromdirect contact with water or high humidity.

Protect electrical devices that move as part ofthe machine from dirt and mechanical damage.Regularly check the operability of thesedevices.

The lockout program, locks, tags and theblocking/restraining devices provided aredesigned for your protection. Yourresponsibility is to follow the program and usethe proper equipment.

Remember :

– Follow procedures.

– Stay alert.

– Do not take anything for granted.

– Verify lockout.

– Each person working on the unit musthave his own lock with only 1 key.

AVERTISSEMENT

Poorly tightened or damagedhydraulic components may injectdangerous jets of fluid. Beforerestarting the machine, be sure thatthe hydraulic system is ready foroperation, and personnel are clear ofaffected areas.

AVERTISSEMENT

Machine parts may moveunintentionally and cause a risk ofinjury. Before restarting the machine,make sure that all personnel are clearof affected areas where machinemovement may occur.

DANGER

There is a risk of an electric shock, ifsufficient precautions are not taken.An electric shock can be fatal.

For maintenance work, disconnectall devices from electric andhydraulic power sources and followCrushing Plant lockout procedures.



– Tag must identify the work being doneand the person(s) who locked andtagged the control.

– Locks and tags are changed with eachshift that comes on.

Work to prevent injury or death. Follow properprocedures at all times!

Maintenance, repair and installation ofelectrical equipment must be performed onlyby qualified personnel who are familiar withthe machinery and equipment in question.

Automatic Functions and UnexpectedStart-ups

Unexpected start-ups during maintenance :

– Lock out and tag machine controlsbefore performing maintenance orrepairs to avoid unexpected start-up.Failure to properly lock out themachine can lead to injury or death.Someone may accidentally start themachine from the control room or anunexpected occurrence may activate acontrol. For example, a power surgemay alter the logic of the controlsystem status causing an unexpectedmachine movement or sequence.

WARNING

Machine parts may moveunintentionally and cause a risk ofinjury. Absence of safety functionsmay cause dangerous machinemovements.

Do not tamper with limit switches orother safety devices included in thesystem.

DANGER

If danger zones are not respectedduring machine operation ormaneuvres there is a risk of seriousinjury or death.

Many devices operate automatically,following certain sequences whichhave been programmed into the logicsystem (i.e. programmable logiccontroller, microcontroller, relaysystem or similar). The danger zoneis any area within the confines ofmoving machine elements, feedmaterial or beneath any objects beinglifted. Do not enter these dangerzones unless the machine has beenproperly safeguarded according tothe Crushing Plant lockout procedureand manufacturer's instructions.



Welding Equipment

Weld repairs are to be performed only byqualified personnel. Welders and welder’shelpers must wear protective clothing andequipment.

Precautions must be taken when torch cuttingand/or welding due to the health hazards posedby many metals. Anyone performing thesetypes of procedures should avoid breathing thefumes. Such procedures should be doneoutdoors or in a well ventilated area with eithera separate clean air supply provided to themechanic or with local exhaust of fumes.Please refer to EU, OSHA, MSHA or otherapplicable standards as appropriate. One of themost frequently used tools around theCrushing Plant is the cutting torch.

Crushing Plants which are equipped withhydraulic components and/or conveyor beltsand/or v-belts should have these componentsdepressurized and adequately covered withflame-proof material so that sparks, weldspatter, etc., cannot reach theses areas.Ruptured high pressure hydraulic lines willquickly vaporize the hydraulic fluid as itreaches the atmosphere. This vaporized fluidcan quickly become a mass of flames, resultingin severe burns for personnel in the immediatearea. Adequate precautions should be made toavoid contact with these components. Neverperform welding or torch cutting activities inthe presence of flammable materials.

Toxic, Corroding and Irritating Agents HotSurfaces and Fires

Before handling chemicals, carefully read thesafety instructions from the supplier of therespective chemical. Hazardous chemicalsmay be in use. Wear protective clothing,gloves, boots, glasses, and respirator whennecessary.

WARNING

Risk of injury. Fire may break out.Never perform welding or torchcutting activities in the presence offlammable materials.

IMPORTANT !

All maintenance personnel who use cuttingand/or welding torches should be advised ifthere are hydraulic components in theimmediate area in which they are working.

IMPORTANT !

Contact Metso or its authorizedrepresentative prior to any welding of majorCrushing Plant components such as mainframe, adjustment ring, bowl, etc.Performing welding on the Crushing Plantcomponents can be detrimental. Beforewelding, always verify that material isweldable! Failure to do so may result inweldment failure and present a risk of injuryand/or property damage.



Refer to the MSDS (Material Safety DataSheets) and Crushing Plant procedures forhandling of these materials.

Avoid prolonged contact with fluids, such asgasoline, diesel fuel, hydraulic oil and cleaningsolvents, which may cause skin irritation orother reactions.

Machine Inertia

Due to the large inertial forces of the CrushingPlant and Crushing Plant components, themachine can not be stopped abruptly. This ispotentially hazardous to personnel. Allpersonnel must stay clear of rotating elementsand other moving parts until the machine hascome to a complete stop. Regularly inspect thestructural elements to maintain safe operation.

Hot Surfaces and Fires

There are hot surfaces on Crushing Plants.Protective gloves and coveralls help protectagainst burns. Be aware of hydraulic system,hoses, fittings, and pipes. Regularly inspectand observe high temperature lines, and fluidlines for leaks or damage. On mobileequipment be cautious around the enginebecause of exhaust gases.

When in contact with hot temperatures, orwhen heated themselves, some hydraulic oilsmay ignite at around 392°F (200°C). Attentionmust be paid to the condition of hydraulichoses and couplings. Remove immediately oilspills from floor, walkways, and pits. Fix allsources of oil leaks and clean up spills.

In case of fire it is recommend to equip theCrushing Plant with manual extinguishingequipment. Legislation and regulations aboutsuitable equipment may vary by country.Familiarize yourself with applicable standards.Personnel must also be trained properly to beable to use fire extinquishing equipment.

A trained person with sufficient fireextinguishing equipment must be presentduring welding maintenance work. Cold wateron hot metal surfaces may cause a violentexplosion. Monitoring after welding must bearranged as required by laws and regulations.If no other regulations apply, monitoring timeis a minimum of one half hour.



Fire Hazards

– Do not smoke while refueling, orwhen handling fuel containers.

– Shut off engine when refueling anduse extra caution if engine is hot.

– When pouring fuel into the tank,ground the funnel or spout against thefiller neck to avoid static electricspark.

– Do not use gasoline or diesel fuel forcleaning parts. Good commercial,nonflammable solvents should beused.

– Do not smoke while using flammablecleaning solvents. Whenever possible,use non-flammable cleaning solvents.

– Do not let greasy, oily rags accumulatein a poorly ventilated area. Store oilyrags and other combustible material ina safe place.

– Never use an open flame to check fuel,battery electrolyte or coolant levels, orto look for hydraulic leaks anywhereon the equipment. Use a flashlight.Know where fire extinguishers arekept, how they operate, and for whattype of fire. Check regularly, at leastmonthly, to be sure they are in theworking area.

– Do not weld or cause open flame inthe presence of flammable materials.

– In the event of a fire, shut down theCrushing Plant, hydraulic power unitand lubrication system if this can besafely done. Warn other people in thearea and commence fire fightingactivities according to applicablerules. It is the responsibility of theOwner to maintain proper training andinstructions in these respects.

Epoxy Versus Zinc

Many Crushing Plants require some type ofbacking when replacing the crushing members.Epoxy resin backing compounds have almostcompletely eliminated the possibility ofworkers being accidentally burned due tomolten zinc either spilling or exploding whenit comes in contact with wet surfaces. Whenepoxy backings are used, care should also betaken when removing the liners with a cuttingtorch . Do not use molten zinc as backingmaterial. Use epoxy only according to specificinstructions from the manufacturer.



Conveyor Belts Crushing Plant Dust

By their nature, Crushing Plant and auxiliaryequipment such as chutes, transfer stations,screens, etc. can create dust and, if notcontained, the dust can escape into the air. Ingeneral, high levels of dust (particularly,respirable silica) in the air can create a hazardof lung disease, depending upon theconcentrations of dust, the length of exposure,and the type of material being crushed. Dustprotective devices and dust warnings may berequired by OSHA, MSHA or local laws.

The Owner and Operator of the Crushing Plantmust identify the material being crushed andascertain whether respirable dust from theapplication poses a health hazard to personnelin the vicinity of the Crushing Plant.If thematerial presents such a hazard the Owner andOperator must take all necessary measures toensure that personnel are protected from thedust. Such measures include, but are notlimited to providing dust collection system,using water spray bars at the feed anddischarge points, crusher transfer points andscreens and providing adequate personalrespiratory protection devices to workers.

Crushing with a choke level may also reducethe amount of dust issuing from the CrushingPlant itself. Because the configuration of eachrock crushing installation is different, Metsorecommends that the Owner and Operatorconsult Metso or a dust consultant aboutpossible alternative means of dust reduction.

WARNING

Do not use conveyor belts aswalkways. Do not climb on them.Always stay clear of any falling ordropping materials or components.Never attempt to stand on, walk on,or step across a conveyor. Neverstand below a running conveyor. Donot use loose clothing, neck ties,necklaces or other loose items whennear conveyors or other moving orrotating equipment. Emergency pullcords should be used only in case ofemergency -do not use them forroutine stoppage of conveyor. Neverattempt to service the conveyorwhile it is energized. Keep in mindhazardous nip points.



Noise and Vibration

• Crushing Plant Noise

Crushing Plant by its very nature is noisy andthe auxiliary equipment found at, on or aroundthe Crushing Plant such as chutes, transferstations, screens, etc., can at times be noisierthan the Crushing Plant itself. TypicalCrushing Plant noise level while crushingrange from 100 - 110 dB measured at 1 m (3ft)from the Crushing Plant.

Metso recommends wearing ear protection at,on and around Crushing Plant, particularlywhen the noise level exceeds 85dB. It isrecommended that the Owner develop asignaling communication system in noisyenvironments to reduce the risk of accidents.Proper machine maintenance and replacementof worn parts can help reduce noise.

The most commonly applied noise reductionprocedures are :

– use of isolation techniques

– equipment enclosures

– operator enclosures

– silencers

Allowable noise levels and exposure limits areregulated by various agencies such as ISO,OSHA, MSHA, etc. Refer to applicable safetyregulations for permissible noise exposures,and take steps to ensure compliance with thoseregulations.

• Vibration

Long term exposure of Operator to vibrationmay result in detrimental health effects.Thereis an increased risk of falling on a vibratingplatform. Avoid standing on a vibratingOperator's platform or walkway.

Unexpected or excessive vibrations may be asign of wear and/or maintenance needs.Excessive vibrations associated with a portablecrushing or screening plant is frequentlycaused by improper cribbing.

It is recommeded to regularly monitorvibration levels of machine componentsincluding, but not limited to :

– bearings

– shafts

– rollers

– structural members (includingconveyor frames, walkways,platforms, hoppers, chutes, etc.)

IMPORTANT !

Metso highly recommends that dustprotective devices such as an appropriaterespirator be worn by anyone exposed toairborne dust to prevent its inhalation.

WARNING

Breathing dust may be hazardous tothe health of anyone working at, on,or around the Crushing Plant. It cancause serious or fatal respiratorydiseases including silicosis! It is theresponsibility of the Owner andOperator to determine the necessityand adequacy of protective devicesand warnings, to provide them, andto ensure that they are used andfollowed!



Improper Work Methods

Improper work methods and motions maycause physical injuries. Use suitable tools,cranes or jacks for moving large and heavyobjects. Overreaching and improper supportfor loads may lead to injuries to the back orother parts of the body. If you are unsure ofproper work methods, contact your safetydirector or other person responsible forensuring the safety at your work place.

When lifting equipment by hand, protect yourback by lifting close to your body and usingyour legs without twisting. Use hoistswhenever possible. Stand clear of hoistedloads and lifting cables.

Rotating Equipment and MovingComponents

Rotating and moving components providepinch points, snagging possibilities and otherpotential hazards. Keep clear of all movingparts until they come to a complete stop. Donot use any body part, tool or other foreignobject to attempt to stop, adjust, clear, or cleanany area in proximity to moving equipmentsuch as vibrating feeder, conveyor belts, drivesor other rotating parts of the crusher. Engagingin such activities can result in severe personalinjury, including death.

Crushers, designed to operate within a specificRPM range for maximum efficiency, aretypically checked with a tachometer. Makesure that any access openings have a protectivecover in place at all times except when RPMreadings are being taken. Never change sheavecombinations without first consulting yourMetso representative.

Ejection of Objects from the Crushing Plant

Ejected objects from the Crushing Plant maycause bodily injury. For example rock can bethrown several meters (several yards) into theair out of the crushing cavity during operation.Ejected materials may include rock, trampmetal, metal rods and work implements. Donot look into crushing cavity while crusher isin operation. Never attempt to clear jam onfeeder, crushing cavity or conveyors whensystem is energized.



Falling Material from Conveyors, Loading,Unloading and Feeding Operations

Rocks or other objects may fall fromconveyors during loading, unloading andfeeding operations. Impact of falling materialmay cause serious bodily injury. To assure safeoperation, all personnel must be alert whenoperating or working at or around the machine.Wear proper protective clothing (includingalso helmet) and protective devices. Keep allnon-operating and non-trained personnel clearof the Crushing Plant at all times.

Never walk under any equipment included inloading, feeding, crushing, conveying,discharging or stockpiling material.

2.3.2 Typical injury types

Crushing

In general, avoid areas where you may beexposed to expected or unexpected machinemovements. Crushing injuries typically occureither between two rotating or moving parts, orbetween a moving component and a stationaryobject.

Keep all body parts, clothing and tools awayfrom areas where they may get trapped,pinched, or crushed, or otherwise come intocontact with moving parts on the CrushingPlant. When moving equipment, be sure thepath is clear. Horns and lights, where provided,are for your safety to alert you of movingobjects. Pay attention to all such devices.

Slipping, Tripping, and Bumping

Items such as hoses, tools, etc., on walkwaysand Crushing Plant floors impede movementand create a tripping and slipping hazard.Good housekeeping reduces the risksconsiderably.

Personnel should wear safety shoes that reducethe risk of slipping and provide protectionagainst falling objects or crushing. Hydraulicoil leaked or spilled on the floor must becleaned up immediately.

To help avoid injury, be aware of partspositioned close to the floor level or protrudingmachine components, changes in elevation ofplatforms, walkways, and narrow accesspoints. It is recommended that safety shoes beworn at all times. Wear safety helmets andother safety equipment as appropriate.

Falling

Use only designated access routes designed forthe purpose, for example walkways andplatforms. Walkways and platforms arefurnished with railings designed to meetapplicable standards. However, in some workphases, railings or platforms may have to betemporarily shifted aside. In those cases,special caution signs or temporary barriersmust be used when working on the machine.Use personal fall protection gear, temporary



barriers, interlocks, or other warning deviceswhere appropriate. Never attempt to operate,service, or repair the Crushing Plant withoutfirst ensuring proper protection against falling.

Guards that are moved aside must be installedimmediately after maintenance work andbefore the machine is returned to operation.Never climb or stand on areas of the CrushingPlant not specifically designated for thatpurpose.

KEEP THE AREA CLEAN!

Cutting

Do not reach in or enter :

– the movement paths of cuttingequipment

– between moving machine components

– between moving loads and machinestructures

Entanglement

To avoid entanglement, avoid wearing looseclothing that could be caught by rotatingshafts, conveyors, and other moving parts .andmaterials. Remove neckties, necklaces, rings,and other jewelry before performing work

assignments. Also protect a long beard or hairfrom entanglement.

Do not touch a rotating roller, sheave, pulley,idler or moving conveyor belts with any bodypart or work implement, as you may becomeentangled and pulled into a hazardous area.

Never attempt to service, repair, ortroubleshoot any moving part of the CrushingPlant while it is energized or otherwise capableof movement.

Burns and Electrical Shocks

Protective gloves and coveralls help protectagainst burns. Be cautious around and nearhydraulic system hoses, fittings and pipes.Regularly inspect and repair leaking ordamaged high temperature lines and fluidlines.

To avoid electrical shocks :

– Power must be shut off and locked outbefore any servicing or maintenancework is done. Unplug or disconnect allauxiliary motors and equipment.

– DO NOT drill blindly into beams,electrical cabinets or other enclosures.

Avoid any contact between moisture or otherfluid and electrical equipment.

WARNING

Do not operate any equipment untilall guard rails and safety deviceshave been re-installed or returned totheir proper operating condition.Failure to do this could result inserious injury or death.

WARNING

Keep safety gates, shrouds, guards,and other protective devices in placeand in good working condition at alltimes. Test emergency stop,electrical interlocks, and related limitswitches frequently.



Impact from Ejected Materials

There are several hazards related to falling,flying or otherwise ejected materials when theCrushing Plant is being operated or serviced.For example, rock can be thrown severalmeters (several yards) into air out of crushingcavity during operation. Ejected materials mayinclude rock, tramp metal, metal rods andwork implements. Keep the safety grate downduring the operation. Wear proper protectiveclothing (including helmet) and protectivedevices. Always use properly maintained andapproved tools and work methods. Stay clearfrom the path of ejected materials, also duringlifting, assembly and dissassembly operations.

Removal of tramp iron jammed between thecrushing members is extremely dangerous.Follow the instructions in the instructionmanual.

Do not look into crushing cavity while crusheris in operation.

2.4 Personal protectiveequipmentand clothing

Personal protective equipment and clothingsuch as foot protection, helmet, hearingprotection, dust protective devices, safetyglasses or other personal protective clothingand equipment should be worn at all times. Allequipment should be maintained in accordancewith applicable standards. Respirators,goggles, protective masks, gloves, boots, andother such equipment shall be cleaned anddisinfected before being used by anotheremployee. The Owner and Operator areresponsible for ensuring that all eye, head,respiratory, and ear protection conforms toapplicable standards.

Hearing Protection

Noise level in the machinery area may exceed85 dB, and exposure to the machinery area insuch circumstances without adequate hearingprotection may lead to hearing loss. Therefore,users must be provided with appropriatehearing protection of the type and to the extentrequired by law.

Eye And Face Protection

General requirements should include :

– The Owner should ensure thatpersonnel for the machine area useappropriate eye or face protectionwhen exposed to eye or face hazardssuch as flying material, molten metal,liquid chemicals, acids or causticliquids, chemical gases or vapors.

IMPORTANT !

Always use right size of protectiveequipment.

IMPORTANT !

It is the responsibility of the Owner andOperator to determine the necessity andadequacy of protective devices and warnings,to provide them, and to ensure that they areused and followed.



– The Owner should ensure that affectedpersonnel use eye protection thatincludes side protection from flyingobjects.

– The Owner should ensure that affectedpersonnel who wear prescriptionlenses while engaged in operationsthat involve possible eye hazards weareye protection that incorporates theprescription in its design, or wear eyeprotection that can be worn over theprescription lenses without disturbingthe proper position of the prescriptionlenses or the protective lenses.

Respiratory Protection

Respiratory protection is required when the aircontains contamination such as harmful dusts,fogs, fumes, mists, gases, smokes, sprays, orvapors. The primary objective is to protect thehealth of workers.

Respiratory protection must be provided by theOwner when such equipment is necessary toprotect the health of personnel. The Ownershall provide the respiratory protection andtraining programs, which are applicable andsuitable for the purpose intended and complywith the latest requirements andrecommendations of health authorities andregulatory agencies.

IMPORTANT !

The enormous degree of convenience as wellas the high safety factor involved when usingplastic backing agents has made the use ofmolten zinc for Crushing Plant liner backingobsolete. See section 2.3.1 «Typicalhazards».

IMPORTANT !

The area should be well ventilated. Epoxyfumes can cause nausea or eye or skinirritation.

IMPORTANT !

Breathing dust may be hazardous to thehealth of anyone working at, on, or aroundthe Crushing Plant.

IMPORTANT !

Metso highly recommends that adequatedust-protective devices such as a respiratorbe worn by anyone exposed to airborne dust,particularly silica dust, to prevent itsinhalation.



Foot Protection

The Owner shall ensure that affected personneluse protective footwear when working in areaswhere there is a danger of foot injuries due tofalling or rolling objects piercing the sole, andwhere feet are exposed to electrical orchemical hazards.

Head Protection

The Owner should ensure that affectedpersonnel wear a protective helmet approvedby OSHA, MSHA (or by other applicableauthority) when working in areas where thereis a potential for head injuries from fallingobjects or walking throughout areas with lowhead clearance.

The Owner should ensure that a protectivehelmet designed to reduce electrical shockhazard is worn by personnel when nearexposed electrical conductors which couldcontact the head.

Hand Protection

The Owner should ensure that personnel useproperly sized appropriate hand protectionwhen hands are exposed to hazards such asthose from skin absorption of harmfulsubstances, cuts or lacerations, abrasions,punctures, chemical burns, thermal andelectrical burns, and harmful temperatureextremes.

Safety Harnesses

The Owner should ensure that any personworking on elevated areas not protected byrailings, or on hazardous places must wearsuitable safety equipment, including safetyharnesses, if there is a risk of falling. Confinedspaces may also require safety harnesses.



Work Clothing

The Owner should ensure that personnel wearappropriate clothing to help protect againsthazardous material and hot surfaces. Looseclothing can get caught in a nip, shaft, or othermoving machine components.

Tools

The Owner should ensure that personnel useappropriate tools for the job. Use tools that arespecially designed to break away or are easilyreleased to help avoid certain accidentsituations such as unexpected movement at anip point or a rotating shaft. Under nocircumstances must tools be allowed to comeinto contact with moving parts while theCrushing Plant is energized.

When working in humid or dampenvironments, use hydraulic tools or electricaltools that are suitably grounded, doubleinsulated, or have ground fault interruptioncircuits.

Safety Locks And Tags

Follow all lock-out tag procedures. Refer toappropriate standards and instructionsprovided by Metso.

The lockout program, locks, tags and theblocking/restraining devices provided aredesigned for Operator’s protection. Operator’sresponsibility is to follow the program and usethe proper equipment.

Remember :

– Follow procedures.

– Stay alert.

– Do not take anything for granted.

– Verify lockout.

– Tag must identify the work being doneand the person(s) who locked andtagged the control.

– Locks and tags are changed with eachshift that comes on.

Work to eliminate injury and death. Followproper procedures at all times!

DANGER

For maintenance work, disconnectall devices from electric powersources. Bring all hydraulic gravityor spring loaded devices to azero-energy status. Follow lockoutprocedures.


3.1 - Protective devices and accessories for machine safety . . . . . . . . . . . . . . C-13.1.1 - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13.1.2 - Emergency-Stop (E-Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13.1.3 - Safety interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13.1.4 - Additional warning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-23.1.5 - Walkways, service platforms, ladders and railings . . . . . . . . . . . . . . . . . . C-3

3.2 - Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

3.3 - Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

3.4 - At the work-site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43.4.1 - Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43.4.2 - During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Section C

MACHINE SAFETY

Machine safety SECTION C

3.1 Protective devices andaccessories for machine safety

3.1.1 Overview

The machine system has many built-in safetyfeatures. Owners and Operators should makethemselves familiar with the function andpurpose of each feature and make sure all ofthe features are enabled. Owners andOperators should never attempt to defeat,bypass or disable any safety features. If any ofthe features are defeated or become disabled,the machine should not be operated untilcorrective action is taken and all safetyfeatures are restored.

3.1.2 Emergency-Stop (E-Stop)

Use the emergency stop when injury mayoccur or human life is in danger fromcontinued operation of the machine. Thisprovides the quickest, most sure way to stopthe machine. Due to the large inertial forces ofthe Crushing Plant and Crushing Plant partsand components, the machine can not bestopped abruptly.

Large red emergency stop buttons are typicallylocated in control panels near the vicinity ofdanger points.

Emergency stops can be, and often are, in theform of pull cords that run paraller toconveyors and surround hazards.

The location of local E-stop buttons may varyon different machines; therefore the locationsof these buttons must be verified from theoperating and maintenance manuals specific tothe equipment and/or from proper training.

In emergency stop situations, the objective isto stop the machine as soon as possible tominimize potential injuries while maintainingthe structural integrity of the machine.

Note : It may be necessary to engagereset switches before movement canresume.

3.1.3 Safety interlocks

A safety interlock is a device that will interruptthe supply of electricity, hydraulic oil orcompressed air to an actuator or motor. Amachine already in operation may need to stopquickly due to Operator error, safetyviolations, or an unexpected machine event.For example, a safety gate may be interlockedto stop a machine if the gate is opened whilethe machine is running.

Interlocks can also be used to prevent suddenunexpected movement of a machine functionor component.

During operation, the logic system (i.e.programmable logic controller,microcontroller, relay system or similardevice) controls the functions of the machine.Interlocks built into the system employ limitswitches and other sensors to help assureproper machine operation.

THEREFORE IT IS IMPORTANT THATINTERLOCKING ARRANGEMENTS ARENOT REMOVED, MODIFIED ORBYPASSED, AND THAT THEY ARECORRECTLY ADJUSTED. LIMITSWITCHES, AND OTHER SENSORSMUST BE KEPT IN GOOD WORKINGORDER.

WARNING

On large complex systems, theE-stop may control only thosecomponents that are in theimmediate area.

CAUTION

Emergency stop not only stops themachine but often it may initiateother protective sequences.

02/2005 METSO MINERALS SAFETY INSTRUCTIONS C-1

SECTION C - MACHINE SAFETY

Electric Motors

Electric drives and motors may be controlledto stop or reduce speeds, as determined by thesafety interlocks at a particular location.

Hydraulic System

Components that help protect the hydraulicsystem include certain valves, such as hoseburst valves, pressure relief valves,counterbalance valves and pilot-controlledthrottle valves as well as pressure transducersand drain valves for pressure accumulators.Metso uses these components whereapplicable in the hydraulic systems tominimize the potential for hazardous situationsto occur.

A hose break valve functions to lock up if fluidflow is discharged too rapidly from anactuating cylinder, as happens if a hose breaksand the loads react to gravity.

The pressure relief valve prevents the systempressure from rising beyond systemcapabilities. It helps protect the entire fluidsystem and any operators in the vicinity frombursting hoses and components.

The pilot-controlled throttle valve helpsprevent uncontrolled actuator movements.

Pressure transducers monitor the systempressure for information or control purposes.

Safety Gates

Some safety gates are designed so that openingor closing of the gates will prevent or stop aspecific machine function in that area.Hydraulic, hydraulic or electric limit interlockswitches may cut off the drive or actuatorpower or initiate an emergency stop mode.

For specific operation, see later sections of thismanual.

Safety gates may also be opened formaintenance purposes when the machine hasbeen stopped. Follow all lockout procedures.

Cable Switches

Cables or ropes connected to the electricalswitches can be used as interlocks also. Theymay stop machine function in areas wherecontrol panels cannot be closely located butwhere Operators may be working. Know thelocations of e-stop pull cords for conveyors.

WARNING

Safety gates must not be openedduring normal machine operation.Exceptions to this rule are defined inthe operating instructions.

C-2 METSO MINERALS SAFETY INSTRUCTIONS 02/2005


3.1.4 Additional warning devices

Horns and Lights

If visual contact between work places isobstructed or if communication is difficult,sound and/or light signaling devices may beused before starting the machine or a machinefunction. The warning device for start-upshould operate so that personnel are givensufficient time to move to a safe distance fromthe machine. It is the responsibility of theOwner to ensure that the Crushing Plant isalways equipped with required horns andlights.

Safety Signs and Labels

Safety signs have colors to determine thedegree of hazard in particular areas. Thesesigns must not be removed. Temporaryplacement of safety signs and danger tagsshould also be used on the control panels towarn of maintenance work and lockoutsituations.

Obey all warning and safety signs on themachine and in the manual.

Safety Warning Colors

Color of safety warnings are typically safetyyellow.

3.1.5 Walkways, service platforms,ladders and railings

The design of walkways, ladders and railingsfollow standards and regulations for theapplication. The walkways provide access tothe machine. Safe operating procedures mustbe followed when on walkways. Never stand,walk or climb in or on any area of the CrushingPlant not designated for such activity. If anarea of the Crushing Plant must be accessedand cannot be reached by designatedwalkways, ladders, or platforms, then theOwner and Operator must make all necessaryarrangements for safe access to the area,including but not limited to safe lifting devicesand fall protection.

3.2 Transport

Observe the following precautions beforetransporting the Crusher Plant:

1. Chock chassis tires securely wheneverconnecting or disconnecting chassisfrom tractor or dolly.

2. Check tire pressure. Use a protectivecage or a clip-on type air chuck andremote in-line valve and gauge wheninflating tires. Never exceed maximuminflation pressures of the tire or rim.

3. Check tightness of wheel lug nuts beforetransport and check frequently duringtransport.

CAUTION

Extreme caution must always beused on machine walkways.

02/2005 METSO MINERALS SAFETY INSTRUCTIONS C-3


4. Check that brake system operatescorrectly.

5. Observe maximum axle and tire loadingcapacities.

6. Protect components being transportedusing appropriate shipping braces andblocking material.

7. Travel may be limited to daylight hoursonly, depending on your specific plantand applicable status regulations.

8. Follow recommended limits on towingspeed.

9. Make sure all lights are on and that theyare operating correctly.

10.Use traffic warning flags, signs andlights as required.

11.Before moving the Crushing Plant,check all roadways and bridges on theroute for weight limits.

12.Check clearance of bridges, overheadlines and other overhead obstructions.

13.Follow all applicable laws andregulations.

3.3 Towing

Observe the following precautions beforetowing the Crusher Plant or its components:

– Check if towing is allowed for eachindividual equipment.

3.4 At the work-site

3.4.1 Precautions

Observe the following minimum precautionsat the work-site:

1. Know the locations of underground andoverhead powerlines and other potentialhazards.

2. Select the work-site with care. Theground must be firm, level and able tosupport the weight of the entire plant.Make sure there is enough room forloading ramps, loaders, conveyors, etc.and for safe maneuvering of trucks andloaders.

3. Check that cribbing is secure and thatplant has not shifted or settled.

4. Make sure that electrical cables areprotected from wear and traffic.

5. Follow pre-operation checks andstart-up procedure covered in theindividual manual supplied with yourspecific unit equipment

3.4.2 During operation

Keep watch

Do not rely too much on automated systems.Observe Crushing Plant equipment while thesystem is running. Pay attention tounauthorized persons approaching the site aswell as any unusual behavior of the equipment(uncommon noise, vibration, smell, reducedoutput, etc.).

Clearing

Crushers Plant equipment can become pluggedand stall because of power failures, surges ofmaterial or other unplanned events. ClearingCrusher is potentially very hazardous. Shutdown the system completely, lock and tag outall applicable controls and follow allinstructions in the instruction manual of yourspecific crusher.

C-4 METSO MINERALS SAFETY INSTRUCTIONS 02/2005

4.1 - General information and safety lockouts . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

4.2 - Mechanical safety during maintenance and repair . . . . . . . . . . . . . . . . . . D-14.2.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14.2.2 - Fire Safety During Maintenance And Repair. . . . . . . . . . . . . . . . . . . . . . . D-24.2.3 - Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-24.2.4 - Confined Spaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

4.3 - Electrical safety during maintenance and repair . . . . . . . . . . . . . . . . . . . . D-34.3.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34.3.2 - Electrical Fault Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-44.3.3 - Program Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

4.4 - Hydraulic safety during maintenance and repair . . . . . . . . . . . . . . . . . . . . D-5

4.5 - General maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6

Section D

SAFETY DURING MAINTENANCE AND REPAIR

Safety during maintenance and repair SECTION D

4.1 General information and safetylockouts

Detailed instructions for the operation of themachine can be found in following sections ofthe manual. Because each machine sectionmay incorporate unique functions, some ofwhich may be automated, maintenancepersonnel should be knowledgeable of theoperation of the machine sections in order toperform the maintenance and repair work assafely as possible.

DO NOT COMPROMISE SAFETY DUE TOTIME PRESSURES.

FOLLOW ALL CRUSHING PLANTSAFETY AND FIRE PREVENTIONPROCEDURES.

Before starting any repair, maintenance ortroubleshooting work on the machine, ensurethe following:

– If you have not been trained toperform the required repairs,maintenance or troubleshooting, oryou are unsure how to safely performthe activity - STOP! Never attempt torepair, maintain or troubleshoot anyaspect of the Crushing Plant unlessyou are thoroughly trained for theactivity and understand how toperform the activity in a safe manner.

– Be sure to coordinate all repair andmaintenance work with other CrushingPlant operations.

– Use lockout and warning signs toinform others that maintenance andrepair work are in progress. Thesesigns should only be removed (after allwork has been completed) by theperson who has placed them there.

– Transmit all knowledge of themaintenance work to the succeedingshift.

– Know the whereabouts of allpersonnel in, on, at and around themachine.

– Never service any machine orcomponent without first referencing itsmaintenance manual.

– Before handling chemicals, refer to theMSDS (Material Safety Data Sheets)and Crushing Plant procedures forhandling of these materials.

4.2 Mechanical safety duringmaintenance and repair

4.2.1 General

DANGER:FOLLOW ALL ESTABLISHEDLOCKOUT PROCEDURES. REFERTO THE APPROPRIATESTANDARDS.

For repair, maintenance ortroubleshooting work, disconnect alldevices from electric, pneumatic andhydraulic power sources and followlockout procedures.The lockout instructions, locks, tagsand the blocking/restraining devicesprovided are designed for yourprotection. Your responsibility is tofollow the instructions and use theproper equipment.Remember:• Follow procedures.

• Stay alert.

• Do not take anything for granted.

• Verify lockout.

• Tag must identify the work beingdone and the person(s) who lockedand tagged the control.

• Locks and tags are changed witheach shift that comes on.

Work to eliminate injury and death.Follow proper procedures at all times!

02/2005 METSO MINERALS SAFETY INSTRUCTIONS D-1

SECTION D - SAFETY DURING MAINTENANCE AND REPAIR

4.2.2 Fire Safety During MaintenanceAnd Repair

Observe all regulations on fire safety. Sourcesfor fires include, but are not limited to thefollowing:

– sparks from grinding

– flames and molten metal from weldingor torching

– electrical arcing

– spontaneous combustion

– smoking.

Before starting any work take the followingsteps to prevent a fire hazard:

– Properly dispose of rags withcombustible material to avoidspontaneous combustion.

– Move flammable materials 10m (33ft)or more away from any fire hazard.

– Clean up all debris.

– Clean up all oil spills and leaks.

– Remove any source of flammablegases, liquids or solids.

– Use proper electrical groundingtechniques for welding.

– Provide adequate fire extinguishingequipment; inspect such fireequipment regularly.

– Arrange for qualified personnel toguard against fire while welding,cutting, or heating operations arebeing performed, as well as asufficient period of time after the workis completed.

– Protect yourself and others fromsparks with proper personal protectiveequipment and clothing.

4.2.3 Preventive Maintenance

Preventive maintenance will both increasesafety and be economically beneficial. It ismore safe and economical to replace a wornpart during a scheduled shut-down than torepair a broken device in the middle of aproduction cycle. A machine or device that isnot in proper condition, and that has been leftwithout regular maintenance and inspections,is a safety risk for its user. For instance,without lubrication a bearing may fail,bringing a production line down. Furthermore,the hot bearing may present a fire hazard orcause skin burns.

Some preventive maintenance suggestions fora machine include:

– observing the maintenance andlubrication instructions of the machineand equipment suppliers

– keeping the machine and surroundingarea clean and orderly

– monitoring the vibration levels of themachine and to help predict bearingfailures

– monitoring the power consumption ofmotors to help detect early failures

– repairing all leaks as soon as possibleto prevent more serious conditions thateventually may occur

– monitoring the condition of pipes andtubes enclosed in ducts; repairingpossible leaks

IMPORTANT !

Be sure all mechanical components arebrought to a zero energy status including allspring driven devices, cylinders,accumulators, drive shafts, pulleys, rollers,gears, etc., prior to entering the machine andperforming the work. Never attempt toperform repair, maintenance, ortroubleshooting work on or in proximity toenergized mechanical components.

IMPORTANT !

Block up and support parts as necessary toprevent any unexpected motion whenperforming maintenance.

D-2 METSO MINERALS SAFETY INSTRUCTIONS 02/2005


4.2.4 Confined Spaces

A confined space means a space that:

1. is large enough and so configured that aperson can enter and perform assignedwork; and

2. has limited or restricted means for entryor exit (for example, the crushing cavity,tanks, vessels, silos, storage bins,hoppers, vaults, and pits are spaces thatmay have limited means of entry.); and

3. is not designed for continuous employeeoccupancy.

Certain confined spaces may require an entrypermit program to allow entry. Be sure that allapplicable procedures are followed. If youhave questions contact your Crushing Plantsupervisor for more information.

4.3 Electrical safety duringmaintenance and repair

4.3.1 General

Be sure all electrical components are broughtto a zero energy status including capacitors andsimilar electrical devices.

Before maintenance work:

– Be sure all control power supplies areturned off, disconnected, and lock outprocedures have been followed.

– Confirm that ALL power sources aredisconnected. Some electrical devicesmay be supplied by more than onepower source.

– Be aware that multiple voltage levelsmay exist in some junction boxes.

DANGER

Confined spaces may contain highconcentrations of gases which maycause injury or death. Follow allestablished safety procedures.

DANGER

Follow all established lockoutprocedures.For maintenance work, disconnect alldevices from electric, pneumatic andhydraulic power sources and followlockout procedures.The lockout instructions, locks, tagsand the blocking/restraining devicesprovided are designed for yourprotection. Your responsibility is tofollow the program and use the properequipment.

Remember:

• Follow procedures

• Stay alert

• Do not take anything for granted

• Verify lockout



WORK TO ELIMINATE INJURYAND DEATH. FOLLOW PROPERPROCEDURES AT ALL TIMES!



– Ensure that during lockout procedures,locks and signs are appropriatelyattached, and subsequently removedonly by the person who installed themafter all work is completed. FollowCrushing Plant lockout instructions forplacement and removal.

– For testing and troubleshooting, clearall personnel from the machine just asthough the machine were beingreturned to production mode.Reactivate the necessary powersupplies and perform the tests. Thenagain disconnect all power suppliesand follow lockout instructions beforefurther maintenance work isperformed.

– Be sure electrical supply voltage isdisconnected before drilling into anystructural frame members. Electricalcables may be inside.

– Verify that electric motors aredisconnected before starting anymaintenance work, thereby preventingthe supply of electricity to the motor.Generally the disconnects are locatedin the drive control room. Each personperforming maintenance work shouldinstall their lock and sign the lockouttag.

4.3.2 Electrical Fault Situations

Electrical faults may be caused by componentfailures such as loose or damaged wiring.

Diagnostics are provided through pilot lights,alarms, and help messages.

4.3.3 Program Changes

An electric outlet may be supplied in the logiccenter and control cabinet for programmingpurposes only. Do not connect any electricaltools to this outlet. The tool may causeelectrical disturbances in the machine controlsystem. This could alter the machine controlprogram and cause unpredictable machineoperation.

NOTE : Do not use the logic center or controlcabinet’s outlet for anything other than aprogramming device!

IMPORTANT !

Electrical connections can and do loosen dueto vibration in transit and thermal expansionof the wires and lugs in operation. This isespecially trua after initial delivery, break inand after major relocation. Looseconnections increase current draw, which canresult in false trips, intermittent circuits, andburned-out components. As part of thestart-up, check and retighten as necessary allelectrical connections in the elctricalenclosure. Repeat after the first forty to fiftyhours of operation. This work must beperformed by properly trained personnel.

IMPORTANT !

Improper phasing will damage backstops inconveyor drive reducers and may damagehydraulic system components.

WARNING

Changes to Metso supplied controlprogram should be made only byMetso personnel. Faulty program codemay cause the machine to behaveunexpectedly. Any changes tointerlock circuitry must be made withextreme caution and be reviewed andapproved in writing by Metso beforeimplementation.



4.4 Hydraulic safety duringmaintenance and repair

Before proceeding with any repair,maintenance or diagnostic procedures on thehydraulic system, bring all components to azero energy status, including cylinders,accumulators, spring loaded hydraulic devices,circuitry between valves and actuators, etc.

– Mineral and other oils and additivescan cause skin irritation. Inhaled oilmist can also cause internal irritation,headache or nausea. Avoid repeatedexposure to these materials. Useappropriate personal protectiveequipment.

– Purge entrapped air from the hydraulicsystem. Entrapped air in the hydraulicsystem can cause erratic andunexpected movements.

– Oil mist in the work area or oil leakingonto floors and walkways will cause aserious risk of slipping. Clean up allspills and repair leaks immediately.

– Hydraulic oil temperature may beextremely high.

– A mixture of air and oil mist mayexplode at higher temperatures.Hydraulic oil spilled on hot machinesurfaces may start a fire.

– Pressurized hydraulic hoses should notbe handled with bare hands sincehigh-pressure leaks may easilypenetrate the skin. Hydraulic fluidpressure in the hoses may exceed 3000PSI/210 bar/21MPa.

Hydraulic hoses are subject to wear and tear.Pressurized hoses tend to straighten up, bendor twist due to reaction forces. Replace allweakened or deteriorated hoses promptly.Keep hoses properly clamped and secured tohelp prevent being whipped by broken hoses.

– Avoid letting dirt and other impuritiesinto the system while doingmaintenance work. Use lint free clothsfor cleaning the hydraulic componentssystem.

– When changing a cylinder, or otherhydraulic device, plug all open portsand hose ends. Catch spilled oil in asuitable storage device and avoidintroducing dirt into the system.Dispose of all waste fluids aspresented by law.

DANGER

Follow all established lockoutprocedures.For maintenance work, disconnect alldevices from electric, pneumatic andhydraulic power sources and followlockout procedures.The lockout instructions, locks, tagsand the blocking/restraining devicesprovided are designed for yourprotection. Your responsibility is tofollow the program and use the properequipment.

Remember:

• Follow procedures.

• Stay alert.

• Do not take anything for granted.

• Verify lockout.



WORK TO ELIMINATE INJURYAND DEATH. FOLLOW PROPERPROCEDURES AT ALL TIMES!

WARNING

Elevated temperatures levels can behazardous and may cause severeburns. Wait until machine cools downbefore doing maintenance or repair.

WARNING

Risk of personal injury due to highpressure fluid jets. Do not check forpressurized leaks with bare hands. Usecardboard or other appropriatetechniques.



– Tighten disconnected pipe and hosecouplings immediately afterreinstallation. Before finishing thework, check all parts and connectionsthat have been serviced or repaired.

– Before starting up the pumps, makesure that maintenance work iscompletely finished in all work areas.When starting up the pumps, stay at adistance from the areas which wererepaired.

– Before opening the main valves, makesure that there is no one workingbetween any parts of the machine,since pressurization of the system maycause machine motion.

– Once the system is in the pressurizedstatus, test repaired system for properoperation before putting system backinto production.

Check the system for possible leaks afterrepair. Leaking fittings must not be tightenedwhen under pressure. To seal threaded fittings,use appropriate sealing rings or a sealingcompound suitable for hydraulics.

4.5 General maintenance work

The following are some of the do's and don'tsto be followed as part of normal CrushingPlant procedures:

– Do not perform any maintenance onmoving machinery. This includes suchitems as adding lubricating oil orgreasing parts while the crusher is inoperation.

– Never clear a jam on or in the feeder,crushing cavity or conveyors whensystem is energized.

– Do not put hands or feet on the releasecylinders, which protect the crusherfrom tramp iron overloads while thecrusher is in operation.

– Do check the manufacturer'srecommendations for periodicmaintenance procedures. Thesemaintenance procedures are designedto not only avoid damage to theequipment but also to avoid harm tothe Operator.

– Do avoid spillage around the crusher.Operator should make it a habit tokeep the area immediately adjacent tothe crusher free from spillage, whichcould cause people to trip and fall.

– Never look into the crushing cavitywhile crusher is in operation.

– When using a crane or other liftingdevice to raise or lower a load keep allpersonnel clear of the area.

– Never detach a lifting device from itsload until the load is securely affixedat its designation, or steps have beenimplemented to prevent the load fromunintended shifting or falling.

– Never walk, stand, crawl or lay underany load hanging from a crane or otherlifting device.


0.1 - Personnel safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10.1.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10.1.2 - Stop accidents before they stop you! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10.1.3 - Do you know your employer’s safety program? . . . . . . . . . . . . . . . . . . . . . 0-10.1.4 - Are you dressed properly for the job? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10.1.5 - Do you understand your machinery? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10.1.6 - Do you have knowledge of working areas? . . . . . . . . . . . . . . . . . . . . . . . . 0-10.1.7 - Are you prepared for emergencies? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-20.1.8 - Before starting check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-20.1.9 - Start-up safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-20.1.10 - Report a defective machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-30.1.11 - Stopping safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3

0.2 - Tips for safe maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-30.2.1 - Read and understand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-30.2.2 - Warning tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-30.2.3 - Lockout electrical service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-30.2.4 - Clothing - safe practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-30.2.5 - Alcoholic beverages and medication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-40.2.6 - Work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-40.2.7 - Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-40.2.8 - Fire hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-40.2.9 - Pressurized systems - hydraulic or air . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-50.2.10 - Use quality parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-50.2.11 - Report necessary repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5

0.3 - Plant safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-50.3.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-50.3.2 - Drive Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-50.3.3 - Operator’s platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-50.3.4 - Electrical lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-60.3.5 - Cranes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-60.3.6 - Mobile cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-60.3.7 - Welding equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-60.3.8 - Lift gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-70.3.9 - Conveyor belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-70.3.10 - Portable plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-70.3.11 - Crushing plant «noise» . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-70.3.12 - Epoxy backing material versus zinc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-70.3.13 - Crushing plant "Dust" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-80.3.14 - General maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-80.3.15 - Thermal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8

Section 0

SAFETY

Safety SECTION 0

0.1 Personnel safety

0.1.1 General

This portion of the instruction manual isintended to illustrate only basic safetyprocedures. Additional precautions may benecessary for the safe operation of a crusher.The information contained in this manual isnot intended to replace safety codes, insurancerequirements, federal, state and local laws,rules and regulations.SAFETY of the operator and maintenancepersonnel is of prime concern. Theseparagraphs are presented as a helpful guide toconstruction equipment personnel and showssome of the daily work problems which theymay encounter.It is the responsibility of the operator to knowwhat specific requirements, precautions andwork area hazards exist and to discuss themwith his supervisor. A common understandingshould be reached by all personnel to assuresafe performance in operating the equipment.The operator is the key to safe job performanceand should study these safety tips to be awareof basic safety precautions to help preventserious injury and damage to property.

0.1.2 Stop accidents before theystop you!

In order to alert you, the user, and thoseentrusted as operators and maintenancepersonnel, dangerous or hazardous operationsare shown in this instruction manual withWARNING notes.The safest machine must still be operated withcare and with knowledge of its performancecapabilities. The most comprehensive safetyprogram must still be followed.Remember that on any job, you are the key tosafety. Good safety practices not only protectthe men around you, they are your own bestprotection. Study this manual and anymanufacturer’s operator’s manuals coveringyour specific equipment. Read all"WARNING" and "CAUTION" instructions.Practice safe operation.INSIST THAT YOUR FELLOW WORKERSDO, TOO. BE ALERT TO POSSIBLE

HAZARDS BEFORE THEY CAUSETROUBLE, AND REMEMBER . . . SAFETYIS UP TO YOU!!!

0.1.3 Do you know your employer’ssafety program?

Company safety records show that the greatestpercentage of accidents are caused bydisregard of simple safety rules. Know observethe overall program and consult yoursupervisor for specific instructions whenstarting a job.

0.1.4 Are you dressed properly forthe job?

You may need any number of special items:safety hat, safety shoes, safety glasses,goggles, heavy gloves, ear protective devices,etc..., for your own protection. Find out whatitems are required and wear them!Loose clothing can catch in moving parts.Keep sleeves buttoned, jackets belted and wearyour special safety equipment. Keep warmwithout restricting your movement. Wristwatches and rings can be dangerous. Keepyour pockets free of objects which may fallout.

0.1.5 Do you understand yourmachinery?

READ THE MANUAL furnished with yourequipment to learn its operating andmaintenance characteristics, capacities andlimitations. Learn the location and function ofall controls, indicators, warning devices andcaution instructions. Learn to recognize themachine’s warning and safety devices. Theywill alert you to conditions such as lowpressure or high temperature that may make ithazardous to continue operating.

0.1.6 Do you have knowledge ofworking areas?

Learn beforehand as much about your workingarea as possible:Be a good housekeeper. Keep the floor clean,free of oiI, grease, rags, cables, chains,buckets, rocks and other hazards. Keep looseparts in a tool box. Use only non-flammablesolutions for cleaning.

HP100/200/300/400/500 CONE CRUSHERS INSTRUCTION MANUAL 0-1

SECTION 0 - SAFETY

Know the weight limitations for any floors onwhich you will operate.Know the clearances in the work area. A littletime spent checking side and overheadclearances, including power lines, can save alot of trouble later.Be careful of dust, smoke or fog, which mayobscure your vision.

0.1.7 Are you prepared foremergencies?

Plan ahead, stay alert, operate sensibly and youwill avoid both having and causing personalinjury and accidental equipment damage. If acareless moment does cause an emergencyreact quickly with the tools and skills at hand.Know the location of and how to use a fireextinguisher and a first aid kit.Know where to get prompt assistance. Anemergency calls for fast action.Don’t stop your safety program with thesegeneral rules. Be equally conscious thatspecific working conditions and yourparticular equipement can require additionalprecautions.

0.1.8 Before starting check

Equipment not properly prepared for operationis unsafe equipment. Run a careful check at thebeginning of your shift. If you find somethingthat needs attention, THINK TWICE beforedeciding to "let it go this time". Even minormechanical defects can lead to personal injuryand accidents.

1. DO NOT allow unauthorized personnelto operate the crusher!

2. MAKE SURE all guards and otherprotective devices are in place, securedand not damaged.

3. CHECK fluid systems: Are they at thecorrect level and completely leak free?

4. CHECK every drain cock, valve andfitting to be sure it is in place andsecure.

5. LOSS of pressure from low fluid levelsmay lead to serious hydraulic failures.

6. CRUSHER SEIZURE from lack of oilor grease is a problem that may causeaccidents.

7. NEVER adjust pressure relief valves toget higher operating pressures. Themanufacturer’s recommended pressuresgive the safest performance with thelongest life.

8. NEVER tamper with safety devices.

9. CHECK the crusher thoroughly forvisual defects, such as leaks, worn hosesor loose parts.

10.INSPECT your machine according tothe operator’s manual and yoursupervisor’s instructions.

11.BEFORE STARTING walk completelyaround your machine. Make sure there isno-one next to, under or on the machine.Warn any personnel nearby that you arestarting up.

REPORT ANY DEFECTS TO YOURSUPERVISOR.

0.1.9 Start-up safely

1. CHECK equipment for warning tags.

2. FOLLOW the recommended startingprocedures as outlined in Section 3,"Operating instructions".

3. AFTER crusher has been started, checkall gauges and instruments to be surethat everything is operating properly.

4. SHUT DOWN immediately if anyimproper readings are observed.

5. TEST all controls for properfunctioning.

6. LISTEN for and report any unusualnoises.

7. RECHECK alarms or other warning andsafety devices.

8. DO NOT stand on the adjustment ringwhile the crusher is running.

9. DO NOT lean or place your hands on oragainst the tramp release cylinders orbetween the adjustment ring and mainframe while the crusher is in operation.


SECTION 0 - SAFETY

10.DO NOT take a chance with a defectivemachine. REPORT IT TO YOURSUPERVISOR.

11.DO NOT look into crushing chamberwhile crusher is operating withoutprotection.

0.1.10 Report a defective machine

Inspect your machine daily, check for loose,worn or damaged parts. Report or correct anyunsafe conditions immediately and do notoperate the machine until they have beencorrected.Even a minor defect can become serious,report any machine defects to your supervisor.

0.1.11 Stopping safely

Be sure crusher is stopped before cleaning,servicing, lubricating, checking belt tension,removing housing covers, working on thehydraulic system, making repairs, orattempting to clear a plugged cavity. MAKENO CHECKS, ADJUSTMENTS ORREPAIRS OF ANY KIND WHILE THECRUSHER IS IN OPERATION.

0.2 Tips for safe maintenance

Perform maintenance with care.

0.2.1 Read and understand

1. Instruction manual furnished with thecrusher, especially section 3, "Operatinginstructions".

2. Instructions for inspection andmaintenance located at the rear ofsection 3, "Operating instructions".

3. Warning plates provided on themachine.

4. Warning notes in the instruction manual.

5. Lubrication guides for periodicservicing also at the section 4.

0.2.2 Warning tags

Before working inside a crusher, be sure to tagand lockout the electrical controls so no oneelse will start it.

Attach warning tags to prevent accidents:

1. If crusher is unsafe for operation.

2. If controls are being serviced.

3. If machine is being repaired.

0.2.3 Lockout electrical service

1. Always lockout all electrical controlsbefore performing any type ofmaintenance work on the crusher.

2. When servicing the hydraulic powerunit, lockout the electrical service to thepower unit as depressing the "STOP"button will only stop the motor.

3. Provide each maintenance man with hisown personal padlock and ONE key.

0.2.4 Clothing - safe practice

1. KEEP HANDS AND CLOTHINGAWAY FROM MOVING PARTS. Donot take chances by wearing loosesleeves, floppy ties, watches and rings.

