CUSTOMER:

PROJECT:

ZGOUNDER SILVER MINE EXPANSION PROJECT

TITLE:

Secondary Screen. Instruction, Operation and Maintenance Manual

PROJECT DOC NUMBER: ED: REV:

ZSM-DFM-4120-SC001-PR-MA-0001 00 00

ISSUE PURPOSE: DATE:

For Information 20/10/2022

PREPARED FS DATE: 20/10/2022

BY:

CHECKED FS DATE:
BY:
20/10/2022

APPROVED JM Artigas DATE: 20/10/2022

BY:

PROJECT DOCUMENT NUMBER:

CHANGES CONTROL SHEET
ED REV DATE SECTIONS CHANGES DESCRIPTIONS
00 00 20/10/2022 1st issue

Este documento es propiedad de DF y

deberá ser gestionado bajo las restricciones
This document contains proprietary
information of DF and is subject to the
Page 1 of 1
detalladas en la portada restrictions set forth on the title page

Date of Printing: 20/10/2022

Operation and Maintenance
Manual

Example picture

CUSTOMER :
Duro Felguera Marocco
ORDER NUMBER:
OA22-0021
MACHINE TYPE:
MF1861-2

IMPORTANT !
It is obligatory to follow the recommendations
of the safety manual N11479516/Rev.00

Metso Outotec Germany GmbH

Harrlachweg 6
D-68163 Mannheim, Germany
 CONTENT INSTRUCTION
MANUAL

__________________________________

DESCRIPTION N11480553-01
__________________________________

SAFETY PROCEDURES N11479516-00

__________________________________

GENERAL INFORMATION N11481555-00

__________________________________

INSTALLATION N11479518-00
__________________________________

OPERATION N11479520-00
__________________________________

CARE AND MAINTENANCE N11479522-00

__________________________________

MECHANSIM ML80 N11481148-01

_________________________________

INSTRUCTION MOTOR
_________________________________
 DESCRIPTION - Metso Mining Screens

DESCRIPTION

1 METSO MINING SCREENS .............................................................................................................................. 3

1.1 Quality ................................................................................................................................................... 3
1.2 Efficient Separation................................................................................................................................. 4
1.3 Application ............................................................................................................................................. 4
1.4 Main Features ........................................................................................................................................ 4
 DESCRIPTION - Metso Mining Screens

1 METSO MINING SCREENS

Metso Screens Mining: They are designed and constructed to meet the most important requirements of reliability of
mining companies.

This line includes the following models:

MF (Multi-Flo), linear motion, like banana

LH (Low Head) linear motion, deck plan
RF (Ripl-Flo), circular motion, like banana
DW (Dewatering) linear motion, deck plan

The screen design and manufacturing is supported by

long experience gained in respected well known
companies like Nordberg, Svedala, Allis Chalmers,
Hewitt Robbins, Tyler e Seco.

Together with this, the modern tools like 3D CAD and

FEA are applied. Each screen is factory tested
monitoring natural frequencies and performing
dynamic analysis. Strain gage measurements allows
validation of finite element results. The continuous
field evaluations result in refined engineering practices
of design and applications. Finite Element Analysis

1.1 Quality

The reliability of the machine is the sum of the quality

of components. Parts of the main structure, as the
mechanism beam and the cross beams are welded into
the highest standards and stress relieving is done on
heavy parts with a high rate of welded joints. There are
no welds on the side plates. The entire assembly is
made using huck bolts, which avoids the stress
concentration produced by the welding and that allows
for easy re-assembly of wear components on the field.
Banana Deck

DESCRIPTION - Metso Mining Screens – N11480553 / Rev. 01 3-5

 DESCRIPTION - Metso Mining Screens

1.2 Efficient Separation Heavy transversal components, as mechanism beams

Multi-Flo
The Metso MF Multi-Flo screens with multi slope deck
inclination, popular called as the "banana form", strongly
surpasses in performance traditional constant slope
screens. The high initial deck inclination decreases in
each 4 foot step section along the screen length. The
beginning steep angle imposes fast material travel rate
decreasing bed depth thickness, removing rapidly most
of undersize grains. When the reduced material amount
come to the lower inclination middle and final screen
sections, the smaller travel speed and in consequence
longer retention time allow removing the remaining near
size particles getting efficient separation level.
Low Head
The Metso LH Low Head screens with horizontal decks
are suitable for processes that require longer retention of
particles, ensuring an efficient level of separation. A
variation of these Low Head is screens for dewatering.
Ripl-Flo
The Metso Ripl-Flo screens with inclined decks combine
the moderate banana shape with circular motion, adding
the benefits of high production and high efficiency of
separation.
are stress relieved.
Square hole section individual cross member support
frames with replaceable "T" cleats and stringers
reducing maintenance time and cost. The stringers
can be adapted to suit the fitting of most screening
media types.
The stiff and rigid side plate arrangement formed by
huckbolted elements without any structure weld
maximizing the fatigue resistance.
The generous dimensioned soft springs sustained by
boxes with built-in friction brakes (optional)
guarantee soft start and stopping minimizing
vibration transmission to the building structure.
The large feed box makes uniform the material bed
distribution, allowing efficient use of all screening
surface.
Corrosion / erosion protection through design form,
and also by the use of rubber lining, polyurethane
coating, marine grade mastic sealers, ceramic plate,
etc.