2. WEAR EYE PROTECTION whenhandling fuel, cleaning fluid, oil orbrake fluid. THESE MATERIALS CANDAMAGE YOUR EYES.

3. WEAR A RESPIRATOR when required.

4. WEAR SAFETY GLASSES whendrilling, grinding or hammering metal.

5. KEEP YOUR POCKETS FREE ofobjects which can fall out and intomachinery.

6. WEAR HARD HAT AND SAFETYSHOES, when required.

7. WEAR GLOVES to protect your handswhen changing cables.

8. WEAR SAFETY GLASSES ANDPROTECTIVE CLOTHING when usinghigh pressure air.

9. WEAR GOGGLES ANDPROTECTIVE CLOTHING whenhandling molten metals; zinc, babbitt,lead, etc...

0-3 HP100/200/300/400/500 CONE CRUSHERS INSTRUCTION MANUAL

SECTION 0 - SAFETY

10.WEAR EAR PROTECTIVE DEVICESwhen required or REDUCE exposuretime as required.

0.2.5 Alcoholic beverages andmedication

1. DO NOT use alcoholic beverages beforecoming to work or while on the job.

2. BEWARE of medicines, tranquilizers orother drugs which can make you sleepyor less alert.

0.2.6 Work area

1. PROMOTE GOOD HOUSEKEEPING,keep the floor clean and dry, free ofdebris and tools. Oily and wet floors,steps and hand rails are slippery. Inwinter,watch out for ice and snow. Wetspots, especially near electricalequipment, are dangerous.

2. DO NOT let material lay and build upon or around the crusher.

3. STORE dangerous fluids in a suitableplace away from unauthorizedpersonnel.

4. NEVER start a diesel or gasoline enginewithin an enclosed area unless there isadequate ventilation. Exhaust fumes cankill!

5. Take appropriate precautions when torchcutting or welding. Anyone performingthese types of procedures should avoidbreathing the fumes because they maypose a health hazard. Such proceduresshould be done outdoors in a wellventiled area with either a separate cleanair supply provided to the mechanic orwith local exhaust of fumes. Please referto the local legislations.

0.2.7 Equipment

1. Use the proper tools; handle tools andheavy parts sensibly.

2. Keep all tools and equipment free ofdirt, oil and grease. Do not drop or tossthem.

3. Use hoisting equipment for heavylifting. Save your back.

4. Lower parts, do not drop them.

5. To prevent slipping, wipe hand leversand knobs clean of oil or grease.

6. Do not use sheaves with cracked rims orspokes.

7. Check for missing, cracked or frayedV-belts.

8. Check for broken, defective or missingparts and replace them. Keep equipmentclean and free of dirt and oil so you canspot loose or defective parts.

9. When using cables to move a load, besure cables are of adequate size andreplace any worn, badly frayed, brokenor kinked ones.

Check end connections for wear.

0.2.8 Fire hazards

1. DO NOT SMOKE while refueling orwhen handling fuel containers.

2. SHUT OFF engine when refueling anduse extra caution if engine is hot.

3. WHEN pouring fuel into the tank,ground the funnel or spout against thefilter neck to avoid static electric spark.

4. DO NOT use gasoline or diesel fuel forcleaning parts. Good commercial,non-flammable solvents are preferred.

5. DO NOT smoke while using cleaningsolvents.

6. DO NOT let greasy, oily ragsaccumulate in a poorly ventilated area.Store oily rags and other combustiblematerial in a safe place.

7. NEVER use an open flame to checkfuel, battery electrolyte or coolant levelsor to look for hydraulic leaks anywhereon the equipment. Use a flashlight!

8. KNOW where fire extinguishers arekept and how they operate and for whattype of fire. Check regularly at leastmonthly to be sure it is in the workingarea.


SECTION 0 - SAFETY

9. In the event of a fire, shut down thecrusher hydraulic power unit andlubrification system if this can be safelydone.

0.2.9 Pressurized systems -hydraulic or air

1. Relieve ALL pressure before opening orremoving any hydraulic or air pressurelines, valves, fittings, etc...

2. Check for worn hoses or damaged lines.

3. High pressure oil can be dangerous.

The machine is fitted withhydro-pneumatic accumulatorsgoverned by national regulationobliging sometimes with periodiccontrols.

0.2.10 Use quality parts

A replacement part for any item should alwaysbe of comparable SlZE, TYPE and QUALITYas the part being discarded.

0.2.11 Report necessary repairs

If your daily check uncovers any item thatneeds attention repair, replacement oradjustment REPORT IT NOW!The most minor defect could result in moreserious trouble IF THE MACHINE ISOPERATED.Only perform the work you’re authorized todo. Do not attempt repairs you do notunderstand.Only work on equipment you thoroughlyunderstand a pressure-loaded part, if carelesslyreleased, could injure anyone in its path.Remember you are entrusted with theoperation and maintenance of a highlyvaluable piece of equipment. TREAT IT ASSUCH!

0.3 Plant safety

0.3.1 General

The safety procedures mentioned here do noteliminate all safety hazards found in the areaof crushing plants. However, they do highlightsome of the procedures which have been foundthrough long experience to improve safetyconditions around crushers and crushingplants. Metso Minerals will welcome inquiriesregarding other suggested safety procedures touse around their crushers and relatedequipment.

0.3.2 Drive Guards

Proper safety precautions start with the initialinstallation of the crusher. Crushers are driveneither by V-belts or by direct couplings tomotors. THE BELT DRIVE OR COUPLINGSHOULD HAVE A PROTECTIVE GUARDAROUND IT.Crusher sheaves in particular are designed formaximum rim speeds. If these speeds areexceeded, it is possible that the sheave couldexplode and cause severe injury or even death.Since the speed of the crusher is quiteimportant for proper operation, most V-beltdrive guards usually have a small openingimmediately opposite the center of the crusherdrive shaft so that a tachometer can be insertedto occasionally check the speed of thecountershaft. This opening should be coveredwith an access door or hatch.

0.3.3 Operator’s platform

Since periodic inspection and maintenancemust be performed on each crusher, IT ISIMPORTANT THAT SOME TYPE OFPLATFORM BE ERECTED AT A LEVELCONVENIENT FOR THE MAINTENANCEMEN WHO MUST INSPECT AND WORKON THE CRUSHER. A good operator’splatform constructed of «solid» floor plateshould have hand railings,toe plates and wiremesh or expanded metal between the platformand the top of the hand railing to prevent toolsfrom dropping off the platform and hittingsomeone working below. Do not fasten theoperator’s platform to the adjustment ring asthe entire adjustment ring raises or lifts veryquickly when trap iron passes through thecrusher.

WARNING (HP100 ONLY)

Because of risk of personnel’s injuriesand damages to the machine, clampingpressure must be maintained to 0 whenbowl is not engaged in both clampingand adjustement ring (this from the timeth bowl is unsrewed until it is screwedagain).


SECTION 0 - SAFETY

0.3.4 Electrical lockout

THE ELECTRICAL POWER SOURCE FORTHE CRUSHING EQUIPMENT SHOULDBE LOCKED OUT WHENEVER ANYONEIS WORKING ON IT.Each maintenance man who normally workson a crusher should be provided with his ownpersonal padlock with only one key. When heworks on any assembly of the crusher, heshould use this padlock to lock out theelectrical controls for the crusher. It is mostimportant that only one key be provided for thelock and that key must be in the pocket of theperson who is working on the crusher. If morethan one person works on the crusher, eachshould have his own lock and key at separatelockout stations for the controls of the crusher.Accidental start-up of crushing equipmentwith men in the immediate area can beresponsible for many accidents on what wassupposedly a "clear" machine.

0.3.5 Cranes

Crushers, like any other type of mechanicalequipment, require normal periodicmaintenance if the operator is to get the mostfor his money from the use of the machine.One of the most flagrant crusher safetyviolations is the use of inadequate and unsafelifting equipment. Although a crusher is not afinely tuned piece of equipment, such as anautomobile engine, the internal parts of acrusher should be assembled and disassembledwith crane facilities that have the capability ofgently and slowly lifting and lowering thevarious parts that make up a crusher. WHENUSING A CRANE, ALWAYS OPERATEWITHIN THE RATED CAPACITY OF THECRANE. THE SAFE RATED CAPACITYINCLUDES WEIGHT OF HOOK, BLOCKAND ANY MATERIALS HANDLINGDEVICES SUCH AS CABLES, SLINGS,SPREADER BARS, ETC. SUBTRACT THEWEIGHT OF ALL THESE TO FIND THETRUE WEIGHT OF THE LOAD THAT CANBE HANDLED SAFELY. Chain falls shouldbe considered only as a last resort to assembleand disassemble a crusher.When it comes to safety, the best should beused.

0.3.6 Mobile cranes

WHEN USING A MOBILE CRANE,ALWAYS OPERATE WITHIN THE RATEDCAPACITY OF THE MACHINE TO AVOIDBUCKLING THE BOOM OR TIPPING.Safe ratings are based on operating the craneon firm, level ground; outriggers should beproperly extended and/or lowered wheneverpossible. Avoid fast swings, hoists or suddenbraking; these can cause overloads. Do nothandle large, heavy loads in strong winds.When moving your crane, check bridgesbefore crossing, make sure they will supportthe weight of the machine. Check clearancesunder bridges, for overhead electrical lines orany overhead obstruction.Check your hitcher, be sure he’s clear beforestarting lift. Make certain he securely attachesthe load.

0.3.7 Welding equipment

Precautions in general must be taken whentorch cutting and/or welding due to the healthhazards posed by many metals. Anyoneperforming these types of procedures shouldavoid breathing the fumes. Such proceduresshould be done outdoors or in a well ventilatedaera with either a separate clean air supplyprovided to the mechanic or with local exhaustof fumes. Please refer to the local legislations.One of the most frequently used tools aroundthe crusher is the cutting torch. Crushers whichare equipped with hydraulic componentsshould have these components depressurizedand adequately covered with flame-proofmaterial so that sparks, weld spatter, etc.,cannot reach these areas. Ruptured highpressure hydraulic lines will quickly vaporizethe hydraulic fluid as it reaches theatmosphere. This vaporized fluid can quicklybecome a mass of flames, resulting in severeburns for personnel in the immediate area.ALL MAINTENANCE PERSONNEL WHONORMALLY USE TORCH CUTTINGEQUIPMENT SHOULD BE ADVISED IFTHERE ARE HYDRAULIC COMPONENTSIN THE IMMEDIATE AREA IN WHICHTHEY ARE WORKING. Then adequateprecautions should be made to avoid contact


SECTION 0 - SAFETY

with these components. Rubber lined hoses arenot immune to the torch cutting equipmentwhich is used in normal plant maintenanceprocedures.

0.3.8 Lift gear

All crusher components must be lifted byequipment permitting slow, even movementsALWAYS COMPLY WITH MAXIMUMLOAD REGULATIONS for the equipmentand remember to add the weights of hoistingaccessories (such as chain, hooks, etc...) to thecrusher weight.

0.3.9 Conveyor belts

DO NOT WALK ON THE BELTS OFCONVEYORS.There must be footbridges with hand rails allalong the conveyors.

0.3.10 Portable plants

If your crushing plant consists of portableequipment, that is, crushing and screeningequipment mounted on trailers, trailer footingor cribbing is extremely important for safeoperation. Check your footing. Your machineshould be on as solid and level a footing aspossible. Use heavy timber mats as needed.Trailers must be raised so that trailer wheels donot touch the ground. Place screw jacks at eachcorner of the trailer or as near the corner aspossible. All four jacks must be an equaldistance from each end. Adjust each jack untilthe unsupported portion of the trailer beamsstop vibrating or until vibrations are reduced toa minimum. NEVER leave your trailer in a lowspot where rains may wash out your footing.PERIODICALLY RECHECK TRAILERFOOTING FOR STABILITY.When moving your trailer, check bridgesbefore crossing, make sure they will supportthe weight of the machine.Check clearances under bridges, for overheadlines or any overhead obstruction. NEVERTRAVEL WITH NEAR CAPACITY LOADS,CHECK LOCAL LAWS, ESPECIALLY ONWEIGHT LIMITATIONS. When traveling onthe highway make sure all headlights,

clearance lights and tail lights are on. Useproper traffic warning flags and signs.

0.3.11 Crushing plant «noise»

Crushing equipment by its very nature is noisyand the auxiliary equipment found in andaround crushing equipment such as chutes,transfer stations, screens, etc..., can at times benoisier than the crusher itself.Typical crusher acoustic power level whilecrushing is between 100 and 130 DBA. Earprotective devices may be required if noiselevels are higher than those allowed by law. Ifear protective devices are undesirable,consideration should be given to reducing theamount of noise exposure that an operator ormaintenance man may be subjected to. In otherwords, shorter working hours.Although alteration of the machinery tochange its noise characterisics may beeconomically impossible, many operators havefound that the installation of a relativelyinexpensive operator’s station can improvenoise conditions. The operator can see theequipment in operation and still be protectedfrom the noise through the installation ofaccoustical tile, double windows, airconditionning equipement, etc. These workingconditions will normally result in a moreefficient operation and reduce potentialinjuries from noise.Many plant operators are finding that anoperator’s tower erected at an elevation abovemost of the equipment provides both safetyfeatures for the operator and increasedefficiency in plant operation.

0.3.12 Epoxy backing materialversus zinc

All crushers require some type of backingwhen replacing the crushing members. Resinssuch as Epoxy Backing Material have all buteliminated the possibility of workmen beingaccidentally burned due to molten zinc eitherspilling or exploding when it comes in contactwith wet surfaces.THE ENORMOUS DEGREE OFCONVENIENCE AS WELL AS THE HIGHSAFETY FACTOR INVOLVED WHENUSING PLASTIC BACKING AGENTS HAS


SECTION 0 - SAFETY

MADE THE USE OF MOLTEN ZINC FORCRUSHER LINER BACKING OBSOLETE !When epoxy backings are used, care should betaken when removing the liners with a cuttingtorch.THE AREA SHOULD BE WELLVENTILATED BECAUSE EPOXY FUMESCAN CAUSE NAUSEA OR POSSIBLE EYEOR SKIN IRRITATION.

0.3.13 Crushing plant "Dust"

Crushing equipment and auxiliary equipmentsuch as chutes, transfer stations, etc.., cancreate dust. Breathing dust may be hazardousto the health of anyone working at, on, oraround the equipement.In general, high levels of dust in the air create ahazard of lung disease, depending upon theconcentrations of dust, the length of exposure,and the type of material being crushed.Metso Minerals highly recommends thatdust-protective devices such as a respirator beworn by anyone exposed to airborne dust toprevent its inhalation.It is the responsability of the operator todetermine the necessity and adequacy of suchprotective devices and warnings, to providethem, and to ensure that they are used andfollowed.It is possible to reduce the amount ofairborne dust by making alterations to thecrushing circuit, such as the addition of a dustcollection system, or the use of water spraybars at the feed and/or discharge conveyor.Crushing with a choke level may also reducethe amount of dust issuing from the crusheritself.

0.3.14 General maintenance work

A certain amount of work must be done in theimmediate area of the crusher during thenormal course of operations on a day-to-daybasis.

1. DO NOT perform maintenance onmoving machinery. This includes suchitems as adding lubricating oil orgreasing parts of the crusher while it isin operation.

2. DO NOT put hands or feet on the tramprelease cylinders which protect thecrusher from tramp iron overloads whilethe crusher is in operation.

3. DO check the manufacturer’srecommendations for periodicmaintenance procedures. Thesemaintenance procedures are designed tonot only avoid damage to the equipmentbut also avoid harm to the operator aswell.

4. DO avoid spillage around the crusher.Crushers seem to attract odd size piecesof rock, gravel, etc... Plant operatorsshould make it a habit to keep the areaimmediately adjacent to the crusher freefrom this type of spillage which couldcause unsuspecting personnel to trip andfall.

5. NEVER LOOK into the crushing cavitywhile the crusher is in operation withoutprotection from possible flying material.

6. WHEN USING A CRANE to raise orlower a load keep all personnel clear ofthe area.

7. NEVER walk, stand, crawl or lay underany load hanging from a crane.

0.3.15 Thermal Procedures

Follow appropriate safety precautions whenhandling dry-ice, liquid nitrogen, or any othercryogenics coolant when cooling variousparts of the crusher.Severe bodily injury can occur when properprecautions are not followed.

REMEMBER - SAFETY IS UP TO YOU !


1.1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 - HP cone crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 - Initial inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.4 - Information included in this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.5 - Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.6 - Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.7 - Crusher capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.8 - Choice of liner and mantle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Section 1

GENERAL INFORMATION ON THE CRUSHER

General information on the crusher SECTION 1

1.1 Introduction

This maintenance manual is designed to helpusers and operators at crushing facilities on theoperation and servicing of HP cone crushers.This manual explains how it is constructed andprovides you with the information needed tooperate it properly.All our crushers are fully assembled and testedbefore shipment. However, certain precautionsshould be taken when using the crusher. Theseprecautions, which are detailed below, areintended to prevent problems caused byimproper use of the crusher.You are strongly advised to read all sections ofthis manual, understand them and put theminto practice.

1.2 HP cone crushers

This instruction manual applies to thefollowing cone crushers: HP100, HP200,HP300, HP400 and HP500.

1.3 Initial inspection

A full check of the crusher should be carriedout when it is delivered to identify any damagesustained in transit and check that all the partsare present. One should also check that nothinghas been mislaid. The supplier should benotified immediately of any missing ordamaged parts so that they can be replaced orrepaired without delay.

1.4 Information included in thismanual

The following diagrams of your crusher comewith this manual:

1. Sketch of the foundations.

2. Pipework diagram for the crusher andlubrication system.

3. Diagram of auxiliary installationssupplied with the crusher.

4. Any other drawings and informationrelevant to your facility.

A catalogue of spare parts together with all theassembly plans will be sent separately in duecourse, usually after delivery.

This manual presents and identifies the partsused to assemble the crusher.

1.5 Spare parts

Metso Minerals does its utmost to have a largestock of parts available at all times for rapidand efficient servicing, repairs andreplacements.To avoid prolonged delivery times andincorrect shipments, please specify thefollowing:

1. Size of the crusher.

2. The crusher's serial number stamped onits ID plate and on the spare partsmanual.

3. The precise quantity of each requestedpart.

4. The full code name and code of the partas specified in the spare parts manual.

5. Comprehensive delivery instructions forthe parcel by sea, rail, road or air.

If you have lost your manual, we will supplyyou with another one on request.Only genuine Metso Minerals parts aremounted for optimal performance. They areguaranteed to be compliant, carefullymanufactured and of quality.

TECHNICAL MANUAL NORDBERG CONE CRUSHERS HP100/200/300/400/500 1-1

SECTION 1 - GENERAL INFORMATION ON THE CRUSHER

1.6 Terminology

To avoid any confusion or misunderstanding,all the terms used throughout this manual todescribe the crusher and its operation aredefined below:FEED (or infeed): the material to be crushed.BOWL LINER AND MANTLE: the partsthat crush.

– Fixed bowl liner.

– Mantle on the head.

CRUSHING CHAMBER (or CAVITY): theinner area enclosed by the bowl liner andmantle.PARALLEL ZONE: when the bowl liner andmantle are closed, during rotation, their lowestparts are parallel over a short distance. Thissurface is known as the parallel zone.GRIP (closed end): the shortest distancebetween the liner and mantle’s summits whenthey are closed during gyration.GRIP (open end): the longest distance at theliner and mantle’s summits when they are openduring gyration.GRADATION: the distance between thebottom of the liner and mantle at the pointwhere they are the closest to each other duringgyration. This determines the size of thecrushed product.MINIMUM GRADATION: the shortestpermissible distance between the bottom of theliner and mantle when they are closed.DISCHARGE OPENING: the distancebetween the bottom of the liner and mantle inopen position during gyration. This enablesrapid discharge of the crushed material.PRODUCT SIZE: size of the screenedproduct after crushing.CAPACITY (output/yield/throughput):crusher output expressed in tons per hour(TPH).OPEN-CIRCUIT OPERATION: whenregular product size does not matter, theproduct only passes through once.CLOSED-CIRCUIT OPERATION: whenregular product size matters; the product isscreened at the crusher outlet and oversizeparticles are redirected to the crusher.

1.7 Crusher capacity

Factors to consider for optimal throughput andperformance:

1. Choice of the crusher cavity (materialsto crush).

2. Minimal segregation of grain size onintake.

3. Feed control

4. Even distribution of the material 360°around the cavity.

5. The discharge conveyor belt should beadequately sized.

6. Appropriate scalping and screening.

7. Automatic feed control

8. Adequate discharge area.

Factors impairing throughput and yield:

1. Sticky material in the feed.

2. Fines in the feed (over 10% of thematerial is undersize).

3. Excessively damp product.

4. High segregation rate on intake.

5. Uneven feed distribution.

6. No in-feed control

7. Inadequate motor power rating.

8. Inadequate conveyor capacity.

9. Insufficient scalping and screening.

10.Inadequate discharge area.

11.Very hard material that is difficult tocrush.

12.Inadequate speed.

Throughput ratings in the sales catalogue arebased on tests of numerous plants processing awide range of materials. For a precise rating ofyour particular plant, please contact MetsoMinerals.


SECTION 1 - GENERAL INFORMATION ON THE CRUSHER

1.8 Choice of liner and mantle

After intensive research and studies, MetsoMinerals has developed a wide range of linersand mantles for a variety of products.However, working conditions vary so muchthat one cannot say with certainty what type ofliner/mantle is best suited to a particular typeof material or process.If excessive wear of the bowl liner and mantleoccurs for any reason whatsoever, we suggestthat the bowl liner and mantle be cut and theiroutline traced on a sheet of paper and sent toMetso Minerals in order to determine the exactcause of the wear (see Figure 1-1).Other liners and mantles of different shapesmay be recommended.In order to best advise you on the type ofliner/mantle you require, we need to have thefollowing details:

1. Dimension of the feed product.

2. Type of feed.

3. Desired size of the crushed product.

4. The circuit of the installation, with thesquare mesh of the screens and thegradation of the crushers.

5. Identification of the bowl liner andmantle.

6. Installed capacity.

7. Crusher throughput rates.

The crusher can be damaged by constantlyworking with an inadequately sized cavity inthe liner and mantle.

Figure 1-1 Wear check

Ref. Description

1 Cut out the mantle or bowl liner

2 Cardboard or thick paper

3 Trace the outline on a sheet of paper inserted in the cutout

2

31

1-3 TECHNICAL MANUAL NORDBERG CONE CRUSHERS HP100/200/300/400/500

2.1 - Installation plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 - Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2.1 - Installing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2.2 - Anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.3 - Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.4 - Removing the crushed material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.5 - Control drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.6 - Installing a V-belt drive for the first time . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.7 - Tautening the V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.7.1 - Tension-Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.7.2 - Relative elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.8 - V-belts - precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.9 - Initial alignment of a flexible coupling sleeve . . . . . . . . . . . . . . . . . . . . . 2-10

2.10 - Crusher drive motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.11 - Piping information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.12 - Information on assembling and dismantling the crusher . . . . . . . . . . . . 2-12

2.13 - General information on servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.14 - List of minimum recommended spare parts . . . . . . . . . . . . . . . . . . . . . 2-14

2.15 - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.16 - Protecting the crusher against corrosion. . . . . . . . . . . . . . . . . . . . . . . . 2-23

GENERAL INSALLATION INFORMATIONS

Section 2

General installation informations SECTION 2

2.1 Installation plan

Concrete blocks or steel constructions must becalculated and sized according to thedimensions and load factors specified in theinstallation documents.The said calculations should also factor in theresults of a preliminary study of the soil’selasticity at the point of casting orconstruction.

2.2 Layout

2.2.1 Installing the machine

The frame’s bearings should rest on a flat, evensurface.Be sure to make allowance for:

– enough height to dismantle bowl andhead assemblies.

– enough width to dismantle theregulator assembly.

– enough room for a hopper feed, chuteand other auxiliary equipment, and forremoval of crushed material, hopper,conveyors, servicing the crusher, etc.

2.2.2 Anchoring

When installing on a concrete block, themachine should be anchored to it with severalfish-tail or hook anchor bolts.These bolts transmit their tractive force to theconcrete bonding by adhesion.The concrete bonding transmits the force fromthe bolts to the concrete block. This forceshould travel from one concrete to the nextthrough their dividing surface.The anchoring key (where relevant) is onlyused to maintain the bolt and the part to bebonded until the concrete sets.

Concreting should be completed as soon aspossible for slender constructions exposed towind, in any event before the crusher isbrought into service, because a hook anchorbolt is twelve times weaker before the concretesets.The anchoring key plays no part in theanchoring strength and a properly set boltcannot buckle or stretch when the nut istightened up.As a general rule, concreting should be done inaccordance with good practice and localregulations.


SECTION 2 - GENERAL INSTALLATION INFORMATIONS

2.3 Feed

Crusher performance is directly proportionalto the feed method; it can only achieve optimalperformance if fed with an adequate amount ofmaterial evenly distributed in the cavity. Forbest performance, certain precautions shouldbe taken in laying out the feed plant; forinstance, it should be easy to dismantle tofacilitate repair work on the crusher itself.

Figure 2-1 Feed

INCORRECT FEED

Here, the material is unevenly distributed,only falling down one side of the feedopening.Uneven distribution causes:

1. Reduced output.

2. Irregular grain size of the crushedmaterial.

3. Excessive adjusting ring bounce.

4. Excessive power consumption.

CORRECT FEED

Here the material is evenly distributed.Uneven distribution causes:

1. Optimal output.

2. Properly graded material.

3. No minimum adjusting ring bounce.

4. Optimal power consumption.



Well-designed feeds should stop the materialwhen it reaches the feed ramp so that itbounces up and falls vertically into the feedchute. This ensures even distribution over thefeeder cone. Well-designed feed assembliesthat take the feeder cavity into account ensureeven distribution throughout the cavity.Segregation must be avoided at all costs toensure even wear of the liner and mantle andthus maximum wear life. For short-headcrushers, feed should be adjusted so that thematerial covers the cone feed plate. Thematerial should spread across the entirecrusher cavity. This feed system ensures highyield or better formed crushed product of asmaller grain size and considerable powersavings. Feed intake assemblies are notsupplied with the crusher because their designdepends on the layout of each crusher.IMPORTANT:WHEREVER POSSIBLE, INSTALL ASIEVE UPSTREAM OF THE CRUSHER TOREMOVE FINE OR STICKY MATERIAL.THIS PREVENTS JAMMING, WHICHCAUSES EXCESSIVE RING BOUNCEAND TIME LOSS. A MAGNETICSEPARATOR MAY ALSO BE USED TOANY REMOVE METALLIC PARTICLESTHAT COULD CAUSE ADJUSTMENTRING BOUNCE.THE CHARACTERISTICS OF THE FEEDSYSTEM SHOULD BE SUCH AS TOMAINTAIN THE CRUSHER IN OPTIMALOPERATING CONDITIONS.

IT IS IMPORTANT TO CONTROL THEFEED INTAKE SPEED IN THECRUSHER. NEARLY ALL THEMATERIAL FALLING INTO THECRUSHER CAN PASS THROUGH THECAVITY ON THE OPEN SIDE.MATERIAL FALLING TO THEBOTTOM OF THE CHAMBERWITHOUT BEING CRUSHED WILLCAUSE RING BOUNCE AND DAMAGETHE SPAN OF THE FRAME. ANADEQUATE HOPPER MAY BE USED TOSLOW DOWN THE SPEED OF THEFALLING MATERIAL IF THE FALLINGDISTANCE IS TOO LONG.Figure 2-1 shows what to do and what not todo.

2.4 Removing the crushed material

The crushed material removal system is notsupplied with the crusher because it toodepends on operating conditions, which varyaccording to layout. The system in question, beit a hopper or dead-bed, should match theinstallation plan’s instructions. It shouldinclude a manhole to allow easy access forcleaning or inspection purposes. Whereverpossible, a dead-bed is preferable to a hopperbecause it absorbs most of the kinetic energybefore the material reaches the conveyor.If a chute is used, it should be angled at morethan 45°, or an even steeper gradient for verysticky material.As indicated on the layout plan, there shouldbe enough clearance for material removalbetween the crusher and the hopper on the onehand and the hopper and take-up conveyor onthe other. This gap should allow the crushedmaterial to flow freely.



2.5 Control drive

We normally recommend V-belt drives due totheir ability to "filter" shocks transmitted fromthe crusher to the motor and withstand jerkswithout slowing down the crusher.The drive belts may be 8V or SPC type and beseparate or twinned. See Figure 2-2.

Figure 2-2 Cross-section of belts

Narrow belts have been designed to reduce thespace required by the drives, thereby makingsavings on installation and reducing the load’soverhang at the shaft ends. Twin belts consistof single belts joined by a band to preventwhiplash and twist. They can be mounted onstandard pulleys.If the motor pulley is directly under the crusheror angled 30° from the vertical, the factoryshould be informed so that the countershaftring can be correctly positioned.Power can be supplied by an electric motor, adiesel engine or a hydraulic motor.The crusher can also be directly coupled to themotor. All specific questions regarding thecrusher drive should be referred to us.

2.6 Installing a V-belt drive for thefirst time

When installing for the first time or whenchanging belts, please follow theseinstructions:

1. Remove all traces of oil, grease or rustfrom pulley grooves.

2. Make sure the pulleys are properlyaligned and the shafts are parallel.

3. Never force a belt around the pulleys.The pulleys should be sufficiently closetogether to allow the belts to pass easily.

To determine the minimum tolerances forshortening or lengthening the centre-to-centredistance between the pulleys. See Table 2-1.Calculate the centre-to-centre distance for astandard length and slope, then make sure theresulting distance can be shortened by thelength indicated in Table 2-1, for easierinstallation of the belts and to avoid anydamage. A longer distance than thecentre-to-centre distance should be possible toallow for lengthening and wear. This extralength is given in the last column of the table.

Ref. Description

1 Single belt

2 Twin belt

1 2



Figure 2-3 Installing the belts

* First length included up to last length notincluded.

Table 2-1 Installing belts, and tolerances

Ref. Description

1 Crusher pulley

2 Bring closer to the motor to mount the belts

3 Drive pulley

4 Move away from the motor to mount the belts

5 Spacing

Minimum distances mm (inches) for mounting or dismantling the belts

Length of belts * mm (inches)

Cross-section of beltsMinimum distance to

tauten the belts8V 8V twin SPC

from 2000 (79) to 2749 (108)from 2750 (108) to 3499(138)from 3500 (138) to 4499 (177)from 4500 (177) to 5499 (216)from 5500 (216) to 6499 (256)from 6500 (256) to 7999 (315)from 8000 (315) to 9999 (394)over 10,000 (394)

40 (1 1/2)40 (1 1/2)40 (1 1/2)45 (1 3/4)45 (1 3/4)45 (1 3/4)

5050

85 (3 3/8)85 (3 3/8)85 (3 3/8)90 (3 1/2)90 (3 1/2)90 (3 1/2)

100100

35 (1 3/8)35 (1 3/8)35 (1 3/8)35 (1 3/8)40 (1 1/2)40 (1 1/2)45 (1 3/4)45 (1 3/4)

40 (1 1/2)45 (1 3/4)55 (2 1/8)65 (2 1/2)85 (3 3/8)95 (3 1/2) 110 (4 3/8)140 (5 1/2)

1 2

3

45



4. Only use new, matching belts from thesame source. Never use new and usedbelts together.

5. Fit the belts and make them run for afew minutes. Tauten the belts until theslack strand bends slightly duringoperation. See Figure 2-4. The slackstrand depends on the position of themotor and the direction of rotation. Anexample of a taut and slack strand isshown in Figure 2-4. The slack strandside is determined by the position of themotor.

Figure 2-4 Determining the slack strand

12

3

4

1

3

2

Ref. Description

1 Crusher pulley

2 Taut strand

3 Drive pulley

4 Slack strand (make a note of the deflection or sag of the belts)



2.7 Tautening the V-belts

Tautening the drive is the term used to definethe method consisting in creating a cornereffect between the belt and the pulley’s groove.This corner effect lets the belts transmit themotor pulley’s force to the crusher pulley.There are several ways of tautening the belts.We describe two simplified methods in thefollowing paragraphs: Tension-Bending, andrelative lengthening. Either method givessatisfactory results if properly implemented,and both have certain advantages for aparticular type of belt.

2.7.1 Tension-Bending

1. Place a ruler at a tangent to the twopulleys. See Figure 2-5.

2. Measure the length of the tangent (freelength of the belts).

3. With the aid of spring scales hangingfrom the centre of one belt, apply aperpendicular force to the belt in such away that the belt's sag equals 0.016(1/64) times the length of the tangent.

Figure 2-5 Tension method

Ref. Description

1 Ruler

2 1/2 length

3 Length

4 Sag = length/64

5 Traction

6 Drive pulley

7 Belt

8 Balance

9 Force (see table)

10 Crusher pulley

12

34

5

67

8910



4. The force should be as indicated inTable 2-2.

Consequently, a new 8V-belt drive with acentre-to-centre distance of 1,575 mm shouldbe tautened in such a way that it sags by 25mm when a force of 15-22 Kg is applied.

5. After running for 2 to 4 hours, the driveshould be tautened again to the upperlimit of bending force.

6. After 24-48 hour, check that bendingforce is within the range given inTable 2-2. Tauten again if necessary.Excessively slack or taut belts willreduce durability and impair properfunctioning of the drive.

AN ADEQUATELY TAUT V-BELT DRIVEMAY APPEAR TOO SLACK. HOWEVER,IT IS BETTER TO TRUST THE SPRINGSCALES THAN YOUR IMPRESSION.

2.7.2 Relative elongation

This belt tensioning method has been devisedfor tensioning twin belts.

1. Tauten until the slack disappears (whenstationary).

2. Wind a 10-15 metre tape measurearound the belts and measure theirlength to within 1 mm. Make a note ofit. See Figure 2-6.

Figure 2-6 Belt tension using the relative lengthening method

Example8V belt = SPC beltsLength of tangent (centre distance) = 1 575 mmBending force (table) = 15 - 22 KgSag = 1 575 mm x 0.016 = 25 mm

Ref. Description

1 Length reading

2 Tape measure

3 Belt

1 2

3



* Multiply these figures by the number of beltson the ply

Table 2-2 Bending forces

3. Multiply the measured length by theratio given in Table 2-3, and add theresult to the initial figure.

4. Tauten until the belt reaches this newlength.

*Single or twinned belts

Table 2-3 Elongation factor

Consequently, a new drive with belts having anoverall length of 3 048 mm should be tauteneduntil it is 3 075 mm long.

5. Check tension periodically and tauten ifnecessary, using the above method. Weshould point out however that thetension-bending method is the easiest.

Usually, slipping is the first sign of incorrecttension. Slipping causes a loss of power andspeed at the crusher pulley and acceleratedwear of the pulley grooves. Such conditionsare usually accompanied by creaking andoverheating of the belts and pulleys. Thesesymptoms are clearly visible, audible andtangible.

Section

Single belts Twinned belts*

Tension minikg

Tension maxikg

Tension minikg

Tension maxikg

8V 15.4 22.7 18.1 27.2

SPC 10.4 15.4 11.8 18.1

ExampleSPC belt = 8V belt Initial length = 3 048 mm (120")Elongation ratio (see table) = 0.009 or 0.9%New length = 3048 mm (120") initial length x 0.009 elongation ratio = 3048 (120") + 27 mm(1-1/16") or 3075 mm (121-1/16").

Section* Ratio Percentage%

8V 0.009 0.9



2.8 V-belts - precautions

Here is a list of do’s and don’ts regarding theproper use of V-belts:

1. Do's. Check belt tension frequentlyduring the first few days of operation.New belts are relatively stiff and requiregreater tension.

2. Don'ts. Excessive or insufficient tensionalso shortens the lifetime of belts andbearings. The tension should beuniform. The belts should appear tautwhen stationary. When in operation, theslack strand should be visible.

3. Do's. Ventilate the drive if it exceeds60°C, otherwise it could sufferdamaged. In this respect, the drivehousing should have perforated orexpanded metal side plates.

4. Don'ts. Oil makes the rubber swell andimpairs its properties. Never let oil orgrease come into contact with the belts.

5. Do's. Check the drive at regularintervals, in particular the followingpoints:

a. Crusher slows down: check tension.

b. Uneven tension: check each belt.

c. Excessive stretching: make sure it isnot overloaded.

d. The belts soften or swell: make sureit is not overloaded.

e. The belts stiffen or crack: check foroverheating.

2.9 Initial alignment of a flexiblecoupling sleeve

For direct control drives, when first mountingor remounting a flexible coupling sleeve, it isalways advisable to align it for greaterdurability and minimum vibration. Aftermounting the two half-sleeves on their shaftends, assemble and align them as follows:

1. Check the gap and angular alignmentbetween the two half-sleeves at fourpoints spaced out at regular intervalsaround the edge. See Figure 2-7. To takethis measurement, use thickness gauges,a calliper rule or a comparator mountedon a magnetic base. The differencesbetween the measured gaps should notexceed 0.38 mm. If any of the fourmeasurements exceeds the others bymore than 0.38 mm, this means that thesleeve is incorrectly aligned at an angle.

2. Check the alignment by placing a ruleron the lines of the outer diameters of thehalf-sleeves. Check at four equallyspaced intervals. See Figure 2-7. Usethickness gauges or a comparator tocheck that the non-parallelism does notexceed 0.38 mm.

3. The gap, angular alignment andparallelism of the coupling sleeve aregreater for direct control drives.

A safety clamp should be mounted on thecountershaft to retain axial clearance.



Figure 2-7 Aligning the coupling

CORRECT PARALLELISM

CORRECT SPACING AND ANGULAR ALIGNMENT

INCORRECT SPACING AND ANGULAR ALIGNMENT

1

1

2

3

4

56

7

8

9

1011

12

13

INCORRECT PARALLELISM

Ref. Description

1 Equal gap

2 Use the gauge to check the gap

3 Hold the thickness gauge against the half-sleeves here

4 At 4 points spaced out 90°, check parallelism using a thickness gauge

5 Half-coupling at the motor end

6 Half-coupling at the crusher end

7 Ruler

8Place the ruler on the half-coupling here

9 At 4 points spaced out 90°, check parallelism using a thickness gauge

10 Gap

11 Angular misalignment

12 Maximum variation 0.38 mm

13 Maximum non-parallelism should be 0.38 mm

Ref. Description



2.10 Crusher drive motor

The crusher’s electric motor may be a squirrelcage rotor motor or a wound-rotor inductionmotor (continuous run) having a startingtorque of around 1.3 times the rated torque.Admissible voltage change: 10%.Abrasion-resistant insulation and protection ofthe stator with thermostatic sensors or CPTmay be required. Motor protection may be ofthe protected type (IP 23) or enclosed (IP 44).In order to work non-stop at the power ratingstated on the layout plan, the motor must havea service factor of 1.15. If the motor's servicefactor is 1, the rated output as stated on themotor's plate should be 15% more than therating stated on the layout plan. However,absorbed power should not exceed the powerstated on the layout plan.If a V-type belt drive is used, make sure themotor shaft end and bearings can bear thepulley' off-centre weight and the belts’off-centre tractive force. The motor must beable to bear these loads over 360°. The motorshaft end must be able to transmit torque peaksand the simultaneous flexing caused by thebelts’ tension and the weight of the pulley. Themotor shaft end should be long enough toallow the pulley hub to be mounted andprevent its rim from rubbing against the motorhousing.For V-type belt drives, the motor should bemounted on two runners so that thecentre-to-centre distance can be adjusted whenmounting and tightening the belts.For direct drive motors, check that thedimensions of the motor shaft end allow acoupling sleeve to be mounted.The documented power ratings apply toelectric motors. If a combustion engine is used,please inform the manufacturer, who willcalculate the power requirement matching theelectric power rating and speed specificationsprovided in the layout documents.

2.11 Piping information

The additional "Lubrication/Hydraulics"manual gives detailed specifications for thetype of oil, temperature and temperatureregulation and any equipment that is or can beused in the lubrication system. Please note thatthe latter is designed for a maximum pressureof 8.6 bars.Please refer to the documents showing thepipes, accessories and other equipmentsupplied with the crusher.Two key factors should be considered: pipingshould be as short and direct as possible, withno high or low points or obstacles, and thereturn pipes to the tank should have adownward gradient of at least 10%.Make sure the insides of the pipes arethoroughly clean. Remove any shavings fromthreaded ends to protect the oil pump and allwear surfaces inside the crusher.Couplings should be designed to allow alllubrication parts (pump, filter, coolant, etc.) tobe dismantled easily.Check that there are no oil leaks at couplings.Oil suction pipes must be fully sealed,otherwise output and pressure will fall andcould damage the crusher. Leaks from suctionpipes are particularly dangerous becauseunlike pressurized pipes they cannot bedetected.

2.12 Information on assembling anddismantling the crusher

HP cone crushers are shipped fully assembledor in separate subassemblies, depending on thesize of the crusher. For road consignments,small crushers are generally shipped complete,ready to lay on their base.In certain cases, these small crushers aredismantled for sea or road transportation ifgauge restrictions apply. As for large crushersthey are dismantled in most cases for shippingpurposes.The following sections provide instructions forassembling and dismantling the crusher'scomponents. Starting with the bowl, thecomponents are presented in the normaldismantling order. Whether the crusher isshipped assembled or dismantled, it must beassembled according to the instructions inthese sections.



Before fitting any part onto the crusher, checkthat the rust protection of machined surfacesand all traces of sand or dust have beenremoved, in particular on lubricated areas andin pipes.Any machined parts or threads that may havebeen damaged in transit must be repairedbefore assembly. After cleaning the contactsurfaces, apply a thin coat of oil.Special care should be taken when moving orinstalling certain components. Strictobservance of safety rules is mandatory whenlifting equipment, including the appropriatehand signals. You should also ensure that thecapacity of all lifting equipment and relatedparts such as cables, hooks etc. is sufficient tobear the stated weights.Use tools specific to each size of crusher forrepairs or maintenance, and heed theinformation provided further on in this chapter.Refer to Figure 2-10 for the tools requiredto handle cone crushers HP400 and HP500.

2.13 General information onservicing

The following precautions must be observedfor all maintenance work and servicing of thecrusher:

1. If parts with machined surfaces orbearing surfaces are removed, theyshould be oiled or covered with aprotective film if put in storage for anylength of time.

2. Handle machined parts with great carebecause their tolerance ranges are small.

3. When dismantling parts with machinedsurfaces, place them on wooden blocksto make sure they do not touch theground.

4. Bronze parts must be handled withspecial care. Any shock to this softmaterial could damage such parts.

5. Clean and oil all machined partsthoroughly before mounting them on thecrusher. Apply a coat of oil toload-bearing surfaces before replacingthem.

6. When assembling two parts that need tobe tightened using a press, cover thecontact surfaces with a thin layer of oil.This will act as a lubricant and preventrust forming.

7. The head bushings and eccentric thrustbearings must be stored vertically.Otherwise they could become distortedinto an elliptical shape. This could leadto huge difficulties when installingfuture parts on the crusher; Sometimes,installation is impossible.

8. All threaded parts should be rubbed witha cloth soaked in molybdenumdisulphide powder then coated withgrease or oil. If that powder is notavailable, simply greasing them maysuffice.

9. Incorrect heating procedures candamage certain parts; please observe thefollowing instructions.

a. Whenever possible, it is better tomount hot parts by immersing themin an oil bath or an oven.

b. Never exceed the requiredtemperature; This could damage theparts.

c. Do not use a blowtorch to mount hotparts because the heat would not beevenly distributed.

d. Propane or acetylene equipmentshould be used to raise thetemperature in special cases.

e. If a blowtorch is used to assemble thegear, avoid the flame coming intodirect contact with the parts beingtreated. Let the heat escape first.

f. When dismantling parts, heat themquickly and evenly. Dismantle themquickly.

10.Screw fastenings

– Screws used without thread brake:

All screws and holes must be cleaned,the screws fitted with grease andtightened to their rated thread torque.



– - Screws used with thread brake:

All screws and holes must be cleanedand degreased before fitting the threadbrake onto the screws. In addition, if apart has been heated for mountingpurposes, the screws must be fittedwithout thread brake. When the part'stemperature has fallen to ambienttemperature, remove the screws, applythe thread brake then tighten them totheir rated thread torque.

2.14 List of minimum recommendedspare parts

Here is a list of critical spares one shouldalways have to hand to guarantee minimaldowntime or when faced with problems.

1. Bowl liner.

2. Bowl liner bolts.

3. Mantle.

4. Ring spacer.

5. Cone feed plate + screws.

Obviously this is only a minimum list ofspares; if the factory has several crushers, thislist should be adjusted accordingly. Pleaseconsult Metso Minerals for a list of sparesspecific to your facility.Before checking spares into the storeroom,check that the protective film applied prior toshipment is still intact.Before replacing a bearing or other importantpart, or when the crusher functions for the firsttime, refer to section 3 "Instructions for use".

2.15 Special tools

Special tools are supplied with the crusher.These include all the hoisting rings; the headlifting washer, the coupling for nitrogencylinders, alignment studs for the sleeve, theeccentric lifting washer, tightening screw, etc.All these tools are painted in the same colouras the crusher and shipped in a separate crate.Option:An inflator gauge and coupling for thenitrogen cylinder can optionally be supplied.



Figure 2-8 Special tools for HP100

Ref. Description

1 Locking wrench

2 Pinion wrench

3 Countershaft wrench

4 Eccentric lifting ring

5 Lifting ring

6 Head lifting ring

7 Hexagonal nut

8 Hexagonal nut

9 Bolt

10 Lifting ring

11 Threaded rod

12 to 17 Lifting ring

18 to 23 Washer

24 Safety wedge

Ref. Description



Parts to handle for HP100

Ecc

entr

ic li

ftin

g w

ashe

r +

3-M

10x5

0

Hea

d lif

ting

ring

4 -

Lift

ing

eyeb

olt

on a

dju

stm

ent c

ap

3 -

Lift

ing

hook

on

ad

just

ing

rin

g

4 -

Lift

ing

hook

on

fram

e

2 -

M6

liftin

g rin

g

1 -

M8

liftin

g rin

g

2 -

M8

liftin

g rin

g

2 -

M10

lifti

ng

ring

3 -

M10

lifti

ng

ring

2 -

M12

lifti

ng

ring

4 -

M12

lifti

ng

ring

2 -

M16

lifti

ng

ring

3 -

M16

lifti

ng

ring

2 -

M20

lifti

ng

ring

1 -

M30

lifti

ng

ring

Frame X

Main shaft X

Adjustment ring X

Locking ring X

Eccentric assembly (eccentric assembly, gear, imbalance, etc.)

X

Eccentric X

Imbalance X

Gear X

Imbalance liner X

Eccentric bushing X

Upper ball washer X

Lower ball washer X

Sleeve X

Head assembly (head, liner, locking bolt, etc.)

X

Head X

Head ball X

Head bushing X

Locking nut

Bowl assembly (bowl liner and adjustment cap) X

Bowl X

Toothed crown X



Figure 2-9 Tools required for HP200, HP300, HP400 and HP500

Ref. Description

1 Inflator gauge set (optional)

2 Teat screws

3 Rod with threaded end sleeve position

4 Washer

5 Lifting ring


7 Head nut wrench

8 45°minimum

9 Correct lifting method.

10 Head lifting washer

11 Adaptor for nitrogen cylinders (optional)

1

2

3 4

5

10

6

7

9

811




Ecc

entr

ic li

ftin

g w

ashe

r +

3-M

10

Ecc

entr

ic li

ftin

g w

ashe

r +

4-M

16

4 -

Lift

ing

eyeb

olt

on a

dju

stm

ent c

ap

3 -

Lift

ing

hook

2 -

M8

liftin

g rin

g

1 -

M10

lifti

ng

ring

2 -

M10

lifti

ng

ring

3 -

M10

lifti

ng

ring

2 -

M12

lifti

ng

ring

4 -

M12

lifti

ng

ring

2 -

M14

lifti

ng

ring

2 -

M16

lifti

ng

ring

3 -

M16

lifti

ng

ring

2 -

M20

lifti

ng

ring

2 -

M24

lifti

ng

ring

1 -

M30

lifti

ng

ring

Frame X

Main shaft X

Adjustment ring X

Locking ring X

Eccentric assembly (eccentric, gear, imbalance, etc.)

Eccentric X X

Imbalance X

Gear X

Imbalance liner X

Eccentric bushing X

Upper ball washer X

Lower ball washer X

Sleeve X

Spherical bearing X

Head assembly (head, liner, locking bolt, etc.) X

Head X

Head ball X

Lower head bushing X

Upper head bushing X

Locking nut X

Bowl assembly (bowl liner and adjustment cap)

X

Bowl X

Bowl adaptor ring X

Toothed crown X




Ecc

entr

ic li

ftin

g w

ashe

r +

3-M

12

Ecc

entr

ic li

ftin

g w

ashe

r +

4-M

16

4 -

Lift

ing

eyeb

olt

on a

dju

stm

ent c

ap

4 -

Lift

ing

hook

2 -

M8

liftin

g rin

g

2 -

M10

lifti

ng

ring

2 -

M12

lifti

ng

ring

3 -

M12

lifti

ng

ring

1 -

M16

lifti

ng

ring

2 -

M16

lifti

ng

ring

3 -

M16

lifti

ng

ring

4 -

M16

lifti

ng

ring

2 -

M20

lifti

ng

ring

4 -

M20

lifti

ng

ring

2 -

M24

lifti

ng

ring

1 -

M30

lifti

ng

ring

Frame X

Main shaft X

Adjustment ring X

Locking ring X


Eccentric X X

Imbalance X

Gear X

Imbalance liner X

Eccentric bushing X

Upper ball washer X

Lower ball washer X

Sleeve X

Spherical bearing X

Head assembly (head, liner, locking bolt, etc.) X

Head X

Head ball X



Locking nut X


X

Bowl X

Bowl adaptor ring X

Toothed crown



Figure 2-10 Tools required for handling the HP400 and HP500

45˚Min.

1

2

3

5

4

Ref. Description

1 Lifting ring

2 Washer (if necessary)

3 Head lifting washer


5 Washer




Ecc

entr

ic li

ftin

g w

ashe

r +

3-M

20x8

0

Ecc

entr

ic li

ftin

g w

ashe

r +

4-M

20x8

0

4 -

Lift

ing

eyeb

olt

on a

dju

stm

ent c

ap

4 -

Lift

ing

hook

on

fram

e

2 -

M8

liftin

g rin

g

1 -

M10

lifti

ng

ring

2 -

M10

lifti

ng

ring

3 -

M10

lifti

ng

ring

4 -

M16

lifti

ng

ring

1 -

M20

lifti

ng

ring

2 -

M20

lifti

ng

ring

3 -

M20

lifti

ng

ring

1 -

M30

lifti

ng

ring

2 -

M30

lifti

ng

ring

3 -

M36

lifti

ng

ring

Frame X

Main shaft X

Adjustment ring X

Locking ring X


X X

Eccentric X

Imbalance X

Gear X

Imbalance liner X

Eccentric bushing X

Upper ball washer X

Lower ball washer X

Sleeve X

Spherical bearing X

Head assembly (head, liner, locking bolt, etc.) X X

Head X

Head ball X



Locking nut X

Locking nut wrench X

Bowl assembly (bowl liner and adjustment cap) X

Bowl X

Bowl adaptor ring X

Toothed crown X




Ecc

entr

ic li

ftin

g w

ashe

r +

3-M

20x8

0

Ecc

entr

ic li

ftin

g w

ashe

r +

4-M

20x8

0

4 -

Lift

ing

eyeb

olt

on a

dju

stm

ent c

ap

4 -

Lift

ing

hook

on

fram

e

2 -

M8

liftin

g rin

g

1 -

M10

lifti

ng

ring

2 -

M10

lifti

ng

ring

3 -

M10

lifti

ng

ring

1 -

M20

lifti

ng

ring

2 -

M20

lifti

ng

ring

3 -

M20

lifti

ng

ring

4 -

M20

lifti

ng

ring

2 -

M24

lifti

ng

ring

2 -

M36

lifti

ng

ring

4 -

M36

lifti

ng

ring

1 -

M42

lifti

ng

ring

2 -

M42

lifti

ng

ring

Frame X

Main shaft X

Adjustment ring X

Locking ring X


X X

Eccentric X

Imbalance X

Gear X

Eccentric bushing X

Upper ball washer X

Lower ball washer X

Sleeve X

Spherical bearing X

Head assembly (head, liner, locking bolt, etc.)

X X

Head X

Head ball X



Locking nut X

Locking nut wrench X


X

Bowl X

Bowl adaptor ring X

Toothed crown X



2.16 Protecting the crusher againstcorrosion

To protect your crusher against rust during aseasonal stoppage, for shipment or storageoutdoors (winter or summer), please observethe following recommendations:

1. Remove the bowl, head, cone feed plate,socket and eccentric assemblies.

Disconnect the oil return pipes to the tankunder the main frame and the feed pipes underthe main shaft. Plug these pipes with stoppers.

2. Use a brush to coat all the insidesurfaces of the main frame with rustpreventive oil.

Use a lubricant with a rust prevention agentdesigned to protect all the interior parts ofenclosed assemblies such as combustionengines, compressors, pumps, reduction gearsand hydraulic assemblies. Rust preventionrepels water from metal surfaces by forming awater-resistant film over them and absorbingthe water in the form of emulsion. Suchproducts are 30 to 40 times more effective thanquality lubricants that do not contain a rustprevention agent.In most applications, the residual protectivefilm left by such products does not needremoving when the crusher is refilled with oiland restarted.Usually 200 litres suffice to cover the crusher.The oil should have a viscosity factor of 32 to66 cSt at 38°C.

3. Use a brush to coat the lower stop of theframe, the outer surface of the mainshaft and all the pinion’s exposedsurfaces with rust preventive oil.Remove the feed pipe from thecountershaft. Insert a pipe into this holeand fill with oil as the countershaftrotates. A small leak may occur at theend of the countershaft; this is perfectlynormal.

Then put the feed pipe back into thecountershaft.

4. Fill the main shaft with oil until oilcomes out of the drainage hole.

5. Coat the outer surface of the eccentric,the boring of the eccentric bearing, thegear and the upper eccentric stop withrust preventive oil.

6. Coat the spherical span of the head, theboring of the head bushing and all thesurfaces of the head near the seal withspecial oil.

7. Reassemble the eccentric and socketassemblies. Apply a coat of oil to thebearing surface and all the socket’sexposed surfaces. Assemble the headassembly then the cone feed plate.

8. Fill the hydraulic unit tank with rustpreventive oil having a viscosity of 32cSt at 38°C. Make sure the oil used inthe hydraulics is compatible withmaterials used, such as Neoprenerubber, polyurethane, bronze, nickel,chromium-plated, steel and cast iron.

Start up the hydraulic system, retainingcylinders, the bowl's hydraulic adjustments(locking is achieved with an oil chamber inpolyurethane on the HP 100) in order that allthe hydraulic components are filled with rustpreventive oil.

9. Paint or spray the machined surfaces ofall the assemblies, bowl, adjusting ring,locking rings and the screw threads witha special asphalt product that becomesfluid with a solvent.

This additive provides a high degree ofprotection to wet metallic surfaces due to thepresence of water. The solvent evaporates,leaving a transparent, greasy film. This affordslong-life protection in severe conditions. Thethin coat of oil does not need to be removed torestart the crusher. Then coat the screw threadswith lithium-based grease (NLGI 1) mixedwith 5-10% of disulphide molybdenum.

10.Reassemble the bowl assembly in thecrusher and cover the adjustment capand hopper with a 2-mm polyethylenesheet to prevent water penetrating andcorroding the threads. These sheetscome in 30-metre x 6-metre rolls. Werecommend black rather thantransparent film (longer lifetime). Theend of the countershaft and the pulleyshould also be protected. The best wayto fix the polyethylene sheet is with ametal sling.

11.Reconnect the oil inlets and outlets. Theremaining oil on metal parts suffices toprotect them against rust.



IF THE ABOVE INSTRUCTIONS AREFOLLOWED, A CRUSHER STOREDOUTDOORS WILL BE PROTECTEDAGAINST RUST CORROSION FOR 6 TO12 MONTHS.If the crusher is stored dismantled, all its partsmust be even better protected; because theaforesaid procedure applies to metal surfacesnot exposed to the elements: sunshine, rain,snow etc.The following protective measures arerecommended when the crusher is stored withits various assemblies exposed to the elements:

1. Cover the sleeve and the outside of themain shaft with a polyethylene sheet.Wrap the sheet around the countershafthousing and stretch it across theadjusting ring.

This protects the inside of the crusher after ithas already been treated with rust preventiveoil. The sheet should be firmly attached.

2. Spray or paint the machined surfaces ofall assemblies, the bowl, cone feedplate, head, socket and eccentric with aspecial asphalt product that becomesfluid thanks to a solvent. The solventevaporates and leaves a dry, acid andhighly resistant film. This affordslong-life protection in extremeconditions, for instance in open airexposed to corrosive fumes. The filmresembles a coat of paint and can easilybe removed by rubbing hard with asolvent.

THE ABOVE RECOMMENDATIONSPROTECT PARTS STORED OUTDOORSAGAINST RUST CORROSION FOR ASLONG AS 24 MONTHS.


3.1 - Checklist when starting up a new crusher. . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 - Preparations prior to start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 - Countershaft speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 - Countershaft rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.5 - Operation of the hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.6 - Initial start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.7 - Daily crusher start-up and shutdown procedures . . . . . . . . . . . . . . . . . . . 3-63.7.1 - Daily start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63.7.2 - Daily shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.8 - Crusher adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.9 - Bowl rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83.9.1 - Rotating the bowl using a hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . 3-93.9.2 - Rotating the bowl using a cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93.9.3 - Rotating the bowl using a hoist or crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.10 - Minimum settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.11 - Checking the screw adjustment of the crusher . . . . . . . . . . . . . . . . . . . 3-113.11.1 - Recommendations for proper crusher operation. . . . . . . . . . . . . . . . . . . 3-11

3.12 - Adjusting ring bounce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.13 - Determining liner and mantle wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.14 - Lubricating the threading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3.15 - Bowl thread and adjusting ring wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3.16 - Difficulty turning the bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.17 - Clearing the crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.18 - Dismantling and installing the bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.19 - Overhaul and repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.20 - Regular inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

INSTRUCTIONS FOR USE

Section 3

Instructions for use SECTION 3

3.1 Checklist when starting up anew crusher

Checks prior to start-up

1. Have the wooden chocks between the bowl liner and mantlebeen removed?

2. Crusher adjustment measured at..............mm (").

3. Drive tension and alignment.

4. Position of the countershaft bushing’s oil groove in relation to the drive.

5. If the eccentric was delivered dismantled, check the play between the pinion/crown teeth. (see section 5)

6. Lateral play of countershaft.

7. Crusher’s anchorage and fastening bolts.

8. Does the design of the concrete block or dead-bed under the crusher allow the free flow of crushed material?

9. Lubrication:

a. Slope of return pipes at least 10% between the crusher and the tank.

b. Check the make and quality of the oil used and check the oil level.

Make and type of oil:

Make: Type:

c. Pipes are installed according to the plans.

d. Accessories such as filters, fan, unit heater, immersion heater, pressure relief valves, thermostats or temperature sensors, pressure switches and breathers are correctly mounted.

e. Alarm device, pressure switches, level controller and thermostat are correctly connected (see hydraulics instructions).

f. The pressure limiter and related pipes are properly mounted.

g. The pump rotates in the right direction.

h. Hydraulic couplings on the unit are correct.

i. Clean filter.

j. Breathers in the countershaft housing and breather in tank correctly fitted.

k. Oil supply and return pipes do not contain foreign bodies. Before connecting, check the condition and cleanliness of the insides of the pipes.

OK Not OK


SECTION 3 - INSTRUCTIONS FOR USE

11.Hydraulics.

a. The right make and type of oil in the oil tank; check the oil level. Specify the name and type:

Make: Type:

b. The retaining system’s accumulators are properly filled with nitrogen.

c. All connections between the hydraulic unit and the crusher are correct.

d. Pipes have been blasted and tested for leaks.

e. At least one adjustment should be made to ensure that the adjusting system and locking cylinders are working properly.

Starting up the oil pump:

1. Oil temperature should be at least 16°C (60°F).

Starting up the crusher’s hydraulics:

1. The countershaft rotates in the right direction.

Starting up the crusher:

1. The crusher must run idle for roughly 1 hour, until thetemperature of the return oil reaches 27°C (80°F).

2. Crusher rotation speed: rpm.

3. Seals underneath the crusher have been checked.

4. Absorbed current running idle (A)

5. Alarm devices (pressure switches, thermostats or temperaturesensors) have been checked and conform.

6. The crusher has run at 50% load for 2 hours.

7. The crusher has run at 75% load for 4 hours.

8. The crusher has run at 100% load for 1 hour.

9. The shut-off valve stopped returning oil to the tank at: °C.

10.Is the material evenly distributed in the cavity?

11.The crusher shuts down in seconds.

OK Not OK



Six hours after initial start-up:

1. The temperature difference between the oil supply and returnis: °C.

2. The customer has been apprised of any recommendationsregarding possible modifications to his installation.

3. The crusher has run at 75% capacity for 6 hours.

Mobile plant:

1. The support surface is properly installed.

2. If rubber wedges are used, they should be no more than 12 mm(1/2") thick. The crusher should not be clamped.

Notes:

OK Not OK



3.2 Preparations prior to start-up

Carrying out inspections as a matter of routinewill go a long way to ensuring optimaloperation of the crusher for many years. Neverrely on your memory when planning regularmaintenance, use a maintenance logbook.Regular checks and inspections will avertstoppages and prolong the crusher’s lifetime.Before starting up the crusher, carry out thefollowing operations:

1. Check that the right lubricating oil isused and that the lubrication system isproperly fitted as explained in thelubrication manual.

2. Start the oil pump motor. Open theinspection hatch on the tank and checkthe oil return pipe to make sure the oil iscirculating. In normal operation, the oilflowing out of the return pipe should fillhalf to two-thirds of the pipe.

3. Remove the wooden chocks between theliner and mantle for transportation.

4. Check the play at the end of thecountershaft. The countershaft must beable to move leftwards and rightwardsby 1.0 mm to 1.5 mm. See paragraph9.2.13 "Mounting the crusherbullwheel".

5. Carry out a final check to ensure thereare no tools or mechanical obstacles onthe crusher. All joints must be properlyfitted. Check for any leaks. Check forany other reasons that may prevent thecrusher from starting.

6. Rotate the countershaft by hand to checkthat the mantle does not touch the bowlliner and that there are no othermechanical hitches. If the mantletouches the bowl liner, refer to the bowladjusting instructions in this section.

7. Use the checklist at the beginning of thissection to ensure all the important pointshave been checked.

8. When all these points have beenchecked, start the crusher following thedetailed instructions in paragraph 3.6"Initial start-up" of this section.

3.3 Countershaft speed

Speed (or revolutions per minutes) is essentialto the proper functioning of the crusher. Theadmissible speed range is given in Table 3-1.The recommended dimensions of the pulleysdriving the crusher are calculated for operationat full capacity. The countershaft will rotate alittle faster when the crusher is running idle.Experience shows that running the crusherwith the correct countershaft rotation speedproduces a maximum amount of material at aconstant grade.

Table 3-1 Countershaft speed

TYPE HP100 HP200 HP300 HP400 HP500

rpm at full capacity

750 - 1200 750 - 1200 700 - 1200 650 - 1000 650 - 950



The crusher's countershaft speed determinesboth the amount of material and the number ofimpacts a particle sustains in the cavity. If thecrusher cannot run at the right speed (rpm), ahigher rotation speed is preferable (no morethan 10% over the rated speed), because ifcountershaft speed is reduced to much lowerthat the recommended rotation speed,performance will be greatly impaired due tojamming in the crushing chamber, which couldblock the crusher.ExampleA countershaft having a recommended speedof 950 rpm can be used at speeds of between950 and 1045 rpm (950 rpm + 10%) withoutaffecting crushing performance.A different rotation speed is recommended incertain applications in order to improve thesize or shape of the particles without affectingthroughput. For such applications, contact thefactory to find out the correct speed of thecountershaft.A HIGHER SPEED CAN ALTER THEMATERIAL OF THE DRIVEN AND DRIVEPULLEYS.

3.4 Countershaft rotation

All HP crushers are designed in such a waythat their countershaft rotates clockwise, asviewed when facing the countershaft. Thedirection of rotation is important because thelocking nut keeps the mantle tight against thehead; we rely on correct rotation to ensure itsself-clamping capacity.

3.5 Operation of the hydraulic unit

The unit should always be powered up whenthe crusher is running to ensure adequateretaining and support pressure. It should alsobe powered up for adjustment and clearingoperations prior to starting up the crusheritself.For further information, please refer to thehydraulic unit’s instructions.

3.6 Initial start-up

Although the crusher has been factory-tested,we recommend first running the crusher idlethen at reduced capacity for several hours afterthe initial start-up or after fitting new rings.This runs in the crusher and ensures that all theparts are working properly and are well oiled.It is also advisable to check oil temperaturemore often during this period. Refer toparagraph OIL TEMPERATURE in thelubrication manual.The initial start-up procedure after fitting anew head bushing or eccentric thrust bearing isas follows:

1. Before starting up the crusher, start upthe lubrication system.

FOR PROPER LUBRICATION OF THEBUSHINGS, THE TEMPERATURE OF THERETURN OIL SHOULD BE AT LEAST 16°C (60° F) BEFORE STARTING UP THECRUSHER. IF NECESSARY, IMMERSIONHEATERS WILL HEAT UP THE OIL.

2. The hydraulic unit should also bepowered up before the crusher.

3. Start up the crusher and let it run idle for1 hour. Make sure the return oiltemperature reaches at least 27°C(80°F).

4. After one hour of operation, startsteadily feeding the crusher for 2 hoursup to 50% of the amperage indicated onthe motor’s nameplate.

5. After 3 hours of operation (paragraph 3and 4), feed the crusher for 2 hours up to75% of the amperage.

CAUTION

The motor’s direction of rotation mustbe checked before mounting the belts.This should be clockwise when facingthe end of the shaft.

DANGER

For HP100 and HP200.

If this precaution is not taken and ittranspires that the direction of rotation iswrong, the pinion screwed onto thecountershaft will come loose and seriousdamage will ensue.



6. After completing the instructions inparagraphs 3, 4 and 5, the crusher cannow run at full capacity up to 100% ofthe amperage or the adjusting ring’sbounce limit.

7. Take an oil sample after initial start-upand send it to the factory for analysis.

8. Start keeping and updating a "crusherevent log", an example is provided at thebeginning of section 4.

3.7 Daily crusher start-up andshutdown procedures

It is important to consult the logbook when thecrusher has not been in use for a while.NOTE DOWN ALL OPERATIONS ANDPOST THEM UP SO THAT ALLPERSONNEL ARE APPRISED OF THEM.

3.7.1 Daily start-up

1. Before starting up the crusher, start upthe lubrication system and make sure thereturn oil temperature is at least 16°C(60°F).

NOTE: FOR PROPER LUBRICATION OFTHE BUSHINGS, THE RETURN OILTEMPERATURE SHOULD BE AT LEAST16°C, OTHERWISE THE IMMERSIONHEATERS START OPERATING TO HEATUP THE OIL. WHEN CRUSHING ATEXTREMELY LOW TEMPERATURES,THE OIL MAY NEED HEATINGCONTINUOUSLY, EVEN WHEN THEMACHINE IS NOT IN USE. USE ISO CC150 OIL ALL YEAR ROUND.

2. The oil takes at least 1 minute tocirculate before the crusher can start up.

NOTE: DO NOT LET THE CRUSHER RUNFOR MORE THAN 15 SECONDS IF THEOIL DOES NOT APPEAR IN THECOLLECTOR UNIT ON THE OIL TANK,BECAUSE THIS COULD CAUSE SERIOUSDAMAGE IN THE CRUSHER. NORMALLYTHERE SHOULD BE ENOUGH OILFLOWING THROUGH THE RETURN PIPETO FILL IT UP TO BETWEEN ONE THIRDAND ONE HALF. LACK OF OIL MAY BEDUE TO SEVERAL CONDITIONS: LACKOF OIL IN THE LUBRICATION SYSTEM,A BROKEN OIL PUMP, A PRIMINGFAILURE IN THE PUMP, A BLOCKEDSUCTION PIPE OR AN INCORRECTLYADJUSTED BYPASS VALVE. REFER TOTHE LUBRICATION MANUAL.

3. The hydraulic unit should be poweredup before the crusher. Check all theindicators on the control box to ascertainthat the hydraulic unit is indeed poweredup and the pressure in its circuits isnormal. If holding pressure is abnormal,adjust the pressure of the circuit asinstructed in the hydraulics manual.

4. Start up the crusher and let it run idle for5 minutes.

5. Gradually start feeding the crusher untilits maximum power requirement isreached (100% of the amperage or theadjusting ring’s bounce limit).

3.7.2 Daily shutdown

1. Stop the feed and let the crusher run for2 to 3 minutes.

2. Shut down the crusher and check howlong it takes to stop; this should be atleast 30 seconds.

3. After shutting down the crusher, the oilpump should continue operating for 2minutes. (Refer to paragraph 3.7.1"Daily start-up" for instructions onreheating oil in extremely lowtemperatures)

4. Shut down the hydraulic unit.



3.8 Crusher adjustments

Crusher adjustments depend on the size of theproduct to process. In most cases, the bowlshould be adjusted so that lower openingbetween the bowl liner and mantle is a littlesmaller than the maximum size of the desiredend product. The bowl also needs adjusting tomake allowance for liner and mantle wear.NOTE: THE INITIAL SETTING,DETERMINED BY THE SIZE OF THEDESIRED END PRODUCT, IS NOT ANABSOLUTE GUARANTEE OF MAXIMUMOUTPUT. THIS DEPENDS BOTH ON THECHARACTERISTICS OF THE MATERIALTO BE CRUSHED AND THE POWER OFTHE DRIVE MOTOR. ADJUSTING RINGBEHAVIOUR CAN ALSO BE A FACTOR.The crusher is adjusted by either lowering orraising the bowl in the adjusting ring. Toreduce the setting, lower the bowl by turning itclockwise (anticlockwise for the HP100). Toincrease the setting, raise the bowl by turning itanticlockwise (clockwise for the HP100). SeeFigure 3-1.

Figure 3-1 Crusher adjustments

Refer to the hydraulics manual to adjust thecrusher.AFTER A NEW ADJUSTMENT, CHECKVISUALLY THAT THE PINION PROPERLYENGAGES THE CROWN ON THEADJUSTMENT CAP, OTHERWISE THEBOWL COULD BECOME TIGHTER ORLOOSER DURING CRUSHING.See Figure 3.9.

Ref. Description

1 Bowl liner

2 Adjusting ring

3 Bowl

4 Parallel zone

5 Mantle

6 Head

1

2

3

456



3.9 Bowl rotation

Figure 3-2 Bowl rotation

1

2 3

4

5

1

2

3

4 5

Hydraulic method

Ref. Description

1 Pinion

2 Hydraulic motor assembly

3 Toothed crown

4 Adjusting ring

5 Adjustment cap Manual method

Ref. Description

1 Adjustment cap

2 Handling hook

3 Turn the cable

4 Handling lug

5 Adjusting ring



3.9.1 Rotating the bowl using ahydraulic system

Turn the bowl in the adjusting ring using thehydraulic system, refer to the instructions inthis section, paragraph 3.18 "Dismantling andinstalling the bowl".

3.9.2 Rotating the bowl using acable

If no handling gear is available, the bowl canbe screwed or unscrewed using a cable. Tomount or dismantle the bowl, proceed asfollows:

1. To allow the bowl to turn in theadjusting ring, set the locking pressureto 0 as explained in paragraph 3.18"Dismantling and installing the bowl".

2. Attach a 20 mm (3/4") cable to a lug onthe adjustment cap and wind it aroundthe outside of the adjustment cap.

3. Wind it around the adjustment capseveral times and attach the loose end ofthe cable to a winch, a truck or a loader.Make sure the cable is horizontalbetween the adjustment cap and thetraction device.

4. Pull the cable gently until it is fullyunwound. Repeat the operation ifnecessary.

3.9.3 Rotating the bowl using ahoist or crane

If a crane or other lifting gear is available,turning the bowl in the locking ring and theadjusting ring requires a bit more dexterity, butless effort. To turn the bowl using lifting gear,proceed as follows:

1. To allow the bowl to turn in theadjusting ring, set the locking pressureto 0 as explained in paragraph 3.18"Dismantling and installing the bowl".

2. Attach the appropriate cables of thelifting gear to the hooks on theadjustment cap, then raise the bowlassembly slightly. By raising the bowlslightly in the threads of the adjustingring, the bowl will float in the thread asshown in Figure 3-3 (floating position).

3. When the bowl is suspended in thefloating position, two people can movethe bowl in the adjusting ring and adjustit as required. After each quarter turn,lower or raise the assembly so that thebowl is again free in the adjusting ring.

Figure 3-3 Bowl thread in the adjusting ring

Ref. DESCRIPTION

1 Crushing position

2 Release position

3 Floating position

4 Adjusting ring

5 Bowl

1 2 3

444

5 5 5



3.10 Minimum settings

The crusher’s minimum recommended settingshould never be reduced at any time, otherwisethe adjusting ring could bounce and damagethe frame’s spans.Table 3-2 shows the minimum admissiblesetting. These settings are given for maximumyield and satisfactory crusher.

Table 3-2 Minimum settings

Crusher size Equipment Minimum recommended setting

HP100

Extra fineFine

MediumCoarse

Extra coarse

6 mm (1/4")9 mm (3/8")9 mm (3/8")

13 mm (1/2")21 mm (13/16")

HP200Standard

FineMediumCoarse

13 mm (1/2")16 mm (5/8")19 mm (3/4")

HP300Standard

FineMediumCoarse

Extra coarse

14 mm (9/16")17 mm (11/16")19 mm (3/4")25 mm (1")

HP400Standard

FineMediumCoarse

16 mm (5/8")22 mm (7/8")25 mm (1")

HP500Standard

FineMediumCoarse

16 mm (5/8")22 mm (7/8")

30 mm (1-3/16")

HP200short head

FineMediumCoarse

5 mm (3/16")6 mm (1/4")

10 mm (3/8")

HP300short head

FineMediumCoarse

5 mm (3/16")6 mm (1/4")

10 mm (3/8")

HP400short head

FineMediumCoarse

6 mm (1/4")10 mm (3/8")10 mm (3/8")

HP500short head

FineMediumCoarse

6 mm (1/4")10 mm (3/8")10 mm (3/8")



3.11 Checking the screwadjustment of the crusher

Check the screw adjustment of the crusher byslowly lowering a piece of lead attached to astrong and flexible cable through the cavitywhile it is running idle. Make sure the piece oflead passes through the parallel zone of thebowl liner and mantle as shown in Figure 3-1.Quickly remove the piece of lead and measurethe thickness of the spacing on the closed sideof the crusher. When the crusher is runningidle, the head turns anticlockwise at roughly300 revolutions per minute. The crusher’s feedslows down the head and reverses the directionof rotation (clockwise) at roughly 10revolutions per minute. For easier checking ofthe setting, the head must rotate as slowly aspossible. See below:

1. Check the setting on start-up bylowering a piece of lead through theparallel zone between the liner andmantle as soon as the crusher reachesfull speed.

2. While the crusher is loaded, stop thefeed. Then lower a piece of lead into theparallel zone between liner and mantleas soon as the cavity empties.

Do not use zinc for this purpose. Zinc is notmalleable enough and could cause theadjusting ring to bounce.To determine whether the setting is the samearound the entire circumference of the cavity,we recommend inserting a piece of lead at 4points 90° from one another. Compare the 4thicknesses to see if the adjusting ring isresting horizontally on the top of the frame orif it is off-centre due to wear on one of thecrusher’s sides caused by uneven distributionof the feed material. See Figure 2-1 for thecorrect feed method.An off-centre adjusting ring can substantiallyreduce crusher tonnage and cause the adjustingring to bounce.

3.11.1 Recommendations for propercrusher operation

Crusher operation can be controlled by varyingthe flow rate of the material fed into thecrusher. A higher feed rate results in higherpower absorption and a lower feed rate resultsin lower power absorption. The crusher’soperating power should be as close as possibleto its power rating, according to the form of thecircuit and the capacity of the control system.Power peaks in excess of 110% of the powerrating should be avoided. This can cause theregulating point to lower in order to keeppower peaks within safety limits.On no account should the crusher run with lowpower for more than a few seconds. Powerabsorbed during crushing should be kept at40% more than the power rating. During thestart-up and shutdown phases, operation at lowpower is acceptable, but operation withcontinuous stop-start of the feed must beavoided at all costs. If it transpires that thecrusher needs to be without feed for more than30 minutes, it should be shut down and onlyrestarted when the feed is available.When the feed rate exceeds the cavity’svolume capacity, a static level of feed starts toform above the cavity.A higher feed rate will increase the level of thematerials above the crusher cavity whereas alower feed rate will reduce the level of thematerials above the crusher cavity and witheven lower rates the feed rate will fall belowthe volumetric capacity of the crushingchamber and the level of materials in thecrusher cavity will start to reduce. For optimalperformance, the level of material in the cavityshould be about 300 mm (12") above the top ofthe cone feed plate.



This guarantees even distribution of the feedaround the crushing chamber and avoidspower peaks caused by minor changes in thefeed rate. A level sensor can be fitted tomonitor the level in the chamber and its signalcan be used to adjust the crusher’s infeed rate.The choice of chamber (the shape of the bowlliner and mantle) and the lower end settingcreate operating conditions with regularabsorbed power of between 75% and 100% ofnominal power. The crusher setting can serveto optimize the crusher’s working powerrequirement. Increasing the setting reducesabsorbed power for a given level in thechamber while increasing the feed ratenecessary to maintain the same level in thechamber. Decreasing the setting increasesabsorbed power for a given level in thechamber but reduces the feed rate required tomaintain the same level in the chamber.Naturally a smaller opening also means thatthe size distribution of the product will besmaller.A hydraulic motor is used for preciseadjustment of the bowl. This adjustment isdesigned to correct the crusher’s feed settingwith or without feed. This system can be usedto correct the crusher setting and its absorbedpower while the crusher is being fed.We advise checking the feed before makingany adjustments. The setting should becorrected to make allowance for liner andmantle wear and guarantee constant productgrading.This setting should not be adjusted more thanonce an hour.

3.12 Adjusting ring bounce

The ring should only bounce when processingtramp iron. If ring bounce persists, this may becaused by an overload.Inefficient screening, segregation in the feed oruneven distribution may cause the ring tobounce. Increase the setting, reduce the feed orchange the liner and mantle to eliminatebounce.Advantage of a ring without bounce:• Longer service life for the crusher’s parts.

• Constant throughput.

• Longer service life for the bowl liner and mantle.

• Less loss of power.

• Lower maintenance costs.

If bounce is the cause of damage to thecrusher, the warranty no longer applies.

Figure 3-4 Ring bounce

Ref. Description

1 Position of adjusting ring in case of bounce

2 Frame

1

2



3.13 Determining liner and mantlewear

Use the following information to determinewhen the jaws (liner and mantle) are worn outand need replacing. Accurate records can bekept to record the degree of jaw wear withoutstopping the crusher. Keep such a record forthe first set of jaws as follows:

1. When crusher adjustments are complete,make a mark on the toothed crown,where it comes into contact with apinion tooth. This will mark the firstsetting. Turning the toothed crown byone tooth causes a very small verticaldisplacement of the bowl. SeeFigure 3-5.

Figure 3-5 Position of the teeth and pinion and of the crown

2. Keep a record of the exact number ofteeth used during the life cycle of thefirst set of jaws. Starting from the firstposition, note down each position untilthe bowl liner and mantle arecompletely worn.

BECAUSE NO TWO CRUSHINGOPERATIONS ARE IDENTICAL ANDBECAUSE OF THE WIDE RANGE OFLINERS AND MANTLES, ONE CANNOTPREDICT IN ADVANCE WITH HOWMANY TEETH A PARTICULAR LINERAND MANTLE SET WILL LAST BEFOREWEARING OUT.IN NORMAL CONDITIONS IT ISGENERALLY THE CASE THAT A LINERWEARS OUT WHEN ITS WEIGHTDIMINISHES BY 50%. THIS CAN VARYACCORDING TO THE APPLICATIONS.DO NOT TIGHTEN THE BOWL UNTILCONTACT IS MADE BETWEEN THEADJUSTMENT CAP AND THEADJUSTING RING.

3. When the bowl liner and mantle wearout, but before removing the bowl fromthe adjusting ring, count by how manyteeth the crown turned, and paint ahorizontal line on the protective apronjust above the adjustment cap, seeFigure 3-6, Figure 3-7 and Figure 3-8.

Ref. Description

1 Guide

2 Cogs of the crown

3 Hydraulic setting assembly

4 Pinion teeth

5 Screw adjustment (unscrew for HP100)

1

9

2

3

45

8

7

6

6 Mark showing the initial position

7Keep a record of the exact number of teeth used during the life cycle of the first set of jaws.

8 Unscrewing adjustment (screw for HP100)

9 Adjustment cap

Ref. Description



Figure 3-6 Checking wear on the bowl liner and mantle - HP100

7

6

5

4

3

2

1

Ref. Description

1 Adjusting ring

2Mark on the protective apron giving the position of the adjustment cap when the jaws are worn.

3 Dimension "A", see Table 3-3

4 Position of the adjustment cap with new bowl liner and mantle.

5 Adjustment cap

6 Protective apron

7 Bowl



Figure 3-7 Checking wear on the bowl liner and mantle - HP200 and HP300

1

3

4

2

5

6

7

Ref. Description

1 Adjusting ring

2 Mark on the protective apron giving the position of the adjustment cap when the jaws are worn.



5 Adjustment cap

6 Protective apron

7 Bowl



Figure 3-8 Checking wear on the bowl liner and mantle - HP400 and HP500

Ref. Description

1 Adjustment cap

2 Bowl



5Mark on the protective apron giving the position of the adjustment cap when the jaws are worn.

6 Adjusting ring

7 Protective apron



4. Fit a new bowl liner and mantle, andtaking account of the number of teeththe crown turned, the degree of liner andmantle wear can be determined bycomparison with the number of teethneeded before the initial liner andmantle set wore out. The mark paintedon the protective apron will also indicatewhen wear limit is approaching. Followthis procedure several times to establishan average, because two jaws do notwear out in exactly the same way.

To facilitate the operator's task, the number ofteeth available for each bowl rotation, as wellas the change in vertical height and theadjustment per tooth are given in Table 3-3.When the bowl liner and mantle are worn, seethe minimum APPROXIMATE heightbetween the top of the adjusting ring and thebottom of the adjustment cap as shown inFigure 3-6, Figure 3-7, Figure 3-8 andTable 3-3.

Because the setting varies depending on whatthe crusher is breaking up, the distancebetween the top of the adjusting ring and thebottom of the adjustment cap also varies.Refer to Table 3-3, and apply the formula fordetermining distance "A".NB: The state of wear of the first set of jawsshould be monitored very closely.When the first set of jaws has worn out and isremoved, cut out a section roughly 100 mmwide from each of them.Take these profiles into account when settingor correcting dimension "A" for the next set ofjaws.These sections of jaw can be sent to MetsoMinerals for profile analysis.

Figure 3-9 Cutting the jaw



Table 3-3 Number of crown cogs and bowl displacement

(*) To determine the type of bowl on your crusher, measure the dimension of the box as shown inthe figures below.

Figure 3-10 HP200 Long bowl Figure 3-11 HP500 Long bowl

Crusher size

Number of crown teeth required for one complete bowl

revolution

Vertical bowl displacement

per cog

Setting variation per

cog

Setting for a 1/4 revolution of the toothed

crown

“A”Approximate

minimum dimension when the jaws are

worn out

HP100 106 0.36 mm(0.014")

0.27 mm(0.009")

7.1 mm(1/4")

A = 50 + (1.59 x CSS)

HP200Short bowl

138 0.28 mm(0.011")

0.18 mm(0.007")

6.3 mm(1/4")

A = 37 + (1.58 x CSS)

HP200Long bowl *

138 0.28 mm(0.011")

0.18 mm(0.007")

6.3 mm(1/4")

A = 50 + (1.58 x CSS)

HP300 156 0.33 mm(.013")

0.23 mm(0.009")

8.73 mm(11/32")

A = 37 + (1.59 x CSS)

HP400 176 0.29 mm (0.011")

0.20 mm (0.008")

8.9 mm (0.352")

A = 26 + (1.69 x CSS)

HP500Short bowl

192 0.26 mm (0.010")

0.18 mm (0.007")

8.5 mm (0.344")

A = 75 + (1.59 x CSS)

HP500Long bowl *

192 0.26 mm (0.010")

0.18 mm (0.007")

8.5 mm (0.344")

A = 0+ (1.59 x CSS)



3.14 Lubricating the threading

It is very important to lubricate the threads ofthe bowl and adjusting ring on a regular basisto ensure the bowl continues to move freely inthe adjusting ring.Grease fittings around the side of the adjustingring lubricate the threads, the bowl remainingengaged in the adjusting ring. See Figure 3-12.The grease is forced into these fittings whenthe bowl is in crushing position and released.Use a lithium-based grease, NLGI 1 or anequivalent type, preferable mixed with 5-10%of molybdenum bisulphite powder (byvolume). For crushing hot products, slag,clinker, etc., a high-temperature grease,preferably mixed with 5 to 10% ofmolybdenum bisulphite powder, isrecommended.

Figure 3-12 Grease fitting

3.15 Bowl thread and adjusting ringwear

Whenever jaws are changed, check the wear ofthe bowl thread and the adjusting ring. Todetermine the degree of wear, check thedifference between the vertical position of thebowl when locked and unlocked. Measure thedistance between the top of the adjusting ringand the bottom of the adjustment cap. Seedimension "A" in Figure 3-13.

Figure 3-13 Adjusting the ring with the head

Ref. Description

1 Grease fitting

2 Adjusting ring

1

2

Ref. Description

1 Adjustment cap

2 Adjustment cap liner

3 Adjusting ring

4 Wedges

5 Dimension "A"

6 Locking cylinder



For a new crusher, the gap between the threadsis 3.57 mm. Any bigger gap is a sign of threadwear. if it attains 8 mm, thread wear equals 4.5mm. This is the authorized maximum.When the bowl's vertical displacement attains8 mm, indicating 4.5 mm of wear, the lockingcylinders and the locking ring must be wedgedto make up the play and lock the bowl.Therefore the spacer sleeve must belengthened by 4.5 mm. See Figure 3-14.The cylinders can only be wedged once. If thevertical displacement between the threads afterlocking and unlocking attains 8 mm, thethreads of the bowl or adjusting ring or bothmust be reconditioned.

Figure 3-14 Spacer sleeve

3.16 Difficulty turning the bowl

Difficulties may be encountered turning thebowl, due to the poor condition of the bowl oradjusting ring threads or both. Often thisoccurs when first assembling the bowlassembly in the adjusting ring, when using asingle cable on the adjustment cap to rotate thebowl. When turning the bowl this way, onegenerally uses a cable with a bullwheelanchored to a tractor or loader.If a single cable is used to turn the bowl in theadjusting ring, the bowl tends to tilt in thethreads of the adjusting ring. This swayingcreates a point of contact between the outerdiameter of the bowl's threads and the flatsurface of the adjusting ring's threads in thedirection of traction, above all if it is nothorizontal. When the bowl is pushed to thecentre of the apparatus, this causes swaying,which chips the threads. This damage isusually confined to the first thread of the bowland the adjusting ring and appears on the flatsurfaces of the threads. The resulting chips candamage the rest of the bowl's threads whenturning in the adjusting ring. The same effectscan occur when dismantling the bowl.

Ref. Description

1 Flat washer

2 Locking screw

3 Spacer sleeve

4 Adjusting ring

5 Locking ring



If stripping occurs on the thread, the methodsbelow can minimize the damage when thebowl is being assembled or dismantled:

– Turn the bowl using a crane or anotherlifting system to maintain theadjusting ring in the floating position(see Figure 3-3). With the bowl in thefloating position, two people cantighten or loosen the bowl to thedesired setting. After each quarterturn, lower or raise the bowl so that itremains free in the adjusting ring.Rotate the bowl by at least 2 completerevolutions using this method.

- OR -– Use a double cable and pull, to turn the

bowl in one direction or the other.

- OR -– Use the bowl's hydraulic adjustment

system to complete at least twocomplete bowl revolutions .

After 2 complete revolutions, a single cablecan be used to continue tightening or looseningit. Pull the bowl slowly (approximately 1 bowlrevolution per minute); considerable force maybe exerted to overcome the friction inside theadjusting ring. One or more of the followingconditions can make it difficult for the bowl torotate in the adjusting ring:

1. Crushing hot materials; using anunsuitable lubricant for the threads.

2. The threads of the bowl and theadjusting ring have not been regularlylubricated.

3. Wear or incorrect fitting of the dust seal.See Figure 3-15.

4. Crusher used with the same setting fortoo long a period.

5. Crusher exposed to bad weather, rain inparticular, without adequate protection.

The following suggestions will eliminate anypossibility of the bowl getting blocked in theadjusting ring:

1. Periodically, release the bowl from itscrushing position and make it turn bymoving it backwards and forwards.

Figure 3-15 Protective apron and seal

2. Add grease in the grease fittings locatedall around the adjusting ring when bowlis engaged in it. Draw up a lubricationmaintenance programme. Use a greaseas recommend in paragraph 3.14"Lubricating the threading".

3. On installation or when the bowl isremoved, clean the threading and coverit with the lubricant recommended inparagraph 5.2 "Assembly instructions".

4. Check the seals of the protective apronoccasionally for wear or damage.

Ref. Description

1 Adjustment cap

2 Seal

3 Bowl

4 Locking ring

5 Protective apron

6 Adjusting the ring

7 Frame

1 2 3

4

5

6 7



When the bowl is blocked in the adjusting ringand cannot turn by the usual means, proceed asfollows:

1. While the crusher is running, feed acertain amount of material into thecrusher when the bowl is in the releasedposition.

2. Pour penetrating oil or antifreeze allaround the circumference of the bowl'sthreading and pour the same solutioninto the grease fittings through theadjusting ring. The penetrating oil orantifreeze will release any build-up ofdust that may have infiltrated throughthe thread gap and will also remove anyrust that may have formed.

Try and unscrew the bowl by applying as muchforce as possible.If this procedure does not produce satisfactoryresults immediately, leave the crusher as is fora few hours, periodically applying penetratingoil or antifreeze around the threads, then repeatthe previous steps.

3.17 Clearing the crusher

If the crusher stops while loaded, do not tryand restart it without first completely emptyingthe crushing chamber. Trying to start it whileloaded can seriously damage the crusher andthe transmission.The crusher may unexpectedly stop for any ofthe following reasons:

– The crusher’s motor lacks electricityor its engine runs out of fuel; too muchfeed enters the crushing chamber andjams the crusher. the dischargeconveyor has stopped, causing thematerial to pile up under the crusher,resulting in jamming and blocking. ortramp iron is stuck in the cavity.

To clear the crusher, do as follows. Thehydraulics cabinet must be powered up. Seethe hydraulic instructions for using theclearing system.

1. Turn the selector switch on the portablecontrol box to MANUAL.

2. Press and hold down the UNRAMMINGbutton until the cylinder rods arecompletely extended. In most cases, thiswill empty the crusher cavity. The redlow pressure indicator should be on.

3. When it has been cleared, if the cavity isnot empty, fit safety wedges between theadjusting ring and the frame to keep theadjusting ring and bowl in the raisedposition in case of a drop in pressure ora cylinder failure, see Figure 3-16.

DANGER

DO NOT TRY AND REMOVEMATERIAL BLOCKED IN THECAVITY BY HAND WITHOUT FIRSTINSTALLING SAFETY WEDGES.THIS IS TO PROTECT HANDS,ARMS OR TOOLS CAUGHTBETWEEN THE LINER ANDMANTLE IN THE EVENT OF AHYDRAULIC FAILURE.

DANGER

NEVER PUT YOUR FEET ORHANDS BETWEEN THE ADJUSTINGRING AND THE FRAME. ALWAYSPLACE SAFETY WEDGESBETWEEN THE FRAME ANDADJUSTING RING WHEN THELATTER IS RAISED AND TRAMPIRON NEEDS REMOVING.



4. Pressing the PRESSURIZE button reststhe bowl and ring assemblies on thesafety wedges.

Figure 3-16 Safety wedge

5. Remove the wedges or the tramp iron tobig to pass through the cavity.

6. When the crushing chamber iscompletely empty, extend themaintaining cylinder rods. This will liftthe adjusting ring and the bowl off thesafety wedges. Remove the safetywedges.

Before returning the adjusting ring to itsnormal position, make sure any personnel inthe vicinity is out of harm's way.Check whether the entire circumference of theadjusting ring is resting on the frame. If not,raise it again and lower it. If the adjusting ringdoes not rest properly on the frame span andthe retaining jacks are pressurized, the lattercould be seriously damaged.IT IS IMPORTANT TO REMOVE ALLMETAL PARTS FROM THE FEED. THERETAINING JACKS ALLOW TRAMPIRON THROUGH. HOWEVER, EXCESSTRAMP IRON CAN DAMAGE THEFRAME SPAN. IF THE FEED CONTAINS ALOT OF FERROUS ITEMS, A MAGNETICSEPARATOR SHOULD BE FITTED. AFRAME DAMAGED BY EXCESS TRAMPIRON WILL NO LONGER BE COVEREDBY THE WARRANTY.

Ref. Description

1 Frame

2 Safety wedge

3 Frame pin

4 Adjusting ring in raised position

4

3

2

1



3.18 Dismantling and installing thebowl

To dismantle the bowl assembly whenreplacing the bowl liner and mantle or to gainaccess to other parts, proceed as follows:

1. Unlock the bowl (see hydraulicsmanual).

2. Turn the bowl in the adjusting ringanticlockwise or clockwise , using thehydraulic system or a crane or a cable asexplained in this section.

3.19 Overhaul and repairs

Possibilities are offered to reconstruct conecrushers or recondition parts that have beenused intensively or are worn after long periodsof operation. It may be advisable andadvantageous to return the crusher to thefactory for this purpose. A thorough overhauldone in time is cheaper than the replacement ofcertain worn parts. We fully dismantle thecrushers and examine all the parts to assesstheir value and remaining service life; wereplace worn parts with new ones.Consult the factory before re-tooling parts likethe head, bowl, adjusting ring or frame. Othersolutions can be found.

3.20 Regular inspections

The best way to keep a crusher in goodworking order after it has been installed andbrought into service to carry out regularinspections. We recommend inspecting thecrusher at regular intervals and maintenancework be carried out in good time. The requisiteinspections and intervals at which they shouldbe carried out are listed in Table 4-1. They areonly given as a rough guide; only you candetermine whether they need carrying outmore or less often. The type of material beingprocessed, the climate and operatingconditions are key factors in determininginspection intervals.Keep the crusher clean and painted. A cleanmachine is easier to service and depreciatesmore slowly than a neglected one.Inspection intervals vary according toconditions of use and applications. Onlyexperience can dictate them.

DANGER (HP100 ONLY)

For reasons of safety and to avoid anydamage to the machine, the lockingpressure should be kept at 0 bars whenthe bowl assembly is not engaged in thelocking and adjusting rings (while thebowl is unscrewed and until it isreassembled).


4.1 - Daily inspection and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

4.2 - Weekly inspection and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

4.3 - Monthly inspection and maintenance/200h. . . . . . . . . . . . . . . . . . . . . . . . 3-5

4.4 - Annual inspection and maintenance/2000h . . . . . . . . . . . . . . . . . . . . . . . 3-5

4.5 - Changing bowl liner and mantle, checks and maintenance . . . . . . . . . . . 3-6

Section 4

REGULAR MAINTENANCE AND INSPECTION

CRUSHER LOGBOOK

Da

te

Tim

e

Am

bie

nt

tem

per

atu

re (

°C)

Oil

tem

per

atu

re(°

C)

Oil

pre

ssu

re (

bar

s) a

t c

ou

nte

rsh

aft

Ab

sorb

ed c

urr

en

t (A

)

Cav

ity

ou

tlet

set

tin

g(m

m) Ch

eck

alar

ms

Sto

pp

ag

e ti

me

(sec

.) a

t c

ou

nte

rsh

aft

Th

e lo

w p

ress

ure

ind

icat

or

for

lock

ing

an

d r

eta

inin

gm

ust

be

off

Ch

eck

dis

char

ge

Th

e b

rea

ther

is c

lean

oil

tan

k

cru

sher

re

turn

Yes No Yes No Yes No

Cru

she

r

Oil

tan

k

Remarks

Crusher size Company

Crusher no. Address

Regular maintenance and inspection SECTION 4

Table 4-1 Maintenance and inspection intervals

4.1 Daily inspection and maintenance

Items List Normal conditions

1 Check the oil level in the tank. Oil in the gauge

2Check the temperature at the inlet and exit of the crusher.

Inlet38°C - 54°C

Return temperature:+0° to 5°C without cooling tower+0° to 8°C with cooling tower

3 Check pressure at the countershaft housing. 1.4 - 2.8 Bars (20-40 PSI)

4 Check input power or current requirement.

5Check setting at cavity outlet.

6 Check support pressure. See hydraulics supplement

7 Check locking pressure. 165 - 193 Bars (2,400 - 2,800 PSI)

8Check feed, distribution and level.

9Check the crusher’s discharge area and accumulation on the arms.

10 Check the imbalance liner

11 Check the time countershaft takes to stop. 30-60 seconds

12Check connections and clamps.

13Check for unusual sounds, signs of wear or excessive strain.

14Liner and mantle worn out, check their condition at regular intervals.

15 Check the adjustment ring for bounce. correct operation when loaded, no bounce

16Check return oil flow in the tank and the pump outlet filter.

TECHNICAL MANUAL GOLDBERG CONE CRUSHERS HP100/200/300/400/500 4-3

SECTION 4 - REGULAR MAINTENANCE AND INSPECTION

Table 4-2 Maintenance and inspection intervals (continued)

4.2 Weekly inspection and maintenance

Ref. list Normal conditions

1Clean/replace the countershaft housing breathers and those of the tank.

2 Check the oil circuits (for leaks).

3Check the liner, mantle and cone feed plate for wear.

4Lubricate the adjustment ring threads with the bowl released then lock the bowl and lubricate them.

5 Check the return filter in the tank.

6 Check that there is no bouncing. correct operation when loaded, no bounce

7Check the tension and condition of the belts.

8 Make sure there are no oil leaks.

9 Check the bullwheel (break, and tightness on shaft).

10Check that the feeder cone screws are tight.

11Check the alarm indicators on the electrical cabinet are in good condition.

12Check the guards of the arms, imbalance, head and the state of wear of the frame span plating.

13 Check the oil level in the tank.

14Check the oil inlet and outlet oil temperatures.

15 Check the oil pressure at the countershaft

16Check the crusher's adjustment and wear of the bowl liner and mantle.

17Check the power or electric current requirement for the crusher.

18Check that no suspicious noise is emitted, nor any unusual vibrations.





4.3 Monthly inspection and maintenance/200h

Ref. List Normal conditions

1Check the pre-load of the accumulators and top up with nitrogen if necessary.

See hydraulics supplement

2Check that the adjustment mechanism pinion cog is properly engaged in the cogwheel.

3Test all alarms, warning lights and lubricating and hydraulic devices (pressure switch, temperature, thermostats).

4 Unlock the bowl and rotate it in one direction then in the other.

5Change the lubricating oil. Change if necessary.

6 Analyse the lubricating oil if in doubt. See the oil contamination table

7 Check the countershaft’s axial clearance.

8Check the guards of the arms, imbalance, head and the state of wear of the frame span.

4.4 Annual inspection and maintenance/2000h


1

Dismantle the crusher completely to check the wear of all rings (head, eccentric, bearing and the surfaces of the pinion and crown).

2 Inspect the frame, head and bowl (check for any fatigues cracks).

3Check the state of couplings, supports, pipes.

4 Check the state of wear of the head ball.

5 Check the state of wear of the pinion and crown.

7Change the gear motor oil.

4-5 TECHNICAL MANUAL GOLDBERG CONE CRUSHERS HP100/200/300/400/500



4.5 Changing bowl liner and mantle, checks and maintenance


1

Inspect the bowl liner and mantle, the bowl's spans and the head.Grind down any defects on the spans (if necessary).

2Inspect the head bushing, head ball, bearing, eccentric ring and seals.

3Check the locking nut and the feeder cone (wear). Replace if necessary.

4Check the guards of the frame's arms, countershaft and frame span.

5 Inspect the threads of the bowl, adjusting and locking ring.

6 Inspect the hydraulics hoses (leaks).

7Check the bowl liner's wedge locks and screws.

8 Check the tightness of the imbalance bolts on the eccentric.

9Check the imbalance liner



Feed– The product must be correctly

distributed all around the crushercavity, both in terms of level and ofgrading.

Advantages: maximum throughput - bettershape - uniform wear of the bowl liner andmantle.

Figure 4-1 Feed



The first setting determined by the desired sizeof the end product is not necessarily the bestfor maximum yield. That depends on thecharacteristics of the material to be crushed,the motor’s absorbed power and the ring’sbounce. We recommend you change settingsgradually to find the best compromise betweenthroughput and yield.

Input power– Run the crusher at 75 to 95% of total

average power WITHOUT RINGBOUNCE.

Advantages: Longer service life for the crusher- higher yield.

Figure 4-2 Input power

75%

95%

1

Item Description

1 Input power


5.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 - Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25.3.1 - Dismantling the bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25.3.2 - Dismantling the bowl liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35.3.3 - Installing the bowl liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.4 - Replacing the bowl's adaptor ring (HP200, HP300, HP400 and HP500) . 5-85.4.1 - Bowl seating (liner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

BOWL, BOWL LINER AND HOPPER ASSEMBLIES

Section 5

Bowl, bowl liner and hopper assemblies SECTION 5

5.1 Description

This section describes the bowl, bowl liner andhopper assemblies The bowl is screwed insidethe adjusting ring, adjustments are made byrotating the bowl anticlockwise or clockwise,according to the desired setting. Bowladjustment determines the gap between thebowl liner and mantle.The adjustment cap is fixed to the top of thebowl and rubs against the joint of theprotective apron fixed to the adjusting ring.This protects the bowl and the locking ring. Aset of locking cylinders is located at the top ofthe adjusting ring.and all round it. Thesecylinders push the locking ring and raise thebowl to the crushing position. The bowl turnswith the adjustment cap with the aid of withthe aid of a hydraulic motor mounted on theadjusting ring.The hopper is placed on two pins on the upperedge of the bowl. The inside of the hopperdirectly feeds the crusher cavity. The shape ofthe bottom of the hopper has been designed sothat the materials build up there, therebyforming a dead-bed that protects the hopperagainst the flow of feed material.Under the hopper and on the bowl are severalwedges and their screws, these wedges holdthe liner firmly on the bowl.

5.2 Assembly instructions

If the bowl, liner and hopper assemblies havebeen dismantled from the crusher for reasonsof transport, they should be cleaned, lubricatedand assembled as follows:

1. To start with, the adjustment cap mustbe dismantled. Remove the screws andwashers retaining the adjustment cap onthe top of the bowl. Raise the adjustmentwith the aid of the lugs welded to it, seeFigure 5-1.

2. Thoroughly clean the bowl, adjustingring and locking ring threads, removingany dust and possibly the protectivevarnish.

3. Rub the threaded surfaces of the bowl,adjusting ring and locking ring with arag soaked in molybdenum disulphide.This produces a lubricating film on thethreaded surfaces, thereby improvingbowl rotation. This is done in ourworkshops at the outset.

4. Cover the threads with greasecontaining 5 to 10% of molybdenumdisulphide.

WHEN CRUSHING HOT MATERIALS SUCHAS CLINKER OR SLAG, AHIGH-TEMPERATURE GREASE MIXEDWITH 5 TO 10% MOLYBDENUMBISULPHIDE POWDER SHOULD BE USED.WHEN MIXED WITH LUBRICATING OIL,IT IS PERFECTLY SATISFACTORY.

5. Reassemble the adjustment cap and theother parts on the bowl.

6. Raise the assembly with slings securedto the lugs around the adjustment cap asshown Figure 5-1. Before reassemblingthe complete assembly, the lockingcylinders must be depressurized asexplained in paragraph 3.18"Dismantling and installing the bowl".

7. Turn the bowl in the locking ring, thenin the adjusting ring as explained inparagraph 3.9 "Bowl rotation".


SECTION 5 - BOWL, BOWL LINER AND HOPPER ASSEMBLIES

Figure 5-1 Handling the bowl assembly

5.3 Maintenance

5.3.1 Dismantling the bowl

1. Release the bowl by releasing thepressure in the locking cylinders asexplained in paragraph 3.18"Dismantling and installing the bowl".

2. Turn the bowl clockwise for HP100and anticlockwise for HP200, HP300,HP400 and HP500 outside theadjusting ring using the hydraulicadjusting system, see Figure 5.2,described in paragraph 3.9 "Bowlrotation".

Ref. Description

1 Feed hopper

2 Sling

3 Shackle

4 Lifting lug

5 Adjustment cap

6 Bowl liner

7 Wedging

8 Bowl

1 2

3

4

5

67

8

DANGER (HP100 ONLY)




Figure 5-2 Hydraulic adjusting assembly

3. Raise the bowl with slings secured to theadjustment cap lugs and lay it onrunners as shown in Figure 5-1.

5.3.2 Dismantling the bowl liner

Dismantle the bowl liner as shown below:

1. Dismantle the adjustment cap asdescribed in paragraph 5.2 "Assemblyinstructions".

2. Make sure the bowl assembly rests onthe bowl liner, not on the bowl. Insertwedges under the bowl liner ifnecessary.

3. Clean the threads of the adjusting ring,locking ring and bowl, removing alltraces of dust and grease.

4. Dismantle the hopper from the bowl.You have access to the lugs that retainthe bowl liner on the bowl. The lugs arelocated on the bowl's adaptor ring,which is fixed with pins.

5. Remove the pins retaining the nut locks.Remove the nut locks. Use a spanner toloosen the barrel nut that presses againstthe rear side of the locking wedge. Thewedges are certainly caught between theedge of the liner and the adaptor ring.Place a chisel against the shoulder of thewedge and strike it with a hammer torelease it. See Figure 5-3.

Figure 5-3 Wedge assembly

6. Use a special wrench to loosen thebarrel nuts by 200 mm. These nuts retainthe wedges against the bowl liner.

Ref. Description

1 Adjustment cap

2 Hood

3 Pinion


5 Toothed crown

6 Adjusting ring

12

3

4

5

6

Ref. Description

1 Nut lock

2 Stop

3 Position of the bolt in the notch of the bowl

4 Square head bolt

5 Ball nut

6 Lug

7 Pin



7. The wedges are wedged between theedge of the liner and the adaptor ringfor HP200, HP300, HP400, HP500and between the edge of the liner andthe bowl for HP100.

Place a chisel against the shoulder of thewedge and strike it with a hammer to release it.Repeat for all the edges. See Figure 5-4.

Figure 5-4 Dismantling the wedge

8. Raise the bowl above the liner.Occasionally the resin may block theliner in the bowl. Hit the liner vertically

to break up the resin. (no sealant resinfor HP100)

Ref. Description

1 Stop

2 Loosen the nut by 20 mm

3 Chisel

4 Lug

5 Bowl liner

6 Sealant resin (no sealant resin for HP100)

7 Ball nut

8 Square head bolt

9 Bowl



9. Break up any remaining resin on thebowl. usually the resin hardly adhere atall to the liner.

10.Check the bowl seating. Grind down anyscratches. If they are deep, refer toparagraph 5.4.1 "Bowl seating (liner)".

The bowl seating should be clean so that thebowl liner fits properly and does not bounce.

5.3.3 Installing the bowl liner

Install the bowl liner as follows:

1. Place the liner on wooden wedges.Make sure the wedges allow the bowl tocompletely cover the liner (for HP200,HP300, HP400, HP500). Lightly coatthe lower surface of the bowl with oil toprevent the resin sticking to it (nosealant resin on HP100).

2. Mark the position of the top of the linerundulation with chalk, see Figure 5-5.

3. The bowl's adaptor ring now fixed,lower the bowl and the adjustment capinto position on the liner. To ensure itlocks into place, position the bowl sothat the lugs are aligned with the tops ofthe bowl liner undulations as shown inFigure 5-5.

4. To be sure that the bowl liner is centredon the bowl, measure the distancebetween the outer diameter of the bowlliner and the inner diameter of the bowlat four different points 90° apart. SeeFigure 5-6. An incorrectly positionedbowl liner will damage its seating.

Figure 5-5 Position of the top of the undulation

5. Pre-assemble each square head bolt, ballnut and wedge. Be sure that thespherical surface of the nut is placedagainst the wedge.

6. Place each wedge in contact with thebowl (for HP100) on the top of thebowl's adaptor ring (for HP200,HP300, HP400 and HP500). Pushthem until they come into contact withthe liner.

NOTE: Be sure that the middle of the taperedpart of each wedge is clean.

7. Check each contact point betweenwedges lugs and the bowl liner as shownin Figure 5-6. Remove or add wedgesunderneath if necessary to achieve acorrect point of contact. The wedges canbe welded.

8. Place square head bolts and barrel nutsbehind the wedges making the that thebolt heads are under the square stopswelded to the bowl. See Figure 5-4.

9. Tighten each nut alternately and inopposition until each lug fits neatlyagainst the jaw’s helix. Use a gauge tocheck that the liner sits correctly allaround the bowl span. The gap shouldnot exceed 0.25 mm. Block up any gapsdue to wear with clay, etc. to prevent thesealant resin from escaping. SeeFigure 5-7.

DANGERRemove the wedges as instructed inthe procedures to avoid bodilyinjury.

DANGERVentilate well and make sure allpersonnel wear respirator masks ifthey need to use a blowtorch toremove parts sealed with resin.

Ref. Description

1 Bowl liner

2 Mark the top of the undulation

3 Top of undulation



Figure 5-6 Mounting the bowl liner

Ref. Description

1 Nut lock

2 View showing the nut lock

3 Bolt stop welded to the bowl

4 Nut lock

5 Lug

6 Contact surface

7 Bowl adaptor ring (HP200, HP300, HP400, HP500)

8 Gap imperative at this point

9 Bowl liner

10 Bowl

11 Wedges, if necessary

12 Wedge (HP200, HP300, HP400, HP500) or bowl (HP100) locking blocks

13 Wedge

14 View showing the locking blocks welded to the adaptor ring (HP200, HP300, HP400, HP500) or bowl (HP100)

15 Square head bolt



Figure 5-7 Checking the gap

NOTE: If the nose of the wedge once in placetouches the vertical wall of the liner, place awedge under the locking wedge so that there iscontact between its sloping side and theundulated surface of the liner. When thewedges are all place and tightly fixed, thereshould still be a small gap between the nose of

the wedge and the outer vertical part of theliner, see Figure 5-6.

10.Refer to Table 6-2 for the approximatequantity of resin. Then pour in the resin,filling the cavity behind the bowl liner.

Ref. Description

1 Bowl

2 Foam seal

3 Bowl liner

4 Sealant resin (no resin on HP100)

5 Wedging

6 Set of wedges

7 Max acceptable play 0.25mm (0.01")



11.Check again that all the wedges and ballnuts are tight when the resin hassolidified.

12.Place the nut locks on the outer parts ofthe barrel nut. Insert the pins through thewedge and the nut lock. Spread the twohalf-ends of the pins so that they remainin place.

13.Weld a block measuring 12 mm x 12mm x 40 mm (1/2" x 1/2" x 1 1/2") justabove the square head of the lockingscrew, see Figure 5-6. The block willprevent the screw head from turningduring crushing.

14.Cover the wedge assembly with foamjoints to prevent ingress of dust andthereby facilitate subsequentdismantling of the liner.

15.Reinstall the hopper by positioning it onthe pins fitted to the bowl.

16.Lubricate the threads of the bowl,locking ring and adjusting ringfollowing the procedure indicated inparagraph 5.2 "Assembly instructions".It is very important that the bowl rotatesfreely in the adjusting ring.

17.Reassemble the rest of the parts.

5.4 Replacing the bowl's adaptorring (HP200, HP300, HP400 andHP500)

To change equipment for a differentproduction job, it may be necessary to changethe adaptor ring.The adaptor ring is simply centred in the bowlthanks to pins. To dismantle the adaptor ring,just lift it and install the new ring, positioningit with the pins. The new adaptor ring alreadyhas the wedge locking blocks. See Figure 5-8.

Figure 5-8 Bowl adaptor ring

5.4.1 Bowl seating (liner)

After a long period of use, the bowl seatingmust re-machined or reconditioned. In whichcase, contact Metso Minerals.

DANGERFollow scrupulously the instructionson the resin boxes. Any contact withthe skin can subsequently causedermatosis. Avoid inhaling anyemanated fumes, above all if theresin has been heated. If the skincomes into contact with the resin,wash straight away with water andsoap.

1 Bowl adaptor ring

2 Wedge locking blocks.

3 Pin

4 Bowl

12

3

4


6.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.1.1 - HP100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.1.2 - HP200 and HP300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.1.3 - HP400 and HP500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 - Mounting the head assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56.3.1 - Dismantling the head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56.3.2 - Replacing the mantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.3.2.1 - HP100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56.3.2.2 - HP200, HP300, HP400 & HP500 . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6.3.3 - Replacing the head wear ring - HP400 and HP500 . . . . . . . . . . . . . . . . . 6-166.3.4 - Replacing the head ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-166.3.5 - Replacing the lower head bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-186.3.6 - Another method for replacing the head bushing . . . . . . . . . . . . . . . . . . . . 6-206.3.7 - Checking the bore of the head and the two bushings . . . . . . . . . . . . . . . . 6-226.3.8 - Installing the head bushing - HP100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236.3.9 - Installing the lower head bushing - HP200 and HP300. . . . . . . . . . . . . . . 6-246.3.10 - Installing the lower head bushing - HP400 and HP500. . . . . . . . . . . . . . 6-256.3.11 - Dismantling the upper head bushing - HP200, HP300, HP400 and HP500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-276.3.12 - Mounting the upper head bushing - HP200, HP300, HP400 and HP5006-276.3.13 - Checking the feeder cone screw - HP100, HP200 and HP300. . . . . . . . 6-286.3.14 - Fitting the feeder cone - HP100, HP200 and HP300 . . . . . . . . . . . . . . . 6-286.3.15 - Replacing the joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

HEAD, MANTLE AND FEEDER CONE ASSEMBLIES

Section 6

Head, mantle and feeder cone assemblies SECTION 6

6.1 Description

6.1.1 HP100

This section describes the head, mantle andfeeder cone assemblies The head and mantle,as well as the bowl and bowl liner form thecrusher cavity.On the top of the mantle, there is the spacerring, these two parts are firmly held on thehead by a locking bolt screwed inside the head.A feeder cone is fixed onto the locking bolt.This plate rotates with the head, evenlyspreading the material in the cavity (orcompaction chamber).Inside the head a bore is machined to receivethe head ball. Two bores receive a headbushing which has a flange ring for fixing thebushing with screws to the lower part of thehead.The bronze ball inside the head is supported bythe sleeve. the head bushing is mounted withplay on the eccentric. The head’s rotation isdriven by being in contact with the ring and theeccentric.When the machine is running idle, the headbushing comes into contact with the sleeve toretain the head ball on the sleeve.Holes in the main shaft guide the oil towardsthe head bushing and into the sleeve.A U-shaped seal machined over the imbalancematches the seal mounted in a groove underthe head, to prevent oil leaks and protect thecrown, pinion and bushing surfaces from dust.A skirt acting as an oil deflector prevents leaksthrough the labyrinth seal.

6.1.2 HP200 and HP300

This paragraph describes the head, mantle andfeeder cone assemblies The head and mantle,as well as the bowl and bowl liner form thecrusher cavity.On the top of the mantle, there is the spacerring, these two parts are firmly held on thehead by a locking bolt screwed inside the head.A feeder cone is fixed onto the locking bolt.This cone rotates with the head, evenlyspreading the material in the cavity (orcompaction chamber).

Inside the head a bore is machined to receivethe head ball. Two bores receive an upper headbushing, and one lower head bushing, the firstfixed with keys, the second with screwsslightly recessed.The ball inside the head is supported by thespherical bearing. the lower head bushing ismounted with play on the eccentric makingcontact between the bushing and the eccentricthe head is rotated.When the machine is running idle, the upperhead bushing comes into contact with thesleeve to maintain contact between the headball and the sleeve.Holes in the main shaft guide the oil towardsthe upper and lower head bushings and into thespherical bearing.A U-shaped seal machined over the imbalancematches the T-shaped seal mounted in a grooveunder the head, to prevent oil leaks and protectthe crown, pinion and bushing surfaces fromdust. A skirt acting as an oil deflector preventsleaks through the labyrinth seal.

6.1.3 HP400 and HP500

This paragraph describes the head, mantle andfeeder cone assemblies The head and mantle,as well as the bowl and bowl liner form thecrusher cavity.The mantle is firmly maintained against thehead with the aid of the locking nut. The lattersupports the feeder cone. The feeder conerotates with the head and distributes thematerials in the crusher cavity.Inside the head a bore is machined to receivethe head ball. This is mounted tight into thehead. Two bores each receive a bushing (upperand lower) tightly mounted.The head ball rests on the concave part of thespherical bearing at the top of the main shaftand the lower head bushing is mounted withplay on the eccentric. The head’s rotation isdriven by being in contact with the ring and theeccentric.When the machine is running idle, the upperhead bushing comes into contact with thesleeve to maintain contact between the headball and the sleeve.


SECTION 6 - HEAD, MANTLE AND FEEDER CONE ASSEMBLIES

Holes in the main shaft guide the oil towardsthe upper and lower head bushings and into thespherical bearing.A U-shaped seal machined over the imbalancematches the T-shaped seal mounted in a grooveunder the head, to prevent oil leaks and protectthe crown, pinion and bushing surfaces fromdust. A skirt acting as an oil deflector preventsleaks through the labyrinth seal.

6.2 Mounting the head assembly

(See Figure 6-1 for HP100)(See Figure 6-2 for HP200 to HP500)If the head, mantle and feeder cone assembliesare dismantled for shipping purposes, thevarious parts must be mounted as follows:

1. If the feeder cone was delivered alreadyfitted on the head, it must be dismantledbefore the head assembly is handled (seeparagraph 6.3.1 "Dismantling thehead").

2. Carefully clean the eccentric, the innerwalls of the head bushings, head balland spherical ring. Make sure allsurfaces are perfectly smooth. If thereare any scratches or rough edges, theyshould be removed with a fine emerycloth. Check all oil passages.

3. Coat generously the outer diameter ofthe eccentric, the bores of the headbushings, the head ball and the bearingwith lubricating oil. Use the crusher'soil.

4. The tools shipped with the crusherinclude a round plate with a tapped holeand a large matching handling ring.

Fit the lifting ring onto the locking bolt.Align the mounting holes and use thescrews provided with the tools to fix thelifting ring onto the locking bolt.

5. With the aid of appropriate handlinggear, raise the head assembly and centreit over the sleeve. The handling ring isoff-centre in relation to the lifting ringso that the tilting angle of the assemblymatches that of the eccentric'scentreline. The highest point of the headassembly must be in line with the thickside of the eccentric. See Figure 6-1 andFigure 6-2.

6. Gently raise the head over the sphericalbearing.

7. The top edge of the eccentric ischamfered, which helps to insert thehead bushing. Gently lower the headassembly onto the eccentric shaking thehead by hand to ease it into place.

8. When the head is resting on thespherical bearing, raise if by 6 mm to 10mm and maintain it in this position.Then start the oil pump and let it run for10 to 15 minutes to remove dust andpre-lubricate the bushings. Turn thepump off, lower the head onto thespherical bearing and remove the liftingring.

9. Fix the feeder cone onto the locking nut.See Figure 6-2.



When the screw is tight, fill the hole withsilicon plastic to cover the head of the screw, inorder to protect the materials and for easydismantling.

Figure 6-1 Installing or dismantling the head assembly (HP100)

Ref. Description

1 Handling ring

2 Sling

3 Lifting ring

4 Head

5 Sleeve

6 Even gap

7 Thick side of the eccentric

8 Minimum play

9 Maximum play

10Dismantling the head assembly:1) Raise the assembly until the ring is no longer guided by the eccentric.2) Centre the head in relation to the sleeve.

11

Mounting the head assembly:1) Centre the head in relation to the sleeve.2) Move the head so that the highest point of the assembly is aligned with the thick side of the eccentric and continue lowering.

4

4

6 16

10 11

557

1

7

89

2

3



Figure 6-2 Installing or dismantling the head assembly (HP200 to HP500)

Ref. Description

1 Handling ring

2 Sling

3 Lifting ring

4 Head

5 Sleeve

6 Even clearance

7 Thick side of the eccentric

8 Minimum clearance

9 Maximum clearance

10Dismantling the head assembly:1) Raise the assembly until the ring is no longer guided by the eccentric.2) Centre the head in relation to the sleeve.

11

Mounting the head assembly:1) Centre the head in relation to the sleeve.2) Move the head so that the highest point of the assembly is aligned with the thick side of the eccentric and continue lowering.

1 2

3

4

5

6 6

7

8

9

10 11



Figure 6-3 Feeder cone assembly

6.3 Maintenance

6.3.1 Dismantling the head

To remove the head for inspection or partreplacement purposes, proceed as follows:

1. Remove the feeder cone.

Loosen the central bolt.

2. Screw the handling ring into the head'slifting plate (supplied with the tools).Position the lifting plate on the lockingbolt with the aid of the holes on thehead, in such a way that the handlingring is at the highest point of the head.Use appropriate bolts supplied with thetools.

3. With the aid of appropriate lifting gear,raise the head assembly until the ring isno longer guided by the eccentric, thencentre the head assembly in relation tothe sleeve Raise vertically.

IF THIS OPERATION IS NOTCARRIED OUT WITH EXTREMECARE, THE HEAD COULD SWAYAND KNOCK AGAINST THESLEEVE, WHICH COULD DAMAGETHE HEAD BUSHING OR OTHERPARTS.

4. Place the head assembly on suitablewedges.

6.3.2 Replacing the mantle

6.3.2.1 HP100To dismantle a worn mantle and replace it witha new one, proceed as instructed below:

1. Dismantle the lifting plate.

2. Grind the two weld seams between thelocking bolt and the spacer ring and themantle.

Figure 6-4 Dismantling the locking bolt (HP100)

Ref. Description

1 Silastic

2 Feeder cone

3 Central bolt

4 Locking bolt

1 23

4

Ref. Description

1 Wrench fastening screw

2 Locking wrench

3 Sledgehammer

4 Locking bolt

5 Loosen

6 Tighten

1

2 3

6

54



Because the mantle tends to stretch duringcrushing, it may be difficult to remove the bolt.In that case the spacer between the mantle andthe locking bolt can be oxygen-cut to eliminatethe tension on the screws, (see Figure 6-5). Tooxygen-cut the spacer ring, some precautionsshould be taken to avoid damaging the head.The blowtorch should be aimed at a tangentialangle to the spacer ring, and it is preferable toburn a groove all the way round beforeactually cutting it off. The locking bolt is nowfree to turn and can be removed.

3. Fix the locking key (supplied with thetools) with the 2 screws into thematching holes on the locking bolt.

Hit the wrench with a sledgehammer to releasethe locking bolt by turning it CLOCKWISE.See Figure 6-4.

Figure 6-5 Cutting a groove in the spacer ring (HP100)

4. Dismantle the locking wrench with itsscrews.

5. Unscrew the locking bolt by hand.

6. Remove the spacer ring.

Figure 6-6 Lifting lug (HP100)

7. Make the lifting lugs according to thedimensions stated in Figure 6-6,welding as instructed below:

A Use electrodes compliant withstandard EN 1600 E19 12 3 LR12, AWS5.4 E 316 L-16 or full wire compliantwith standard EN ISO 13343 G 18 8 Mn,AWS A 5-9 ER 307 Si (workshop).

B- DO NOT preheat the mantle.

C- Clean the eye bolt welding surfacesthoroughly.

D- A 6 mm weld seam is required oneither side of the eye bolt.

E- THE WELDING SHOULD BEIMPECCABLE.

(See welding equipment in the "SafetyInstructions" manual).

DANGERVentilate well and make sure allpersonnel wear respirator masks ifthey need to use a blowtorch toremove parts sealed with resin.

Ref. Description

1 (Section) Circular groove

2 Direction of the blowtorch flame

1

2

Ref. Description

1 100 mm

2 50 mm

3 Diameter of hole: 50 mm

4 R: 50 mm

5 Thickness of the plate: 10 mm

DANGERWhen the mantle is handled withwelded eye bolts, make sure they arethe right size and the welding issolid.Use welding rods that are suitablefor manganese.

1

2

23

45



Figure 6-7 Handling the mantle (HP100)

8. Raise the mantle with slings, placingsuitable shackle in the lifting lugs. SeeFigure 6-7.

9. Inspect the mantle and the head beforereassembling.

a. Remove any rough edges, traces orblisters of paint from the bowlseating.

b. Clean the seating of the liner on thehead, this surface should be free ofany defects.

c. Check the head’s threads and thelocking bolt. Remove any remainingburrs or rough edges and clean thethreads thoroughly.

d. Check the seating of the spacer ringon the locking bolt, which should befree of burrs and rough edges.

e. If the locking bolt is not replaced,check that the screw rests properlyon the spacer ring.

Otherwise (change the retaining locking boltscrew), the screw threads or head could bedamaged and the mantle would no longer befirmly attached to the head.

f. Lightly coat the bowl seating withoil, to prevent corrosion.

10.Lift the mantle with a sling and suitableshackle inserted in the welded liftingrings (see step 7) or with slings attacheddirectly to the moulded hooks on themantle.

11.It is very important for the mantle to beproperly fitted to the head. If the mantlewere to bounce, extensive damage couldbe caused to the head at the level of thespan. Install the mantle as follows:

a. Before lowering the mantle onto thehead, coat the bottom of the mantleseating with grease over a length of25 mm.

b. Lower the mantle over the head.

c. Grease the head threads with lithiumgrease containing 5 to 10% ofmolybdenum disulphide (oranti-seize paste, subject to seeagreement with Metso). Screw thelocking bolt by hand anticlockwisewithout the spacer ring.

d. Loosen the screw, fit the spacer ringonto the liner.

Ref. Description

1 Mantle

2 Lifting with moulded hooks

3 Lifting with welded eye bolts

4 Slings

14

1 3

2



e. Bring the locking bolt close to thespacer ring. Position the mantle sothat the gap between the spacer ringand the locking bolt is equal allaround the edge. If the gap is uneven,

the mantle can be adjusted by hittingit at the top or raising its bottom. Donot rely on the tightness of the bolt toalign the mantle correctly.

Figure 6-8 Correct position of the mantle (HP100)

12.Fix the locking wrench (supplied withthe tools) onto the locking bolt with theaid of the 2 screws (supplied with thetools).

13.Bring the locking bolt into contact byhand with the spacer ring by turning itanticlockwise with the aid of the lockingwrench mounted on the locking bolt.

14.Use a gauge to check that the mantleseating is in contact with the head setliner. The gap should not exceed 0.25mm (0.010'). If the gap is wider due towear, lift the mantle, cover the bottom ofthe head with clay or another materialthen refit the mantle.

15.Make a vertical mark on the mantle, thespacer ring and the locking bolt.

16.With a sledgehammer, strike the wrenchto lock the locking bolt by making itturn ANTICLOCKWISE, to obtain adisplacement of 80 to 100 mm.

17.After tightening the locking bolt ontothe head:

– Apply 2 3-mm weld seamsdiametrically opposite over a length of30 mm (1.2 inches) between themantle and the spacer ring.

– Use electrodes compliant withstandard EN 1600 E19 12 3 LR12,AWS 5.4 E 316 L-16 or full wirecompliant with standard EN ISO13343 G 18 8 Mn, AWS A 5-9 ER 307Si (workshop).

– Apply 2 3-mm weld seamsdiametrically opposite over a length of30 mm (1.2 inches) between the spacerring and the locking bolt. The weldshould not interfere with thedistribution cone on the locking bolt.

– Use rods compliant with standard ISO(2560), E515 B 120 29 (H), NF (EN499) E 423 B 32 H 5, WAS (A 5.1) E7018 or cored wire compliant withstandard WAS A518 . E70C-6MH4,EN 758: T 42 3 M M2 H5.

Ref. Description

1 Mantle

2 Equal distance

3 Locking bolt

4 Spacer ring

5 Head

1

3

22

4

5



– The weld seams between the mantleand the spacer ring and those betweenthe spacer ring and the locking boltshould be in a quincunx and spaced45° apart.

18.Cut the lifting lugs or moulded hooks onthe mantle.

19.Fit the head referring to the instructionsgiven in paragraph 6.2 "Mounting thehead assembly".

6.3.2.2 HP200, HP300, HP400 & HP500To dismantle a worn mantle and replace it witha new one, proceed as instructed below:

1. Dismantle the lifting plate.

2. Grind the two weld seams between thelocking bolt and the spacer ring andbetween the spacer ring and the mantle.

Figure 6-9 Dismantling the locking bolt

Figure 6-10 Cutting a groove in the spacer ring

3. Screw the M10 lifting ring (suppliedwith toolkit) onto the locking wrench(supplied with the tools) (forHP200/400/500).

Lift the wrench with slings attached tothe handle (HP300) or with suitableshackle attached to the lifting ring(HP200/400/500).

Lower the wrench into the imprint of thelocking bolt and fit the L30 washer andM30 screw (for HP200/300) and the L42washer and M42 screw (for HP400/500)supplied with the tools to lock thewrench onto the bolt. Hit the wrenchwith a sledgehammer to release thelocking bolt by turning it CLOCKWISE.See Figure 6-9.

4. Dismantle the locking wrench with itsscrew.

Raise the locking wrench with a slingand suitable shackle inserted in thelifting eye bolt.

5. Screw the M30 (for HP200/300) or M42(for HP400/500) handling ring (suppliedwith the tools) onto the locking bolt.

Unscrew the locking bolt by hand.

Lift the locking bolt with a sling andplace suitable shackle into the liftingring.

6. Remove the spacer ring.

DANGERThe weld should not interfere withthe feeder cone support on themantle’s locking bolt.

Ref. Description

1 Wrench fastening screw

2 Locking wrench

3 Sledgehammer

4 Locking bolt

5 Loosen

6 Tighten

7 Pins

1

2

3

4

5

6

7

Ref. Description

1 (Section) Circular groove

2 Direction of the blowtorch flame

1

2



Figure 6-11 Handling the mantle

Figure 6-12 Lifting eye bolt

7. Since April 2011, each crusher comeswith a mantle lifting accessory. Thisaccessory is included in the toolbox andis designed to handle only new and wornMetso mantles for Metso HP conecrushers.

Please refer to the IM-308000000instruction manual for instructions onsetting up, using and maintaining thelifting accessory.

INFORMATION:If the production date of yourcrusher is earlier than April 2011, pleasecontact Metso to procure this accessory andfind out the technical alterations top make tothe crusher.

Ref. Description

1 Mantle

2 Lifting with moulded hooks

3 Lifting with welded lugs

4 Lifting with the lifting accessory

5 Slings

Ref. Description

1 100 mm

2 50 mm

3 Diameter of hole: 50 mm

4 R: 50 mm

Thickness of the plate: 10 mm

1

2

23

4

5

DANGER

When the mantle is handled with weldedeye bolts, make sure they are the rightsize and the welding is solid.

Use welding rods that are suitable formanganese.



If you do not have a lifting accessory,make the lifting lugs to the stateddimensions Figure 6-12 and use thewelding procedure given below:

A Use electrodes compliant withstandard EN 1600 E19 12 3 LR12, AWS5.4 E 316 L-16 or full wire compliantwith standard EN ISO 13343 G 18 8 Mn,AWS A 5-9 ER 307 Si (workshop).

B- DO NOT preheat the mantle.

C- Clean the eye bolt welding surfacesthoroughly.

D- A 6 mm weld seam is required oneither side of the eye bolt.

E- THE WELDING SHOULD BEIMPECCABLE.

(See welding equipment in the "SafetyInstructions" manual).

8. Raise the mantle with slings, placingsuitable shackle in the lifting lugs. SeeFigure 6-11.

9. Inspect the mantle and the head beforereassembling.

a. Remove any remaining sealant resinon the head.

b. Remove any rough edges, traces orblisters of paint from the bowlseating.

c. Clean the seating of the liner on thehead, this surface should be free ofany defects.

d. Check the head’s threads and thelocking bolt. Remove any remainingburrs or rough edges and clean thethreads thoroughly.

e. Check the seating of the spacer ringon the locking bolt, which should befree of burrs and rough edges.

f. If the locking bolt is not replaced,check that the screw rests properlyon the spacer ring.

Otherwise (change the retaininglocking bolt screw), the screwthreads or head could be damagedand the mantle would no longer befirmly attached to the head.

g. Lightly coat the bowl seating withoil, to prevent corrosion.

h. Check that the mantle has holes forpouring the resin as described inparagraph 14. Otherwise, cut out 25 x40 mm 2 notches diametricallyopposed in the top of the mantle forpouring the resin. See Figure 6-14and Figure 6-15.

10.Lift the mantle with a sling and suitableshackle inserted in the liftingaccessory's lugs, the welded lifting ringsor with slings attached directly to themoulded hooks on the mantle (see step7).

11.It is very important for the mantle to beproperly fitted to the head. If the mantlewere to bounce, extensive damage couldbe caused to the head at the level of thespan. Install the mantle as follows:

a. Before lowering the mantle onto thehead, coat the bottom of the mantleseating with grease over a length of25 mm.

b. Lower the mantle over the head.

c. Grease the head threads and thelocking bolt with lithium greasecontaining 5 to 10% of molybdenumdisulphide (or anti-seize paste, seeMetso agreement). Screw the lockingbolt by hand anticlockwise withoutthe spacer ring.

d. Loosen the screw, fit the spacer ringonto the liner.

e. Bring the locking bolt close to thespacer ring. Position the mantle sothat the gap between the spacer ringand the locking bolt is equal allaround the edge. If the gap is uneven,the mantle can be adjusted by hittingthe top or raising the bottom of it. Donot rely on the tightness of the bolt toalign the mantle correctly.



12.Fit the locking key (supplied with thetools) with the pins into the matchingholes on the locking bolt.

Fit washer L30 and screw M30 (forHP200/300) and washer L42 and screwM42 (for HP400/500) supplied with thetools to lock the wrench onto the bolt.

13.Bring the locking bolt into contact byhand with the spacer ring by turning itanticlockwise with the aid of the lockingwrench mounted on the locking bolt.Make a vertical marl on the mantle, thespacer ring and the locking bolt thenstrike the locking wrench with asledgehammer to achieve thedisplacement stated in Table 6-1.

Table 6-1 Displacement value before heating the mantle

Figure 6-13 Correct position of the mantle

14.Use a gauge to check that the mantleseating is in contact with the head setliner. The gap should not exceed 0.25mm (0.010'). If the gap is wider due towear, lift the mantle, cover the bottom ofthe head with clay or another materialthen refit the mantle to prevent anyleaking of the sealant. See Figure 6-14.

15.Make a vertical mark on the liner, thespacer ring and the locking bolt.

16.Heat the lower part of the mantle with aflame at roughly 55°C above ambienttemperature.

17.With a sledgehammer, strike the wrenchto lock the locking bolt by making itturn ANTICLOCKWISE, to obtain adisplacement of 20 to 30 mm.

Crusher Displacement value

HP200 60 mm

HP300 85 mm

HP400 130 mm

HP500 175 mm

Ref. Description

1 Mantle

2 Equal distance

3 Locking bolt

4 Spacer ring

5 Head

1

3

22

4

5



18.After tightening the locking bolt ontothe head:

– Apply 2 3-mm weld seamsdiametrically opposite over a length of50 mm (2 inches) between the mantleand the spacer ring.

– Use electrodes compliant withstandard EN 1600 E19 12 3 LR12,AWS 5.4 E 316 L-16 or full wirecompliant with standard EN ISO13343 G 18 8 Mn, AWS A 5-9 ER 307Si (workshop).

– Apply 2 3-mm weld seamsdiametrically opposite over a length of50 mm (2 inches) between the spacerring and the locking bolt. The weldshould not interfere with thedistribution cone on the locking bolt.

– Use rods compliant with standard ISO(2560), E515 B 120 29 (H), NF (EN499) E 423 B 32 H 5, WAS (A 5.1) E7018 or cored wire compliant withstandard WAS A518 . E70C-6MH4,EN 758: T 42 3 M M2 H5.

– The weld seams between the mantleand the spacer ring and those betweenthe spacer ring and the locking boltshould be in a quincunx and spaced45° apart.

Figure 6-14 Installing the mantle

DANGERThe weld should not interfere withthe feeder cone support on themantle’s locking bolt.

Ref. Description

1 Pouring channel

2 Locking bolt

3 Mantle

4 Maximum admissible play 0,25mm (0,01")

5 Filling hole

6 Clean this surface with oil

7 Head

8 Set of wedges

1

23

4

5

678



Figure 6-15 Installing the mantle

19.Cut the lifting lugs or moulded hooks onthe mantle.

20.When the mantle has cooled down, fillthe cavity with sealant resin up to thetop of the head.

The sealant resin is a hard-wearing, non-metallic and resilient material. It is available invarious quantities.Each packet contains a large box of resin and asmall box of hardener for mixing.No special handling, preparation or equipmentis necessary to use it. The resin cannot bereused. It can be prepared at the place of use,without any prior training required for thepersonnel. Just follow the instructions on thepackaging. When the resin has been mixed, itmust be used without delay. if the preparedquantity is not enough, the operation can berepeated and liquid resin poured on the resinthat has already solidified.IF THE RESIN IS TOO COLD, IT WILLHARDEN SLOWLY AND WILL BE TOOVISCOUS TO FILL THE SPACE BETWEEN

THE TWO WALLS THAT ARE TOO CLOSETOGETHER. IF IT IS TOO HOT, THEMIXTURE CAN HARDEN IN THE BOXBEFORE IT IS POURED. TO AVOID THIS,IMMERSE THE BOXES IN WATERBEFORE OPENING THEM TO BRINGTHEM TO A TEMPERATURE OFBETWEEN 16°C AND 32° DO NOT USETHE RESIN WHEN THE CRUSHER FEEDEXCEEDS 80°C. UNOPENED BOXES OFRESIN CAN BE KEPT FOR 12 MONTHSFROM THE DATE OF PRODUCTION.Table 6-2 gives the approximate quantity ofsealant resin required.Use the filling holes moulded in the mantle oroxygen-cut two holes measuring 25 mm x 40mm, diametrically opposed, at the top of themantle, to pour the sealant resin.Make a pouring channel in sheet metal orcardboard to pour the resin. To speed up theoperation, it can be poured at several places atthe same time. See Figure 6-14 andFigure 6-15.

Ref. Description

1 If there are no filling holes, cut out notches

2 Min r: 10 mm

3 Top of the mantle

4 25 mm

5 40 mm

1

34

5

2



If 25 x 40 mm notches are used to pour theresin, they must be blocked with a 3 mm (1/8")metal sheet welded to the mantel. Thisprevents dust penetrating the threads of thelocking bolt and the head.

21.Install the head, following theinstructions given in paragraph 6.2"Assembling the head assembly".

Table 6-2 Requisite quantity of sealant resin

Figure 6-16 Installing the head wear ring (HP400 and HP500)

DANGER

Follow scrupulously the instructions onthe resin boxes. Any contact with theskin can subsequently cause dermatosis.Avoid inhaling any emanated fumes,above all if the resin has been heated. Ifthe skin comes into contact with theresin, wash straight away with water andsoap.

TypeStandard

Short head (HP200/300)Option (HP400/500)

HP200

HP300

HP400

HP500

HP200

HP300

HP400

HP500

Requisite quantity of resin for the mantle

• Average weight (kg)20 25 30 40 20 25 30 40)

Requisite quantity of resin for the bowl liner

• Average weight (kg)30 35 50 80 30 35 50 90

The sealant resin comes in kits of 10 kg and 5 kg after mixing.

Ref. Description

1 Head wear ring



6.3.3 Replacing the head wear ring -HP400 and HP500

For a crusher equipped with an extra-thin shorthead, a wear ring must be placed behind themantle to protect the head. This wear ring is inseveral parts. Align the bottom of the ring withthe bottom of the head and weld only the upperpart. See Figure 6-16.

6.3.4 Replacing the head ball

The head ball rests on the sleeve (HP100) orthe spherical bearing (HP200 to HP500). Ballwear is therefore usually minimal. However,through a lack of oil or contaminated oil, theball is worn so much that its spherical surfaceis uneven; it must be replaced, seeFigure 6-17and proceed as follows :

1. Remove the bolt fixing the head ball tothe head.

If the bolt was fitted with Loctite, itmust be heated by flame to atemperature of approximately 205°C.

2. The ball is partially recessed in the head:

a. Place a wooden wedge under thehead in such a way that there is onlya short distance between the ball andthe wedge, to allow the ball to lowercorrectly.

b. Use a 50 x 50 mm rafter, place itbetween the welded washer and thebore of the head, and strike until thehead ball is released.

3. When the worn head ball has beendismantled, upturn the head and cleanthe head bore receiving the ball.

4. To reduce the diameter of the head ball,place it in a refrigerated bath for 4 to 6hours. This will require approximately23 kg of carbon dioxide snow. Measurethe outer diameter of the ball and theinside of the head bore to determinewhether the ball can be mounted.



Figure 6-17 Replacing the head ball

5. Secure the head ball use a lifting ringplaced in the central hole of the ball, andlower it into its housing. Ensure itsbearing surface comes into contact withthe head. Check 4 points with the aid ofa gauge. Ensure the pin hole in the headball is aligned with the pin in the head.See Figure 6-18.

1 2

3

4

5

9

8

7 6

Ref. Description

1 Bolt and flexible washer

2 Washer

3 Head

4 Pins

5 Head ball

6 Wooden wedges

7 Lower head bushing

8 Upper head bushing

9 Weld 6 mm

DANGER

Use well insulated gloves to handlecarbon dioxide snow, which can causeserious burns.



Figure 6-18 Assembling the head ball

6. Fit the screw into the washer welded inthe head bore, then screw it into the ball.

7. Heat the ball to ambient temperaturethen remove the screw and clean all thethreads and the hole with a solvent.Then apply Loctite 277 to the threads ofthe screw, and refit it with its washer.

6.3.5 Replacing the lower headbushing

(See Figure 6-19).The lower head bushing mounted tightly in thehead is kept in place by headless screws ref. 6for HP200 and HP300. The bushing is keptin place by screws for HP100, HP400 andHP500.If the lower head bushing needs to bedismantled, upturn the head and proceed asfollows:

1. Use a saw with a suitable blade to cutthe bronze ring in two places. Adjust thesaw so that it follows and is guided bythe head bushing bore hole, seeFigure 6-20.

Ref. Description

1 Head ball

2 Lifting ring



Figure 6-19 Installing the upper and lower head bushings

2. Measure the distance between the bladeand the head’s bore hole. Deduct a fewtenths of millimetres from the resultingdistance to be sure the saw does notdamage the head.

3. Adjust the saw to the sawing depthdetermined in paragraph 2.

12

3

4

5

6

8

9

11

10

7

Ref. Description

1 Washer

2 Head ball


4 Head


6 Screw slightly recessed (HP200/300)

7 Counterbore and screw (HP100/HP400/HP500)

8 T-joint

9 Retainer lock and its support

10 Pins

11 Screws and locking washers

DANGERProtective equipment must be worn.In particular, protect your head witha shock-resistant mask throughoutthe operation.



4. Saw a test cut to ensure the sawingdepth is correct. Make any necessaryadjustments.

5. Saw the head bushing along the conedistance.

6. Repeat at the diametrically opposedpoint. The bushing should be practicallyfree after the second cut.

Figure 6-20 Removing the bushing by sawing

6.3.6 Another method for replacingthe head bushing

On HP200, HP300, HP400 and HP500, toreplace the upper head bushing, the lower headbushing needs to be dismantled. To recoverand reuse the lower head bushing, upturn thehead and proceed as follows:

1. Remove the screws retaining thebushing on the head.

2. Make a centring plate as shown inFigure 6-21.

3. Slide the plate vertically through thebushing until it is behind the bushing.Turn the centring plate 90°. SeeFigure 6-22.

4. Holding the plate in position, screw athreaded rod 24 or 27 mm in diameterinto the welded nut in the centre of theplate. The threaded rod should be longerthan the height of the bushing.

5. Place a bar measuring 25 mm x 75 mmover the threaded rod and tighten firmlywith a nut.

6. Place runners between the bar and headdrum as shown in Figure 6-23.

7. Fill the bushing's bore with carbondioxide snow to make it narrower.Cooling time: roughly 2 hours.

1

2

3

4

5

Ref. Description

1 Circular saw


3 Base of the saw

4 Use a suitable saw blade

5 Sawing depth



8. Use the threaded rod as a cylinder.Tighten the nut until the bushing comesout. Cylinders can also be used.

9. Unscrew the nut and place additionalrunners under the bar then tighten thenut until the bushing comes out.

Figure 6-21 Centring plate


Ref. Description

1 Dimension on lower flat metal strips inside the bushing

2The diameter of the plate should be 3 mm less than the outer diameter of the bushing

3 Centring plate

4 25 mm

5 Weld a 24 or 27 mm nut

Ref. Description

1Slide the centring plate through the bushing and turn through 90°

2 Bushing

3 Centring plate



Figure 6-23 Dismantling the lower head bushing

6.3.7 Checking the bore of the headand the two bushings

Before fitting the new head bushing, check thatthe head’s bore hole is clean and smooth, freeof scrapes etc.Also check that the bore has notbeen deformed after being heated. Measure thebore from the bottom upwards.

Ref. Description

1 Bar - Same length or longer than the inner diameter of the head

2 Runners

3 Centring plate


5 Threaded rod



6.3.8 Installing the head bushing -HP100

(See Figure 6-24).To install the bushing, proceed as follows:

1. Clean the bore of the head and outercircumference of the bushing.

2. Fill the new head bushing with carbondioxide snow to make it narrower. 90 kgof carbon dioxide snow are required toreduce the outer diameter of the headbushing. Use a piece of wood measuring100 mm x 100 mm to leave a largeenough gap around it in the headbushing for the requisite quantity ofcarbon dioxide snow.

Wrap the outside of the head bushing withseveral layers of fibre glass to prevent frostforming, which could impede reassembly of

the bushing into the head. This also helps coolthe bushing right down.The cooling process takes about two hours.DO NOT USE THIS METHOD FOR THEHEAD’S BORE HOLE; IT WOULDSHRINK.

3. Measure the outer diameter of the balland the inside of the head bore todetermine whether the ball can bemounted.

4. Fit two lifting rings (supplied with thetools) into the bushing's handling holes.

5. Raise the bushing and centre it over thebore hole. Lower it rapidly into thehead.

6. Push the bushing in until it rests on theunderside of the head.

Figure 6-24 Head assembly

DANGERWear well-insulated gloves whenhandling the carbon dioxide snow .This substance can cause seriousburns.

DANGERMake sure the handling holes drilledon the head match up.

Ref. Description

1 Head

2 Head bushing

3 Head bushing fixing screw

4 Washer

43

21



7. Clean the holes and screws with solventthen insert the screws with Loctite 277.

8. Lock the 8 M8 x 20 screws.

9. Install the bushing head as explained inparagraph 6.2 "Mounting the headassembly". When reassembling thefeeder cone, cover the head of the screwretaining the cone with silastic.

AFTER FITTING A NEW HEAD BUSHING,REFER TO PARAGRAPH 3.6 "Initialstart-up".

6.3.9 Installing the lower headbushing - HP200 and HP300

(See Figure 6-25).To install the bushing, proceed as follows:


2. Fill the new head bushing with carbondioxide snow to make it narrower. 90 kgof carbon dioxide snow are required toreduce the outer diameter of thebushing. Use a piece of wood measuring100 mm x 100 mm to leave a largeenough gap around it in the bushing forthe requisite quantity of carbon dioxidesnow.

Figure 6-25 Fitting screws slightly recessed

Ref. Description

1 Head


3 Inner diameter of the head bushing

4 "A" See Table 6-3

5 Screw slightly recessed

12

3

4

1

5



Table 6-3 Information on slightly recessed screws

Wrap the outside of the head bushing withseveral layers of fibre glass to prevent frostforming, which could impede reassembly ofthe bushing into the head. This also helps coolthe bushing right down.The cooling process takes about two hours.DO NOT USE THIS METHOD FOR THEHEAD’S BORE HOLE; IT WOULDSHRINK.

3. Measure the outer diameter of thebushing and the inside of the head boreto determine whether the bushing hascooled down enough.



6. Push the bushing until the lowersurfaces of the cylindrical bushing andthe head are aligned.

7. After fitting the bushing, drill and tapthe head and bushing to fix the slightlyrecessed screws as shown in Figure 6-25and in Table 6-2.

8. Clean the holes and screws with solventthen insert the screws with Loctite 277.Check that the screws do not protrudebeyond the head.

9. With a CHS-type wrench lock thescrews.

10.Install the bushing head as explained inparagraph 6.2 "Mounting the headassembly". When reassembling thefeeder cone, cover the heads of thescrews retaining the cone with silastic.

AFTER FITTING A NEW LOWER HEADBUSHING, REFER TO PARAGRAPH 3.6"Initial start-up".

6.3.10 Installing the lower headbushing - HP400 and HP500

(See Figure 6-26).Replace the head bushing as follows:

1. Clean the bore of the head and outercircumference of the bushing. Clean theholes fixing the bushing in the head.

2. Fill the new head bushing with carbondioxide snow to make it narrower. 90 kgof carbon dioxide snow are required toreduce the outer diameter of thebushing. Use a piece of wood measuring100 mm x 100 mm to leave a largeenough gap around it in the bushing forthe requisite quantity of carbon dioxidesnow.

Type Number of screws "A"

Dimension of the

slightly recessed screws

HP200 3 16.5 mm M16x40

HP300 4 18.5 mm M16x40




Figure 6-26 Lower head bushing

Wrap the outside of the head bushing withseveral layers of fibre glass to prevent frostforming, which could impede reassembly ofthe bushing into the head. This also helps coolthe bushing right down.The cooling process takes about two hours.DO NOT USE THIS METHOD FOR THEHEAD’S BORE HOLE; IT WOULDSHRINK.

3. Measure the outer diameter of thebushing and the inside of the head boreto determine whether the bushing hascooled down enough.

4. Paint or draw a line outside the bushingat right angles to one of the mountingholes. Paint or draw a line at the top ofthe head at right angles to the tappedholes. These lines must serve tocorrectly align the holes for mountingthe bushing and the head.



7. Make sure immediately that the holesare well enough aligned to allow the tapscrews to be screwed into the head.Otherwise, turn the bushing slightlyuntil the tap screws are properlyscrewed in.

8. Temporarily tighten the tap screws at50% of the torque stated in Table 6-3.Use a thickness gauge to check whetherthe bushing is tight against the head allaround. Check at least four points.

9. WHEN THE bushing has been broughtto ambient temperature, remove thepreviously inserted tap screws, clean thenew tap screws and self-locking nutsand the holes tapped in the head with anoil-free solvent. The apply Loctite 277to the threaded surfaces, fit the tappedscrews and washers and tighten thesescrews to the FINAL torque as specifiedin Table 6-4. NEVER REUSESELF-LOCKING TAP SCREWS.

10.Install the head as explained inparagraph 6.2 "Mounting the headassembly". When reassembling thefeeder cone, the screw heads must beprotected to ensure the seal.

Ref. Description

1 Head


3 Locking bolt

4 Loctite 277

5 Washer




AFTER FITTING A NEW LOWER HEADBUSHING, REFER TO PARAGRAPH 3.6"Initial start-up".

Table 6-4 Information on the screws

6.3.11 Dismantling the upper headbushing - HP200, HP300, HP400 andHP500

(See Figure 6-27).The upper head bushing is mounted slightlytightened in the head and retained by retainerlocks.If upper head bushing needs to be dismantled,turn the head and proceed as follows:On the HP200 and HP300, the lower headbushing must be dismantled beforedismantling the upper head bushing. On theother hand, on the HP400, the lower headbushing does not need to be removed beforethe upper bushing.

1. Read the instructions in paragraph 6.3.5"Replacing the lower head bushing" inthis section, the "sawing" and "cooling"procedures are the same as fordismantling and installing the upperhead bushing.

Remove the 4 rail stops by loosening thescrews. If these screws were fitted withLoctite, they must be heated to around 205°C.

2. Remove the head bushing by sawing.

3. Check the head's bore, which must beclean. Check the dimensions of thisbore.

6.3.12 Mounting the upper headbushing - HP200, HP300, HP400 andHP500

(See Figure 6-27).To mount the head bushing, proceed asfollows:


2. Cool the bushing with carbon dioxidesnow for at least two hours.

3. Install the handling rings and bring thebushing into position over the bore hole.

4. Quickly lower the bushing until it fitsinto the bottom of the bore hole,aligning the grooves of the bushing'sretainer lock with those of the rail stopsupports.

5. Put the rail stops in place using lockingplates and screws. Fit the screws withLoctite 277, after cleaning the holes andscrews with solvent.

6. After tightening the retainer locks, pullthe stop plates over the fastenings onHP200, HP300 and HP500, remount thelower head bushing as instructed in thissection.

AFTER INSTALLING THE NEW HEADBUSHINGS, SEE PARAGRAPH 3.6 "Initialstart-up".

Type

Dimension of the screws

(Ref. 3 Figure 6-26)

Thread torque

Quantity

HP400 M10 x 25 60 N.m 8

HP500 M10 x 25 60 N.m 8



Figure 6-27 Fitting the upper head bushing

6.3.13 Checking the feeder conescrew - HP100, HP200 and HP300

Check the feeder cone and central bolt forwear; replace if necessary.IF A FEEDER CONE FALLS INTO THECAVITY, IT CAN CAUSE SERIOUSDAMAGE. Regularly check that the cone’slocking bolt is tight. If in doubt, change thebolt.

6.3.14 Fitting the feeder cone -HP100, HP200 and HP300

Set the one down on the screw, insert the screw(HM20 for HP100 and HM30 forHP200/300) and tighten it. The cone has amale part that fits into the female part of thescrew, to prevent the cone rotating.

Ref. Description

1 Head

2 Rail stop support

3 Retainer lock


5 Rail stop support welded on both sides

6 Screw and washer

1

24

3

5

6

4 3

A-A



6.3.15 Replacing the joints

(See Figure 6-28 and Figure 6-29)The T-shaped polyurethane joint (I-shaped forHP100) glued into the machined groove underthe head is not subject to wear. Should it bedamaged for any reason whatsoever, it shouldbe replaced straight away. This joint protectsthe pinion and crown assembly and bushingsfrom airborne dust, which causes rapid wear,contaminates the oil and clogs up the oil filter.

1. Remove the worn seal and scrape offany remaining debris in the seal groove.

2. Clean the groove thoroughly with aquick-drying oil-free cleaner.

The diameter of the spare seals is the same orslightly larger than required. Insert the newseal into the groove without glue and mark outthe required length. Remove the seal and makea clean cut at the desired length. The seal mustbe able to be mounted in its groove withoutforcing.

3. Apply the adhesive to the bottom of thehead's throat. Use just enough adhesiveto ensure the bond.

4. Put the joint in place in its groove assoon as the adhesive is applied. Pressthe joint in such a way that of is firmlyfixed to the contact surface. Thebonding is complete after more or less 3minutes.

Figure 6-28 Replacing the joint HP100

Figure 6-29 Replacing the joint HP200, HP300, HP400 and HP500

DANGERMake sure the area is well ventilatedwhen handling chemical products toavoid inhaling toxic fumes.

Ref. Description

1 Head

2 T-joint

3

Thoroughly clean the surface of the joint before applying the activator and the adhesive to the bottom of the head's throat.

Ref. Description

1 Head

2

Thoroughly clean the surface of the joint before applying the activator and the adhesive to the bottom of the head's throat.

3 T-joint

1

2

3


7.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 - Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.2.1 - Instructions for HP100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.2.2 - Instructions for HP200, HP300, HP400 and HP500 . . . . . . . . . . . . . . . . . . 7-2

7.3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57.3.1 - Replacing the sleeve (HP100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57.3.2 - Replacing the spherical bearing (HP200, HP300, HP400 and HP500) . . . 7-6

Section 7

SLEEVE ASSEMBLY

Sleeve assembly SECTION 7

7.1 Description

This section describes the sleeve assembly.The sleeve with its spherical bearing supportsthe head assembly and helps transmit thecrushing force to the frame. The sleeve ismounted on the shaft and fixed with a series of8-8 screws.The spherical bearing pinned to the top of thesleeve protects the head ball bolted under thehead. The upper surface of the bearingcomprises a series of circular oil grooves. Thebearing is lubricated by pressurized oil flowingthrough the passages between the main shaftand the sleeve.

7.2 Assembly instructions

7.2.1 Instructions for HP100

See Figure 7-1.If the sleeve has been dismantled in order todismantle the eccentric for shipping or repairpurposes, reinstall the eccentric assembly thenproceed as follows:

1. In the toolkit, take the 3 pilot studs (withthreaded ends) and screw them into the3 tapped holes on the upper part of themain shaft.

2. Screw 3 lifting rings onto the sleeve andsling it.

3. Heat the sleeve as specified in Table 7-1,over the ambient temperature andquickly fit the sleeve onto the mainshaft.

4. Rapidly lower the sleeve onto the mainshaft, guiding it with the aid of the pilotstuds. Make sure the seating of thesleeve is firm on the shaft.

Unscrew the 3 pilot studs at the top of theshaft. Fit the retaining screws and washerspositioning the sleeve onto the main shaft.Tighten gradually up to the torque specified inTable 7-1.

NOTE: When the assembly has cooled down,check the tightening torque.

Figure 7-1 Mounting the sleeve (HP100)

DANGERUse safety gloves when handling hotparts.

Ref. Description

1 Sleeve

2 Bolt

3 Washer

4 Lifting eye bolt (3)

5 Aligning pins (3)

6 Main shaft

1

3

2

5

6

4


SECTION 7 - SLEEVE ASSEMBLY

Table 7-1 Temperatures for mounting the sleeve and screw tightening torque (HP100)

7.2.2 Instructions for HP200, HP300,HP400 and HP500

See Figure 7-2.If the sleeve and spherical bearing have beendismantled in order to dismantle the eccentricfor shipping or repair purposes, reinstall theeccentric then proceed as follows:

a. Assembling the sleeve

1. In the toolkit, take the 3 pilot studs (withthreaded ends) and screw them into the3 tapped holes on the upper part of themain shaft.

2. Screw 2 lifting rings onto the sleeve andsling it.

3. Heat the sleeve as specified in Table 7-2,over the ambient temperature andquickly fit the sleeve onto the mainshaft.

4. Lower the sleeve onto the main shaft,guiding it with the pilot studs. Makesure the seating of the sleeve is firm onthe shaft. Check with thickness gaugesin the holes of the outer diameter of thesleeve that they are firmly in contactwith the main shaft. See Figure 7-3.

Unscrew the 3 pilot studs at the top of theshaft. Fit the retaining screws and washerspositioning the sleeve onto the main shaft.Tighten gradually up to the torque specified inTable 7-2.

NOTE: WHEN THE ASSEMBLY HASCOOLED DOWN, CHECK THETIGHTENING TORQUE.

b. Mounting the spherical bearing

1. A new spherical bearing can be fitted inone of two ways:

Pre-heating: Pre-heat the sleeve toabove ambient temperature, as specifiedin paragraph 7.3.2 "Replacing thespherical bearing (HP200, HP300,HP400 and HP500)". See Table 7-2.

Cooling: COOL the spherical bearing toabove ambient temperature, as specifiedin paragraph 7.3.2 "Replacing thespherical bearing (HP200, HP300,HP400 and HP500)". See Table 7-4.

2. Fit the lifting rings to the outer diameterof the bearing. See Figure 7-4.

3. Sling the spherical bearing.

4. Position the spherical bearing, guiding itwith the pilot studs. Then lower thebearing onto the sleeve.

Above ambient temperature Sleeve screw

Centigrade (°C)

Fahrenheit (°F)

Retaining screw Tightening torque N.m.

80° 145° M14 x 60 mm 179




Figure 7-2 Assembling the sleeve

Table 7-2 Temperatures and screw tightening torque for mounting the sleeve

Ref. Description

1 Sleeve

2 Bolt

3 Washer

4 Pilot studs

5 Lifting rings

6 Main shaft

1

2

3

4

5

6

Type

Above ambient temperature Sleeve screw

Centigrade(°C)

Fahrenheit(°F)

Dimensions Tightening torque (N/m)

HP200 80° 145° M16 x 80 mm 260)

HP300 70° 125° M16 x 90 mm 260)

HP400 94° 168° M20 x 100 mm 470)

HP500 83° 150° M20 x 80 mm 470



Figure 7-3 Checking contact between sleeve and shaft

Table 7-3 Temperature for the 2nd heating of the sleeve

Table 7-4 Cooling the spherical bearing

Figure 7-4 Mounting the spherical bearing

Ref. Description

1 Contact

2 Sleeve

3 Main shaft

4 Checking gauge

Type

Above ambient temperature

Centigrade(°C)

Fahrenheit(°F)

HP200 45° 80°

HP300 45° 80°

HP400 45° 80°

HP500 45° 80°

Type


Centigrade(°C)

Fahrenheit(°F)

HP200 45° 80°

HP300 45° 80°

HP400 45° 80°

HP500 45° 80°

Ref. Description

1 Spherical bearing

2 Main shaft

3 Screw and washer

4 Sleeve

5 Lifting ring

1

5

2

4

3



7.3 Maintenance

7.3.1 Replacing the sleeve (HP100)

The depth of the oil grooves should be used todetermine the degree of wear of the sleeve andwhether it needs replacing. When the sphericalbearing surface is worn to such an extent thatthe depth of the lubrication grooves is reducedto 2.5 mm (0.098"), the sleeve should bereplaced. Measure the depth of the grooves asshown in Figure 7-5.

Figure 7-5 Measuring the depth of the oil grooves

To remove the sleeve, proceed as follows:

1. Remove the three retaining screws fromthe sleeve on the shaft.

2. Insert the 3 dismantling screws(supplied with the tools) into the holesof the sleeve provided for the purpose,see Figure 7-6. Slowly and evenly heatthe lower part of the sleeve whilegradually also tightening the 3

dismantling screws. When the sleevehas reached the temperature specified inTable 7-1, it should have dilated enoughto move freely on the shaft. Remove thedismantling bolts.

3. Fit the lifting rings into the top of thesleeve.

4. Sling and raise the sleeve.

NOTE: IF THE SLEEVE IS NOTPROPERLY TIGHT AGAINST THE SHAFT,REPLACE THE SLEEVE.NOTE: IF THE DIAMETER OF THESHAFT IS DAMAGED, A SLEEVE WITHAN APPROPRIATE BORE CAN BEMACHINED.

Figure 7-6 Dismantling the sleeve

Ref. Description

1 Gauge

2 New contour of the sleeve

3 Worn sleeve

4 Minimum depth of the oil grooves 2.5mm (0.098")

5 Oil groove

1 2

4

5

3

Ref. Description

1 Dismantling bolt

2 Sleeve

3 Main shaft

4 Heating part to help dismantle the sleeve

1

2

4

3



7.3.2 Replacing the sphericalbearing (HP200, HP300, HP400 andHP500)

The depth of the oil grooves should be used todetermine the degree of wear and whether itneeds replacing. When the spherical bearingsurface is worn to such an extent that the depthof the lubrication grooves is reduced to 2.5 mm(0.098"), the sleeve should be replaced.Measure the depth of the grooves as shown inFigure 7-7.If the bearing starts moving slightly on thesleeve, this is not really a problem, because thepins prevent the bearing from turning.Replace the spherical bearing as follows:

1. Fit the 3 dismantling screws (suppliedwith the tools) into the spherical bearingas shown in Figure 7-7.

2. Screw in the dismantling screwsalternately, if necessary heating part ofthe sleeve.

3. Remove the dismantling screws and fitthe lifting rings onto the outer diameterof the bearing.

4. Sling and raise the spherical bearing.

Figure 7-7 Measuring the depth of the oil grooves

5. The new bearing is fitted by heating thesleeve. Heat the upper part of the sleeveto over ambient temperature, asspecified in Table 7-4; this will widenthe bore hole in the sleeve to allow thebearing to descend.

6. Align the bearing over the sleeve,guiding it with the pilot studs and lowerthe bearing into the bore hole of thesleeve.

Ref. Description

1 Gauge

2 New contour of the bearing

3 Worn bearing

4 Minimum depth of the oil grooves 2.5mm (0.098")

5 Oil groove

1 2

3

4

5



NOTE: MAKE SURE THAT THE BEARINGRESTS FIRMLY ON THE SLEEVE.

Figure 7-8 Dismantling the spherical bearing

Ref. Description

1 Dismantling bolt

2 Spherical bearing

3 Sleeve

4 Heating part to help dismantling

5 Shaft

1

2

3

4

5


8.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.2 - Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28.2.1 - Mounting the eccentric assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28.2.2 - Checking and adjusting the play between and at the bottom of the teeth. . 8-3

8.3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48.3.1 - Dismantling the eccentric assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48.3.2 - Imbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48.3.3 - Upper thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58.3.4 - Replacing the upper thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68.3.5 - Eccentric bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78.3.6 - Dismantling the eccentric bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78.3.7 - Checking the bore of the eccentric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88.3.8 - Inspecting the main shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98.3.9 - Installing the eccentric bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98.3.10 - Re-sealing the eccentric bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-118.3.11 - Adjusting play between the teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-118.3.12 - Replacing the toothed crown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-118.3.13 - Dismantling the imbalance and the toothed crown . . . . . . . . . . . . . . . . . 8-118.3.14 - Installing the eccentric assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

ECCENTRIC ASSEMBLY

Section 8

Eccentric assembly SECTION 8

8.1 Description

This section describes the eccentric assembly,comprising the eccentric, the eccentricbushing, the crown and the imbalance. Theoutside of the eccentric is off-centre andslightly at an angle to the vertical axis ofrotation, transmitting its movement to thehead. A bronze ring is mounted inside theeccentric. A toothed crown bolted to thebottom of the eccentric is driven by thecountershaft pinion. The eccentric rotatesaround the main shaft. The eccentric assemblyrests on thrust bearings, the upper thrustwasher in bronze is fixed to the bottom of the

eccentric and the lower thrust washer in steel isfixed to the frame. These are there to reduceeccentric assembly wear through friction. Theplay between and at the bottom of the teethbetween the crown and the pinion ismaintained in this assembly by adding orremoving adjusting wedges. The imbalance isdissymetrical, in such a way that the greatestweight is directly opposite the centrifugalforce generated by the swaying of the head.This imbalance forms an oil and dust sealbetween the rotating head and the fixed mainframe, with a system of baffles with "U" and"T" joints.

Figure 8-1 Mounting the eccentric assembly

Ref. Description

1 Slings

2 Lifting rings

3 Lifting ring

4 Main shaft

5 Upper thrust washer

6 Lower thrust washer

7 Frame

8 Eccentric

9 Imbalance

10 Gear

11 Pinion

1

2

3

4

5

67

8

9

11

10


SECTION 8 - ECCENTRIC ASSEMBLY

8.2 Mounting instructions

8.2.1 Mounting the eccentricassembly

See Figure 8-1.If the eccentric assembly has been dismantled,proceed as follows to mount it:

1. Carefully clean the machined surfacesof the main shaft and the bore of theeccentric bushing. Sand all burrs orscrapes with emery cloth. Carefullyclean the upper and lower thrustwashers.

2. Make sure the retaining screws and lockwashers of the thrust washers are tight.

3. Fix the lifting ring (supplied with thetools) to the top of the eccentric usingthe holes provided for the purpose.Screw the two handling rings (suppliedwith the tools) into the lifting ring. Coatthe main shaft, the eccentric bushing andthe two thrust washers with a thin layerof oil.

4. Anchor the two handling rings toappropriate lifting gear. The bevellededge on the lower eccentric bushing letsyou centre the assembly. Lower theassembly until the upper thrust washerrests on the lower thrust washer. Youmay need to turn the eccentric slightly tofully engage the toothed crown with thepinion. Make sure the eccentric restsfirmly on the lower thrust washer.

5. Make sure the toothed crown is fullyengaged with the pinion. See Figure 8-2.The play between and at the bottom ofthe teeth must match the values given inTable 8-1. After adjusting the playbetween and at the bottom of the teeth,remove the lifting ring.

Table 8-1 Checking pinion/crown play

Table 8-2 Thickness of the wedges

Type of crusherPlay between the teeth Minimum play at the bottom on the

teeth

mm Inches mm Inches

HP100 0.560 - 0.710 0.022 - 0.028 1.670 0.066

HP200 0.457 - 0.813 0.018 - 0.032 1.905 0.075

HP300 0.508 - 1.016 0.020 - 0.040 2.388 0.094

HP400 0.640 - 1.150 0.025 - 0.045 3.454 0.136

HP500 0.890 - 1.400 0.035 - 0.055 3.480 0.137

Thickness of wedges

Adjusting the play

HP100 HP200 HP300 HP400 HP500

mm Inches mm Inches mm Inches mm Inches mm Inches mm Inches

3.0 0.1181 1.90 0.075 1.87 0.073

1.7 0.0669 1.03 0.040 1.00 0.039

0.4 0.0157 0.17 0.007 0.15 0.006



Figure 8-2 Checking pinion/crown play

8.2.2 Checking and adjusting theplay between and at the bottom ofthe teeth

See Figure 8-2.The check and adjust the play between and atthe bottom of the teeth, proceed as follows:

1. Dismantle the imbalance.

2. Pull the countershaft outwards untilthere is no more play between theconical pinion and the innercountershaft bushing.

NOTE: IF NEED BE, SLACKEN THETRANSMISSION BEFORE TAKINGMEASUREMENTS.

3. Turn the countershaft until one of thecrown's teeth is vertical. See Figure 8-2.

4. Eliminate any play between the innereccentric bushing and the shaft bypushing the eccentric with the aid of acylinder placed between the eccentricand the frame so as to bring the crown asclose as possible to the pinion. Do notapply any more force than is strictlynecessary to achieve this, and maintainthe eccentric in this position while youtake measurements.

5. To check the play between the teeth,rotate the countershaft until one of thepinion teeth touches the tooth and thecrown. Measure the play between theteeth on the other side of the tooth withthe aid of spacer rings. See Figure 8-2.

6. Then measure the play at the bottom ofthe teeth. See Figure 8-2.

7. The play between and at the bottom ofthe teeth may be less than the tolerancespecified in Table 8-1. If that is the case,dismantle the eccentric and add spacerrings under the lower bushing asdescribed in "Installing the lower thrustwasher and spacer rings". This will raisethe eccentric assembly and thus increasethe play between and at the bottom ofthe teeth. If the play is more than itshould be, remove some spacer rings.

NOTE: WHEN THE CRUSHER LEAVESTHE FACTORY, THE THICKNESSESUNDERNEATH THE THRUST WASHERSARE THE EXACT THICKNESS REQUIREDTO ADJUST THE PLAY BETWEEN ANDAT THE BOTTOM OF THE TEETH. THETHICKNESSES, ALBEIT INITIALLYPLACED ON THE CRUSHER TO ADJUSTPLAY BETWEEN THE TEETH, ARE ALSOUSED TO OFFSET WEAR. REFER TO THEMAINTENANCE PART OF THIS SECTION.

Ref. Description

1 Gear

2 Pinion

3 Play between the teeth

4 Play at the bottom on the teeth

5The tooth of the crown must be vertical for accurate measurements

4 1

2

35



8.3 Maintenance

8.3.1 Dismantling the eccentricassembly

To dismantle the crusher's eccentric assembly,proceed as follows:

1. Fix the lifting ring (supplied with thetools) to the top of the eccentric usingthe holes provided for the purpose.Screw two handling rings and anchorthem to appropriate lifting gear. SeeFigure 8-1.

2. Remove the eccentric from the shaft,maintaining it totally vertical.

3. Lift the assembly out of the crusher andset it down on wooden wedges preparedfor the purpose.

8.3.2 Imbalance

The crushers have a shield around theimbalance to prevent any wear to it caused byfriction of the materials. Check the wear of theshields and the build-up of materials on theimbalance, this could impair the balancing.See Figure 8-3. If the shields are verydamaged, they must be replaced before theimbalance itself sustains damage. On theHP100/200/300/400, the shield is crewed tothe imbalance. On the HP500, the shield iswelded to the imbalance.Replacing the imbalance shield forHP100/200 and HP300/400:

1. Slide the shield over the imbalance andfix it.

2. Caulk all around the bottom between theimbalance and the inner diameter of theshield. Do not caulk two zones 130 mm(5") long at 180° directly under the drainholes.

Replacing the imbalance shield for HP500:

1. Wrap the shield firmly to keep aminimum gap between the shield andthe imbalance. Trim the circumference ifnecessary.

2. Chamfer the longitudinal joint up to thetotal thickness of the shield and positionthe joint in the centre on the reinforcedside of the imbalance. Spot welding inplace.

3. Weld the shield to the imbalance asshown in Figure 8-3.

4. Weld the cover to the shield andimbalance.

Material discharge in the frame must bechecked every day to ensure there are nomaterials above all in the ballast. This is oftencaused by branches or roots that get caught onor between the arms of the frame. This canlead to rapid wear of the imbalance.The useful life of the shield can be extendedwith a hard metal facing on the outer surface.The "U" and "T" joints at the top and bottom ofthe imbalance are not subject to contact orwear. These joints protect the crown and thrustwashers from ingress of dust.



Figure 8-3 Imbalance liner

8.3.3 Upper thrust washer

When the eccentric has been removed from thecrusher, examine the upper thrust washer.Excessive wear may cause 2 operatingproblems.This causes the crown's teeth to descenddeeper into the pinion's teeth and thus distortsthe functional play. To make up for this wear,spacer rings need to be inserted under thelower thrust washer. See paragraph 8.2.2"Checking and adjusting the play between andat the bottom of the teeth".

The second problem caused by thrust wear is areduction of the oil grooves.If the depth is less than the minimum specifiedin Table 8-3, the thrust washer must bereplaced. If absolutely necessary, the groovecan be deepened by machining.NOTE: THE ABSOLUTE WEAR LIMIT OFTHE THRUST WASHER IS ATTAINEDWHEN ITS CONTACT SURFACE IS LEVELWITH THE HEAD OF THE RETAININGSCREWS.

1

2

2

3

HP500

HP100/200/300/400

Ref. Description

1 Shield ring

2 Imbalance liner

3 Seal



Figure 8-4 Wear limit for lubricating grooves

Table 8-3 Groove depth

8.3.4 Replacing the upper thrustwasher

See Figure 8-5.To replace an upper thrust washer, proceed asfollows:

1. Before you can access the thrust washer,the' bowl, head, sleeve and eccentricassemblies must be dismantled. Refer tothe corresponding sections fordismantling these assemblies.

2. Turn the eccentric over so that the thrustwasher is facing upwards.

3. Unscrew the screws retaining the washerto the eccentric.

4. Screw the lifting rings into the holesprovided for the purpose.

5. Lift the thrust washer. There is playbetween the outer diameter of thewasher and the inner diameter of theeccentric.

6. The new thrust washer must be free ofburrs.

7. Remove the lifting rings from the oldwasher and fix them to the new thrustwasher. Fit the thrust washer by aligningits holes with those of the eccentric.Make sure the thrust washer's surfacerests on that of the eccentric.

8. Fit new lock washers. Insert the screwsthen tighten the screws alternately andin staggered rows to the thread torquespecified in Table 8-4.

Ref. Description


2 Oil grooves

3 Groove depth when new

4 Minimum groove depth

Type of crusher

Groove depth

When new Minimum

HP100 8 mm (5/16") 6.7 mm (17/64")

HP200 8 mm (5/16") 6.7 mm (17/64")

HP300 10 mm (25/64") 8.7 mm (11/32")

HP400 11 mm (7/16") 9.7 mm (3/8")

HP500 11 mm (7/16") 9.7 mm (3/8")

1 2

43



Figure 8-5 Upper thrust washer

Table 8-4 Thread torque for fixing the upper thrust washer

8.3.5 Eccentric bushing

When dismantling the eccentric, check thefastening and wear of the eccentric bushing.When the bushing moves in the eccentric,follow the instructions in paragraph 8.3.10"Re-sealing the eccentric bushing".NOTE: WEAR ON THE ECCENTRICBUSHING WILL BE MOREPRONOUNCED ON THE THICK SIDE OFTHE ECCENTRIC, WHERE THECRUSHING FORCE IS CONCENTRATED.THIS IS NORMAL AND THERE IS NOCAUSE FOR CONCERN. WHEN ACERTAIN DEGREE OF WEAR ISATTAINED, THE BUSHING MUST BEREPLACED.

8.3.6 Dismantling the eccentricbushing

The bushing is kept in place by resin retainerlocks cast in pockets in the bushing theeccentric; these pockets face one another. Toreplace the bushing, proceed as follows:

1. Drill a series of holes in each notchfilled with resin on the bushing side. SeeFigure 8-6.

Figure 8-6 Releasing the bushing

Ref. Description


2 Eccentric

3 Bolt

4 Lock washer

Type of crusher

Retaining screws for the upper thrust

washer

Tightening torque (N.m)

HP100 M8x20 45

HP200 M8x20 45

HP300 M10x25 90

HP400 M10x25 90

HP500 M14x35 250

4

12

3

Ref. Description

1 Drill a series of holes in the resin

2 Notches for resin

3 Eccentric bushing

4 Eccentric

21 3 4



2. Chisel the drilled hole and carefullyremove any remnants of resin tofacilitate dismantling.

3. Turn over the eccentric onto woodenwedges placed so as to clear a way forthe bushing. See Figure 8-7.

4. Cut out a washer 25 mm thick with adiameter slightly smaller than the outerdiameter of the bushing. The outerdiameter of the washer must be free ofburrs.

Figure 8-7 Dismantling the eccentric bushing

5. Centre the plate on the bushing. Makesure the plate is not in contact with theinner diameter of the bushing.

6. Use a wooden block measuring 100 x100 mm and strike the plate until thebushing is completely freed from theeccentric.

If difficulties arise, there is anothermethod for dismantling the eccentricbushing. This consists in sawing theentire height of the bushing at twodiametrically opposed points. Thesawed notches are over the entirethickness of the bushing withouttouching the bore of the eccentric. Seeparagraph 6.3.11 "Dismantling theupper head bushing - HP200, HP300,HP400 and HP500".

8.3.7 Checking the bore of theeccentric

Before installing the eccentric bushing, makesure that the bore is clean inside the eccentricand that all resin has been removed from thenotches.Check the bore, make sure its dimension iswithin limits. Measure the bore at the bottomand top of the eccentric.Check roundness with micrometer callipers.If the bore has tightened, it can be machined toits original dimension. If the bore is notconcentric, it can be re-machined.Contact the factory for the concentricity if thebore needs to be machined above its normaldimension.

Ref. Description

1 Wooden block

2 Plate

3 Wooden wedges

4 Eccentric bushing

5 Eccentric

1 2

345



8.3.8 Inspecting the main shaft

When an eccentric bushing needs to bereplaced, in particular if it has been jammed onthe main shaft, the shaft must be checked. Alltraces of lead and bronze must be removedfrom the shaft with very fine emery cloth.Make sure to move only in a horizontal andperipheral direction.Check with the factory to determine whetherthe condition of the shaft warrants itsreplacement.If the eccentric bushing has jammed againstthe main shaft, it can be removed as follows:

1. There is a longitudinal groove on theinner diameter aligned with the large oilhole. Use a very hard-wearing circularsaw fitted with an appropriate metalblade (the eccentric bushing is made ofbronze and lead) to cut the side of thebushing. Set blade depth to between 20mm (0.75") and 25 mm (1") maximum.

2. Saw the bushing at the location of thelongitudinal groove.

3. With a lever, pry open the bushing at thepoint of cutting by placing a bar into thecut and levering outwards.

4. Be careful not to scratch the main shaftwith the saw's blade because this couldimpair the performance of the neweccentric bushing.

8.3.9 Installing the eccentricbushing

The eccentric bushings are machined with aplay of a few tens of millimetres in the bore. Ifthere is a problem on installation due to stockshortages or shipping problems, the followingprocedure using carbon dioxide snow isrecommended:

1. Make sure all the resin has beenremoved from the notches and that theinner bore of the eccentric is clean.

2. Thoroughly clean all the surfaces of thenew bushing.

3. Fill the bushing's bore with carbondioxide snow to narrow its diameter.This operation requires 90 kg of carbondioxide snow. A runner measuring 100 x100 mm leaves enough room for thecarbon dioxide snow to narrow thebushing.

4. Wrap the outer diameter with severallayers of glass wool to prevent theformation of frost, which would delayputting the bushing in place. Thisenvelope also serves to maintain the lowtemperature. Let the bushing cool downfor roughly two hours.

NOTE: DO NOT USE THIS METHOD FORTHE ECCENTRIC'S BORE, THAT WOULDTIGHTEN IT UP.

5. Measure the outer diameter of thebushing and the eccentric's bore todetermine whether the bushing hascooled down enough. Fit the two liftingrings (supplied with the tools) to the topof the eccentric bushing.

6. Draw or paint a line on the outerdiameter of the bushing along both sidesof the oil holes (one large hole and onesmall hole), see Figure 8-8. The draw orpaint a line along the two faces of the oilholes in the eccentric up to its top. theselines are used to properly align thebushing's oil holes with the eccentric.

DANGERMake sure not to leave any traces onthe shaft by removing all remnantsof lead and bronze.




7. Use the lifting rings and washers(supplied with the tools) to lift thebushing. See Figure 8-9. Centre thebushing with the top of the eccentric'sbore. Quickly lower the cooled bushinginto the bore while aligning the notcheswith the oil holes.

Figure 8-8 Aligning the bushing and the eccentric

Figure 8-9 Position of the bushing in the eccentric

NOTE: THE OIL HOLES IN THE BUSHINGMUST BE ALIGNED WITH THOSE OFTHE ECCENTRIC. THE NOTCHES AT THETOP OF THE BUSHING MUST BEALIGNED WITH THOSE OF THEECCENTRIC. THESE NOTCHES CAN BESLIGHTLY OFFSET, BUT ON NOACCOUNT MUST THE OIL HOLES BEMISALIGNED.

8. When the bushing is in place, its topmust be aligned with the top of theeccentric.

9. Prepare the sealant resin and fill thenotches up to the top.

Ref. Description

1 Mark along the oil holes

2 Minimum hole

3 Eccentric bushing

4 Maximum hole

1

2

34

Ref. Description

1 Lifting rings

2 Notches

3 Eccentric bushing

4 Eccentric

1

234



10.The eccentric, bushing and resin must beat a temperature of between 16°C and32°C.

11.When the resin has solidified, removeany excess resin to adjust the alignmentbetween the bushing and the eccentric.

NOTE: AFTER MOUNTING THEECCENTRIC BUSHING, SEE 3.6 "Initialstart-up".

8.3.10 Re-sealing the eccentricbushing

If the bushing frees itself and starts turning inthe eccentric due to wear of the resin retainerlocks, it must be re-cast. Drill, clean andremove the resin in the notches and cast anadequate amount of resin, taking care to alignthe oil holes. See Figure 8-8 and Figure 8-6.NOTE: BEFORE RE-CASTING ANDMAKING RESIN RETAINER LOCKS,CHECK THAT THE BUSHING ISPROPERLY INSTALLED. SEEPARAGRAPH 8.3.9 "Installing the eccentricbushing".

8.3.11 Adjusting play between theteeth

When the thrust washer and teeth are so wornthat play can no longer be maintained, thismust be adjusted by adding or removing spacerrings until the play matches the valuesspecified in Table 8-1. Adding spacer ringsincreases play while removing them reduces it.An adequate mounting is necessary.NOTE: ONE SHOULD AVOID MESHINGTHE BOTTOM OF THE TEETH AS MUCHAS POSSIBLE, SOME PLAY MUST BELEFT AT THE BOTTOM OF THE TEETH,HOWEVER WORN THEY ARE. SEETable 8-1.

8.3.12 Replacing the toothed crown

The crown is mounted at the bottom of theeccentric. When inspecting the eccentric,check the crown for wear.Marks or flaking on the face of the teeth aresigns of heavy wear. These marks may be dueto incorrect contact between the teeth furtherto incorrect spacing under the lower thrustwasher, to crusher overload or to acontaminated oil supply. Worn crowns aremore liable to broken teeth, which can causeheavy damage inside the crusher. One shouldtherefore not leave it too long before changingworn crowns.

8.3.13 Dismantling the imbalanceand the toothed crown

See Figure 8-12.After dismantling the crusher's eccentricassembly as instructed in paragraph 8.3.9"Installing the eccentric bushing", theassembly can be dismantled as describedbelow:

1. Place the eccentric assembly on woodenwedges. Separate the imbalance and theeccentric by unscrewing the retainingscrews traversing the imbalance andfixed to the edge of the eccentric. If thescrews were fitted with Loctite, heatwith flame up to around 205°C.

2. Fit the 4 lifting rings (supplied with thetools) to the edge of the imbalance.

3. Lift the imbalance vertically to releasethe locating pin.

4. Remove the eccentric's retaining screwon the crown located on the edge of theeccentric. If the screws were fitted withLoctite, heat to around 205°C.

5. The crown is tight on the outer diameterof the eccentric. Fit the eccentric'slifting ring as well as the handling rings(supplied with the tools).



6. Raise the assembly to roughly 40 mmabove appropriate wooden wedges. Heatthe crown gradually around its outerdiameter. The crown's outer diameterwill expand and the crown will fall of itsown accord.

7. Set the eccentric down on woodenwedges, maintaining access to the thrustwasher.

8. Unlock then remove the retainingscrews of the thrust washer on theeccentric. Remove the thrust washer.

9. On HP100, HP200 and HP300Remove the screws fixing the imbalanceshield, as well as the 2 screws blockingthe handling holes. Fix 2 lifting ringsinto these holes and raise the imbalanceshield. Fit the new shield. Do not forgetto replace the 2 screws blocking thehandling holes after removing the liftingrings.

Figure 8-10 Dismantling the imbalance shield (HP100)

Ref. Description

1 Sling

2 Shield retaining screws

3 Imbalance liner

4 Imbalance

5 Lifting ring

4

5

1

2

3



Figure 8-11 Dismantling the imbalance shield (HP200 and HP300)

8.3.14 Installing the eccentricassembly

1. Turn over the eccentric to gain easyaccess to the thrust washer and place iton wooden wedges.

2. Put in place the thrust washer, checkinghole alignment. Insert and tighten thescrews mounted with new lock washers.

3. Set the crown down on wooden wedges,its teeth against the wedges, seeFigure 8-12.

4. Turn the eccentric the right way up. Fitthe handling rings into the lifting ring,then fix it to the top of the eccentric.

5. With an appropriate lifting device, raisethe eccentric above the crown. Adjustcentring and perpendicularity betweenthe eccentric and the crown.

1

2

3

4

6

5

Ref. Description

1 Sling

2 Lifting ring

3 Shield retaining screws

4 Imbalance liner

5 Eccentric assembly

6 Screws blocking the handling holes



Figure 8-12 Raising the imbalance and eccentric

6. Heat the crown regularly to roughly45°C above ambient temperature.

NOTE: IT IS VERY IMPORTANT TO HEATTHE GEAR ASSEMBLY UNIFORMLYAND THAT THE HEAT IS NOTCONCENTRATED ON ONE SURFACETHEREBY CREATING A HOT SPOT THATCOULD DESTROY TREATMENT OF THEGEARING. A CHEMICAL MARKINGMETHOD ACTING AT A PREDEFINEDTEMPERATURE MUST BE USED FORENSURE UNIFORM HEATING.

7. Measure the outer diameter of theeccentric and the bore of the crown, andmake sure that the bore is slightly largerthan the eccentric. Quickly lower theeccentric onto the crown, lining up theholes. Since the holes are equidistant, nospecial alignment is necessary. Makesure the eccentric fits smoothly at thebottom of the crown's bore.

8. Clean the screws and holes then applyLoctite 271 to the threads of the screwsfixing the crown to the eccentric.

1

2

3

4

5

67

8

9

10

Ref. Description

1 Imbalance/eccentric fastening

2 Imbalance

3 Eccentric

4 Eccentric bushing

5 Eccentric/crown fastening

6 Wooden wedges


8 Toothed crown

9 Pin

10 Lifting ring



9. Lock these screws by tightening themalternately to the torque specified inTable 8-5.

10.If the crown has been replaced, theeccentric is fitted without the imbalanceassembly. This lets one check the playbetween the crown's teeth and thepinion. See the instructions in paragraph8.2.2 "Checking and adjusting the playbetween and at the bottom of the teeth".

11.Fit the 4 lifting rings (supplied with thetools) to the inner edge of theimbalance.

12.Carefully lower the imbalance onto theeccentric as shown in Figure 8-12.Align the pin hole in the imbalance withthe eccentric's pin.

13.Insert the largest screws fixing theimbalance, the eccentric and la crown.

14.Alternately tighten the screws instaggered rows to the thread torquespecified in Table 8-5.

15.Before installing the eccentric assemblyin the crusher, check the pinion teeth forwear or damage by turning thecountershaft.

16.Install the eccentric assembly asdescribed in paragraph 8.3.14"Installing the eccentric assembly".

NOTE: CHECK THE THREAD TORQUEOF THE SCREWS RETAINING THEECCENTRIC AND THE IMBALANCE TOTHE CROWN EACH TIME THE LINER ISCHANGED AND WHEN THE HEAD ISDISMANTLED.

Table 8-5 Information on the toothed crown's retaining screws

Type of crusherEccentric/crown retaining screw

Imbalance/crown retaining screw

Tightening torque (N.m)


Centigrade(C°)

Fahrenheit (F°)

HP100 M12 x 70 M12 x 70 135 45° 80°

HP200 M14 x 70 M14 x 70 167 45° 80°

HP300 M16 x 70 M16 x 70 260 45° 80°

HP400 M20 x 100 M20 x 120 470 34° 61°

HP500 M24 x 110 M24 x 140 810 32° 57°


9.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19.1.1 - Countershaft housing - HP100 and HP200. . . . . . . . . . . . . . . . . . . . . . . . . 9-19.1.2 - Assembling the countershaft housing - HP300, HP400 and HP500 . . . . . . 9-29.1.3 - Checking axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.2 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-69.2.1 - Dismantling the countershaft assembly and replacing the pinion - HP100 and HP200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-69.2.2 - Dismantling the countershaft housing HP300, HP400 and HP500 . . . . . . . 9-99.2.3 - Replacing the pinion - HP300, HP400 and HP500 . . . . . . . . . . . . . . . . . . . 9-99.2.4 - Dismantling the countershaft bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-109.2.5 - Dismantling the countershaft bushings - HP100 and HP200 . . . . . . . . . . 9-149.2.6 - Assembling the countershaft bushings - HP100 and HP200 . . . . . . . . . . 9-169.2.7 - Examining prior to mounting a countershaft bushing - HP100 . . . . . . . . . 9-199.2.8 - Examining prior to mounting a countershaft bushing - HP200, HP300, HP400 and HP500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-199.2.9 - Mounting the countershaft - HP100 and HP200 . . . . . . . . . . . . . . . . . . . . 9-199.2.10 - Mounting countershaft bushings - HP300, HP400 and HP500 . . . . . . . . 9-209.2.11 - Mounting the countershaft housing - HP300, HP400 and HP500. . . . . . 9-249.2.12 - Oil leak at the countershaft on the control side . . . . . . . . . . . . . . . . . . . . 9-259.2.13 - Mounting the crusher bullwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-259.2.14 - Dismantling the crusher bullwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-269.2.15 - Replacement of the HP100 and HP200 counter-shaft casing shield . . . 9-289.2.16 - Replacement of the HP300 counter-shaft casing shield . . . . . . . . . . . . . 9-289.2.17 - Replacement of the HP400 counter-shaft casing shield . . . . . . . . . . . . . 9-289.2.18 - Replacement of the HP400 counter-shaft casing shield . . . . . . . . . . . . . 9-28

Section 9

COUNTERSHAFT, COUNTERSHAFT HOUSING AND BULLWHEEL ASSEMBLIES

Countershaft, countershaft housing and bullwheel assembliesSECTION 9

9.1 Description

This section describes the countershafthousing, countershaft and bullwheelassemblies.Power is transmitted to the crusher'scountershaft motor by a V-belt transmission ora coupling sleeve. At one end of thecountershaft is mounted a pinion the rotationof which is transmitted to the eccentric by thetoothed crown. The countershaft is supportedby two bronze bushings. These two bushingsare prevented from rotating by pins inserted inthe countershaft housing. The bushings have aflange at their end that receives the axial loadboth from the pinion and the oil deflector. Thelatter is inserted tight on the countershaftcontrol side.

The deflector's role is to centrifuge on thecover the oil coming from the lubrication ofthe housing's bushings. The countershafthousing returns the oil to the tank. Thiscountershaft housing is solidly fixed with largescrews.The oil seal is formed between the frame andthe countershaft housing by an O-ring seal or alip seal. A shield protects the part of thecountershaft housing exposed to wear causedby the falling crushed materials.NOTE: ON HP100 ST HP200, THECOUNTERSHAFT HOUSING IS BUILTINTO THE FRAME.

9.1.1 Countershaft housing - HP100and HP200

Figure 9-1 Countershaft housing HP100

Ref. Description

1 Pinion

2 Inner countershaft bushing

3 Outer countershaft bushing

4 Lock washer

5 Spacer

6 Hub

7 Crusher bullwheel

1 2 3

4 5 6 7


SECTION 9 - COUNTERSHAFT, COUNTERSHAFT HOUSING AND BULLWHEEL ASSEMBLIES

9.1.2 Assembling the countershafthousing - HP300, HP400 and HP500

To assemble the various components of thecountershaft assembly, see paragraph 9.2"Maintenance" in this chapter. If thecountershaft housing was dismantled forshipment, it must be reassembled as follows:

1. Lubricate and correctly position theO-ring seal in the appropriate groove onthe flange on the pinion side of thecountershaft housing. This forms a sealbetween the drum of the main frame andthe countershaft housing. SeeFigure 9-2.

Figure 9-2 Countershaft housing seal

2. A bearing seal must be fitted in thegroove of the countershaft housing, onthe pinion side. This seal suppresses anyvibrations between the countershafthousing and the frame.

This seal is split. Fit the seal into the groove ofthe countershaft housing, on the pinion side,and glue the two ends together. There shouldbe no gap between the two ends of the seal.

If there is no glue, maintain the bearing sealwith the aid of metal wire twisted at the ends.Cover the seal with grease and proceed asexplained in paragraph 3. If metal wire is used,remove it when the seal is in place in the boreof the frame, see Figure 9-4 (Step 1).

Ref. Description

1 Frame

2 Countershaft housing

3 Bearing seal

4 O-ring seal

143

2


SECTION 9 - COUNTERSHAFT, COUNTERSHAFT HOUSING AND BULLWHEELASSEMBLIES

3. Fill the bore of the frame at the locationsof the O-ring seals with a strip ofsilicone seal. See Figure 9-3.

4. Slide a long tube at the bullwheel sideend of the countershaft to balance theweight of the other end. See Figure 9-3.

NOTE: IF THERE IS NOT ENOUGH SPACETO USE A TUBE FORCOUNTERBALANCING PURPOSES,PUSH THE COUNTERSHAFT HOUSINGINTO THE BORE OF THE FRAME AS FARAS POSSIBLE. REST THE INTERIORFLANGE OF THE HOUSING (PINIONSIDE) TEMPORARILY ON THE FRAME'SGUIDE LOBE. RAISE THECOUNTERSHAFT HOUSING WITH ASLING THREADED INSIDE THECRUSHER THEN CONTINUE FITTINGTHE HOUSING IN AS FAR AS POSSIBLE.

Figure 9-3 Mounting the countershaft assembly

5. With the aid of hoisting gear (overheadtravelling crane or other gear), place theguide lobe of the countershaft housingon the guide lobe of the frame.

6. Screw the 3 tension bolts into the outerhousing flange matching the 3 holes at120° angles on the frame, see step 1 inFigure 9-4.

7. Because the countershaft housing ismounted tight in the frame, graduallytighten each of the 3 bolts in turn tokeep the housing aligned, until contactis made between the housing's flangesand the frame.

8. Remove the bolts and fit shim washersunder the screw heads and repeat theprevious operation. Tighten each of thebolts again alternately until they reachthe bottom of the threaded holes.Seestep 2 in Figure 9-4.

9. Replace the tension bolts with normalbolts that will fix the countershafthousing for good.

2

1

3

10

Ref. Description

1 Bearing seal

2 O-ring seal


4 Sling

5 Tube

6 Centring lobe on housing

7 Guide lobe on frame

8 Frame bore

9 Pinion

10 Frame



10.Continue pushing the countershafthousing in by successive turns on thebolts until the flanges of the frame andthe countershaft housing come intocontact. See step 3 in Figure 9-4.

11.Place the sleeve onto the countershafthousing, engaging the notches on thesleeve with the bosses of the housing.On HP500 the sleeve is in two parts.See Figure 9-5.

Figure 9-4 Installing the countershaft housing

9.1.3 Checking axial play

See Figure 6-5.If the crusher was shipped completelyassembled, the axial play was correctlyadjusted in the workshop; but we recommendyou check this on arrival. The countershaftmust be able to move axially by the valuespecified in Table 9-1.

Table 9-1 Axial play

Ref. Description

1 Frame

2 Shim washers

3 Tension bolts


5 Washer

6 Final bolts

7 Contact

STEP 1

STEP 2 STEP 3

1 3

4

1

1

2 3

4

17 5

4

6

TypeAxial play

(tolerances)

HP100 1.3 mm (0.050") - 1.8 mm (0.070")

HP200 1.3 mm (0.050") - 1.8 mm (0.070")

HP300 0.8 mm (0.031") - 1.6 mm (0.062")

HP400 0.8 mm (0.031") - 1.6 mm (0.062")

HP500 0.8 mm (0.031") - 1.6 mm (0.062")



Figure 9-5 Mounting the housing sleeve

Figure 9-6 Axial play

Ref. Description

1 Countershaft housing sleeve


3 Bosses

Ref. Description

1 Pinion

2 Inner housing bushing

3 Outer housing bushing

4 Axial play

5 See Table 9-1

6 Contact



9.2 Maintenance

9.2.1 Dismantling the countershaftassembly and replacing the pinion -HP100 and HP200

See Figure 9-7.

Figure 9-7 Countershaft assembly

When dismantling the eccentric assembly, it isadvisable to check the condition of the pinion(wear or broken teeth). Extensive metal pittingor erosion on the sides of the teeth are signs ofexcessive wear. This may be due to poorcontact of the pinion teeth with the crownresulting from incorrect spacing or crusheroverload or even poor quality oil. A wornpinion is more vulnerable to tooth breakagethat a pinion in good condition.

What is more, running the crusher with a wornpinion can cause serious damage to othercrusher parts. An excessively worn musttherefore be replaced. To get the best out of thedrive gear and pinion, it is advisable to changethe crown at the same time.

Ref. Description

1 Pinion

2 Headless screw

3 Frame

4 Seal

5 Countershaft

6 Lip seal

7 Oil ring

8 Cover



11 Thread on countershaft and pinion

12 Lock washer

112 2 3 4 5

6

7891011



If a new pinion is mounted with a worn crown,the profile of the crown's worn teeth canrapidly damage the new pinion. If a new pinionor crown are mounted, check the play of theteeth as explained in paragraph 8.2.2"Checking and adjusting the play between andat the bottom of the teeth".To dismantle the countershaft assembly,replace the bushings, pinion or other parts,proceed as follows:

1. Remove the bowl, head, sleeve, andeccentric assemblies.

2. Dismantle the crusher's bullwheel. Todismantle the crusher's bullwheel,proceed as follows:

a. First remove the hub's retainingscrews.

b. Insert the screws into the hub'stapped holes.

Figure 9-8 Bullwheel assembly

3. Dismantle the cover of the oil ring aswell as the seals.

4. Heat the oil ring to roughly 27°aboveambient temperature.

DANGERIf the bullwheel is hard to separateform its removable hub, tap it with ahammer, maintaining pressure on thethrust screws.

Ref. Description

1 Bullwheel

2 Spacer

3 Hub

4 Screw in mounting position

5 Retainer lock

1

5

2

4

3



5. Place a lever between the oil ring andthe frame, applying moderate force. Assoon as the ring starts to slide, pull ithorizontally to extract it from thecountershaft.

NOTE: on the HP100, to dismantle the pinion,you need to dismantle the thrust washer.

6. Loosen the lock washer screws. Sincethe screws were mounted with Loctite,heat to roughly 205°C in order tounscrew them.

7. Place the pinion key (supplied with thetools) as shown in Figure 9-9.

8. Place the countershaft key (suppliedwith the tools) at the end of it. Tap thekey with a hammer to turn thecountershaft anticlockwise.

9. Fit a lifting ring (supplied with thetools) into the hole between the teeth ofthe pinion. Then unscrew thecountershaft completely and lift thepinion.

10.Remove the thrust washer.

Figure 9-9 Dismantling the pinion


Ref. Description

1 Pinion

2 Pinion locking wrench

3 Retainer lock

4 Countershaft key

5 Countershaft

6 Countershaft bushing

7 Headless screw

8 Lock washer

35 4

21 1

8

6 7



9.2.2 Dismantling the countershafthousing HP300, HP400 and HP500

See Figure 9-10.To dismantle the countershaft assemblyhousing and countershaft in order to replacethe housing's bushings, the pinion or otherparts, proceed as follows:

1. Remove all oil pipes that could impedethe dismantling of the countershafthousing.

2. Dismantle the crusher's bullwheel. Thebullwheel must be removed before thecountershaft housing, because it couldsustain damage.

Figure 9-10 Dismantling the countershaft housing

3. Remove the screws retaining thehousing on the frame.

4. Screw the extraction screws (supplied inthe crusher's tools) in the 3 tapped holesevenly spaced out in the housing cover.

5. Gradually and alternately tighten eachextraction screw to remove thecountershaft housing without itjamming.

NOTE: IF DIFFICULTIES AREOCCASIONALLY ENCOUNTERED INREMOVING THE COUNTERSHAFTHOUSING AS EXPLAINED ABOVE, YOUCAN HEAT THE FRAME TO ABOUT 55°C(100°F) ABOVE AMBIENTTEMPERATURE.

6. Continue tightening the extractionscrews until the countershaft housingworks free.

7. Slide a long tube at the countershaft endin place of the bullwheel to balance theweight. Remove the countershafthousing with the aid of appropriatelifting gear. (See Figure 9-3).

8. Remove the countershaft housing cover.

9. Heat the oil deflector to roughly 27°C(50°F above ambient temperature.

10.Place a lever between the oil ring andthe countershaft, applying moderateforce. As soon as the ring starts to slide,pull it horizontally to extract it from thecountershaft.

11.Remove the countershaft pinionassembly from the countershaft housing.

9.2.3 Replacing the pinion - HP300,HP400 and HP500

When dismantling the countershaft housing, itis advisable to check the condition of thepinion (tooth wear or breakage). Extensivemetal pitting or erosion on the sides of theteeth are signs of excessive wear. This may bedue to poor contact of the pinion teeth with thecrown resulting from incorrect spacing orcrusher overload or even poor quality oil.

Ref. Description

1 Frame

2 Tension bolts

3 Housing cover

4 Countershaft


1 2

3

4

5




A worn pinion is more vulnerable to toothbreakage that a pinion in good condition. Whatis more, running the crusher with a wornpinion can cause serious damage to othercrusher parts. An excessively worn musttherefore be replaced. To get the best out of thedrive gear and pinion, it is advisable to changethe crown at the same time. If a new pinion ismounted with a worn crown, the profile of thecrown's worn teeth can rapidly damage thenew pinion. If a new pinion or crown aremounted, check the play of the teeth asexplained in paragraph 8.2.2 "Checking andadjusting the play between and at the bottomof the teeth". To replace the pinion do asfollows:

1. Remove the countershaft pinionassembly from the countershaft housing.Place the countershaft on appropriatewedges.

2. Slowly heat the pinion with a blowtorchto roughly 100°C. With the aid of arafter, strike the pinion while continuingto heat it. As soon as the pinion starts toslide, grab it with both hands and take itoff the shaft.

3. Heat the replacement pinion in an oilbath (see temperatures in Table 9-2).With the aid of insulating gloves, slidethe pinion on the countershaft, matchingup the retainer lock grooves. Push thepinion on the shaft in such a way that theshaft protrudes from the pinion by thedistance specified in Table 9-2.

NOTE: IF THE COOLING PINION STARTSTO GRIP THE SHAFT, HEAT IT WHILECONTINUING TO STRIKE IT WITH THEAID OF A RAFTER. REMEMBER THATTHE BLOWTORCH FLAME MUST BEDIRECTED ALL AROUND THE PINIONTO PREVENT ANY LOCALOVERHEATING.

Figure 9-11 Position of the pinion

Table 9-2 Position of the pinion and requisite heating temperatures

9.2.4 Dismantling the countershaftbushings

Generally, when the bushings are worn andneed changing, they have play in thecountershaft housing. In which case, thebushings can easily be removed from thehousing. However, due to machiningtolerances or crusher overload or insufficientlubrication, a bushing can be gripped or even

jammed in the housing. If that is the case, it isharder to dismantle.Proceed as follows:

1. Remove the countershaft housing fromthe frame and the countershaft from itshousing as explained in paragraph 9.2.2"Dismantling the countershaft housingHP300, HP400 and HP500".

Ref. Description

1 Pinion

2 Countershaft

A Position of the pinion

1

2

Type Position of pinion"A"Above ambient temperature

Centigrade(C°)

Fahrenheit (F°)

HP300 4 mm (5/32") 100° 180°

HP400 5 mm (3/16") 147° 261°

HP500 FLUSH 133° 240°



NOTE: Since the countershaft housings of theHP100 and HP200 are an integral part of theframe, dismantle the countershaft as explainedin paragraph 9.2.1 "Dismantling thecountershaft assembly and replacing thepinion - HP100 and HP200".

2. Make an extractor as shown inFigure 9-2.

3. Insert this extractor horizontally into thebushing and place it behind the bushing.Turn it 90°C to apply it against thebushing.

4. Hold this extractor with an rod M24threaded at both ends and longer thanthe bushing by a hundred millimetres.Screw this rod into the nut welded onthe extractor.


5. Place a flat piece (25 x 75 x 305 mm)across the other end of the rod and fixthe assembly with a nut.

6. Push the bushing out of the countershafthousing with the aid of a rafter or a tube,tapping the centring plate. SeeFigure 9-13. If this method still fails toextract the bushing, we suggest thefollowing method (see Figure 9-14 ):

a. Use the extractor described earlier,but the threaded rod and thetransverse flat piece must be longer.Place tow wooden wedges betweenthe flat piece and the countershafthousing flange.

For HP100 and HP200, the inner countershaftbushing is kept in place by a headless screwtraversing the frame and placed at 12h. Thisscrew must be removed before the bushing.Since this screw is glued with Loctite, heat toaround 205°C (400°F) before loosening it.

b. Work simultaneously on the centringdevice nut and the rafter or thrusttube.

c. When the bushing reaches thecross-wide flat piece, unscrew thenut from the threaded rod, increasethe thickness of the wedging andrepeat the operation (b).

d. Repeat operations (b) and (c) untilthe bushing comes completely out ofthe housing.

1

2

3

4

5

6

Ref. Description

1 Extractor


3 Slightly under the outer diameter of thebushing

4 M24 nut welded onto the plate

5 Slightly under the inner diameter of thebushing

6 Insert this plate horizontally and place itbehind and against the bushing



Figure 9-13 Dismantling a bushing with thrust

213

45

6

7

Ref. Description


2 Extractor

3 Rafter

4 Threaded rod


6 Cross-wide flat piece

7 Pin



Figure 9-14 Dismantling a countershaft bushing with traction and thrust

1

2

3

4

56

Ref. Description


2 Wooden wedge


4 Extractor

5 Threaded rod




9.2.5 Dismantling the countershaftbushings - HP100 and HP200

Generally, when the bushings are worn andneed changing, they are no longer tight in theframe. In that case, the bushings can beremoved from the frame without any difficulty.However, due to machining tolerances orcrusher overload or insufficient lubrication, abushing can be gripped or even jammed in thehousing. If that is the case, it is harder todismantle.Proceed as follows:Bushing on bullwheel side:

1. Since the countershaft housing on theHP100 and HP200 is an integral partof the frame, remove the crusher'scountershaft as described in paragraph9.2.1 "Dismantling the countershaftassembly and replacing the pinion -HP100 and HP200".

2. Make an extractor as shown inFigure 9-15.

3. Insert this extractor horizontally into thebushing and place it behind the bushing.Turn it 90°C to apply it against thebushing.

4. Holding the plate in position, screw athreaded rod into the nut welded ontothe extractor; the rod must be slightlylonger than the bushing and threaded atboth ends.

Figure 9-15 Extractor

Ref. Description

1 Extractor


3 Slightly under the outer diameter of thebushing

4 M24 nut welded onto the plate

5 Slightly under the inner diameter of thebushing

6 Slide the extractor in the bushing and turnit 90°.

12

4

2

6

3

25

5



5. Place a flat piece (25 x 75 x 250 mm)across the other end of the rod and fixthe assembly with a nut. (SeeFigure 9-16).

Figure 9-16 Dismantling the countershaft bushing (bullwheel side)

6. Use the threaded rod as a cylinder.When the bushing rests against thetransverse flat piece, unscrew the nutand wedge.

7. Repeat step 6 until the bushing has comecompletely out of the housing.

Bushing pinion side:

1. The inner countershaft bushing ismaintained in the bore of the housing(an integral part of the frame) by par aheadless screw positioned at 12h. SeeFigure 9-17. This screw must beremoved before the bushing isdismantled. Since this screw is gluedwith Loctite, heat to around 200°C (°F)before unscrewing it.

2. Place the extractor at the end of the rod.Press the extractor against the bushingto release the latter from its housing.

Ref. Description


2 Extractor

3 Threaded rod


5 Wedging

6 Nut

2

1

34

6

5



Figure 9-17 Dismantling the bushing pinion side

9.2.6 Assembling the countershaftbushings - HP100 and HP200

After examining the frame, the new bushingscan be mounted. If the bushing-frameassembly is slippery, mount the bushings,making sure that the oil grooves are in theposition stated in step 4. If the bushings aremounted slightly tight, cool them down tomount them as explained in step 5.Proceed as follows:

1. Remove the locating pins (bushing onbullwheel side).

2. Replace the pins with rods of the samediameter and slightly longer than thebushings. These rods will serve as aguide. See Figure 9-18.

3. To fit the inner countershaft bushing,align the hole in the bushing with thehole in the frame, receiving the headlessscrew.

Figure 9-18 Mounting a countershaft bushing

4. The inner and outer bushings areidentical. However the position of theiroil groove differs. Determine thisposition as follows:

a. The longitudinal oil groove of theinner bushing should be situated at12h. See Figure 9-19.

b. The longitudinal oil groove of theouter bushing is usually situated at6h. See Figure 9-19. However thisposition must be changed it the motoris situated above the crusher in aregion 45° either side of the verticalaxis. See Figure 9-20.

NOTE: The bushing must then be turned sothat the longitudinal groove is situated at 12h.This position lets the transmission exert itstractive force outside the groove and thereforedoes not impede the oil supply.

Ref. Description


2 Extractor

3 Bar

4 Headless screw

1 2

4

3

Ref. Description


2 Guide rod

3 Frame

3 1 2



Figure 9-19 Position of the countershaft bushing lubrication grooves

Ref. Description


2 Oil groove positioned at 12h

3 Frame



6 Oil groove positioned at 12h for vertical transmission, with themotor under the crusher bullwheel.

7 Oil groove positioned at 6h for horizontal transmission, with themotor over the crusher bullwheel.

1

2

3

4

5

7

6



Figure 9-20 Vertical control - motor under crusher

5. Line the bores of the new bushings withcarbon dioxide snow for 2 to 3 hours tofacilitate assembly. Approximately 22kg of carbon dioxide snow are needed toreplace both bushings.

NOTE: COVER THE OUTSIDE OF THECOOLED BUSHING TO PREVENTFORMATION OF CONDENSATION,WHICH COULD IMPEDE ASSEMBLY OFTHE BUSHING IN THE HOUSING. THISALSO HELPS TO ACHIEVE MOREUNIFORM COOLING.

NOTE: If the frame temperature exceeds 24°C(75°F), you can use ice instead of carbondioxide snow. Measure the outer diameter ofthe bushing and the housing bore to determinewhen the bushing has cooled down enough.

6. Quickly slide the bushing into thehousing using the guide rods.

NOTE: align the hole of the inner bushingwith the hole in the frame of the headlessscrew. See Figure 9-15.NOTE: Check that the oil groove is properlypositioned at 12h and that the hole in the outerdiameter of the bushing is properly alignedwith the hole in the frame receiving theheadless screw. DO NOT USE THE GUIDEROD TO MOUNT THE INNER BUSHINGIN HP100.NOTE: Clean the threads of the headlessscrews and the tapping of the hole in the framewith a solvent. The apply Loctite 277 to thethreaded surfaces and fit the headless screws.Screw in until the screw comes into contactwith the bushing. DO NOT TIGHTENEXCESSIVELY: TOO MUCH PRESSUREMAY DEFORM THE BUSHING'S BORE.

7. If the assembly was not completed soonenough and the bushing works looseduring assembly, or if you have nomeans of cooling, you can insert thebushings by hitting them if you protectthem with a piece of wood. The guiderods particularly are useful in that case.

NOTE: EXERT MODERATE PRESSURETO PREVENT THE BUSHING JAMMING.

8. Remove the guide rods and replace themwith the two pins you previouslyremoved.

Ref. Description

1 Crusher bullwheel

2 With crusher vertical

3 Drive bullwheel

1

2

3




9.2.7 Examining prior to mounting acountershaft bushing - HP100

Check the bore of the countershaft housingbuilt into the frame. Check the straightness ofthe countershaft. Since the countershaft ismounted between points, the out-of-roundnessshould not exceed 0.1 mm. If theout-of-roundness is greater, the shaft must bereplaced. If the bore of a countershaft bushinghas contracted due to excessive tightening inthe housing, the latter may jam in the bushing.Finally a bent shaft (which can be detected byexamining the alignment of the retainer lockgrooves) must be replaced with a new shaft.

9.2.8 Examining prior to mounting acountershaft bushing - HP200,HP300, HP400 and HP500

When mounting new bushings it is advisableto check the housing/bushing adjustment.The housing bore and the outer diameter of thebushing must be checked to ascertain thisadjustment. If it is too tight, the bore of thehousing must be altered to bring it withintolerance. Excessive tightness can cause theinner diameter of the bushing to contract, andtherefore reduce the play between it and thecountershaft. If the diameter of thecountershaft housing bore is smaller than itshould be, contraction can therefore be putdown to overheating.NOTE: On the HP200, check the bore of thecountershaft housing, which is built into theframe. Check the straightness of thecountershaft. Since the countershaft ismounted between spikes, out-of-roundnessshould not exceed 0.1 mm. If out-of-roundnessis greater, the shaft must be replaced. If thebore of a countershaft bushing has contracteddue to excessive tightening in the housing or ifa curved countershaft is used, this may jam inthe bushing. Finally a bent shaft (which can bedetected by examining the alignment of theretainer lock grooves) must be replaced with anew shaft.

9.2.9 Mounting the countershaft -HP100 and HP200

See Figure 9-7.Assembly is the reverse of the dismantlingprocedure, subject to the following remarks:

1. Fix the locking plate on the pinion.Clean the threads of the screws and theholes in the pinion with solvent. ApplyLoctite 242 to the threads and screw thescrews into the pinion. Tighten firmly.

HP100 thread torque: 140 N.m.

HP200 thread torque: 180 N.m.

2. Install the lifting ring in the hole of thepinion between the teeth. Lower thepinion into the frame, this is horizontaland aligned with the bushing bore.

3. Screw the countershaft into the pinionby turning clockwise. Hold the pinionwith the special wrench and turn thecountershaft with the appropriatewrench. See Figure 9-9.

4. Screw until the end of the countershaftcomes into contact with the lockingplate fixed to the pinion. Usually thecountershaft can be mounted withoutresorting to using a hammer to hit thewrench.

5. Once the end of the countershaft is incontact with the locking plate, strike thewrench with a hammer to make sure thecontact is effective.

6. Heat the oil deflector to roughly 27°Cabove ambient temperature and mount itas quickly as possible on thecountershaft.

7. If difficulties arise, push the oil ringwith a rafter. The ring is correctlymounted when:

– For HP100 there is 1.3 mm to 1.8mm, of play between the oil deflectorand the countershaft bushing. Checkwith a gauge.



8. When the oil ring has cooled down,remove the gauge and fit thecompression ring.

9. Apply silicone sealant to the face of thecountershaft housing before fixing itshousing cover onto it. Fit the cover bymatching up the bolt holes.

Gradually and alternately tighten the retainingscrews.

Figure 9-21 Oil ring

9.2.10 Mounting countershaftbushings - HP300, HP400 andHP500

When the countershaft and its housing havebeen fully examined, the new bushings can bemounted. If the bushing-frame assembly isslippery, mount the bushings, making sure thatthe oil grooves are in the position stated in step3.

If the bushings are mounted slightly tight, coolthem down to mount them as explained in step4. Proceed as follows:

1. Remove the locating pins from thehousing flange.

Replace the pins with rods of the samediameter and slightly longer than thebushings. These rods will serve as aguide. See Figure 9-22.

Ref. Description

1 Frame

2 Seal

3 Cover

4 Oil ring

5 Countershaft

6 Compression ring

7 Axial play, see Table 9-1

3

4

1 2

5

67



NOTE: In HP100 and HP200: To fit the innercountershaft bushing, align the hole in thebushing with the hole in the frame, receivingthe headless screw.

Figure 9-22 Mounting a countershaft bushing

2. The inner and outer bushings areidentical. However the position of theiroil groove may differ. Determine thisposition as follows:

a. The longitudinal oil groove of thecountershaft bushing on the pinionside should be situated at 12h. SeeFigure 9-24.

b. The longitudinal oil groove of thecountershaft bushing on thebullwheel side should be situated at6h. See Figure 9-24. However thisposition must be changed it the motoris situated above the crusher in aregion 45° either side of the verticalaxis. See Figure 9-23. The bushingmust then be turned so that thelongitudinal groove is situated on theupper part. This position lets thetransmission exert its tractive forceoutside the groove and therefore doesnot impede the oil supply.

Ref. Description


2 Guide rod


12

3



Figure 9-23 Vertical control - motor under crusher

Ref. Description

1 With crusher vertical

2 Drive bullwheel

3 Crusher bullwheel

1

2

3



Figure 9-24 Position of the countershaft bushing lubrication grooves

3. Line the bores of the new bushings withcarbon dioxide snow for 2 to 3 hours tofacilitate assembly. Approximately 22kg of carbon dioxide snow are needed toreplace both bushings.

NOTE: COVER THE OUTSIDE OF THECOOLED BUSHING TO PREVENTFORMATION OF CONDENSATION,WHICH COULD IMPEDE ASSEMBLY OFTHE BUSHING IN THE HOUSING. THISALSO HELPS TO ACHIEVE MOREUNIFORM COOLING.

Ref. Description



3 Oil groove positioned at 6h for horizontal or vertical transmission, with themotor over the crusher bullwheel.

4 Oil groove

5 Oil groove positioned at 12h for vertical transmission, with the motor underthe crusher bullwheel.



1 2 3

4

5

6

7



NOTE: If the temperature of the countershafthousing exceeds 24°C, you can use ice insteadof carbon dioxide snow. Measure the outerdiameter of the bushing and the housing boreto determine when the bushing has cooleddown enough.

4. Quickly slide the bushing into thehousing using the guide rods.

NOTE: On HP100 and HP200, align thehole in the countershaft bushing with the holein the frame. See Figure 9-7. Check that the oilgroove is properly positioned at 12h and thatthe hole in the outer diameter of the bushing isproperly aligned with the hole in the framereceiving the headless screw. DO NOT USETHE GUIDE ROD TO MOUNT THE INNERBUSHING OF THE HP200.

5. Clean the threads of the headless screwsand the tapping of the hole in the framewith a solvent. The apply Loctite 277 tothe threaded surfaces and fit theheadless screws. Screw in until thescrew comes into contact with thebushing. DO NOT TIGHTENEXCESSIVELY: TOO MUCHPRESSURE MAY DEFORM THEBUSHING'S BORE.

6. If the assembly was not completed soonenough and the bushing works looseduring assembly, or if you have nomeans of cooling, you can insert thebushings by hitting them if you protectthem with a piece of wood. The guiderods particularly are useful in that case.

NOTE: EXERT MODERATE PRESSURETO PREVENT THE BUSHING JAMMING.

7. Remove the guide rods and replace themwith the two pins you previouslyremoved.

9.2.11 Mounting the countershafthousing - HP300, HP400 and HP500

See Figure 9-2.Whether the countershaft is dismantled forinspection purposes or to replace parts, it isadvisable to replace the seals: O-ring seal orlip seal between the housing and the frame, flator silicone seal between the housing cover andthe countershaft housing or frame,compression ring between the oil ring andhousing cover.These seals can "age" and lose their qualityover time. They are not expensive and it isbetter to replace them than to run the risk ofdismantling in order to fix an oil leak.To mount the countershaft assembly housing,proceed as follows:

1. Mount the countershaft assembly in thecountershaft housing.

2. To hold the countershaft in place, use aC-clamp as shown in Figure 9-25. Youcan also place the pinion against a wallor on solid wooden wedges.




Figure 9-25 Mounting the countershaft

3. Heat the oil ring to roughly 27°C aboveambient temperature and mount it asquickly as possible on the countershaft.

4. If difficulties arise, push the oil ringwith a rafter. The ring is correctlymounted when the axial play matchesthe values specified in Table 9-1, checkwith a gauge. See Figure 9-21.

5. When the oil ring has cooled down,remove the gauge and fit thecompression ring.

6. The oil ring is equipped with a ring sealto form a seal between the oil ring andits housing. Check that this ring can turnfreely in the groove machined in thering. Remove all burrs or dirt that mayhave gathered on the ring. Replace it ifnecessary.

7. Check the ring bore before mounting thering on the countershaft housing. Thebore should be smooth.

8. Apply silicone sealant to the face of thecountershaft housing before fixing itshousing cover onto it. Fit the cover bymatching up the bolt holes.

9. Gradually and alternately tighten theretaining screws.

9.2.12 Oil leak at the countershafton the control side

If an oil leak occurs at the countershafthousing cover, this may be due to thecompression ring positioned on the oil ring.Faulty parts must be replaced. SeeFigure 9-21.Check the breather. A clogged breather may bethe cause of an oil leak.Return piping with an insufficient gradient, orexcessively viscous oil may be the cause of anoil leak. Minimum oil return gradient: 25 mmfor 305 mm. (8% or 5°)Check the inside of the return piping, and theircondition.All such defects can cause an oil leak behindthe cover of the deflector.

9.2.13 Mounting the crusherbullwheel

See Figure 9-26.To fit the crusher bullwheel into its hub,proceed as follows:

1. Refer to the piping plan and install.

2. Remove the removable hub of thebullwheel by removing the lockingscrews.

3. Clean the shaft, retainer lock, faces andouter cone of the hub as well as thetapered bore of the bullwheel on whichit is to be mounted. Remove shavings,traces of varnish or paint.

4. Place the spacer and the removable hubin the tapered bore of the bullwheel,taking care to place the smoothhalf-holes opposite the tappedhalf-holes.

5. Oil the thread and the rounded end ofthe screws (or the underside of the headfor screws with heads).

6. Fit the screws in the tapped holes on thebullwheel without tightening them, thehub remaining free on the rim.

Ref. Description


2 Clamp

3 Pinion

1

3



7. Slide the assembly onto the shaft up tothe desired position, not forgetting theretainer lock (pinned bullwheel version).

8. Tighten the screws uniformly andalternately. The screws must betightened to the necessary torque.

Table 9-3 Thread torque - HP100



Table 9-6 Thread torque- HP400


9. If there is a risk of oxidization, fill theother holes with grease.

9.2.14 Dismantling the crusherbullwheel

See Figure 9-26.To dismantle the crusher's bullwheel, proceedas follows:

1. First remove the hub's retaining screws.

2. Insert the screws into the hub's tappedholes.

Bullwheel Torque N.m.Magic lock hub

Torque N.m.Veco bloc hub

500-6 SPC 195 275

630- 4/8V 270 360

Bullwheel Torque N.m.

560-8 SPC 360

630- 6/8V 360


630-10 SPC 360

630- 8/8V 360


800-12 SPC 560

762- 12/8V 406,7

902- 10/8V 610


800-12 SPC 560

762- 12/8V 610

902- 12/8V 610

1016- 12/8V 610

DANGERIf the bullwheel is hard to separateform its removable hub, tap it with ahammer, maintaining pressure on thethrust screws.



Figure 9-26 Bullwheel assembly

Ref. Description

1 Bullwheel

2 Bolt

3 Retainer lock

4 Spacer

5 Hub

6 For dismantling

7 For mounting

6

7

2

5

4

3

1



9.2.15 Replacement of the HP100and HP200 counter-shaft casingshield

1. To replace the counter-shaft casingshield, remove the bowl assembly asindicated in paragraph 5.3.1"Dismantling the bowl".

2. Remove the head assembly as indicatedin paragraph 6.3.1 "Dismantling thehead".

3. Withdraw the worn shield and replace itwith a new shield.

4. Refit the head assembly as indicated inparagraph 6.2 "Mounting the headassembly".

5. Refit the bowl assembly as indicated inparagraph 5.2 "Assembly instructions".

9.2.16 Replacement of the HP300counter-shaft casing shield

1. To replace the counter-shaft casingshield, remove the bowl assembly asindicated in paragraph 5.3.1"Dismantling the bowl".

2. Remove the head assembly as indicatedin paragraph 6.3.1 "Dismantling thehead".

3. Remove the bush assembly as indicatedin paragraphs 7.2 "Assemblyinstructions" to 7.3.2 "Replacing thespherical bearing (HP200, HP300,HP400 and HP500)".

4. Remove the crank assembly as indicatedin paragraph 8.3.1 "Dismantling theeccentric assembly".

5. Replace the worn shield with a newshield.

6. Refit the crank assembly as indicated inparagraph 8.3.14 "Installing theeccentric assembly".

7. Refit the bush assembly as indicated inparagraphs 7.2 "Assembly instructions"and 7.3.2 "Replacing the sphericalbearing (HP200, HP300, HP400 andHP500)".

8. Refit the head assembly as indicated inparagraph 6.2 "Mounting the headassembly".

9. Refit the bowl assembly as indicated inparagraph 5.2 "Assembly instructions".


1. To replace the counter-shaft casingshield, remove the casing assembly asindicated in paragraph 9.2.2"Dismantling the countershaft housingHP300, HP400 and HP500”, thenreplace the worn shield with a newshield.

2. Refit the counter-shaft casing assemblyas indicated in paragraph 9.1.2"Assembling the countershaft housing -HP300, HP400 and HP500".


1. Withdraw the worn half-shield locatedat the central side of the frame and thenwithdraw the worn half-shield on theexternal side of the frame.

2. Fit the new half-shield in place on theexternal side of the frame, then the newhalf-shield on the central side of theframe.


10.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.2 - Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110.2.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110.2.2 - Setting up the crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-510.3.1 - Frame and arm liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-510.3.2 - Replacing the shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-610.3.3 - Replacing the lower thrust washer and the spacer rings . . . . . . . . . . . . 10-610.3.4 - Replacing a sealing joint - HP100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-710.3.5 - Replacing the sealing joint for HP200, HP300, HP400 and HP500 . . . . 10-810.3.6 - Replacing the frame pins - HP100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-910.3.7 - Replacing the frame pins - HP200 and HP300 . . . . . . . . . . . . . . . . . . . . 10-910.3.8 - Replacing the frame pins - HP400 and HP500 . . . . . . . . . . . . . . . . . . . 10-1010.3.9 - Replacing the frame pins - HP100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1110.3.10 - Replacing the pin rings - HP200 and HP300 . . . . . . . . . . . . . . . . . . . 10-1410.3.11 - Replacing the pin rings - HP400 and HP500 . . . . . . . . . . . . . . . . . . . 10-1610.3.12 - Frame contact surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

10.3.12.1 - General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1610.3.12.2 - Wear on the adjusting ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1910.3.12.3 - Installing the bronze and steel liners . . . . . . . . . . . . . . . . . . . . 10-20

10.3.13 - Dismantling the protective cylinders - HP100 . . . . . . . . . . . . . . . . . . . 10-2110.3.14 - Mounting the protective cylinders - HP100 . . . . . . . . . . . . . . . . . . . . . 10-2210.3.15 - Dismantling the protective cylinders- HP200, HP300, HP400 and HP500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2410.3.16 - Mounting a protective cylinder - HP200, HP300, HP400 and HP500 . 10-2610.3.17 - Replacing an accumulator - HP100, HP200, HP300, HP400 and HP500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2710.3.18 - Dismantling the locking ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3010.3.19 - Installing the locking ring - HP100. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3010.3.20 - Installing the locking ring - HP200, HP300, HP400 and HP500 . . . . . 10-3310.3.21 - Replacing the frame - HP300, HP400 and HP500 . . . . . . . . . . . . . . . 10-37

FRAME, ADJUSTING RING AND RETAINING CYLINDER ASSEMBLIES

Section 10

Frame, adjusting ring and retaining cylinder assemblies SECTION 10

10.1 Description

This section deals with the frame, the adjustingring and the protective mechanism.The frame bolted to its foundations or a metalchassis equipped with vibration dampers formsa rigid support for the other components.A liner welded to the inside of the frame andthe arm liners protect the inside of the frameagainst wear; these liners must be replaced.An adjusting ring resting on a conical seatingmachined in the upper part of the frame has afemale thread for adjusting the bowl. Alocking ring over the adjusting ring pressesagainst the inner face of the bowl threadsthanks to cylinders placed between the lockingring and the adjusting ring, thereby preventingthe bowl from turning during crushing.A protective apron fixed to the adjusting ringprotects the locking cylinders and the bowl'sthreads against airborne dust.Hydraulic cylinders pinned to the frame andtraversing the adjusting ring keep the latterpressed firmly against the conical part of theframe. Abnormal operating conditions ortramp iron in the crusher can strain the bowland the adjusting ring and lift them by pullingon the cylinder's rods. This movement pushesthe oil in the cylinders into the accumulators,where the pressure of the nitrogen increases.When the excess load has passed, thecompressed nitrogen returns the oil to thecylinders, the cylinder rods retract and theadjusting ring returns to rest on the frame.Vertical pins fixed to the frame guide theadjusting ring when it lifts off the frame.A thrust washer bolted to the drum of theframe supports the eccentric. Wedges insertedunder the washer adjust play between and atthe bottom of the teeth of the crown andpinion.On HP100 and HP200, a labyrinth seal intwo parts: one on the frame, the other on theeccentric, prevent any oil leaking and protectthe crown, pinion and bearing surfaces againstingress of dust. The seal is made of specialplastic and is glued in a groove of the framearound the crown.The countershaft is supported by two bronzebushings.On HP300, HP400 and HP500, a U sealglued into a groove of the frame around thecrown forms a seal with the T seal behind theimbalance.

The main shaft, mounted in the central drum ofthe frame, supports the sleeve and serves as aspindle around which the eccentric rotates.

10.2 Mounting instructions

10.2.1 General

In most cases, the components of the frame,adjusting ring and protective mechanism areshipped assembled. However, the assemblymay be shipped as separate parts if there arespace restrictions. In that case, the mountingprocedure is provided in the part dealing withmaintenance.

10.2.2 Setting up the crusher

Whether the crusher is shipped fullyassembled or in separate parts, the frame mustbe made level on its foundations. Twomaterials are used to do this: concrete andresin. Formerly, concrete would be used almostexclusively for embedding purposes. However,resin has tended to be used instead of concretefor some years.In most cases, resin is preferable since it iseasy to prepare and use.Epoxy resin stands up well to static anddynamic loads and vibrations and is veryresilient. It is available in packs of differentquantities. Each pack includes two products,the resin itself and a hardener, which you mixin just before using it. The kit includes fullinstructions. No particular equipment,preparation or handling is required to use resin.


SECTION 10 - FRAME, ADJUSTING RING AND RETAINING CYLINDERASSEMBLIES

Figure 10-1 Embedding

To install the frame assembly or the completecrusher, see Figure 10-1 and proceed asfollows:

1. Flame-cut 4 holes in a 10-mm metalplate and place it around the bondingholes. Thread one or more suitableslings through the lifting lugs on thelower section of the frame. SeeFigure 10-2.

Ref. Description

1 Crusher

2 Foundations

3 Resin mortar after removing the cast

4 Clamping bolts

5 Form work

2

14

3

15

DANGERDo not use lifting hooks on theadjustment cap to lift the entiremachine because such hooks are notstrong enough; this could lead to aserious accident or damage.


SECTION 10 - FRAME, ADJUSTING RING AND RETAINING CYLINDER ASSEMBLIES

Figure 10-2 Handling the crusher

2. Lift the frame and coat the footing of theframe with a thin layer of oil to preventthe resin from adhering to the crusher.

3. Place the crusher on the block over the10-mm washers.

NOTE: WHEN USING CONCRETE, PLACETHE FRAME ON WOODEN WEDGESPLACED AT THE FOUR CORNERS OFTHE FRAME RATHER THAN ON METALWASHERS BECAUSE THE WOOD WILLRETRACT WITH THE CONCRETE.NOTE: THE WEDGES SHOULD RAISETHE FRAME ABOUT 50 TO 60 CM ABOVETHE BLOCK’S BEARING FACE TO HAVEAN ADEQUATE THICKNESS OFBONDING CONCRETE.

NOTE: THE SURFACE OF THE BLOCKRECEIVING THE CONCRETE SHOULDBE ROUGH AND THOROUGHLYCLEANED BEFORE BONDING. THISSURFACE SHOULD ALSO BETHOROUGHLY SOAKED WITH WATERAND REMAIN DAMP TO AVOID THEBLOCK RAPIDLY ABSORBING WATERFROM THE BONDING CONCRETE.HOWEVER, REMOVE ANY EXCESSWATER JUST BEFORE POURING THECONCRETE. ADD A RUST PREVENTIVEAGENT TO THE BONDING CONCRETE.

4. Set the level of the crusher by sliding theC-shaped washers around the foundationbolts so that there is a gap of between 12and 20 mm between the frame and theblock (optimal thickness for the resin).

5. Then build the form work on either sideof the frame, which is where the resinwill be poured. Use battens measuring25 mm x 50 mm to build the form work.Place and fasten the form work about 12mm from the base of the frame outsidethe crusher in line with the vertical sidesinside the crusher. See Figure 10-1. Theform work should be coated with 3layers of ordinary wax on either side.This prevents the wood from sticking tothe resin. All seals should be caulked toprevent leaks when you pour in theresin.

6. Mix and pour the resin as per theinstructions. In cold weather, heat theresin to 18°/27°C. For better results,store the resin in a warm room beforeuse. To avoid air bubbles forming underthe crusher, pour the resin in one placeat a time, covering an area of about 600mm on either side. Then return to thepoint where the resin stopped previouslyand pour more in. Continue until theform work is full.

NOTE: DO NOT FILL MORE THAN ONESURFACE WITH RESIN AT THE SAMETIME.

Ref. Description

1 Adjusting ring

2 Slings

3 Frame

4 Frame lugs

12

3

4



Pour have the necessary average number of kgfor bonding the crusher with a layer of mortar12 to 20 mm thick, see Table 10-1.

7. The resin usually dries in roughly 6hours if the seating, crusher and resinare at an ambient temperature of 21°C atthe time of casting.

8. When the seating is dry, clamp thecrusher firmly to its foundations.

*All these quantities include enough mortarfor one adequate bonding layer. If the surfaceis uneven, increase the quantities by 10%.

Table 10-1 Requisite quantity for bonding

If the crusher is mounted on a steelconstruction, it is simply straightened up andbolted to the latter.To install the crusher on a steel construction,proceed as follows:

1. Remove all slag and weld spatters fromthe metal structure up to the base of theframe. Grind down any protrudingseams under the frame's base.

2. Thread one or more slings through thelifting lugs on the lower sections of theframe. See Figure 10-2.

3. Flame-cut 4 washers 305 mm x 305 mm6 mm thick with a hole in the middle,matching the fixing bolt, and place themover it.

4. Raise the frame and place is on the steelconstruction.

5. Level the crusher by sliding U-shapedwashers around the foundation bolts onthe top of the cross-piece. The 4U-shaped washers may vary inthickness. Use the top of the main shaftto level the crusher in both directions.

6. When the crusher has been set in place,measure the gap between the frame'sfooting and the metal structure at 3different points as shown inFigure 10-3. These surfaces must bewedged to form a support between theframe's footing and the structure. Thewedges, which may vary in thickness,must be roughly the same width of theframe's footing; 610 mm to 915 mmlong, depending on the size of thecrusher. Generally, 915 mm wedges areused for the HP400 and HP500.

7. When the wedges are in place under theframe's footing, spot weld them to thestructure to dampen vibrations.

8. When the crusher is securely bolted tothe structure, check whether you can liftthe crusher.

9. Check the fastenings periodically: afterone week, one month, six months, oneyear.

Type of crusher

Requisite quantity of resin*:

12 mm mortar 20 mm mortar

HP100 35 kg 55 kg

HP200 45 kg 65 kg

HP300 45 kg 65 kg

HP400 45 kg 65 kg

HP500 85 kg 130 kg

DANGERDo not use lifting hooks on theadjustment cap to lift the entiremachine because such hooks are notstrong enough; this could lead to aserious accident or damage.



Figure 10-3 Location of the wedges

10.3 Maintenance

10.3.1 Frame and arm liners

See Figure 10-4.When the machine is stopped to change thebowl liner and mantle, check the frame andarm liners for wear.When the head has been dismantled, lower thearm liners. These can be placed fromunderneath the crusher, when the head is notdismantled, but this is fairly difficult.

The frame liner is generally shipped in pieces,which makes it easier to fit. If the liner isshipped as one piece, its ends must overlap sothat its diameter is smaller than that of theadjusting ring threads. The height at which theliner must be welded inside the frame is easyto see with the aid of the remaining welds ofthe old liner.

4

5

3

2

1

Ref. Description

1 Spacer plates

2 Wedges

3 Frame footing

4 Structural frame

5 Holes for the retaining screws



Figure 10-4 Frame and arm liners

10.3.2 Replacing the shaft

One very seldom needs to dismantle the shaftfrom the frame. Achieving perfect alignmentbetween the frame's shaft and the hub is amajor and difficult task; we thereforerecommend you have this done by aspecialized workshop that has the necessaryresources.

10.3.3 Replacing the lower thrustwasher and the spacer rings

See Figure 10-5.To replace a damaged or worn lower thrustwasher, or add spacer rings to restore thenormal play the teeth, proceed as follows:

1. To gain access to the washer, the bowl,head, sleeve and eccentric assembliesneed to be removed. Refer to the chapterdealing with these assemblies.

2. Remove the thrust washer's retainingscrew.

3. Screw a lifting ring into each of the 2holes drilled in the thrust washer.

4

32

1

2

3

4

1

HP100

HP200, HP300, HP400, HP500

Ref. Description

1 Frame

2 Weld

3 Frame liner

4 Arm liner



4. Using appropriate lifting gear, removethe thrust washer.

5. Check that the contact surfaces of thenew thrust washer and spacers are freeof scratches, burrs and other roughedges.

6. Refer to the eccentric assembly section,8.2.2 "Checking and adjusting the playbetween and at the bottom of the teeth"for how to check the play between andat the bottom of the teeth. Ifsupplementary spacers need to theadded, place them on the upper face ofthe existing stack. If a new washer needsto be mounted, use the two previouslifting rings, make sure the thrustwasher rests properly on the spacers andthe holes are correctly aligned.

7. Put the washers and the retaining screwsback in place. Make sure the washer iscorrectly mounted (streaks under thehead of the screws). Tighten the screwsenergetically.

Figure 10-5 Mounting the thrust washer

10.3.4 Replacing a sealing joint -HP100

See Figure 10-6.Generally the joints are not affected by wear. Ifin spite of everything they should be damagedthey would need replacing. The joints preventoil leaks and protect the machined surfaces ofthe gear assembly and the thrust washersagainst ingress of dust. Replace the joint asshown below:



3. The diameter of the spare seals is thesame or slightly larger than required.Insert the new seal into the groovewithout glue and mark out the requiredlength. Remove the seal and make aclean cut at the desired length. The sealmust be able to be mounted in its groovewithout forcing. For U seals, draw a linewith a crayon at the point where thejoint sticks out of the groove.

4. Joint gluing instructions:

a. Apply a very thin layer of activatorin the bottom of the groove. Leave todry (partial sticking may be causedby excess activator).

b. Apply the adhesive at 12 points (seefigure) along the bottom of thegroove approximately 5 to 10 mmapart.

c. Place the joint and press down so thatthe two surfaces remain in contactfor more or less 3 minutes.

Ref. Description

1 Lower thrust washer

2 Retaining screw

3 Lock washer

4 Spacer ring

1

2

3

4



Figure 10-6 Replacing the sealing joint

10.3.5 Replacing the sealing jointfor HP200, HP300, HP400 and HP500

See Figure 10-6.Generally the U seal is not affected by wear. Ifin spite of everything it should be damaged itwould need replacing. The joints prevent oilleaks and protect the machined surfaces of thegear assembly and the thrust washers againstingress of dust. To replace it, proceed asfollows:



3. After removing the new"made-to-measure" sealing joint from itsshipping box, thoroughly clean thebottom of the sealing joint with coarsesandpaper to remove the surface "gloss"before cementing the joint. These jointsare coated with a parting agent to allowthe joint to be released from its mouldduring production. For the joint toadhere correctly to the adhesive, thisparting agent must be totally removed.

NOTE: IF THE PARTING AGENT IS NOTTOTALLY REMOVED, THE JOINT COULDMOVE DURING THE OPERATION!

4. APPLY A VERY THIN LAYER OFACTIVATOR TO THE OUTERBOTTOM EDGE OF THE JOINT. Iftoo much activator is applied, this couldbring about partial vulcanization of thejoint.

5. apply a small amount of ADHESIVETO THE BOTTOM OF THE GROOVERECEIVING THE JOINT of the mainframe. Apply only the amount ofadhesive required to guarantee minimalpressure.

6. Position the joint in the groove as soonas possible after applying the adhesive.Apply enough pressure to the bottom ofthe joint to ensure contact between thejoint and the bottom of the groove.

Figure 10-7 Replacing the seal

Ref. Description

1 Frame seals

1



10.3.6 Replacing the frame pins -HP100

See Figure 10-8.The frame pins prevent the adjusting ring formturning. They reposition the ring when trampiron passing through the crushing chamber liftsit. Repeated lifting of the adjusting ring is notnormal and can be averted throughappropriately graded feed. Incorrect operationwith excessive bounce of the ring will lead towear on the pins and damage the pin rings inthe frame.

Figure 10-8 Replacing a frame pin (HP100)

The wear is visible under the adjusting ring inthe frame pins region. The rotating headtransmits force to the bowl and the adjustingring that makes it turn in the same direction asthe head, thereby causing wear to the pins andrings only on one side.The pins should be replaced as follows:

1. Remove the screw from the frame pinabove the adjusting ring.

2. Depressurize the protective cylindersand the accumulators. Take out the wornpins by hitting the top of the adjustingring. The pin support may need to beheated.

3. Push the new pins from underneath theframe by hitting or heating the pinsupport or cooling the pin to makefitting easier.

4. The pin must be in contact with thebottom of its bore hole.

5. Fix each pin with the aid of screws fittedwith normal thread brake.

6. Repressurize the protective cylinders.

10.3.7 Replacing the frame pins -HP200 and HP300

See Figure 10-9.The frame pins prevent adjusting ring fromturning and reposition it when tramp ironpassing through the crushing chamber lifts it.Repeated lifting of the adjusting ring is notnormal and can be averted throughappropriately graded feed. Incorrect operationwith excessive bounce of the ring will lead towear on the pins and expand the bore holes inthe adjusting ring.The wear is visible under the adjusting ring inthe frame pins region. The rotating headtransmits force to the bowl and the adjustingring that makes it turn in the same direction asthe head, thereby causing wear to the pins andrings only on one side. The pins should bereplaced as follows.

1. Depressurize the protective cylinders.Make sure the pressure in the hydraulicprotective system equals 0.

Ref. Description

1 Frame

2 Adjusting ring

3 Frame pin

4 Pin retaining screw

4

2

1

3



2. Raise the adjusting ring with a crane orother lifting gear. Turn it to centre thepins in the frame's holes and the ring.

Figure 10-9 Replacing a frame pin (HP200 and HP300)

3. Remove the screw under the frame pin,the washer and the retaining plate undereach pin.

4. Take out the worn pins from underneaththe frame using a hydraulic cylinder.The pin support may need to be heatedor the pin cooled. Dismantle theprotective cylinders and theaccumulators during this procedure.

5. Push the new pins by hitting or heatingthe pin support to make fitting easier.

6. Fix each pin with the aid of a retainingplate, lock washer and screw.

7. Repressurize the protective cylinders.

8. After fitting the new pins, put the coversback on the pins.

10.3.8 Replacing the frame pins -HP400 and HP500

See Figure 10-10.The frame pins prevent adjusting ring fromturning and reposition it when tramp ironpassing through the crushing chamber lifts it.Repeated lifting of the adjusting ring is notnormal and can be averted throughappropriately graded feed. Incorrect operationwith excessive bounce of the ring will lead towear on the pins and expand the bore holes inthe adjusting ring.The wear is visible under the adjusting ring inthe frame pins region. The rotating headtransmits force to the bowl and the adjustingring that makes it turn in the same direction asthe head, thereby causing wear to the pins andrings only on one side. The pins should bereplaced as follows.


2. Unscrew the ball nut on the protectivecylinder's piston rod. Since this nut wasfitted with Loctite, it must be heated toroughly 205°C (400°F) before it can beunscrewed.

3. Fix all the protective cylinders to theouter diameter of the main frame.

4. With a crane or other suitable hoistingequipment, lift the adjusting ringassembly, including the lock ring andthe locking cylinders to take them out ofthe main frame.

5. Remove the snap rings from the top ofeach pin to be replaced.

6. Heat the boss of the adjusting ring whileguiding the worn pin through the bottomof the adjusting ring hitting it with asledgehammer. You can also drill thecentre of the pin before heating the boss.

Ref. Description

1 Frame cover

2 Adjusting ring

3 Frame pin

4 Retaining plate

5 Screw and washer

6 Frame

12

3

4

5

6



7. Before fitting the new pins on the mainframe, they must be immersed in carbondioxide snow for roughly 2 hours.

8. Just before fitting the pin, heat theadjusting ring for roughly 10 minutes.Then quickly insert the cooled pin intothe adjusting ring and hit it with asledgehammer until it is tight. Refit thesnap ring.

9. install the adjusting ring assembly onthe main frame. The base of theadjusting ring must be coated withgrease, lithium NLG1 No.1 with 3%molybdenum disulphide powder.

10.Refit the cylinders' domed nuts asdescribed later.

11.Repressurize the protective cylinders.

Figure 10-10 Replacing a frame pin (HP400 and HP500)

10.3.9 Replacing the frame pins -HP100

See Figure 10-11To replace the pin ring, proceed as follows:

1. Place a U ring 15 mm thick around theretaining cylinder rods, between theunderside of the adjusting ring and thecylinder nut.

DANGERWear well-insulated gloves whenhandling the carbon dioxide snow.This substance can cause seriousburns.

Ref. Description

1 Frame pins

2 Adjusting ring

3 Pin ring

4 Snap ring

5 Lock ring, screw and lock washer

10-11TECHNICAL MANUAL NORDBERG CONE CRUSHERS HP100/200/300/400/500


2. Raise the adjusting ring until theretaining cylinders are completelyextended, as described in paragraph 3.17"Clearing the crusher". As soon as thering is fully raised, place the 3 safetywedges, supplied with the crusher, at anequal distance from the pins, betweenthe frame and the ring. Then lower thering so that it rests on the safety wedges.

3. The frame pins must first be removed(see removing the frame pins in thissection).

4. To remove the pin rings, use a flatwasher and an extractor support. SeeFigure 10-11.

5. Place the support between the frame andthe adjusting ring.

6. Place the flat washer against the lowerface of the frame ring.

DANGERDo not try and remove the pin ringswithout first fitting the safetywedges, even though the protectivecylinders have been depressurized;there may still be residual pressurethat could lower the adjusting ringand cause serious damage.



Figure 10-11 Replacing the pin rings

7. Engage an M20 screw in the flat washerand screw it onto the extractor supportuntil the pin ring is completelyextracted.

8. Before fitting the new pin rings, thesemust be cooled for more or less 2 hoursin carbon dioxide snow.

9. Use the backed-up washer as specifiedin Figure 10-11.

3

9

7

1

8

7

1110

2

3

4

56

Ref. Description

1 Flat washer

2 Adjusting ring

3 Extractor support

4 M20 screw

5 Pin ring

6 Frame

7 Backed-up washer

8 Safety wedge

9 Welded M20 nut

10 Removal

11 Mounting




10.Use a flat washer 80 in diameter andplace it against the frame, on theopposite side from the backed-upwasher (See Figure 10-11).

11.Engage an M20 screw in the flat washerand screw it onto the backed-up washer.

12.Screw until the flange ring rests on thebottom of its seating.

13.You can also use the hydraulic holdingsystem. In that case, push the ring on byabout 10 mm (proceed in series of 2opposed rings).

14.Put a plate 20 mm thick onto the ringsand lower the bushing to complete thefitting process.

15.Mount the pins again (see mounting pinsin this chapter).

16.Raise the adjusting ring, remove thesafety wedges.

17.Lower the adjusting ring onto the frame.Restore normal pressure in theprotective cylinders.

18.Remove the U rings that were putaround the retaining cylinder rods.

It is advisable to change the pin rings and thepins at the same time. In that case, it ispreferable to dismantle the adjusting ring.


2. Separate the protective cylinders fromthe adjusting ring.

3. Raise the adjusting ring with a crane orother lifting gear.

4. Mount the pins again (see mounting pinsin this chapter).

5. Replace the pin rings (see replacing thepin rings in this chapter).

6. Increase the adjusting ring and lower itonto the frame, aligning the pins withthe frame's ringed holes.

7. Remount the protective cylinders (seechapter on mounting a protectivecylinder).

8. Restore normal pressure in theprotective cylinders.

10.3.10 Replacing the pin rings -HP200 and HP300

See Figure 10-12.To replace the pin rings, proceed as follows:

1. Raise the adjusting ring until theretaining cylinders are completelyextended, as described in paragraph 3.17"Clearing the crusher". As soon as theadjusting ring is fully raised, place the 3safety wedges, supplied with thecrusher, at an equal distance from thepins, between the frame and theadjusting ring. Then lower the adjustingring so that it rests on the safety wedges.

DANGERDo not try and remove the pin ringswithout first fitting the safetywedges, even though the protectivecylinders have been depressurized;there may still be residual pressurethat could lower the adjusting ringand cause serious damage.



Figure 10-12 Safety wedge

2. Remove the 6 screws retaining the pinrings in the adjusting ring and removethe pin covers.

3. Measure the distance between thebottom of the pin ring and the top of theframe boss. See Figure 10-13.

4. Cut 3 pieces of 76 x 6 mm tubing to themeasured length (see step 3). Cut eachtube in the middle lengthwise, asspecified in Figure 10-13.

5. Place each tube section around theframe pin as shown Figure 10-13. Holdthe half-tubes in place with electricconduits.

6. Raise the adjusting ring then remove thesafety wedges.

7. Pressure up the retaining cylinders tolower the adjusting ring under the 3 splittubes. Maintain pressure in the cylindersuntil the tubes force on the rings,enabling you to remove them.

Figure 10-13 Dismantling the pin rings

8. When the adjusting ring rests on theframe, raise the adjusting ring again andplace the safety wedges at the pointswhere the rings were removed, to allowyou to remove the 3 other rings.

9. Remove the 3 remaining rings asspecified in steps 5, 6 and 7.

10.Raise the adjusting ring and insert thesafety wedges.

11.Before replacing the new pin rings, theymust be cooled for roughly 2 hours incarbon dioxide snow.

Ref. Description

1 Adjusting ring

2 Pin ring

3 Frame pin

4 Teat screw

5 Safety wedge

6 Retaining plate

7 Screw and lock washer

8 Frame

12

3

4

5

6

7

8

Ref. Description

1 Necessary space

2 Measure this distance

3 Tube split in two parts

3

1

2



12.Just before fitting the pin rings, heat thebosses on the adjusting ring for 10minutes. Then rapidly mount the rings inthe bosses until the ring is aligned withthe bottom of the adjusting ring, tightenthe screw retaining the ring to theadjusting ring.

13.Raise the adjusting ring, then move the 3safety wedges, to let you insert the 3other rings. Rest the adjusting ring onthe safety wedges.

14.Insert the 3 pin rings (see step 12).

15.After fitting the new frame pins, coverthe holes in the adjusting ring with newplugs.

16.Raise the adjusting ring and remove thesafety wedges. Lower the adjusting ringonto the frame and restore normalpressure in the protective cylinders.

10.3.11 Replacing the pin rings -HP400 and HP500

See Figure 10-8.To replace the pin rings, proceed as follows:


2. Unscrew the ball nut over the adjustingring from the protective cylinders' pistonrod. Since this nut was fitted withLoctite, it must be heated to roughly205°C (400°F) before it can be removed.



5. Remove the snap rings from the groovesin the pin rings.

6. Heat the bosses on the frame whileeasing out the worn pins with asledgehammer.

7. Before fitting the new pins on the mainframe, they must be immersed in carbondioxide snow for roughly 2 hours.

8. Just before fitting the pin rings, heat theframe boss for roughly 10 minutes. Thenquickly insert the cooled ring into thehole of the boss.

9. Fit the snap ring to the bottom of thering.

10.Install the adjusting ring assembly onthe main frame. The base of theadjusting ring must be coated withgrease, lithium NLG1 No.1 with 3%molybdenum disulphide powder.

11.Refit the nuts of the cylinder domed nutsas described later.

10.3.12 Frame contact surfaces

10.3.12.1 General informationThe contact surface of the frame must beperiodically checked for wear. Irregular feedand the friction between the adjusting ring andthe frame's contact surface cause wear on thecontact surface. Excessive bounce of theadjusting ring will accelerate and aggravate thewear on the span.As standard on all cone crushers, a bronze lineris welded on the frame, see Figure 10-14.Using a liner made of bronze alloy givescontact surfaces that are easy to replace. Usinga soft alloy avoids rapid wear of the adjustingring and the frame.In addition to the bronze liner on the frame, asecond liner in steel can be added.





This steel liner is very important because it letsthe adjusting ring tilt and straighten upcorrectly when it rises as tramp iron passesthrough.To determine thee precise degree of wear ofthe bronze and steel liners, proceed as follows:

1. Starting with the first pin on the left ofthe countershaft and moving clockwise,paint or mark the numbers 1, 2, 3, 4, 5and 6 on the outer side of the adjustingring or on the frame's boss.

Figure 10-14 Liners on the frame's bearing surfaces

2. Measure the distance from the bottom ofthe adjusting ring to the top of theframe's boss, as specified inFigure 10-16 and note down thedimensions.

3. Measure these points at regular intervalsand compare them with the originaldimensions. By comparing the 2 sets ofdimensions, one can determine thedegree of wear of the liners or thecontact surfaces and see whether thewear is localized or uniformlydistributed around the crusher. This isthe only method for determining wearon the liners.

4. When any of the dimensions are smallerthan the initial dimension given inTable 10-2, the bronze liner and the steelliner must be replaced. This verticaldimension means there is only 1.5 mm(1/16") of wear on the liner.

Ref. Description

1 Steel liner

2 Bronze liner

3 Contact surface

4 Frame

1

2

3

4



Table 10-2 Wear on bronze liners

Figure 10-15 Markings for determining wear

This difference of 8 mm (5/16") between thetwo measurements indicates that the surfacesare worn. On the basis of the table, the linersmust be replaced.When you check for wear using the abovemethod, and you find a difference of 6 mm(1/4") or more between two points, the linermust be partially worn on one side, causing theadjusting ring to tilt on the frame. This tilt iscaused by uneven distribution of the materialsin the crusher cavity. Uneven distributioncauses the adjusting ring to work mainly onthis face, which causes excessive wear to thissurface. If the difference between the 2 pointsvaries by between 6 and 10 mm, the bronzeliner and the steel liner must be replaced.To remedy this problem, the crusher's feed andits distribution in the crusher cavity should bereviewed, see paragraph 2.3 "Feed".When replacing the bronze liner, the steel linermust be replaced too. The welding andmounting procedures are given further on inthis section.The described method can also be used todetermine the degree of wear between theadjusting ring and the frame, when the crusheris not fitted with liners.If you notice that the span is worn wheninspecting the wear surfaces of the adjustingring and frame, installation and re-machiningplans can be provided, as can the weldingprocedures.

Type Initial dimensions Dimensions measured periodically

Differences

HP100 15 mm (19/32") 7 mm (9/32") 8 mm (5/16")

HP200 20 mm (3/4") 12 mm (1/2") 8 mm (5/16")

HP300 35 mm (1-3/8") 27 mm (1 - 1/16") 8 mm (5/16")

HP400 40 mm (1-9/16") 32 mm (1 - 1/4") 8 mm (5/16")

HP500 40 mm (1-9/16") 32 mm (1 - 1/4") 8 mm (5/16")

Ref. Description

1 Frame cover

2 Frame pin

3 Measure and note down the wear here

4 Paint or mark the numbers 1,2,3 etc.

5 Retaining plate

6 Screws and washers

7 Bronze liner

8 Steel liner

9 Play

1

2

3

4

56

7

8

9



NOTE: BEFORE A LINER CAN BEMOUNTED ON AN OLD CRUSHER, THEFRAME AND THE ADJUSTING RINGMUST BE RECONDITIONED AS NEW.

10.3.12.2 Wear on the adjusting ringThere is play between the steel liner and thelower face of the adjusting ring; this play mustbe maintained when replacing the liner. After along period of activity, remember to changethe liner if there is no more play between thelower face of the adjusting ring and the steelliner.NOTE: IT IS VERY IMPORTANT THATTHE PLAY BE MAINTAINED BETWEENTHE LOWER PART OF THE RING ANDTHE LINER.IF THE ADJUSTING RING WERE TOREMAIN SUPPORTED ON THE UPPERLINER, IT COULD SUFFER SERIOUSDAMAGE.

Figure 10-16 Wear liners

To determine if the play between the top of thesteel liner and the bottom of the adjusting ringis correct, proceed as follows:

1. Place balls of clay or mastic on the topof the steel liner or on the frame.

2. Then lower the adjusting ring onto theframe. When the adjusting ring rests onthe span, the clay or mastic will becompressed, showing the exact amountof play between the adjusting ring andthe steel liner.

3. Raise the adjusting ring and measure thethickness of the compressed clay ormastic.

a. If the thickness of the clay or masticis less than 1 mm (0.04") theminimum specified in Figure 10-16,the lower surface of the adjustingring must be hard-surfaced andmachined to obtain the minimumplay, see Figure 10-17.

b. If the thickness of the clay or mastic isgreater than 4 mm (5/32") theminimum specified in Figure 10-16,the lower surface of the adjusting ringmust be hard-surfaced and machinedto obtain the maximum play.

1

2

3

45

6

7

Ref. Description

1 Adjusting ring

2 Frame pin

3 Measure this distance

4 Frame

5 Bronze liner

6 Steel liner

7Play of 1 mm to 4 mm after fitting the liners



Example

Figure 10-17 Adjusting ring span

4. If there is a difference of 6 mm (1/4") ormore between the various measuredpoints, this means that the adjusting ringhas been knocked on one side. Thiscauses the adjusting ring to tilt on theframe. Fitting a bronze and steel linerwill not resolve the problem. Theadjusting ring tilts due to unevendistribution of the materials in thecrusher cavity. Uneven distributioncauses the adjusting ring to work mainlyon this face, which causes excessivewear to this surface. To remedy thisproblem, the adjusting ring's span mustbe hard-surfaced and re-machined.Contact the factory for the spanreconditioning procedure (welding andre-machining).

To remedy this problem, the crusher's feed andits distribution in the crusher cavity should bereviewed.

10.3.12.3 Installing the bronze and steellinersProceed as follows:

1. Depressurize the protective cylinders asdescribed in the paragraph ondepressurizing in the hydraulicssupplement.

2. Unscrew the ball nut over the adjustingring from the protective cylinders' pistonrod. Since this nut was fitted withLoctite, it must be heated to roughly205°C (400°F) before it can be removed.



5. Remove the old liners.

6. Weld the bronze sectors (seeFigure 10-18). preheat the inside of theframe to around 50°C (122°F). Place thebronze liners in position and spot weldthem to the frame. Preheat the inside ofthe frame again to a temperature ofbetween 80°C (176°F) and 100°C(212°F), and finish welding the bronzeliners. Preheating is necessary forproper penetration and resistance of thewelding material.

7. Weld the protective liner on top of themain frame in individual segments (seeFigure 10-18).

8. After checking the gap between thesupport bar and the underneath of theadjusting ring, as described earlier inthis part on the wear of the adjustingrings, install the adjusting ring assemblyon the main frame. The adjusting ringsmust be coated with grease, lithiumNLG1 No.1 with 5-10% of molybdenumdisulphide powder.

1.0 mm (1/32")

Minimum admissible play between the steel liner and the lower face of the adjusting ring.

0.2 mm (008")Thickness of the clay or mastic.

0.8 mm (1.32")

The machining dimension of the lower part of the adjusting ring, to obtain the minimum play.

Ref. Description

1 Adjusting ring

2 Lower surface of the ring

1

2



9. Refit the cylinders' domed nuts asdescribed later.

Figure 10-18 Welds

10.3.13 Dismantling the protectivecylinders - HP100

See Figure 10-19.A cylinder leaks requires immediate attention.Any external leak around a piston rod orinternal leak of the piston will cause theadjusting ring to bounce. There is an externalleak if oil oozes between the cylinder's pistonrod and nose. If the protective mechanismoften needs hard-surfacing, this may point toan oil leak inside the cylinders. To change orrepair a leaky cylinder, proceed as follows:

1. Shut of the power supply to lower thepressure. Make sure the pressure hasfallen to 0.

2. Disconnect the protection circuitcoupling (the circuit feeding the upperchamber of the cylinder) and theunramming circuit coupling (the circuitfeeding the lower chamber of thecylinder).

3. Attach a sling around the body of thecylinder and use suitable liftingequipment.

4. Remove the barrel nut on the cylinderrod; it the nut was fitted with Loctite,heat to around 200°C (400°F) beforeremoving the nut.

5. Remove the pins split at both ends onthe lower spindle of the cylinder.

6. The lower spindles are mounted to slidein the holes of the frame's ribs. Removethe spindles with a hammer.

7. Extricate the cylinder rod from theadjusting ring taking care not to damageand pipes or couplings.

8. See the hydraulics manual for how toreassemble the circuit.

DANGER

On no account disconnect the hydrauliccouplings without first ascertaining thatthe pressure has dropped to zero.Disconnecting a pressurized hose isdangerous because the energyaccumulated by the fluid will eject thehose with such force that this couldseriously injure the user.



10.3.14 Mounting the protectivecylinders - HP100

See Figure 10-19.To mount a new or repaired cylinder, proceedas follows:

1. Push the cylinder rods down, pistonagainst the bottom of the cylinder on theclevis side.

2. Screw a nut onto the lower end of thethread.

3. Support the cylinder with suitable liftingequipment, the cylinder rod pointingupwards. Slide the cylinder rods throughthe holes of the ring and install thesmooth spindle and the pin.

4. Put wedges under the cylinder to makeup the play in the clevis: mark the rodwhere it comes out of the cylinder.

5. Screw the ball nut until the end of therod is flush with the upper face of thenut; measure the rod extension using themark you made earlier. This should be atleast 10 mm, otherwise turn the nutmore.

6. Remove the ball nut, refit it withLoctite.

7. Apply the Loctite to the thread of therod, over an area of between 15 and 55mm under the lower face of the ring.

8. Screw the nut until the top of the nut is15 mm from the adjusting ring.

9. Reconnect the hydraulic circuits andhoses connecting it to the accumulator.

10.All the components of the protectivemechanism assembly are designed for207 bars.

11.Before operating the protectivemechanism or after maintenance work,purge all the air from its circuit: loosenthe drain plugs of the cylinders andaccumulators (purging pressure ofroughly 20 bars).

12.After assembling and purging thecircuit, test it at a pressure of 207 bars.



13.Before assembly, check theaccumulators' inflating pressure, whichshould be 83 bars.

Figure 10-19 Protective cylinders assembly- HP100

Ref. Description

1 Adjusting ring

2 Retaining cylinder circuit

3 Unramming circuit

4 Spindle

5 Ball nut

6 Nut

7 Protective cylinder

8 Frame rib

9 Accumulator

10 Piston rod

1 510 6

2

3

4 8 9

7



10.3.15 Dismantling the protectivecylinders- HP200, HP300, HP400and HP500

See Figure 10-20 and Figure 10-21.A cylinder leaks requires immediate attention.Any external leak around a piston rod orinternal leak of the piston will cause theadjusting ring to bounce. There is an externalleak if oil oozes between the cylinder's pistonrod and nose. If the protective mechanismoften needs hard-surfacing, this may point toan oil leak inside the cylinders. To change orrepair a leaky cylinder, proceed as follows:

1. Shut of the power supply to lower thepressure. Make sure the pressure hasfallen to 0.

2. Disconnect the protection circuitcoupling (the circuit feeding the upperchamber of the cylinder) and theunramming circuit coupling (the circuitfeeding the lower chamber of thecylinder).

3. Attach a sling around the body of thecylinder and use suitable liftingequipment.

4. Remove the barrel nut on the cylinderrod; it the nut was fitted with Loctite,heat to around 200°C (°F) beforeremoving the nut.

5. Remove the pins split at both ends onthe lower spindle of the cylinder.

6. The lower spindles are mounted to slidein the holes of the frame's ribs. Removethe spindles with a hammer.

7. Lift the cylinder and accumulator out ofthe crusher while sliding the piston rodthrough the hole in the adjusting ring.Make sure not to damage any of thehoses.

8. Loosen the tap screw on the accumulatorflange.

9. Dismantle the accumulator byunscrewing the couplings and slidingthe accumulator out of its lock ring. Seereplacing the accumulator in thissection.

10.See the hydraulics manual for how toreassemble the circuit.

DANGEROn no account disconnect thehydraulic couplings without firstascertaining that the pressure hasdropped to zero. disconnecting apressurized hose is dangerousbecause the energy accumulated bythe fluid will eject the hose with suchforce that this could seriously injurethe user.



Figure 10-20 Protective cylinder assembly - HP200, HP300, HP400 and HP500

Ref. Description

1 Adjusting ring

2 Ball nut

3 Nut


5 Union

6 Accumulator

7 Frame rib

8 Spindle

9 Unramming circuit

10 Retaining cylinder circuit

1 2

3

6

4

5

78

9

10



Figure 10-21 Cylinder rods and nuts HP200, HP300, HP400 and HP500

10.3.16 Mounting a protectivecylinder - HP200, HP300, HP400 andHP500

See Figure 10-20 and Figure 10-21.To mount a new or repaired cylinder, proceedas follows:

1. Remount the accumulator on the body ofthe cylinder.

2. Push the cylinder rods down, pistonagainst the bottom of the cylinder on theclevis side.

3. Screw a nut onto the lower end of thethread.

2 1

4

5

6

HP200 HP300

HP400/500

Ref. Description

1 Piston rod

2 Adjusting ring

4 Protective cylinders

5 Hexagonal nut

6 Ball nut



4. Support the cylinder with suitable liftingequipment, the cylinder rod pointingupwards and the largest tapped orificeon the accumulator side. Raise thecylinder by sliding the rod through theholes of the adjusting ring and pass theclevis at the base of the cylinder on theframe's rib.

5. Make sure the spindle is in goodcondition and is free of burrs.

6. Align the bore holes of the cylinderclevis with the hole in the frame. Coatthe spindle with oil and slide it into thelug, if need be tap it lightly with ahammer. Refit the two cotter pins on theends of the spindle.

7. Make sure the piston rod is completelylowered and rests on the bottom of thecylinder. Measure la distance betweenthe top of the adjusting ring and the topof the piston rod.

8. Turn the special ball nut several timeson the piston rod and put the rod out ofthe cylinder by the length specified inTable 10-3. When the piston rodprotrudes from the cylinder by therequisite length, remove the ball nutfrom the rod.

9. Clean the piston rod threads over adistance of 100 mm with alcohol oracetone, then apply Loctite 242 to thethreads.

Table 10-3 Maximum rod distance

10.Turn the ball nut on the rod until ittouches the bottom of the adjusting ring.FIT THE BALL NUT WITH THEESPHERICAL SURFACE DIRECTEDTOWARDS THE TOP OF THEADJUSTING RING.

11.Check the distance again between thetop of the adjusting ring and the top ofthe rod. s should match the distance youfound in steps 7 and 8.

12.Clean the thread of the piston rodunderneath the adjusting ring withoil-free solvent. After cleaning thethread, apply Loctite 242 to the fourthreads of the rods, starting 20 mm(0.79") from the bottom of the adjustingring. Then turn the hexagonal nut on therod until there is a gap of 20 mm (3/4")between the top of the hexagonal nutand the bottom of the adjusting ring.

13.Reconnect the hydraulic circuits andhoses connecting it to the accumulator.

14.When the cylinder is installed and thehydraulic circuits reconnected, themechanism must be purged to removeany trapped air. Check that there are noleaks by pressurizing the circuit. See thehydraulics section of the manual formore information on purging and tests.

15.When the protective circuit ispressurized, check the distance betweenthe top of the lower nut and the bottomof the adjusting ring; this should havebeen adjusted in step 7. If it is incorrect,depressurize and correct by adjustingthe barrel nut.

10.3.17 Replacing an accumulator -HP100, HP200, HP300, HP400 andHP500

See Figure 10-22.A faulty accumulator, nitrogen escaping intothe atmosphere or internal leak in the vessel isdangerous and requires immediate action. Inany of these cases, the accumulator will fill upwith oil and will thus no longer have elasticityand powerful thrust will develop if the crusheris overloaded or tramp iron passes through it.The accumulator's preload must be checkedevery 200 hours (1 month).

Type Adjustment

HP200 12 mm (1/2")

HP300 23 mm (1")

HP400 25 mm (1")

HP500 25 mm (1")



Before reloading the accumulator, check thegas pressure. If the preload pressure is too low:reload the accumulator. If normal pressurecannot be maintained in service, theaccumulator must be replaced. For the HP100see paragraph 12.1.8 "Checking accumulatorpreload" and for the HP200-300-400-500 seeparagraph 12.2.1.6 "Checking accumulatorpreload". To replace a faulty accumulator,proceed as follows:

1. Power down the hydraulic unit, lowerthe pressure as explained in thehydraulics manual by opening the valveprovided for the purpose in thehydraulic unit. Make sure the pressuregauge on the hydraulic circuit reads 0.

Figure 10-22 Replacing an accumulator

2. Remove the valve protection on top ofthe accumulator (HP100) andunderneath the accumulator (HP200,HP300, HP400 and HP500) and the plugon the valve rod. Remove the washerthat was under the plug. With theinflation checking equipment suppliedas an optional extra, make sure thecoupling screwed to the base iscompatible with the accumulator valve.Fully unscrew the upper knurled buttonof the inflation checking equipment onthe accumulator with the lower knurledbutton on the inflation checkingequipment.

DANGEROn no account disconnect thehydraulic couplings without firstascertaining that the pressure hasdropped to zero. disconnecting apressurized hose is dangerousbecause the energy accumulated bythe fluid will eject the hose with suchforce that this could seriously injurethe user.

Ref. Description


2 Bolts fixing the accumulator to the cylinder

3 Accumulator

4 U-bolt for accumulator

1

4

2

3



Open the purge screw until all the nitrogen hasbeen released. When the pressure gauge reads0, the accumulator is considered empty.Dismantle the inflation checking equipment.

Figure 10-23 Depressurizing the accumulator

3. Remove the screw and the washers ofthe U-bolt holding the accumulator onthe cylinder, attach a sling around theaccumulator and use suitable handlingequipment.

4. With a wrench, lock the union on the topof the accumulator and turn it clockwiseuntil it can be removed.

5. Coat the thread of the coupling and theinner thread of the accumulator. Thenscrew the coupling into the accumulator.

6. Carefully place the new accumulatorand its union near the retaining cylinderand screw the union into the partprovided for the purpose in thecylinder's barrel, the accumulator mustbe as straight as possible. Tightenfirmly.

7. Fit the flange with screws and washers.

8. Preload the new accumulator asexplained in paragraph 12.1.8 "Checkingaccumulator preload" for the HP100 andparagraph 12.2.1.6 "Checkingaccumulator preload" for theHP200-300-400-500. The accumulatorcould be damaged by incorrectpreloading before pressurizing the oil.

9. When the accumulator is in place and allthe connections have been made, purgethe various circuits then pressurize thecircuit and check for leaks. See thehydraulics manual for instructions onpurging and testing pressure in thehydraulic circuit.

Ref. Description

1 Lower screw of the blow head

2 Protective plug

3 Knurled screw

4 Accumulator

5 Protective plug

6 Purge screw

12

3

4

5

6



10.3.18 Dismantling the locking ring

To check or replace parts, dismantle thelocking ring as instructed below:

1. Dismantle the bowl assembly asexplained in paragraph 5.3.1"Dismantling the bowl" of this section.

2. Remove the screw traversing the lockingring. These screws prevent the lockingring from turning while you aredismantling the bowl and protect thelocking cylinders if they are pressurizedwhen the bowl is not in place.

3. Make sure that the circuit is at zeropressure then disconnect the hoselinking the first locking cylinder to theelbow on the adjusting ring.

4. Screw the lifting ring to the locking ringand carefully lift the locking ring andthe locking cylinders.

5. One or more cylinders can now bedismantled for repair or replacement.Disconnect the hoses on each side of thecylinder and unscrew the headless screwretaining the cylinder in its housing.

10.3.19 Installing the locking ring -HP100

To install the locking ring on the adjustingring, proceed as follows:

1. Thoroughly clean the thread of theclamping ring and the thread of the bowland the adjusting ring. The holes in therings fixing the oil chamber must also becleaned and all trimmings must beremoved. With a brush, coat the casingof the clamping ring chamber withISO-XM2 grease.

2. When the clamping ring is turned over,pass the two valves through theclamping ring. Put the oil chamber flatin the casing.

3. Position the valves:

a. Push the valve through the clampingring to keep it in position, fit thespring and tighten the flat screw byhand.

b. Repeat this operation on the secondvalve.

4. Position of the polyurethane wedge:

a. Coat the oil chamber with grease.

b. Place the polyurethane wedge on thechamber.

c. Do not place the bevelled edge of thepolyurethane wedge opposite avalve.

5. Place the mechanism between strips ofplastic (Colson collars) and return theclamping ring assembly to the rightposition.

6. Tightening the valves:

a. Screw the flat nut onto the valve andcompress the spring to 21 mm(0.83").

b. Lock the locknut.

c. Repeat this operation on the secondvalve. See Figure 10-24.

7. Lower the locking ring and screw thelifting rings. Install the slings betweenthe bolts of the ring and suitable liftinggear then raise the locking ring onto theadjusting ring as shown in Figure 10-24.

8. Turn the locking ring until the locatinghole is aligned with the matchingmounting marks on the adjusting ring.

DANGER(HP100 ONLY)




NOTE: IF THE MOUNTING MARKS ARENOT ALIGNED WITH ONE ANOTHER,THE LOCKING RING THREADING WILLBE OUT OF PHASE WITH THEADJUSTING RING THREADING,SLOWING DOWN THE BOWL AND

SOMETIMES PREVENTING IT FROMTURNING IN THE ADJUSTING RING. THECORRECT POSITION OF THE LOCKINGRING ON THE ADJUSTING RING ISEXTREMELY IMPORTANT.

Figure 10-24 Aligning the locating holes and fitting the oil chamber

9. Lower the locking ring onto theadjusting ring, watching the tube fixedto the adjusting ring.

10.Remove the retaining device. (Colsoncollar)

11.Remount the nuts and locknuts withnormal thread brake on the dowelstraversing the locking ring.

Ref. Description

1 Locking ring

2 Slings

3 Locating hole in the locking ring

4 Clamp

5 Polyurethane wedge

6 Oil chamber

7 Tube

8 Locating hole in the adjusting ring

1 2

4

3

5

87

6



NOTE: Respect dimension A = 9 mm (0.35")+/- 0.5 mm (see Figure 10-25) between thenuts and the locking ring with the six dowels.

12.Reconnect the hose between the oilchamber and the threaded tubetraversing the locking ring, positionedon the adjusting ring. This hose connectsthe oil chamber with the hydraulic unitthrough a hole in the adjusting ring. SeeFigure 10-24.

Figure 10-25 Connecting hoses to the oil chamber

Ref. Description

1 Adjusting ring

2 Oil chamber

3 Polyurethane wedge

4 Locking ring

5 Hose

6 Tube

7 Nut and locknut

8 Hose connecting the oil chamber to the hydraulic unit

9 Dowel

10 Dimension "A"

11 Purge plug

Purge valve

1 7

8

3

5

4

2

10

6

9

11

12



Fill and purge the oil chamber with thehydraulic unit. To do so, carry out a lockingoperation with the locking circuit valve open,when the oil flows clear and without bubblesfrom the bleed valve, close the circuit with thebleed plug.Install the dust ring.

13.Cover the locking ring, bowl andadjusting ring threads with molybdenumdisulphide powder. This process makesfor better bowl rotation. A layer ofmolybdenum bisulphide is alreadyapplied in the factory.

NOTE: WHEN THE EQUIPMENTCRUSHES MATERIALS AT HIGHTEMPERATURES SUCH AS CLINKER,USE A SPECIAL HIGH-TEMPERATUREGREASE MIXED WITH 5 TO 10% OFMOLYBDENUM BISULPHIDE.

14.Install the bowl. The oil chamber mustbe at zero pressure (unlocked) asdescribed in the hydraulics manual.

15.Close the locking circuit valve inside thehydraulic unit and restore the circuit'sservice pressure. Check the circuit forleaks.

10.3.20 Installing the locking ring -HP200, HP300, HP400 and HP500

To install the locking ring on the adjustingring, proceed as follows:

1. Carefully clean the threads the bowl'slocking ring and the adjusting ring. Thebores of the locking cylinders must beclean and free of burrs.

2. Mount the locking cylinders in the boresof the adjusting ring, see Figure 10-26and secure them with the aid of headlessscrews.

Figure 10-26 Installing the locking cylinders

3. Screw the lifting ring to the lockingring, sling and position the locking ringover the adjusting ring. SeeFigure 10-27.

4. Turn the locking ring in such a way thatthe hole traversing it is aligned with theone in the adjusting ring. SeeTable 10-4.

Ref. Description

1 Locking cylinder

2 Locking ring

3 Adjusting ring

4 Headless screw

1

2

3

4



Figure 10-27 Aligning the locating holes

NOTE: IF THE LOCATING HOLE IN THELOCKING RING IS NOT IN LINE WITHTHAT OF THE ADJUSTING RING, THETHREADS OF THE TWO RINGS WILL NOLONGER BE IN PHASE, WHICH WILLIMPEDE OR EVEN PREVENT THE BOWLFROM BEING SCREWED INTO THEADJUSTING RING. IT IS VERYIMPORTANT TO CORRECTLY ALIGNTHESE TWO HOLES.

5. Lower the locking ring onto theadjusting ring. Make sure the lockingcylinders are at zero pressure.

6. Refit the screws and spacer sleevestraversing the locking ring and screwedinto the adjusting ring.

2

4

Ref. Description

1 Locking ring

2 Locating hole in the locking ring

3 Slings

4 Locating hole in the adjusting ring

5 Adjusting ring

6 Bores for locking cylinders

7 Spacer sleeve

8 Bolt

9 Locking cylinder

10 Lifting ring



Screw each screw in the adjusting ring,observing the distance from the bottom of thelocking ring. See Figure 10-28.This distance lets the locking ring movevertically when the locking cylinders arepressurized.

Figure 10-28 Fixing the screws

7. Reconnect the hose to the elbow, on theadjusting ring. This hose connects allthe cylinders to the hydraulic unitthrough a hole in the adjusting ring. SeeFigure 10-29.

After all the cylinders have beenconnected to the hoses, and beforeinstalling the bowl, raise the pressure inthe hydraulic system to its maximum(172 bars, 2500 PSI) for HP200, HP300and 193 Bars (2,800 PSI) for HP400 andHP500. Maintain the pressure for 10minutes to check for any leaks in thecylinders and at the hose couplings.

8. Cover the locking ring, bowl andadjusting ring threads with molybdenumdisulphide powder. This process makesfor better bowl rotation. A layer ofmolybdenum bisulphide is alreadyapplied in the factory.

NOTE: WHEN THE EQUIPMENTCRUSHES MATERIALS AT HIGHTEMPERATURES SUCH AS CLINKER,USE A SPECIAL HIGH-TEMPERATUREGREASE MIXED WITH 5 TO 10% OFMOLYBDENUM BISULPHIDE.

9. Install the bowl. The locking cylindersmust be at zero pressure (unlocked).

Ref. Description

1 Locking ring

2 Bolt

3 10 mm (before locking - HP200/ HP300)

4 Spacer sleeve

5 Adjusting ring

12

3

4

5



Table 10-4 Position and diameter of the locating holes

Figure 10-29 Connecting the hoses of the locking cylinders

Type Position of the locating hole Diameter of the locating holes

HP200 Over the countershaft housing 10 mm (3/8")

HP300 15° to the right of the countershaft housing 12 mm (1/2")



Ref. Description

1 Locking rings

2 Plug

3 90° elbow

4 Hole in the adjusting ring for connection between the cylinders and the hydraulics cabinet

5 Locking cylinder no. 1

6 Hose

7 Adjusting ring

1

2

3

4

5

67



10.3.21 Replacing the frame -HP300, HP400 and HP500

See Figure 10-30.These crushers are equipped with a removablehoop placed in the frame's bore on the pinionside. This ring absorbs the minimal movementbetween the countershaft housing and theframe's bore. Such movements in the frame'sbore could damage it.The ring very rarely needs to be replaced.Given the importance of the adjustmentbetween the ring and the frame's bore, it wouldbe preferable to entrust the dismantling andreassembly of this ring to a workshop havingthe necessary tooling.

1. Remove the countershaft housingassembly.

2. Since the frame ring was fitted withLoctite, it must be heated to roughly205°C (400°F) before it can be lifted.

3. Remove the frame's ring frame from itsbore.

4. Remove all traces of Loctite and cleanthe frame's bore and the outer diameterof the new frame ring with oil-freesolvent then dry.

5. Apply Loctite to the outer diameter ofthe ring and leave to dry for 3 to 5minutes.

6. Cool the ring so that the temperaturedifference at least 10°C (18°F) betweenthe ring and the frame.

7. Apply Loctite 680 to the frame's bore.

8. Fit the ring in the frame. Let the Loctiteharden for 6 hours before installing thecountershaft housing in the frame.

9. Install the countershaft housing asdescribed in the countershaft section.

Figure 10-30 The frame's wearing ring

Ref. Description

1 Frame

2 Hoop

3 Seal


5 Wearing ring

1

2

3

4

5


11.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.2 - Installation, operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11.3 - Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11.4 - Winter mode operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

11.5 - Oil contamination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

11.6 - Crusher breather HP400 and HP500 short head . . . . . . . . . . . . . . . . . 11-5

11.7 - Breather and fan - HP500 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-611.7.1 - Prolonged storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-611.7.2 - Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-711.7.3 - Fitting the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-711.7.4 - Fan layout and fitting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-711.7.5 - Before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-811.7.6 - Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-911.7.7 - Routine servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-911.7.8 - Servicing the bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-911.7.9 - Motor maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1011.7.10 - Servicing the transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1011.7.11 - Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1011.7.12 - Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11

Section 11

LUBRICATION SYSTEM

Lubrication system SECTION 11

11.1 Description

The oil the pump sucks into the oil tank isdischarged towards the filter. A bypassdischarge valve is installed to protect the filterparts from any excess pressure that could buildup if the filters are too dirty or the oil too cold.There is a clogging indicator on top of thefilter. It indicates excessive pressure drop inthe filter. If the indicator is constantly in thered zone, the filter cartridge must be changed.This pressure gauge indicates when the filtercartridges fitted in the filter box needreplacing.

Figure 11-1 Internal oil flow

The oil is cooled by a cooling tower or watercooler. A check valve bypasses the coolerwhen the oil is too cold.A check valve on the crusher prevents pressurebuilding up on the countershaft. It also protectsthe pump and the other parts.The pressurized oil is introduced towards thespherical part, at the main shaft, towards theparts in contact with the eccentric bushing, theeccentric bushings and the head then throughthe sleeve towards the sleeve's contact surface.

The oil spills over the sleeve and the top of thehead and eccentric bushings. It falls throughthe holes of the head and goes down throughwide slits in the imbalance and is thenrecovered in the frame under the eccentric's'gear assembly. The oil also flows under thehead bushing and the eccentric bushing thenthrough wide slits in the imbalance beforebeing recovered in the main frame under theeccentric crown.


SECTION 11 - LUBRICATION SYSTEM

The oil flowing from the bottom of theeccentric bushing traverses the thrust bearingsunder the eccentric before being recovered inthe frame. The oil recovered in the frame flowsand is projected onto the teeth of the crownand pinion. A separate line bypassing the mainshaft's supply line injects the oil in thecountershaft housing rings. All the oil is finallyrecovered in a pan under the pinion and isreturned by gravity to the oil tank.

11.2 Installation, operation andmaintenance

Before trying to install or operate a newcrusher, please read the following instructionscarefully. See the Lubrication Supplement inthe HP manual fro detailed information on therequisite components.

11.3 Oil specifications

Use a paraffin-rich lubricating oil: It musthave: a highly resistant film, high adhesivecapacity for metal surfaces, and stable physicaland chemical properties. It should have the EP(Extreme Pressure) properties of sulphurphosphide agents, lead naphtenate or otheranti-galling agents compatible with the metalsused in the construction of crushers (bronze,antifriction metal, cast iron and steel).Furthermore, the oil should have a highviscosity index, good water separation ability,good antifoaming properties, have goodcorrosion protection, resist oxidation and havewear-resistant agents.

The viscosity of the oil used should be:– 135 to 165 cSt at 40°C,

– 13 cSt or more at 100°C

Moreover, the oil’s viscosity index should be90 or more.Various classification systems are used todescribe viscosity characteristics. Our oilspecifications are as follows:

– ISO Grade 150

– AGMA Grade 4 EP

Consult the factory for specific advise(information and full specifications) whenused in particular conditions, for instancewhen handling burning products or in extremeclimates and weather conditions when theheating or cooling systems are unsuitable.Unsuitable lubricants can damage the crusherand their use will invalidate all warrantiescovering our crushers.All the major oil companies make a productmeeting these specifications. If your localsupplier cannot recommend a product havingthe aforesaid properties, please do not hesitateto consult Metso Minerals.NOTE: Some degree of oil consumption isnormal. If this exceeds 30 cl per hour, seesection 13 "Frequently asked questions".

Table 11-1 Oil flow

TypeOil flow

Litres per minute

HP100 72 / 83

HP200 103 / 114

HP300 121 / 132

HP400 190 - 210

HP500 227 - 246



Figure 11-2 Location of the tank

NOTE: IF A VERTICAL SCAVENGECANNOT BE AVOIDED, A TRAP SHOULDBE FITTED FOR VERTICAL DROPS OFOVER 1220 MM. THE TOP OF THE TRAPSHOULD BE AT LEAST 305 MM UNDERTHE CRUSHER’S SCAVENGE FORPROPER RUN-OFF, BUT AVOID ANADDITIONAL VERTICAL DROP ABOVETHE TRAP.NOTE: THE DUST PENETRATING THECRUSHER’S SEALS CONTAMINATESTHE LUBRICATING OIL, CAUSESEXCESSIVE INTERNAL WEAR ANDCOULD CAUSE THE BUSHINGS TO FAIL.SEE Figure 11-3 FOR INSTALLING THETRAP.

Ref. Description

1 Crusher

2 At least 1.3 m, plus 25 mm for each horizontal distance of 0.3 m

3 Tank



Figure 11-3 Oil scavenge trap (HP500)

11.4 Winter mode operation

This operating mode heats the pipes in periodsof cold weather. This must be fitted from 0°C.This system maintains a temperature ofbetween 20°C and 25°C in the tank, pumpingthe oil intermittently in the pipework when thecrusher is stationary. (See the lubrication unitmanual).

If "Winter" mode cannot be implementedbefore the lubrication pump unit motor isstarted, the pipework and the cooler must beheated to bring the entire to a temperature ofroughly 20°C.

Ref. Description

1 Vent - Place the breather in a relatively clean location where it can easily be serviced.

2 A hose pipe at least 50 mm long (supplied by the customer)

3 Maximum 1220 mm

4 Minimum 305 mm

5 Crusher feed

6 Recovery system

7 Cleaning hole



11.5 Oil contamination

Change the oil as and when necessary. If noabnormal contamination is detected, it isrecommended to renew the lubricant every2000 hours. Metso Minerals recommendsregular analysis of oil samples. This analysisshould at least indicate the amounts of thefollowing chemicals in PPM:Copper (Cu), Aluminium (Al), Iron (Fe), Silica(Si), Chromium (Cr), Lead (Pb).And also the percentage of solid particles, thepercentage of water and the viscosity at 40°C.The sample must be taken on the return line inthe unit.

Lubricant pollution is normal. What isabnormal is an increase in the degree ofpollution between two sample analyses.During the first weeks of operation, rapidcontamination of the oil is possible. This iscaused by the running-in of the mechanicalparts. In due course the degree of pollutionmeasured at regular intervals should stabilize.A rapid rise in the degree of pollution may beindicative of an operating malfunction. Thedistribution of chemical components will helplocate the possible source of wear (ferrous,metallic, non-metallic). Contact MetsoMinerals for further information if the analysisvalues exceed those given in the table below.

1 PPM = 1mg/kg

Table 11-2 Lubricating oil pollution factors

11.6 Crusher breather HP400 andHP500 short head

A breather must be connected to thecountershaft housing next to the bullwheel asspecified in Figure 11-4. This breathermaintains the atmospheric pressure in thecrusher to ensure the oil drains freely. Installthe air inlet far away from the crusherbullwheel, in a dust-free area, the breather andthe bullwheel must be connected to a flexiblepipe. This arrangement is suggested becausethe swirls of dust thrown up by the bullwheelwill clog up the filter and impair its efficiency.

To check whether the crusher's breather isworking properly, remove the filter completelyand place a thin sheet of paper on the elbowonto which the filter was screwed.The paper should be sucked slightly inwards.This means that the crusher is properlyventilated. If the paper is pushed fullyoutwards, this means that there is a ventilationproblem inside the crusher, since the papershould be sucked inwards.

ContaminationChemical component

If the analysis gives results lower than the following values, no further investigation is necessary

Copper (Cu) 210 PPM

Aluminium (Al) 10 PPM

Iron (Fe) 50 PPM

Silica (Si) 65 PPM

Chromium (Cr) 1.5 PPM

Lead (Pb) 190 PPM

Total solid particles 0.2%

Water 1%

Viscosity at 40°C 140 mm²/s



If the breather is not working, one possiblecause is that the pipe inside the crusher isblocked. If that is the case, remove the breatherand its pipes and clean the hole with

compressed air. Usually the countershaft doesnot need to be removed to clean any dust thathas gathered in this pipe.

Figure 11-4 Vent installation

11.7 Breather and fan - HP500Standard

The breather and fan are used to inject air intothe crusher to prevent the oil from beingpolluted by dust. The breather, fan and all theparts required to connect it to the crusher(hoses, clamp connections and packing) areshipped loose. These parts must be connectedto the right of the countershaft housing whenlooking at the crusher bullwheel. SeeFigure 11-5.NOTE: The breather motor should be turnedon at the same time as the pump unit.

11.7.1 Prolonged storage

Machines shipped to the customer and kept instorage for as long as two years need specialstorage conditions to keep them in goodworking order. These devices should bepacked in cases wrapped in polythenesheeting. Moreover, the rotors should beturned by hand once a month.For best results, keep the devices in a cool, dryand sheltered place.

Ref. Description

1 Crusher pulley


3 Hose

4 Vent



11.7.2 Handling

Small devices should be handled with care andlifted only by the base, never by the shaft,backbone or casing. Larger devices should alsobe lifted by the base or by the lifting ringwhere appropriate. Be careful not to drop orshake the equipment because this could causedamage to the shaft or bullwheel invisible tothe naked eye but liable to lead to vibrationproblems.

11.7.3 Fitting the fan

The fan should be placed no more than 3.6 mfrom the crusher. The breather can be fitteddirectly on the fan, as Figure 11-5 shows, in adust-free area. If the fan is fitted in a dustyarea, the breather should be installed in arelatively dust-free environment where it iseasy to service. The breather and fan must beconnected with a wide diameter hose pipe(100-150 mm).The fans and motors must be mounted onstructurally sound foundations, like concretefor instance. The equipment should be set leveland wedged on the foundations or bonded onthe spot. This prevents the mechanism fromseizing up by fixing it on an even surface. As ageneral rule, if vibration absorbers are used,fans should first be fixed to a steel base plate;the vibrations are then absorbed between thesteel base plate and the foundations, therebymaking it more stable.

11.7.4 Fan layout and fittingprocedure

1. Assemble the motor, the coupling andthe fan before fixing the latter.

2. When the fan is in its final location, thewarping of the support plate must becompensated with wedges the thicknessof which must be measured with the aidof gauges. Incorrect wedging can causeseizing up or bending of the shaft orcoupling, incorrect alignment of themotor and/or bearings generating highlevels of vibration and premature failureof the transmission parts.

3. After wedging, each fixing bolt must begradually tightened with a torquewrench until the torque value matchingthe dimension of the bolt used for thefoundations is reached.

4. When the device is completely fixed tothe foundations, check the alignment ofthe coupling again. If this is out of line,loosen the foundation bolts and checkthe alignment again.

5. When the device is secured to thefoundations and the coupling is aligned,replace the liners and check thepipework, etc. The device is now readyfor operation.

6. Make sure the device rotates in the rightdirection. In that case, increase thespeed and check motor intensity toascertain that the static pressure of thesystem is sufficient to bother overloadof the motor.

7. Check for vibrations. If they exceed 1.0MIL at 3600 rpm or 1.5 MILS at 1800rpm, an engineer specialized inbalancing should adjust the device toattain these levels.



Figure 11-5 Vent and fan

11.7.5 Before start-up

1. Fastenings - all the fixing bolts, the hubmounting screw, the bullwheel lockingbolts and the bearing locking rings mustbe tightened.

2. Bearings - Make sure they are welllubricated.

3. Pull the fan turbine by hand to seewhether it works unimpeded, does notseize up or knock against the fanhousing. Otherwise, you may need tomove it on the shaft or readjust thebearings if they move.

4. Motor - check the electric circuit of themotor. The power line’s normalcharacteristics should match those onthe motor’s nameplate. The motorshould be wired and fitted with fuses incompliance with the national electricalCode and local codes.

5. The V-type belt transmission should belined up with the belts with the righttension.

6. The couplings between the fan andcountershaft should not be distorted.The ducts should never rest on the fan.The expansion joints between the ductcouplings should only be used shouldthe need arise (vibrations, expansion).All duct joints should be airtight toprevent air leakage. All debris should beremoved from ducts and the fan.

Ref. Description

1 Vent

2 Fan


4 Crusher pulley



11.7.6 Start-up

1. Run the motor for a short time to checkthat the turbine is rotating in the rightdirection. The motor should be startedaccording to the manufacturer’sinstructions. There are arrows on the fanindicating the correct direction ofrotation and airflow.

2. Fan speed can now be increased. Watchout for anything unusual like vibrations,overheating bearings and motor etc.Check fan speed on devices equippedwith a V-type belt transmission andadjust the drive bullwheel (on adjustabletransmissions) to achieve the desiredrotation speed.

3. Check the current absorbed by the motorin relation to the ampere rating to besure that the motor is not overloaded.

11.7.7 Routine servicing

1. An inspection schedule should be drawnup for all parts and pivoting accessories.Inspection frequency depends on thedegree of risk of the operation and thelocation. Inspections can be weekly inthe initial stages until the schedule isinstituted.

2. Alignment- Misalignment can causeoverheating, wear out the dust-proofseals, cause the bearings to fail or causean imbalance.

3. Equipment - check that all bolts andadjusting screws are tight.

4. Airflow - make sure that no obstaclesblock ingress or egress of air in theducts.

5. On high-speed fans, the bearings tend toheat up. Consequently, there is no pointreplacing a bearing because it is hot tothe touch. Place a contact thermometeragainst the bearing and check thetemperature.

6. Turbine - check for accumulated dustand dirt on the turbine's vanes. Cleancarefully with a jet of water, compressedair or a metal brush. This helps toprevent imbalance. If the blades arealuminium, make sure not to damagethem. Cover the bearings so that watercannot enter the bearing. The turbineshould be centred to prevent the bladesfrom striking the device's housing. Makesure the turbine rotates in the rightdirection. Never run a fan faster than itsrated speed without first checking withthe factory.

11.7.8 Servicing the bearings

In most applications lithium grease should beused. This type of grease retards corrosion, iswater-resistant and supports temperature ofbetween -34°C (-30°F) and 93°C (200°F) withintermittent peaks of up to 121°C (250°F).When greasing the bearings, it is important notto apply too much grease. This is particularlytrue if the bearings have longer lubricationchannels and if the bearings are not visible. Inthat case, more bearing failures are due toexcessive lubrication rather than to a lack ofgrease. It is preferable to apply only a squirt ofgrease regularly when they are not visible.When the bearings are visible, pump the greaseuntil a small band of grease forms around thebearing joints. It is very important to grease thefan bearings while it is running.

DANGERbe extremely careful when workingon or near rotating equipment toavoid injury.



11.7.9 Motor maintenance

Lubricate the motor’s bearings according tothe manufacturer’s instructions. Refer to thelubricating instructions on labels on the motor.If there is no label, follow theserecommendations:

– Motors fitted with threaded plugs orgrease connections should belubricated when hot and stationary.

– On each cover replace a threaded plugwith a grease connection.

– Remove the other plug for the greaseoverflow.

– At low pressure, lubricate, run andlubricate again until the grease againreaches the overspill.

– Leave the motor running for tenminutes to remove excess grease.

– Replace the threaded plugs.

Motors not fitted with threaded plugs or greaseconnections may be lubricated by removingthe flanges, cleaning the grease chamber andfilling the circumference of the chamber tothree quarters full. See Table 11-3 forrecommended lubricating intervals.

11.7.10 Servicing the transmission

If the belts slip on start-up, they are too slackand must be tensioned. Check regularly forwear, alignment and belt and bullwheeltension. When the belts show signs of wear,replace all the belts at the same time with newones. The new belts do not work properly withused belts due to the length difference. Thebelts and bullwheels must be clean and free ofgrease. After fitting the new belts, check thetension half way between the bullwheels.Leave the device running for 4 to 6 hours, thenyou will need to re-tension the belts becausenew belts tend to stretch in the first hours ofoperation.

Table 11-3 Recommended lubricating intervals

11.7.11 Trouble-shooting

Here follows a list of the most commonproblems encountered on fans. These pointsshould be checked to avoid unnecessary delaysand the cost of factory repairs.

1. Weak or inefficient backflow:

a. Total system resistance greater thanexpected.

b. Too slow.

c. Poor fan suction or exhaust.

d. Air leaks in the system.

e. Damaged turbine.

f. Wrong direction of rotation.

g. Turbine mounted at the rear of theshaft.

HP range Standard operation8 hours a day

Intensive operation24 hours a day

Dirty/dusty

Very intensive operationVery dirty

Extreme temperatures

1.5 - 7.5 5 years 3 years 9 months

10-40 3 years 1 year 4 months

50-150 1 year 9 months 4 months



2. Problems of vibration and noise:

a. Bearings, couplings or turbine orV-type belt transmission misaligned.

b. Unstable foundations. The fan isfixed on uneven foundations, notwedged or bonded.

c. Presence of foreign matter in the fan,causing an imbalance.

d. Worn bearings.

e. Damaged turbine or motor.

f. Adjusting bolts and screws broken orloose.

g. Bent shaft.

h. Worn coupling.

i. Imbalance in the turbine or fan drivemotor.

j. Too fast or incorrect direction ofrotation.

k. Vibration problems.

3. Overheated bearings:

a. Too much lubricant.

b. Misaligned.

c. Damaged turbine.

d. Bent shaft.

e. Dirty bearings.

f. Belts too tight.

11.7.12 Breather

The breather, which is connected to the fan,has a replaceable filter cartdridge. It isimportant to replace this cartridge when it isdirty, to prevent the overheating or prematurewear of the bearings.


HYDRAULIC SYSTEM

Section 12

12.1 - Hydraulic system HP100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-112.1.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-112.1.2 - Using the hydraulic unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-112.1.3 - Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-112.1.4 - Locking oil chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-212.1.5 - Holding cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-212.1.6 - Hydraulic adjustments assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

12.1.6.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-312.1.6.2 - Hydraulic adjustments assembly. . . . . . . . . . . . . . . . . . . . . . . . . 12-8

12.1.7 - Connecting the hydraulic hoses to the crusher . . . . . . . . . . . . . . . . . . . . 12-812.1.8 - Checking accumulator preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1012.1.9 - Purging and testing the pressure of the hydraulic system . . . . . . . . . . 12-11

12.1.9.1 - Starting up the hydraulic unit. . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1112.1.9.2 - Locking circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1112.1.9.3 - Unramming circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1212.1.9.4 - Holding circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12

12.1.10 - Pressurizing the holding circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1212.1.11 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

12.1.11.1 - Depressurizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1312.1.11.2 - Replacing a holding cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

12.1.12 - Replacing an accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1512.1.13 - Replacing the oil chamber (HP 100) . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15

12.2 - Hydraulic system HP200, HP300, HP400 and HP500 . . . . . . . . . . . . 12-1512.2.1 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15

12.2.1.1 - Using the hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1612.2.1.2 - Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1612.2.1.3 - Locking cylinders assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1612.2.1.4 - Hydraulic adjustments assembly. . . . . . . . . . . . . . . . . . . . . . . . 12-18

12.2.1.4.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1812.2.1.4.2 - Assembly with a welded gear motor bracket . . . . . . . . 12-1812.2.1.4.3 - Assembly with a bolted gear motor bracket . . . . . . . . . 12-2112.2.1.4.4 - Hydraulic adjustments assembly . . . . . . . . . . . . . . . . . 12-26

12.2.1.5 - Connecting the hydraulic hoses to the crusher . . . . . . . . . . . . . 12-2612.2.1.6 - Checking accumulator preload . . . . . . . . . . . . . . . . . . . . . . . . . 12-2712.2.1.7 - Purging and testing the pressure of the hydraulic system. . . . . 12-28

12.2.1.7.1 - Locking circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2912.2.1.7.2 - Unramming circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2912.2.1.7.3 - Holding circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2912.2.1.7.4 - Braking circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30

12.2.1.8 - Pressurizing the holding circuit . . . . . . . . . . . . . . . . . . . . . . . . . 12-3012.2.2 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30

12.2.2.1 - Depressurizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3012.2.2.2 - Replacing a holding cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3012.2.2.3 - Replacing an accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3312.2.2.4 - Repairing a locking cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-35

Hydraulic system SECTION 12

12.1 Hydraulic system HP100

12.1.1 Description

Hydraulic holding cylinders pinned to theframe and traversing the adjusting ring keepthe latter pressed firmly against the conicalpart of the frame. Abnormal operatingconditions or tramp iron in the crusher canstrain the bowl and the adjusting ring and liftthem by pulling on the cylinder's rods. Thismovement pushes the oil in the cylinders intothe accumulators, where the pressure of thenitrogen increases. When the excess load haspassed, the compressed nitrogen returns the oilto the cylinders, the cylinder rods retract andthe adjusting ring returns to rest on the frame.The lower chambers of each cylinder(unramming or clearing circuit) areinterconnected.The two circuits are fed by the hydraulic unitvia two hoses.In addition to the hydraulic support andunramming functions, the crusher features alocking and adjusting device. The locking ringis on the adjusting ring. An oil chamberlocated between these two rings provides theholding force. The locking ring holds the bowlin place in the adjusting ring when the oilchamber is pressurized. When the pressure inthe oil chamber drops, the pinion of the gearmotor can be turned. The pinion drives thetoothed crown; the latter with its slides pushesthe adjustment cap and rotates the bowlassembly. The gap between the bowl liner andmantle (adjustments) widens or narrowsaccording to the direction of rotation.The HP100 crusher is equipped with ahydraulic cabinet performing support, clearing,locking and adjusting functions.

12.1.2 Using the hydraulic unit

The hydraulic unit should always be poweredup when the crusher is running to ensureadequate locking and holding pressure. It isalso on for adjusting and clearing operations.Refer to the hydraulics manual,INSTRUCTIONS FOR USING THECRUSHER'S ADJUSTING, UNRAMMINGFUNCTIONS AND DISMANTLING ANDINSTALLING THE BOWL.

12.1.3 Oil specifications

For the hydraulics, use a paraffin-rich oil(without naphthalene) having a protective film,strong adhesiveness to metallic surfaces, andstable physical and chemical properties. Eachlubricant should have a high viscosity level,have rapid water separation properties againstrust and corrosion, resist emulsion andoxidation and have good wear resistanceproperties.Recommended oil (ISO 3448) ISO VG32.Its viscosity should be:

– 28.8 to 35.2 cSt at 40°C kinematicviscosity

– 4.9 cSt or more at 100°C

In addition, its viscosity index should be atleast 95.Appropriate lubricants are essential toprotecting the parts of your crusher. They areavailable from most major oil companies.Using the wrong oil can damage the crusherand invalidate its terms of warranty.NOTE: DO NOT USE NON-FLAMMABLEHYDRAULIC FLUIDS BECAUSE THEHYDRAULIC CIRCUIT HAVE NOT BEENDESIGNED FOR SUCH FLUIDS.NOTE: NON-FLAMMABLE HYDRAULICFLUIDS MAY NOT BE COMPATIBLEWITH THE LININGS, SEALS,ACCUMULATOR COMPONENTS, HOSESAND OTHER PARTS OF THE HYDRAULICSYSTEM. THE USEFUL LIFE OF THEPUMP COULD BE SHORTENED AND THEPAINT INSIDE THE TANK COULDSOFTEN AND DISAPPEAR.NOTE: WHEN FILLING THE CRUSHER’SHYDRAULIC CIRCUITS, MAKE SUREYOU DO NOT OPERATE THE PUMPWITHOUT OIL. WHEN THEHYDRAULICS ARE FULL OF OIL ANDTHE HOLDING SYSTEM ISPRESSURIZED, KEEP THE OIL LEVEL ATTHE MIDDLE OF THE OIL GAUGE.Approximately 100 litres are needed to fill thetank of the hydraulic system, the holdingcylinders, accumulators, locking cylinders andhydraulic hoses.

TECHNICAL INSTRUCTIONS CRUSHERS A CONE HP100/200/300/400/500 12-1

SECTION 12 - HYDRAULIC SYSTEM

12.1.4 Locking oil chamber

To install the oil chamber, refer to paragraph10.3.19 "Installing the locking ring - HP100"in section 10 "Frame, adjusting ring andretaining cylinder assemblies" andFigure 12-1.

12.1.5 Holding cylinder assembly

To install the holding cylinders, refer toparagraph 10.3.20 "Installing the locking ring -HP100" in section 10 "Frame, adjusting ringand retaining cylinder assemblies" andFigure 10-19.

Figure 12-1 Connecting the oil chamber hoses

Ref. Description

1 Adjusting ring

2 Oil chamber

3 Locking ring

4 Hose

5 Tube

6 Connection of the oil chamber to the hydraulics cabinet

1

32

6

5

4

TECHNICAL INSTRUCTIONS NORDBERG CONE CRUSHERS HP100/200/300/400/500 12-2


12.1.6 Hydraulic adjustmentsassembly

See Figure 12-2.

12.1.6.1 GeneralThe hydraulic adjustments system (whichrotates the bowl) is always delivered alreadymounted on the adjusting ring. However, inrare cases (delivery, etc.) the adjustingassembly may be dismantled.

Figure 12-2 Hydraulic adjusting mechanism

Ref. Description

1 Toothed crown

2 Adjustment cap

3 Adjusting ring


5 Pinion

4

5

3

1

2

12-3 TECHNICAL INSTRUCTIONS NORDBERG CONE CRUSHERS HP100/200/300/400/500


If the assembly is dismantled, proceed asfollows:

1. Position the motor mounting bracketover the pins on the adjusting ring asshown in Figure 12-3. Screw the bracketonto the adjusting ring.

2. Install the gear motor under the bearingplate as shown in Figure 12-3. Itsposition is important, the gear motor'slubrication taps must be in line with thehole of the plate and the feedconnections towards the exterior toassemble the hoses on the hydraulicmotor.

Then place the bearing plate assembledwith the gear motor on the top of themotor mounting bracket. Fit the holdingscrews and flat washers. DO NOTTIGHTEN.

3. If the pre-assembly of the gear motor onthe bearing plate does not allow you tomount it above the motor mountingbracket, first mount the bearing platealone on the top of the motor mountingbracket. Fit the holding screws and flatwashers. DO NOT TIGHTEN.

Then install the gear motor under thebearing plate as shown in Figure 12-3.Its position is important. The gearmotor's lubrication taps must be in linewith the hole of the plate and the feedconnections towards the exterior toassemble the hoses on the hydraulicmotor.

4. Mount the pinion on the shaft of the gearmotor and fix the washer with the screw.

5. Assemble the roller on its support, thisis welded to the outer diameter of theadjusting ring.

6. Place the toothed crown in such a waythat it rests on the top of the roller.

7. Fix the slides on the top of the toothedcrown as shown in Figure 12-3, usingthe screws and washers.

8. Centre the toothed crown on theadjustment cap.

9. Use the horizontal adjusting screw onthe bearing plate to position the pinionso that the teeth of the crown arethree-quarters engaged in the teeth ofthe pinion. Then tighten the lockingbolts.



Figure 12-3 Assembling the hydraulic adjusting mechanism on the adjusting ring

1

2

3

13

5

6

3

7

8

9

10

11

12

19

18

17

16

15

14 4

Ref. Description

1 Guard plate

2 Locking bolt

3 Washer

4 Bearing plate

5 Pin

6 Bolt

7 Slide

8 Toothed crown

9 Self-locking nut and washer

10 Roller support

11 Adjusting ring

12 Roller

13 Motor mounting bracket

14 Adjusting screw

15 Locking nut

16 Washer and 3 screws

17 Pinion

18 Hydraulic motor

19 Reduction gear

20 Lubrication tap

Ref. Description



Figure 12-4 Hydraulic hose connections HP100

213

4

56789

Ref. Description

1 Holding cylinders

2 Adjusting ring

3 Hydraulic adjustments assembly

4 Accumulator

5 Unramming circuit

6 Holding circuit

7 Loosening circuit

8 Tightening circuit

9 Locking circuit



Figure 12-5 Taps and connections on the gear motor

Ref. Description

1 Breather tap

2 Levelling tap

3 Tightening and loosening connection

1

2

3

2

1

3



10.Connect the unit's hydraulic hoses to thehydraulic adjustments system on thecrusher. See paragraph 12.1.7"Connecting the hydraulic hoses to thecrusher".

11.The gear motor is filled with oil when itleaves the factory. Check the oil levelbefore start-up and every 1000 hours ofcrusher operation. To do so, proceed asfollows:

a. With the gear motor in a verticalposition, remove the levelling tapplug in the middle of the gear motor.The oil level should be visible in thelevelling tap.

Table 12-1 Oil specification for the hydraulic adjusting system

b. If necessary, fill as specified inTable 12-1. Filling takes place via thebreather tap on the upper part of thegear motor.

12.Turn the hydraulic adjustments system360° to ascertain that the teeth of thepinion and the toothed crown engageproperly. Adjust play with the bearingplate adjusting screw.

When the control is positioned correctly,tighten the locking bolt.

13.Fit the protective hood on the bearingplate to prevent materials jamming theteeth of the crown and pinion.

12.1.6.2 Hydraulic adjustmentsassemblyHydraulic motor maintenance should seldombe necessary. Given the complexity of theinternal components, only the supplier of theequipment is fully equipped to dismantle andreplace parts and reassemble the assembly.

12.1.7 Connecting the hydraulichoses to the crusher

See Figure 12-4.When the hydraulic unit has been installed andthe hydraulic adjusting mechanism mountedon the ring, connect the hoses linking the unitto the hydraulic motor to the oil chamber andholding cylinders, make the connections to thecrusher as follows.The five hoses linking the unit to the crusherare the same.All orifices and hoses are clearly indicated, tofacilitate connection of the hoses between theunit, crusher and hydraulic motor, the numbers(1, 2, 3, 4 et 5) are marked on the various inletsand outlets.NOTE: This connection is not valid for theHP200, HP300, HP400 and HP500.

1. Connect the loosening hose to theconnection on the right of the hydraulicmotor.

NOTE: IT IS VERY IMPORTANT THATTHE HOSES AND CONNECTION REMAINCLEAN THROUGHOUT THE ASSEMBLYPROCEDURE.

2. Connect the tightening hose on theconnection on the left of the hydraulicmotor.

3. CHECK THE MOTOR AND BRAKEHYDRAULIC CONNECTION.

4. Connect the locking circuit hose to theconnection on the side of the adjustingring.

5. Connect the unramming hose to the Tconnection on the unramming circuit,located on the crusher and connectingall the lower chambers of the protectivecylinders. See Figure 12-6.

6. Connect the holding circuit hose to the Tconnection on the holding circuit,located on the crusher and linking all theupper chambers of the protectivecylinders. See Figure 12-6.

Reduction gear

Type of oilISO-L-CKC-150 (ISO 12925-1

standard)

Quantity 2.7 litres in the vertical position



Figure 12-6 Connecting the holding and unramming cylinders

1

2

3 4 5

Ref. Description

1 Holding circuit

2 Unramming circuit

3 Distributor

4 Holding cylinder

5 Accumulator



12.1.8 Checking accumulatorpreload

(Holding circuit)After prolonged use or after dismantling theprotective mechanism, the preload pressure inthe accumulators must be checked. Theaccumulators are preloaded with nitrogen andbefore carrying out any checks, the pressure inthe holding circuit must be zero; to achievethis, open the corresponding valve in thehydraulic unit. When carrying out a check,make sure the accumulators are not in directsunlight and the outdoor temperature isroughly 20°C. To connect the checking deviceand check the preload pressure of theaccumulators, proceed as follows:

1. The holding circuit and theaccumulators must be empty of oil, seethe hydraulics manual.

2. See Figure 12-7, remove the valveguard on top of the accumulator and theplug on the valve stem. Remove thewasher that was under the plug.

Figure 12-7 Accumulator valve

3. Use the inflation checking equipment(optional extra).

The inflation checking equipment isrequired to connect an accumulator to anitrogen cylinder to increase the preloadin the accumulator. The inflationchecking equipment comprises a3-metre hose equipped with a rotatingcoupling at one end and a gland bolt nut(left-hand thread) at the other end a unitequipped with a purge screw and acharging valve and a pressure gauge.

The checking equipment checksaccumulator preload. It is used to inflateor deflate the accumulator.

4. Fully remove the upper knurled knob ofthe inflation checking equipment, makesure the purge screw is closed.

5. Screw the inflation checking equipmentonto the accumulator with the lowerknurled knob of the inflation checkingequipment.

6. Connect the inflation checkingequipment to the nitrogen cylinderinflator with the hose.

The relief valve should limit pressure tothe maximum value equal to themaximum pressure of the accumulator(this value is cold-stamped on theaccumulator).

7. Screw in the upper knurled knob, thepressure value appears on the pressuregauge.

8. If the pressure is higher than therequired pressure, slowly unscrew thepurge screw until the requisite pressureof 83 bars is attained.

9. If the pressure is lower than the requiredpressure, slowly open the nitrogencylinder valve until the requisitepressure is attained.

10.Close and disconnect the nitrogencylinder.

Ref. Description

1 Valve system

2 Accumulator

3 Valve plug

4 Valve guard

5 Washer

1

5

4 3

2

CAUTION

The coupling of the nitrogencylinder (delivered as an optionalextra) varies according to country.



11.Unscrew the upper knurled knob on theinflation checking equipment andunscrew the purge screw.

12.Dismantle the inflation checkingequipment from the accumulator.

13.Check the valve's airtightness withsoapy water; if the valve leaks, repeatthe pressure-checking operation. If thevalve still leaks, change it.

14.Put the valve plug back on.

15.perform the same operation on the otheraccumulators.

16.Close the hydraulic unit valve.

17.Pressurize the holding circuit.

12.1.9 Purging and testing thepressure of the hydraulic system

After making the initial connection, orwhenever any circuit has been opened toreplace or repair a component, you must purgeit to remove the air in the circuit. You do notneed to remove all the air because a smallpocket of air will not impair the working of thecrusher if it is started up for the first time, eachcircuit must be purged before beingpressurized.NOTE: WHILE FILLING AND PURGINGTHE HYDRAULIC CIRCUITS, CHECKTHE LEVEL IN THE TANK FREQUENTLYAND TOP UP IF NECESSARY.

12.1.9.1 Starting up the hydraulic unitBefore purging the system or any of thecircuits, oil needs to be circulated in all thecircuits of the hydraulic unit. Starting up theunit for purging or pressure testing purposes,see the hydraulics manual.

NOTE: DO NOT PUMP THE OIL IN THEHOLDING CIRCUIT BEFOREPRELOADING THE ACCUMULATORSWITH NITROGEN. THIS COULDDAMAGE THE BLADDER AND THEACCUMULATOR WOULD NEED TO BEREPLACED.

12.1.9.2 Locking circuitTo purge and test the locking circuit, proceedas follows:

1. Start up the hydraulic unit, see thehydraulics manual.

2. lower the locking pressure, see thehydraulics manual.

3. Unscrew the plug of the oil chambervalve that is not being used. When theoil is clear and therefore free of air, plugthe valve and tighten the connection.

4. Raise the locking pressure, see thehydraulics manual.

DANGER

NEVER INFLATEACCUMULATORS WITH ANYGAS OTHER THAN NITROGEN,EVEN PARTIALLY.

ANOTHER GAS COULD CAUSETHE CIRCUIT TO EXPLODE.

DO NOT USE OXYGEN.

DANGER

ON NO ACCOUNT SHOULDYOU PURGE A CIRCUIT WHENIT IS PRESSURIZED.

A CONNECTION THATBREAKS OR PRESSURIZED OILESCAPING COULD CAUSEBODILY INJURY.

WEAR SUITABLE SAFETYGLASSES WHEN PURGINGCIRCUITS.

12-11TECHNICAL INSTRUCTIONS NORDBERG CONE CRUSHERS HP100/200/300/400/500


12.1.9.3 Unramming circuitThe six cylinders are connected by pipeworkall around the frame.The cylinder chambers (unramming side) willbe purged independently.On each cylinder, proceed as follows:

1. Start up the hydraulic unit (see thehydraulics manual).

2. The pressure should be 14 bars. (See thehydraulics manual)

3. Loosen the unramming hose couplingsconnected to the bottom of the holdingcylinder by roughly 1 and a half turns.When the oil flows clear, without anybubbles or spluttering, tighten thecouplings again. Do likewise for theother cylinders.

4. Lock the cylinders at the end of theupper stroke by lifting the ring to itsmaximum, activate unramming andcheck the seals of the couplings. Tightenthem if necessary.

5. Lower the adjusting ring onto the frame.

12.1.9.4 Holding circuitThis circuit comprises six cylinders andaccumulators connected by pipeworksurrounding the frame hoop.The cylinders and accumulators of each groupwill be purged simultaneously, as follows:


2. Bring the pressure in the holding circuitto 14 Bars, see the hydraulics manual.

3. Loosen the purge screw at the bottom ofthe accumulator until the oil escapes.Tighten the screw again as soon as theoil flows without bubbles.

On each cylinder, loosen the couplingsto let the oil flow. When the oil flowsclear and free of bubbles, tighten thecouplings.

4. Do likewise for the other cylinders andaccumulators.

5. Pressurize the holding circuit asexplained later in the paragraphPRESSURIZING THE HOLDINGCIRCUIT. Check all couplings for leaks,tighten if need be.

6. Run two complete pressurizing anddepressurizing cycles alternately on theholding circuit, to expel any air stilltrapped in it and return it to the tank.

12.1.10 Pressurizing the holdingcircuit

After having made all the connections, purgedthe circuits and fixed any leaks, pressurize theholding circuit before starting up the crusher.Maintain the holding circuit at therecommended pressure to ensure adequateprotection in case of overload. The holdingpressure should be maintained between theminimum and the maximum specified in thehydraulics manual table.If the pressure exceeds the recommendedpressure, relieve the pressure as described inparagraph 12.1.11.1 "Depressurizing" in theMaintenance part of this chapter. If thepressure is too low, proceed as follows:

DANGER

WHILE THE ADJUSTING RINGIS IN ITS UPPERMOSTPOSITION, THE AREAAROUND THE RING SHOULDBE CLEAR, TO AVERT ANYACCIDENTS CAUSED BY THERING ACCIDENTALLYDESCENDING. PUT SAFETYWEDGES IN PLACE. KEEP THEUNRAMMING BUTTONDEPRESSED TO CHECK FORAND REPAIR ANY LEAKS.

THE RING WILL DESCEND IFTHE UNRAMMING BUTTON ISRELEASED.



1. Check that the oil used is therecommended one.


2. Check the preload pressure of theaccumulators and adjust if necessary.See the instructions in paragraph 12.1.8"Checking accumulator preload".

3. Pressurize the holding circuit. (see thehydraulics manual)

The crusher cannot function with too low aholding pressure, otherwise the ring couldbounce and damage the frame span. To restorecorrect pressure, see the hydraulics manual.

12.1.11 Maintenance

12.1.11.1 DepressurizingBefore carrying out any maintenance work ona hydraulic device, the relevant oil circuitsmust be depressurized, this is extremelyimportant for the personnel carrying outrepairs. Several circuits are usuallydepressurized while the crusher is running andare only pressurized for specific operations. Asa general rule, check the pressure gaugesbefore doing any maintenance. The holdingcircuit however remains pressurized thanks tothe accumulators, even after a prolongedstoppage of the pump. proceed as instructed inthe hydraulics manual.

12.1.11.2 Replacing a holding cylinder(See Figure 12-8).See section 10 "Frame, adjusting ring andretaining cylinder assemblies" for the methodto follow for dismantling and installing aholding cylinder. See paragraph 10.3.13"Dismantling the protective cylinders -HP100".The parts of the cylinder that can be replacedinclude:

– Wiper seal

– Blower

– Rod seals

– Piston seals

– Anti-extrusion ring

We recommend changing the O-ring sealswhenever components are dismantled There isa leak if oil oozes between the cylinder's pistonrod and nose or if holding pressure cannot bemaintained. When a cylinder leaks, it must bereplaced straight away.A leaking cylinder is harmful because it causesthe adjusting ring to bounce.If the cylinder needs to be repaired, werecommend changing all the seals at the sametime. These seals are available in a kit.Be sure to have the necessary quantities orparts to be able to repair the damagedcylinders. During repairs, it is very importantthat the working surface be clean and free ofdust. To dismantle, check, reassemble or repaira holding cylinder, proceed as follows:

1. Unscrew the 7 hexagonal socket headcap screws retaining the head of thecylinder on the body. (HP100) Orunscrew the head.

2. Gently pull the piston to take the piston,rod and head assembly completely outof the cylinder.

3. To dismantle the piston and rod,unscrew the piston and pull the rodthrough the bore of the cylinder head.

4. Remove all the seals (wiper seal, pistonand rod seals, O-ring seal andanti-extrusion rings) from the head andpiston.



Figure 12-8 Holding cylinder (HP100)

5. Clean the rod, piston, cylinder head andcylinder. All the cylinder's surfaces andparts in contact with the cylinder mustbe thoroughly cleaned and free of dust.If the cylinder is pitted with rust or ifburrs appear, replace the cylinder.

6. Use the cylinder plan to fit the seals onthe head and piston. Then slide the rodthrough the head, turning slowly (thehead is fixed).

7. Lightly oil the surfaces of the cylinderrod, piston, head, seals and bore. Gentlyinsert the assembled piston, rod andhead in the cylinder, while turning therod and the piston (fixed cylinder)

8. Lower the head onto the cylinder andlock the 7 hexagonal socket head capscrews.

9. The holding cylinder is ready to bereassembled on the crusher.

Ref. Description

1 Piston

2 Set of seals

3 Cylinder head

4 Wiper seal

5 Cylinder rod

6 Cylinder head retaining screw

7 O-ring seal

8 Retaining ring

9 Cylinder assembly

126

3

4

5 7 8 9



12.1.12 Replacing an accumulator

See Figure 12-9.See section 10 "Frame, adjusting ring andretaining cylinder assemblies" for moreinformation on dismantling and reassemblingan accumulator. If it was necessary todismantle the accumulator to change thebladder or to inspect other parts, contact thefactory for instructions on reassembling theaccumulator.

Figure 12-9 Accumulator assembly

12.1.13 Replacing the oil chamber(HP 100)

See section 10 "Frame, adjusting ring andretaining cylinder assemblies" for informationon dismantling and fitting the oil chamber. Seeparagraph 10.3.19 "Installing the locking ring -HP100".There is a leak if oil oozes under the protectiveapron or if locking pressure cannot bemaintained. When the oil chamber leaks, itmust be replaced immediately.A leak in the oil chamber is harmful because itwill destroy the threads of the bowl and theadjusting ring.

12.2 Hydraulic system HP200,HP300, HP400 and HP500

12.2.1 Description

Hydraulic holding cylinders pinned to theframe and traversing the adjusting ring keepthe latter pressed firmly against the conicalpart of the frame. Abnormal operatingconditions or tramp iron in the crusher canstrain the bowl and the adjusting ring and liftthem by pulling on the cylinder's rods. Thismovement pushes the oil in the cylinders intothe accumulators, where the pressure of thenitrogen increases. When the excess load haspassed, the compressed nitrogen returns the oilto the cylinders, the cylinder rods retract andthe adjusting ring returns to rest on the frame.The lower chambers of each cylinder(unramming or clearing circuit) areinterconnected.The two circuits are fed by the hydraulic unitvia two hoses.In addition to the hydraulic support andunramming functions, the crusher features alocking and adjusting device. The locking ringis on the adjusting ring. A series of cylinderslocated between the two rings performs thelocking function. The locking ring holds thebowl in position in the adjusting ring.

Ref. Description

1 Valve guard

2 Nitrogen filling valve

3 Bladder and valve assembly

4 Valve

5 Rubber-coated ring

6 Spacer

7 Locking nut

8 Purge screw

9 Piston

10 Anti-extrusion ring

11 O-ring seal

12 Washer

1 2

3

4

5

6

7

87

9

10

11

12

13

14

15

13 Spring

14 Body

15 Valve nut

Ref. Description



When the pressure in the locking cylindersdrops, the pinion of the gear motor can beturned. The pinion drives the toothed crown;the latter with its slides pushes the adjustmentcap and rotates the bowl assembly. The gapbetween the bowl liner and mantle(adjustments) widens or narrows according tothe direction of rotation.All HP crushers are equipped with a hydraulicunit performing holding, unramming, lockingand adjusting functions.

12.2.1.1 Using the hydraulic unitThe hydraulic unit should always be poweredup when the crusher is running to ensureadequate locking and holding pressure. It isalso on for adjustment and clearing operations.Refer to the hydraulics manual,INSTRUCTIONS FOR USING THECRUSHER'S ADJUSTING, UNRAMMINGFUNCTIONS AND DISMANTLING ANDINSTALLING THE BOWL.

12.2.1.2 Oil specificationsFor the hydraulics, use a paraffin-rich oil(without naphthalene) having a protective film,strong adhesiveness to metallic surfaces, andstable physical and chemical properties. Eachlubricant should have a high viscosity level,have rapid water separation properties, protectagainst rust and corrosion, resist emulsion andoxidation and have good wear resistanceproperties.RECOMMENDED OIL ISO-L-HM32 (ISO11158 standard).Its viscosity should be:

– 28.8 to 35.2 cSt at 40°C kinematicviscosity

– 4.9 cSt or more at 100°C

In addition, its viscosity index should be atleast 95.Appropriate lubricants are essential toprotecting the parts of your crusher. They areavailable from most major oil companies.Using the wrong oil can damage the crusherand invalidate its terms of warranty.NOTE: DO NOT USE NON-FLAMMABLEHYDRAULIC FLUIDS BECAUSE THEHYDRAULIC CIRCUITS HAVE NOT BEENDESIGNED FOR SUCH FLUIDS.

NOTE: NON-FLAMMABLE HYDRAULICFLUIDS MAY NOT BE COMPATIBLEWITH THE LININGS, SEALS,ACCUMULATOR COMPONENTS, HOSESAND OTHER PARTS OF THE HYDRAULICSYSTEM. THE USEFUL LIFE OF THEPUMP COULD BE SHORTENED AND THEPAINT INSIDE THE TANK COULDSOFTEN AND DISAPPEAR.NOTE: WHEN FILLING THE HYDRAULICCIRCUITS, MAKE SURE YOU DO NOTOPERATE THE PUMP WITHOUT OIL.WHEN THE HYDRAULIC TANK IS FULLAND THE HYDRAULIC HOLDINGSYSTEM IS PRESSURIZED, KEEP THEOIL LEVEL AT THE MIDDLE OF THE OILGAUGE.Approximately 100 litres are needed to fill thehydraulic tank, the holding cylinders,accumulators, locking cylinders and hydraulichoses.

12.2.1.3 Locking cylinders assemblyTo install a locking cylinder refer to paragraph10.3.21 "Installing the locking ring - HP200,HP300, HP400 and HP500" of section 10"Frame, adjusting ring and retaining cylinderassemblies", Figure 12-10 and Figure 12-11.



Figure 12-10 Installing a locking cylinder

Figure 12-11 Connecting the hoses of the locking cylinders

1

2

3

4

1

2

3

45

7

6

Ref. Description

1 Locking bolt

2 Locking cylinder

3 Locking ring

4 Adjusting ring

Ref. Description

1 Locking rings

2 Plug

3 90° elbow

4 Adjusting ring

5 Hose

6 Cylinder no. 1

7Hole in the adjusting ring for connection between the cylinders and the hydraulics cabinet



12.2.1.4 Hydraulic adjustmentsassemblySee Figure 12-12.

12.2.1.4.1 General

Generally, the hydraulic adjusting system(which turns the bowl) is delivered alreadymounted on the ring. However, in rare cases,for delivery reasons, the adjusting assemblymay be dismantled.

12.2.1.4.2 Assembly with a welded gearmotor bracket

1. Position the bracket over the pins on theadjusting ring as shown in Figure 12-13.Weld the mounting bracket to theadjusting ring. Make sure the motormounting bracket is level and straight onthe adjusting ring before welding.

2. Install the gear motor under the bearingplate as shown in Figure 12-14. Itsposition is important; the gear motor'slubrication taps must be in line with thehole of the plate and the feedconnections towards the exterior toassemble the hoses on the hydraulicmotor.



Then install the gear motor under thebearing plate. Its position is important;the gear motor's lubrication taps must bein line with the hole of the plate and thefeed connections towards the exterior toassemble the hoses on the hydraulicmotor.

4. Mount the pinion on the shaft of the gearmotor. Fix the washer with the screw.

5. Assemble the roller on its support thenfit; this is welded to the outer diameterof the adjusting ring, see Figure 12-12.See Table 12-2 for the correct position.




Figure 12-12 Hydraulic adjusting mechanismTable 12-2 Position of the cam

Ref. Description

1 Adjustment cap

2 Toothed crown

3 Pinion


5 Adjusting ring

6 Roller support

7 Roller

1

2

3

4

5

6 7

TypePosition of the top of the roller at

the top of the adjusting ring

HP200 200 mm (7-7/8")

HP300 152 mm (6")

HP400 231 mm (9-1/8")

HP500 240 mm (9-1/2")



Figure 12-13 Assembling the hydraulic adjusting mechanism on the adjusting ring (continued)

7. Fix the slides on the top of the toothedcrown as specified in Figure 12-14,using the screws and washers.

8. Centre the toothed crown on theadjustment cap. See Figure 12-12.

9. Use the adjusting screw (Ref. 16 and 17)on the bearing plate to position thepinion so that the teeth of the crown arethree-quarters engaged in the teeth ofthe pinion. Then tighten the screws,washers and nuts (Ref. 15).

13 1415

1617

20 1918

Ref. Description

1 Guard plate

2 Screws and washers

3 Pinion cover

4 Pinion

5 Screws, washers and nuts

6 Bearing plate

7 Play

8 Gear motor

9 Adjusting ring

10 Pins

11 Mounting bracket

12 Toothed crown

Ref. Description

13 Plug

14 Reduction gear


16 Locking screw


18 Hydraulic motor

19 Brake

20 Plug



10.Connect the hydraulic hoses of the unitto the hydraulic adjustments system. seeHYDRAULIC CONNECTIONS in thelubrication/hydraulics manual.

11.The gear motor is filled with oil when itleaves the factory. Check the oil levelbefore start-up and every 1000 hours ofcrusher operation.

To do so, proceed as follows:

a. With the gear motor in a verticalposition, remove the levelling tapplug in the middle of the gear motor.

The oil level should be visible in thelevelling tap.

b. If necessary, fill as specified inTable 12-3. Filling takes place via thebreather tap (Ref. 13 inFigure 12-13) on the upper plate ofthe gear motor.


12.Turn the hydraulic adjustments system360° to ascertain that the teeth of thepinion and the toothed crown engageproperly. Adjust play with the bearingplate adjusting screw.

When the plate is positioned correctly,tighten the locking bolt.

13.Fit the protective hood on the bearingplate to prevent materials jammingbetween the teeth of the crown andpinion.

12.2.1.4.3 Assembly with a bolted gearmotor bracket

1. Position the bracket over the pins on theadjusting ring as shown in Figure 12-14.Fix the motor mounting bracket on theadjusting ring with the screws, seeFigure 12-14 for HP200 and HP300 andFigure 12-15 for HP400 and HP500.

2. Install the gear motor under the bearingplate as shown in Figure 12-15. Itsposition is important; the gear motor'slubrication taps must be in line with thehole of the plate and the feedconnections towards the exterior toassemble the hoses on the hydraulicmotor.



Then install the gear motor under thebearing plate. Its position is important;the gear motor's lubrication taps must bein line with the hole of the plate and thefeed connections towards the exterior toassemble the hoses on the hydraulicmotor.

4. For the HP200 and HP300 mount thepinion on the gear motor shaft. Fix thewasher with the screw, seeFigure 12-14. And for the HP400 andHP500, mount the pinion, ring and sealon gear motor shaft, then fix the washerwith the screw, see figure 12-17.

5. Assemble the roller on its support thenset and weld it on the outer diameter ofthe adjusting ring. See Table 12-2 forthe correct position.


Type of oil

Reduction gear ISO-L-CKC-150(as per standard ISO 12925-1)



Figure 12-14 Assembling the hydraulic adjusting mechanism on the adjusting ring - HP200 and

HP300

1

2

35

21

20

19

18

17

16

12

13

15

14

6

4

7

8

9

10

11

22

Ref. Description

1 Guard plate

2 Locking bolt

3 Washer

4 Bearing plate


6 Pins

7 Screw + washer + nut for fixing the motor mounting bracket

8 Bolt

9 Washer

10 Slide

11 Toothed crown

12 Adjusting ring

13 Roller

14 Self-locking nut and washer

15 Roller support

16 Reduction gear

17 Hydraulic motor

18 Pinion

19 3 screws and washers for fixing the pinion

20 Locking nut

21 Locking screw

22 Lubrication tap

Ref. Description



Figure 12-15 Assembling the hydraulic adjusting mechanism on the adjusting ring - HP400 and

HP500

1

8

7

611

4

5

93

12

2

10

Ref. Description

1 Guard plate

2 Screws and lock washers

3 Bearing plate

4Screw and washers for adjusting the plate


6 Screws, washers and nuts for fixing the motor mounting bracket

7 Reduction gear

8 Hydraulic motor

9 Adjusting ring

10 Toothed crown

11 Pin

12Screws, washers and nuts for fixing the reduction gear

Ref. Description



Figure 12-16 Hydraulic connections - HP200, HP300, HP400 and HP500

1

2

3

4

6 7 8

9 10

11

12

5

Ref. Description


2 Brake

3 Hydraulic motor

4 Holding cylinders

5 Braking circuit

6 Locking circuit

7 Loosening circuit

8 Tightening circuit

9 Unramming circuit

10 Holding circuit

11 Accumulator

12 Adjusting ring



7. Fix the slides on the top of the toothedcrown as specified in Figure 12-14,using the screws and washers.

8. Centre the toothed crown on theadjustment cap.

9. Use the adjusting screw on the bearingplate to position the pinion so that theteeth of the crown are three-quartersengaged in the teeth of the pinion. Thentighten the locking bolts.

Figure 12-17 Taps and connections on the gear motor

3

2

1

3

6

9

8

7

5

1

2

4

4

Ref. Description

1 Breather tap

2 Levelling tap

3 Tightening/loosening connection

4 Brake connection

5 Seal

6 Bushing

7 Pinion

8 Tightening washer

9 Bolt

Ref. Description



10.Connect the hydraulic hoses of the unitto the hydraulic adjustments system. Seechapter 12.1.7 "Connecting thehydraulic hoses to the crusher".

11.The gear motor is filled with oil when itleaves the factory. Check the oil levelbefore start-up and every 1000 hours ofcrusher operation. To do so, proceed asfollows:

a. With the gear motor in a verticalposition, remove the levelling tapplug in the middle of the gear motor.The oil level should be visible in thelevelling tap.

b. If necessary, fill with oil as specifiedin Table 12-4. Filling takes place viathe breather tap or the levelling tap,see Figure 12-17 and Figure 12-5.


12.Turn the hydraulic adjustments system360° to ascertain that the teeth of thepinion and the toothed crown engageproperly.

If necessary adjust play by loosening thelocking bolt, then turn the adjustingscrew of the bearing plate. When theplate is positioned correctly, tighten thelocking bolt.

12.2.1.4.4 Hydraulic adjustmentsassembly

Hydraulic motor maintenance should seldombe necessary. Given the complexity of theinternal components, only the supplier of theequipment is fully equipped to dismantle andreplace parts and reassemble the assembly.

12.2.1.5 Connecting the hydraulichoses to the crusherSee Figure 12-16.When the hydraulic unit has been installed andthe hydraulic adjusting mechanism mountedon the ring, connect the hoses linking the unitto the hydraulic motor, the locking and holdingcylinders, make the connections to the crusheras follows.• The six hoses linking the unit to the

crusher are the same.

• All orifices and hoses are clearly markedat the factor, to facilitate connection of thehoses to the cabinet, crusher and hydraulicmotor, the numbers (1, 2, 3, 4, 5 and 6) aremarked on the various inlets and outlets.Beware, this connection is not compatiblewith the HP100.

1. Connect the loosening circuit hose to theconnection on the left of the hydraulicmotor.

NOTE: IT IS VERY IMPORTANT THATTHE HOSES AND CONNECTION REMAINCLEAN THROUGHOUT THE ASSEMBLYPROCEDURE.

2. Connect the tightening circuit hose tothe connection on the right of thehydraulic motor.

3. Connect the brake's hose to the brakecoupling just above the hydraulic motor;see Figure 12-17.

NOTE: CHECK THE MOTOR AND BRAKEHYDRAULIC CONNECTION.

4. Connect the locking circuit hose to theconnection on the side of the adjustingring.

5. Connect the unramming hose to the Tconnection on the unramming circuitlocated on the crusher and connectingall the lower chambers of the protectivecylinders. See Figure 12-18.

6. Connect the holding circuit hose to the Tconnection on the holding circuit,located on the crusher and linking all theupper chambers of the protectivecylinders. See Figure 12-18.

Type of oil

Reduction gearISO-L-CKC-150

(as per standard ISO 12925-1)

BrakeISO-L-CKC-150

(as per standard ISO 12925-1)



Figure 12-18 Connecting the holding and unramming cylinders

12.2.1.6 Checking accumulator preload(Holding circuit)After prolonged use or after dismantling theprotective mechanism, the preload pressure inthe accumulators must be checked. Theaccumulators are preloaded with nitrogen.Before carrying out any checks, the pressure inthe holding circuit must be zero; to achievethis, open the corresponding valve in thehydraulic unit. When carrying out a check,make sure the accumulators are not in directsunlight and the outdoor temperature isroughly 20°C. To connect the checking deviceand check the preload pressure of theaccumulators, proceed as follows:

1. The holding circuit and theaccumulators must be empty of oil, seethe hydraulics manual.

2. See Figure 12-19. Remove the valveguard at the bottom of the accumulator;as well as the plug on the valve stem.Remove the washer that was under theplug.

Figure 12-19 Accumulator valve

3. Use the inflation checking equipment(optional extra).

The inflation checking equipment isrequired to connect an accumulator to anitrogen cylinder to increase the preloadin the accumulator. The inflationchecking equipment comprises a3-metre hose equipped with a rotatingcoupling at one end and a gland bolt nut(left-hand thread) at the other end a unitequipped with a purge screw and acharging valve and a pressure gauge.

The checking equipment checksaccumulator preload; it is used to solelyinflate or deflate the accumulator.

Ref. Description

1 Holding cylinders

2 T coupling

3 Holding circuit

4 Unramming circuit

5 Accumulator

1

23

4 5

Ref. Description

1 Valve system

2 Accumulator

3 Valve plug

4 Valve guard

5 Washer

CAUTION

The coupling of the nitrogencylinder (delivered as an optionalextra) varies according to country.

1

5

4 3

2



4. Fully remove the upper knurled knob ofthe inflation checking equipment, makesure the purge screw is closed.

5. Screw in the inflation checkingequipment onto the accumulator withthe lower knurled knob of the inflationchecking equipment.

6. Connect the inflation checkingequipment to the nitrogen cylinder reliefvalve with the hose. The relief valveshould limit pressure to theaccumulator's maximum pressure. Thisvalue is cold-stamped on theaccumulator.

7. Screw in the upper knurled knob on theinflation checking equipment. Thepressure value appears on the pressuregauge.

8. The pressure is higher than 83 bars forthe HP200/HP300 and 105 bars for theHP400/HP500. Unscrew the purgescrew until the necessary pressure isattained.

9. If the pressure is lower than the requiredpressure of 83 bars for theHP200/HP300 and 105 bars for theHP400/HP500, open the nitrogencylinder valve until the requisitepressure is attained.

10.Close and disconnect the nitrogencylinder.

11.Unscrew the upper knurled knob on theinflation checking equipment andunscrew the purge screw.

12.Dismantle the inflation checkingequipment from the accumulator.

13.Check the valve's airtightness withsoapy water; if the valve leaks, repeatthe pressure-checking operation. If thevalve still leaks, change it.

14.Put the valve plug back on.

15.perform the same operation on the otheraccumulators.

16.Close the hydraulic unit valve.

17.Pressurize the holding circuit.

Reminder of preload pressures:HP100 to 400: 83 bars (1200 PSI)HP500: 105 bars (1500 PSI)

12.2.1.7 Purging and testing thepressure of the hydraulic systemAfter making the initial connection, orwhenever any circuit has been opened toreplace or repair a component, you must purgeit to remove the air in the circuit. You mustpurge it to remove the air in the circuit. You donot need to remove all the air because a smallpocket of air will not impair the working of thecrusher. If it is started up for the first time,each circuit must be purged before beingpressurized.NOTE: WHILE FILLING AND PURGINGTHE HYDRAULIC CIRCUITS, CHECKTHE LEVEL IN THE TANK FREQUENTLYAND TOP UP IF NECESSARY.STARTING UP THE HYDRAULIC UNITBefore purging the system or any of thecircuits, oil needs to be circulated in all thecircuits of the hydraulic unit. (For starting upthe unit for purging or pressure testingpurposes, see the hydraulics manual).NOTE: DO NOT PUMP THE OIL IN THEHOLDING CIRCUIT BEFOREPRELOADING THE ACCUMULATORSWITH NITROGEN. THIS COULDDAMAGE THE BLADDER AND THEACCUMULATOR WOULD NEED TO BEREPLACED.

DANGER

NEVER INFLATEACCUMULATORS WITH ANYGAS OTHER THAN NITROGEN,EVEN PARTIALLY. ANOTHERGAS COULD CAUSE THECIRCUIT TO EXPLODE. DONOT USE OXYGEN.



12.2.1.7.1 Locking circuit

To purge and test the locking circuit, proceedas follows:


2. lower the locking pressure, see thehydraulics manual.

3. Follow the locking circuit hose up to thethreaded coupling on the side of theadjusting ring. Loosen the coupling toallow the oil to escape. When the oilflows clean without bubbles orspluttering, tighten the coupling.

4. Raise the locking pressure, see thehydraulics manual.

12.2.1.7.2 Unramming circuit

This circuit comprises six cylinders andaccumulators connected by pipeworksurrounding the frame hoop. The cylinderchambers (unramming side) will be purgedindependently o each cylinder, proceed asfollows:


2. Bring the pressure up to 14 Bars. (Seethe hydraulics manual)

3. Loosen the unramming hose couplingsconnected to the bottom of the holdingcylinder by roughly 1 and a half turns.When the oil flows clear, without anybubbles or spluttering, tighten thecouplings. Do likewise for the othercylinders.

4. Lock the cylinders at the end of theupper stroke by lifting the ring to itsmaximum, activate unramming, checkthe seals of the couplings, tighten themif necessary.

5. Lower the adjusting ring onto the frame.

12.2.1.7.3 Holding circuit

This circuit comprises six cylinders andaccumulators connected by pipeworksurrounding the frame hoop.The cylinders and accumulators of each groupwill be purged simultaneously, as follows:


2. Bring the pressure in the holding circuitto 14 Bars (200 PSI), see the hydraulicsmanual.

3. Loosen the purge screw at the bottom ofthe accumulator until the oil escapes.Tighten the screw again as soon as theoil flows clear without bubbles.

Loosen the couplings on each cylinderto let the oil flow. When the oil flowsclear and free of bubbles, tighten thecouplings.

4. Do likewise for the other groups ofcylinders and accumulators.

5. Pressurize the holding circuit asexplained later in paragraphPressurizing the holding circuit. Checkall couplings for leaks, tighten if needbe.

6. Run two complete pressurizing anddepressurizing cycles alternately on theholding circuit, to expel any air stilltrapped in it and return it to the tank.

DANGER

ON NO ACCOUNT SHOULDYOU PURGE A CIRCUIT WHENIT IS PRESSURIZED. ACONNECTION THAT BREAKSOR PRESSURIZED OILESCAPING COULD CAUSEBODILY INJURY. WEARSUITABLE SAFETY GLASSESWHEN PURGING CIRCUITS.

DANGER

WHILE THE ADJUSTING RINGIS IN ITS UPPERMOSTPOSITION, THE AREAAROUND THE RING SHOULDBE CLEAR, TO AVERT ANYACCIDENTS CAUSED BY THERING ACCIDENTALLYDESCENDING. PUT SAFETYWEDGES IN PLACE. KEEP THEUNRAMMING BUTTONDEPRESSED TO CHECK FORAND REPAIR ANY LEAKS. THERING WILL DESCEND IF THEUNRAMMING BUTTON ISRELEASED.



12.2.1.7.4 Braking circuit

THE BRAKING CIRCUIT ISINTERCONNECTED WITH THELOOSENING AND TIGHTENINGOPERATIONS. Therefore, purge the brakingcircuit as explained below:

1. Follow the unit's hose up to the hole onthe side of the brake, forming an integralpart of the gear motor mounted on theadjusting ring. Loosen the coupling tolet the oil flow. Tighten the coupling assoon as the oil flows clear withoutbubbles or spluttering.

12.2.1.8 Pressurizing the holdingcircuitAfter having made all the connections, purgedthe circuits and fixed any leaks, pressurize theholding circuit before first starting up thecrusher. Maintain the holding circuit at therecommended pressure to ensure adequateprotection in case of overload. The holdingpressure should be maintained between theminimum and the maximum specified in thehydraulics manual table.If the pressure exceeds the recommendedpressure, relieve the pressure as described inparagraph 12.2.2.1 "Depressurizing" in theMaintenance part of this chapter. If thepressure is too low after initial installation orrepairs, proceed as follows:

1. Check that the oil used is therecommended one.


2. Check the preload pressure of theaccumulators and adjust if necessary.See the instructions in paragraph12.2.1.6 "Checking accumulatorpreload".

3. Pressurize the holding circuit. (see thehydraulics manual)

The crusher cannot function with too low aholding pressure, otherwise the ring couldbounce and damage the frame span. To restorecorrect pressure, see the hydraulics manual.

12.2.2 Maintenance

12.2.2.1 DepressurizingBefore carrying out any maintenance work ona hydraulic device, the relevant oil circuitsmust be depressurized, this is of vitalimportance for the personnel carrying outrepairs on the crusher. Several circuits areusually depressurized while the crusher isrunning and are only pressurized for specificoperations. As a general rule, check thepressure gauges before doing anymaintenance. The holding circuit howeverremains pressurized thanks to theaccumulators, even after a prolonged stoppageof the pump. proceed as instructed in thehydraulics manual.

12.2.2.2 Replacing a holding cylinderSee Figure 12-20 and Figure 12-21.Refer to section 10, "Frame, adjusting ringand retaining cylinder assemblies" for themethod to follow for dismantling andinstalling a holding cylinder. See paragraph10.3.15 "Dismantling the protective cylinders-HP200, HP300, HP400 and HP500".The parts of the cylinder that can be replacedinclude:• the cylinder head or the protective seals

• the rod seals

• the piston seals

• the bearing segments.

We recommend changing the O-ring sealswhenever components are dismantled There isa leak if oil oozes between the cylinder's pistonrod and nose or if holding pressure cannot bemaintained. When a cylinder leaks, it must bereplaced straight away.A leaking cylinder is harmful because it causesthe adjusting ring to bounce.If the cylinder needs to be repaired, werecommend changing all the seals at the sametime. These seals are available in a kit.



Figure 12-20 Holding cylinder (HP200-HP300)

1 2 3 4 5 6 5

7891011

12

Ref. Description

1 Rod assembly

2 Wiper seals

3 Cylinder head

4 O-ring seal

5 Piston seal


7 Cylinder assembly

8 Piston bearing segment

9 Retaining ring

10 Rod bearing segment

11 Rod seal




Figure 12-21 Holding cylinder (HP400-HP500)

Ref. Description

1 Rod assembly

2 Rod bearing segments

3 Piston bearing segments

4 Cylinder assembly

5 Seal


7 Wiper seal

8 Retaining ring

9 O-ring seal


11 Seal

12 O-ring seal


14 Cylinder head



Be sure to have the necessary quantities orparts to be able to repair the damagedcylinders. During repairs, it is very importantthat the working surface be clean and free ofdust. To dismantle, check, reassemble or repaira holding cylinder, proceed as follows:

1. Unscrew the cylinder head from thecylinder. (Use a socket key fixed in thenotches of the outer diameter of thecylinder head.)

2. Gently pull the piston to take the piston,rod and head assembly completely outof the cylinder.

3. To dismantle the piston and rod,unscrew the piston and pull the rodthrough the bore of the cylinder.

4. Remove all the seals (wiper seal, pistonand rod seals, O-ring seal andanti-extrusion rings) from the head andpiston.

5. Clean the rod, piston, cylinder head andcylinder. All the cylinder's surfaces andparts in contact with the cylinder mustbe thoroughly cleaned and free of dust.If the cylinder is pitted with rust or ifburrs appear, replace the cylinder.

6. Use the cylinder sketch to fit the sealson the head and piston. Then slide therod through the head while turning itand reassemble the piston on the rod.

7. Lightly oil the surfaces of the cylinderrod, piston, head, seals and bore. Gentlyinsert the assembled piston, rod andhead in the cylinder, while turning therod and the piston in the fixed cylinder.

8. Screw the head onto the cylinder andtighten firmly.

9. The holding cylinder is ready to bereassembled on the crusher.

12.2.2.3 Replacing an accumulatorSee Figure 12-22.See section 10 "Frame, adjusting ring andretaining cylinder assemblies" for moreinformation on dismantling and reassemblingan accumulator. See paragraphs 10.3.17"Replacing an accumulator - HP100, HP200,HP300, HP400 and HP500" and 10.3.18"Dismantling the locking ring". If it wasnecessary to dismantle the accumulator tochange the bladder or to inspect other parts,contact the factory for instructions onreassembling the accumulator.



Figure 12-22 Accumulator assembly

Ref. Description

1 Protective valve

2 Filling valve

3 Seal

4 Bladder and valve assembly

5 Valve


7 Spacer

8 Locking nut

9 Purge screw

10 Machined plug

11 Locking nut

12 Piston


14 O-ring seal

15 Washer

16 Spring

17 Accumulator

18 Valve nut

Ref. Description



12.2.2.4 Repairing a locking cylinderSee Figure 12-23.See section 10 "Frame, adjusting ring andretaining cylinder assemblies" for moreinformation on dismantling and fitting thelocking cylinders. See paragraph 10.3.21"Replacing the frame - HP300, HP400 andHP500".

Figure 12-23 Locking cylinder

There is a leak if oil oozes under the protectiveapron or if locking pressure cannot bemaintained. When a cylinder leaks, it must bereplaced straight away.

A leak in the locking cylinder is harmfulbecause it will destroy the threads of the bowland the adjusting ring. If the cylinder needs tobe repaired, we recommend changing all theseals at the same time. These seals areavailable in a kit. Proceed as follows:

1. Disconnect the couplings on the faultycylinder. Loosen the pressure screwretaining the cylinder in the lockingring. The cylinder is now free and can beremoved.

Be sure to have the necessary quantities orparts to be able to repair the damagedcylinders. During repairs, it is very importantthat the working surface be clean and free ofdust. To dismantle, check, reassemble or repaira locking cylinder, proceed as follows:

2. Dismantle the thrust washer on thecylinder nose and the plug on the bottomof the cylinder.

3. Extract the piston by pushing it fromunderneath with a wooden pole insertedthrough the hole at the bottom of thecylinder, and if need be gently tapping itwith a hammer.

4. Remove the seal, anti-extrusion ring andwearing rings of the piston.

5. Thoroughly clean the piston and thecylinder barrel. All surfaces must beclean and dust-free. If the cylinder ispitted with rust or if burrs appear,replace the cylinder.

6. Reassemble the new wearing rings onthe piston and position them in theirgroove. Fit the seal and anti-extrusionring on the piston.

7. Lubricate the surfaces of the piston,seals and cylinder with hydraulic oil.Put the piston back in place in thecylinder while turning it and pushing itat the same time to the bottom of thecylinder.

8. When the piston is installed, reassemblethe thrust washer on the cylinder noseand the plug on the bottom of thecylinder.

9. Fit the locking cylinder as specified insection 10.

Ref. Description

1 Piston

2 Thrust washer

3 Cylinder

4 Plug

5 Wearing ring

6 Coupling

7 Wearing ring

8 Piston seal

10 Machined screw


Section 13

FREQUENTLY ASKED QUESTIONS

Frequently asked questions SECTION 13

Crusher problems Possible causes Comments/Solutions

Section ref.

Section Supplement

Crusher overheating

1. Damaged pumpInadequate throughput

1. Check the backflow of oil returned by the pump (l/min).

5 Lubrication

2. Bowl liner and mantle unsuited to the application.

2. Too much fine materials fins in the crusher cavity, entailing excessive input power.

1

3. A special feed generates too much heat in the crusher.

3. An oil cooler must be fitted. Lubrication

4. Insufficient lubrication of the crusher.

4. Check the pressure relief valve, which may be faulty due to wear. It may be bypassing the crusher. Check the quality of the oil used.

Lubrication

5. V-type drive belts are too taut 5. Adjust belt tension.

6. Lubrication too contaminated. 6. Replace the lubricant as per the specification.

5 Lubrication

7. No axial play on the countershaft.

7. Axial play of the countershaft: 0.8 to 1.2 mm for the HP100; 1.3 to 1.8 mm for the HP 200 and 0.8 to 1.6 mm for the other crushers.

5

8. Upper thrust washer worn out.

8. The lubricating grooves are worn, preventing proper lubrication of the surface and causing the temperature to rise. Replace the washer.

5

10. The crusher absorbs to much power.

10. Poor feed conditions, too much fine product or crusher working too hard. Tramp iron causes overloads.

1

11. Crusher adjustments too narrow.

11. Do not adjust the crusher below its minimum gradation setting. Check bounce on the adjusting ring.

3


SECTION 13 - FREQUENTLY ASKED QUESTIONS

Crusher problems

Possible causes Comments/SolutionsREF. Section

Section Supplement

Crusher overheating (continued)

12. The lubrication holes in the shaft are clogged with mud or rubble.

12. Clean the vertical and horizontal holes in the shaft with compressed air.

13. The unit heater is clogged up with mud or rubble or block on the outside (curtains).

13. Clean the unit heater. Lubrication

14. The lower head bushing is warped.

14. Crushing with insufficient mechanical force, power under 40%.

The crusher remains without feed for too long, too many fines in the feed.

Oil pressure too low, high temperature, wrong oil viscosity (too low)

Oil contaminated due to the presence of foreign particles upstream of the filter, or filter obstructed.

15. Eccentric bushing surface warped.

15. Lubricating failure due to too high a temperature of the oil, incorrect oil viscosity (too low).

Incorrect feed, excessive quantity of fines in the feed or crusher gradation set too fine.

Large amount of impurities in the feed, causing overload.

Insufficient film of oil. The surface of the main shaft was damaged earlier.

Play between the main shaft and the eccentric bushing.

Incorrect adjustment between the shaft and the frame. Check it with a thickness gauge.

5 Lubrication




REF. Section

Section Supplement

Sleeve unlocked

1. Sleeve screws broken.Play between the sleeve and the shaft due to wear.

1. Check the gap between the shaft and the sleeve. If necessary recondition the sleeve by hard-surfacing and machining, to achieve maximum screw adjustment or if the shaft is damaged, mount a sleeve with a smaller bore. Replace the screws using the correct thread torque, tighten after cooling the assembly.

5

The crusher uses too much oil

1. The T and/or U seals are worn or damaged.

1. Replace the seals. 5

2. Faulty pressure relief valve. 2. The relief valve is incorrectly set or the spring remains in the closed position. Replace the relief valve. Too much oil flow in the crusher.

Lubrication

3. Oil is too cold. 3. Fit an immersion heater to heat the oil to 27°C.

Lubrication

4. The oil in the crusher is too viscous.

4. Use the right oil. 5 Lubrication

5. The crusher is not properly ventilated.

5. Clean the breathers at the countershaft housing or on the cover.

5 Lubrication

6. Oil return blocked with mud or rubble.

6. Inspect the oil return and clean if necessary.

None

7. Oil return unsuitable. 7. Check the oil return gradient (minimum 25 mm for 300 mm) or if the diameter of the oil return tube is too small. Replace the return tube with a suitable one.

None

Production is reduced

1. Too fine a feed causes irregular wear on the bowl liner and mantle that when corrected reduces grip.

1. Replace the bowl liner and mantle or adjust the bowl for a bigger opening.

1

2. Too low or high an operating speed.

2. Check countershaft speed. 3

3. Much too much debris in the feed (wood, roots, etc.).

3. Remove the debris. 2




Section ref.

Section Supplement

Production is reduced

(continued)

4. Materials are too large at the feed, preventing correct feed.

4. Reduce the dimensions of the materials at the feed.

2

5. Too much sticky material in the feed, blocking the bowl liner and mantle inlet.

5. Remove sticky products. None

6. Incorrect feed distribution. 6. Correct feed distribution. 2

7. The bottom of the mantle have a "duckbill" shape.

7. Contact the factory.Replace the bowl liner and mantle.

None

8. The bowl liner and mantle in the parallel zone area have worn too quickly.

8. Contact the factory. Replace the bowl liner and mantle, use another type of profile.

1

The crusher is blocked

1. V-type drive belts are too slack

1. Tauten the V-type belts. Control

2. Electric problems on the motor.

2. Check the crusher's off-load power rating and power absorbed by only the motor (without the belts). If both readings are similar, have the motor tested by an electrician.

None

3. Clogging under the crusher. 3. Check the passage of materials in the sheet metal work under the crusher. Fit a rotation checker on the discharge conveyor and have it driven by the crusher feed.

2

4. Countershaft speed too slow. 4. Check countershaft speed. (rpm).

3

5. Oil pressure too low. 5. Check to have a correct pressure.

5 Lubrication




Section ref.

Section Supplement

The crusher is blocked(continued)

6. Feed opening problem. Since crushing only occurs at the bottom of the chamber, motor power take-off.

6. Check the profile of the bowl liner and mantle...

1

7. The bowl liner and mantle look like a "duckbill".

7. Cut the "duckbill".

Replace the bowl liner and mantle.

None

5

8. The bowl liner and mantle wear out quickly in the parallel zone.

8. Replace the bowl liner and mantle with suitable profiles. Contact the factory.

1

Oil leak 1. The T and/or U seals are worn or damaged.

1. Replace the seals. 5

2. The O-ring or lip seals are damaged or worn (countershaft housing).

2. Replace the joints and thoroughly clean the pinion side interlocking, lag with silicone.

5

Countershaft jammed or

broken

1. Belts too tight. 1. Check the tension of the belts and the alignment of the bullwheels.

2. No lubrication or not enough oil on the countershaft bushings.

2. Check the connection between the main oil pipe and the oil inlet in the countershaft box. Remove any valve or other device restricting the countershaft oil supply pipe.

None

3. The lubrication grooves in the bushing are incorrectly positioned.

3. The belt drive should not pull the countershaft against the lubrication groove.

5

4. No play at the end of the countershaft.

4. Adjust axial play to 0.8 to 1.2 mm for HP100, 1.3 to 1.8 mm for HP 200 and 0.8 to 1.6 mm for other crushers.

5




Section ref.

Section Supplement

Countershaft jammed or

broken (continued)

5. Countershaft bent, generally due to excessive vibrations at the end of the countershaft.

5. Replace the countershaft. 5

6. The oil grooves in the outer countershaft bushing are clogged up with mud or debris.

6. Clean the oil grooves. 5

7. Crown or pinion teeth broken. 7. Replace the crown or pinion. 5

8. Incorrect play between teeth or at the bottom of the teeth between the crown and the pinion.

8. Adjust the play between and at the bottom of the teeth.

5

Water is mixed with oil

1. Accumulation of water coming through the imbalance cover.

1. Drill holes and weld return tubes.

2. Breather blocked on the oil tank.

2. Replace the breather.

Bowl blocked 1 Accumulation of dust or rust in the thread of the bowl adjusting ring du bowl due to:

• Too hot a feed.

• Insufficient lubrication of the threading.

• The adjustment cap cover is worn or the dust prevention collar is damaged.

• No weather protection.

• The crusher has run too long for the given settings.

• Bowl or adjusting ring threads damaged.

• The threads are broken.

1. Try any of the following solutions:

• Put penetrating oil in the threads.

• Relieve the pressure in the holding and locking cylinders and let the products pass through the crusher.

• Feed small pieces of wood through the crusher.

• Throw small pieces of soft steel into the crusher.

• Heat the adjusting ring.

• Heat the adjusting ring and cool down the bowl.

• DO NOT REMOVE THE FRAME'S ADJUSTING RING.

5




Section ref.

Section Supplement

The bowl mantle or liner are detached

1. The thread torque of the nut's locking bolt is not correct, nor is the play between the head of the screw and the locking nut.

1. Apply the correct thread torque.

5

2. Wrong position of the locking nut on the spacer ring.

2. Change the locking nut. 5

3. The locking nut knocks against the top of the head.

3. Insufficient play between the bottom of the locking nut and the top of the head. This should be about 10 mm.

4. Liner/mantle or head spans damaged.

4. Remake the spans. None

5. Insufficient play for the seal between the mantle and the head.

5. The play should be between 6 mm and 10 mm.

5

6. Cylindricality defect. 6. This should not exceed 3 mm .

None

7. Mantle not secured to the head.

7. Check at the bottom of the mantle with a gauge. The gap should not exceed 0.1 mm.

5

8. Mantle not centred on the head.

8. Dismantle the mantle and reinstall correctly.

5

9. Mantle-The crusher rotates too long without feed.

9. The maximum time without feed should not exceed 30 minutes.

None

10. Mantle too thin. 10. Wear should not exceed 2/3 of the mantle.

None

11. The old sealant resin was not completely removed before the new mantle was installed.

11. Remove all the old sealant resin.

5




Section ref.

Section Supplement

The bowl mantle or liner are detached

(continued)

12. The tightening lugs of the bowl liner touch the outer diameter of the liner or the screws have worked loose.

12. Wedge the lug or tighten the screw.

5

13. Bowl liner too thin. 13. Wear should not exceed 2/3 of the bowl liner.

None

14. Too much tramp iron passes through the crusher.

14. Too much tramp iron will loosen the bowl liner.

2

15. The span on the bowl liner or bowl is damaged.

15. Remake the spans to the original dimensions.

None

16. The old sealant resin was not completely removed before the new bowl liner was installed.

16. Remove all the old sealant resin.

5

Oil leak at the end of the

countershaft housing, bullwheel

side

1. The crusher is not at atmospheric pressure.

1. Clean the breather of the countershaft housing.

5 Lubrication

2. Not enough oil returns from the countershaft housing or oil deflector, above all when the oil is cold.

2. Clean the oil inlet hole in the countershaft housing.

None

3. Defective lip seals. 3. Replace the lip seals. 5

4. The crusher is not level. 4. Level the crusher.

Excessive vibrations

1. Imbalance or imbalance liner worn.

1. Remake the imbalance, consult the factory. Replace the imbalance line.

5

2. Play incorrectly adjusted at the bottom of the teeth.

2. Reassemble the eccentric and wedge it.

5

3. Bent countershaft. 3. Replace the countershaft. 5




Section ref.

Section Supplement

Excessive vibrations

(continued)

4. The crusher's bullwheel turns with difficulty.

4. Remove the accumulated dust on the spokes of the bullwheel.

5

5. If the crusher is mounted as a mobile unit, the ground should be correctly prepared.

5. Check the seating. 0

6. Unsuitable foundations. 6. Check the foundations. 2

7. Bowl liner loose or worn. 7. Dismantle the bowl liner and replace or change it.

5

8. Countershaft speed too high (rpm).

8. Use the correct speed. 5

9. Imbalance liner missing. 9. Replace the liner; consult the factory.

5

Wear on the head span and bowl

1. The crusher runs with the bowl liner and mantle loose.

1. Make sure the bowl liner and mantle are properly mounted and that the locking nut is tight enough.

5

2. The crusher runs with damaged bowl liner and mantle.

2. Excessive wear on the bowl liner and mantle accelerates wear on the bowl and head spans.

None

3. The crusher runs with worn bowl liner and mantle.

3. Excessive wear on the bowl liner and mantle accelerates wear on the bowl and head spans.

None

4. Mantle and bowl liner broken. 4. Running with broken bowl liner and mantle accelerates wear on the bowl and head spans.

None

5. Intermittent feed while the new bowl liner and mantle are being run in.

5. For crushers without freewheeling clutch, starting the feed loosens torque when the feed slows down head rotation. Avoid intermittent feed when new bowl liner and mantle are mounted.




Section ref.

Section Supplement

Dust enters the

lubrication system

1. No breather on the crusher. 1. Fit a breather on the top of the countershaft housing.

5 Lubrication

2. The breathers on the crusher or the oil tank do not work properly.

2. Clean the breathers on the countershaft and the oil tank. To check, with the crusher running, a sheet of paper placed on the breather pipe should be sucked slightly inwards.

Lubrication

3. The crusher bullwheel sends dust towards the breather.

3. Position the breather further away from the bullwheel.

5 Lubrication

4. Dust penetrated the crusher when parts were being dismantled.

4. Cover the sleeve and the eccentric with a plastic sheet.

None

5. The oil return between the crusher and the tank is too vertical.

5. Dust may have been sucked towards the sleeve; add another breather on the oil return pipe. Consult the factory.

None

6. No seal between the oil tank and its cover.

6. Fit a seal or apply silicone. Lubrication

7. The hose between the fan and the countershaft housing is damaged or disconnected.

7. Check the hose and the couplings.

8. The breather hose or couplings are damaged or disconnected.

8. Check the hose and the couplings.

Wear on the crown and

pinion teeth

1. The oil is dirty. 1. Replace the oil and clean the tank.

Lubrication

2. Tooth wear too low. 2. Defective eccentric thrust washers, adjust the eccentric assembly with spacer rings.

5

3. Tooth wear too high. 3. Lower the eccentric assembly by removing spacer rings.

5




Section ref.

Section Supplement

Wear on the crown and

pinion teeth (continued)

4. Crusher overworking. 4. Generally revealed by adjusting ring bounce. Reduce the amount of feed.

1.5

5. Too much play at the end of the countershaft.

5. Adjust play to 0.8 to 1.2 mm for HP100; 1.3 to 1.8 mm for HP 200 and 0.8 to 1.6 mm other crushers.

5

Noise on the drive gear and pinion

1. Incorrect play between the teeth and at the bottom of the teeth.

1. Adjust play. 5

2. The crusher runs with a new crown and an old pinion, or vice versa.

2. 5

The adjusting ring is tilted

1. Contact surfaces damaged between frame and adjusting ring, due to ring bounce.

1. Feed incorrectly distributed in the crusher cavity. Turn the ring 180°.Check the pressure in the holding cylinders. If too low, increase it.

2

5

Hydraulics

2. Too frequent overload or unsuitable bowl liner and mantle profiles, causing the adjusting ring to bounce.

2. Too much fine product in the feed, refer to paragraph "bowl liner and mantle selection". Increase the feed in the crusher.Increase the gap between bowl liner and mantle.Materials clogged, water the feed.

1

3

Bowl bounce 1. Wear on the adjusting ring and bowl threads.

1. Re-machine the surface of the threads at 45° to achieve a uniform slope, provided the threads are not irreparably damaged.

None

2. lack of pressure in the locking cylinders.

2. Restore normal pressure in the locking cylinders.

5 Hydraulics

3. Crusher adjustments too narrow.

3. Increase the gap until the bowl no longer jumps.

3

4. Bowl liner and mantle too thick.

4. Not enough threads engaged. Mount thinner bowl liner and mantle.

None

5. Gap adjustment too wide. 5. Not enough threads engaged. Reduce the gap.

3




Section ref.

Section Supplement

Bowl bounce (continued)

6. Check that the hydraulic hoses and locking cylinders are correctly connected.

6. When the hydraulic unit is running, the hose between the cabinet and the locking cylinders must be "taut".

Hydraulics

Light signal indicating low pressure in

the tightening circuit

1. Possible leak on the unit or tightening circuit.

1. If the signal comes on more than once in the space of 10 minutes, look for leaks on the unit and the tightening circuit.

Hydraulics

Light signal indicating low pressure in

the unramming

circuit

1. Possible leak on the unit or unramming circuit.

1. If the signal comes on more than once in the space of 3 hours, look for leak on the unit and the unramming circuit.

Hydraulics

Locking bolts on the feeder

cone are broken

1. Too much feed in the crushing chamber.

1. Reduce the amount of feed. 1

2. Feed contains large pieces of product.

2. Reduce the size of the input products or increase the admission opening by changing the bowl liner and mantle.

1

3. The contact surfaces between the feeder cone and the locking nut are worn.

3. Hard-surface and re-machine the locking nut. Replace the feeder cone.

5

4. The feeder cone bolts are loose.

4. Tighten the bolts to their thread torque.

None

5. Drop too high. 5. Reduce the drop between the feed box/belt and the feeder cone.

None




Section ref.

Section Supplement

Bounce on the adjusting

ring

1. Overload or incorrect profile of the bowl liner and mantle.

1. Excessive quantity of fines in the feed.

Too much feed.

Opening too narrow.

Sticky materials.

1

3

2. Operation with too little cylinder pressure.

2. Cylinder seal defect.

The unit does not repressurize the cylinders automatically (faulty pressure switch).

Leak in the cylinder circuit valve inside the unit.

Leak in the cylinder pressure relief valve or valve left open.

Leak or defect on the hose or coupling...

Hydraulics


Metso MineralsP.O. Box 30733101 TampereFinlandPhone: +358 20 480 140Fax: +358 20 480 141

Metso Minerals (France) S.A.41, rue de la République71009 MACONFrancePhone:+33( 0) 3 85396200Fax:+33( 0) 3 85396328

Instruction Manual © 07/2015 Metso Printed in Mâcon

Crusher wear parts | Jaw | Cone - NORDBERG HP100, HP200, … · 2020-04-20 · NORDBERG HP100,...

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Transcript of Crusher wear parts | Jaw | Cone - NORDBERG HP100, HP200, … · 2020-04-20 · NORDBERG HP100,...