The powerful vibration of Metso MF Multi-Flo screens All components are standardized worldwide, as well
combines high throughput with risks avoidance of as our supply chain, manufacturing and services.
blinding and caking.

1.3 Application

The Metso Multi-Flo screens are specially indicated for

large material volumes handling with high undersize
grain contents. There is no restriction to the process type.
The machines can be used in dry or wet applications.
The Metso Multi-Flo screens allow easy plant upgrade
fitting well in place of old traditional machines
increasing separation capacity up to 60%.

The Metso Low Head screens are suitable for

applications that require high separation efficiency and
also in plants with limited height.
Worldwide standard components construction
Normally the Metso MF Multi-Flo screens are designed (mechanism beam, cross member, feed box, springs, side
to accept screen media like Trellex Panelcord or Trellex frame, etc.)
305 LS system, but also can be prepared for any other
type specified by customer.

1.4 Main Features

Heavy Duty Design features include:

Time proven universality accepted Low-Head

mechanisms.

DESCRIPTION - Metso Mining Screens – N11480553 / Rev. 01 4-5

 DESCRIPTION - Metso Mining Screens

Square hole section

Side plates reinforced by stiffeners

Feed box with liners

DESCRIPTION - Metso Mining Screens – N11480553 / Rev. 01 5-5

SAFETY PROCEDURES

FOREWORD
This Instruction Manual provides guidance to first time operators of the equipment as well
as providing technical procedures as a reference for the experienced equipment operator.
Read — study — and keep for future reference.

Illustrations and instructions guide the operator through correct procedures for checking,
installing, operating and maintaining the equipment and accessories.

Operating techniques outlined in the book are basic. Operating skills and additional
techniques will develop as the operator gains knowledge of the equipment and its
capabilities.

Continuing improvement and advancement of product design may result in changes to

your new machine which may not be included in this publication, however each publication
is reviewed and revised, as required, to up-date and include appropriate changes in the
later editions.

The description and specifications in this manual were in effect at the time this manual was
approved for printing. Metso Minerals reserves the right to discontinue models at any time
and to change specifications or design, without notice and without incurring obligation.

Whenever a question arises regarding your equipment, or this publication, please consult
your Metso Minerals representative for the latest available information.

This manual is to be used as a general guide concerning technical information. All

technical information required for correct installation of your equipment must be obtained
from the installation drawings and technical data furnished for your particular equipment.

SAFETY PROCEDURES – N11479516 / Rev. 00 1-35

SAFETY PROCEDURES

SAFETY
Basic rules regarding safety in and around a screening plant are outlined in
section a, entitled “SAFETY PROCEDURES”.

Operator safety and the safety of others depends upon reasonable care and
judgment in the operation of this screen. A careful operator is good insurance
against an accident.

Most accidents, no matter where they occur, are caused by failure to observe
and follow simple fundamental rules or precautions. For this reason
recognizing hazards and taking steps to avoid them can prevent most
accidents before an accident occurs.

Regardless of the care used in the design and construction of this type of
equipment, there are conditions that cannot be completely safeguarded against
without interfering with reasonable accessibility and efficient operation.
Warnings are included in this instruction manual to highlight these conditions.

SAFETY PROCEDURES – N11479516 / Rev. 00 2-35

SAFETY PROCEDURES

SAFETY PROCEDURES

1 Introduction ............................................................................................................................ 4
1.1 General .............................................................................................................................. 4
1.2 Definitions ......................................................................................................................... 6
2 SAFETY INSTRUCTIONS.................................................................................................... 7
2.1 Safe products and the crushing plant .................................................................................. 7
2.2 Safety and you ................................................................................................................... 7
2.2.1 Objective ..................................................................................................................... 7
2.2.2 Safety Signs, Labels And Symbols ............................................................................... 8
2.2.3 Some General Safety Instructions ................................................................................ 8
2.2.4 Blasting ..................................................................................................................... 10
2.2.5 Portable Plants ........................................................................................................... 10
2.2.6 Mobile Equipment Transportation .............................................................................. 10
2.3 Typical risks in crushing plant working environment........................................................ 11
2.3.1 Typical hazards .............................................................................................................. 12
2.3.2 Typical injury types ....................................................................................................... 23
2.4 Personal protective equipment and clothing ...................................................................... 25
3 MACHINERY SAFETY ...................................................................................................... 29
3.1 Protective devices and accessories for machine safety ...................................................... 29
3.1.1 Overview ................................................................................................................... 29
3.1.2 Emergency-Stop (E-Stop) .......................................................................................... 29
3.1.3 Safety interlocks ........................................................................................................ 29
3.1.4 Additional warning devices........................................................................................ 31
3.1.5 Walkways, service platforms, ladders and railings ..................................................... 31
3.2 Transport.......................................................................................................................... 31
3.3 Towing ............................................................................................................................... 32
3.4 At the work-site .................................................................................................................. 32
3.4.1 Precautions .................................................................................................................... 32
3.4.2 During operation ........................................................................................................... 33
4 SAFETY DURING MAINTANANCE REPAIR ................................................................. 33
4.1 General information and safety lockouts........................................................................... 33
4.2 Mechanical safety during maintenance and repair ............................................................. 34
4.2.1 General ...................................................................................................................... 34
4.2.2 Fire Safety During Maintenance and Repair ............................................................... 34
4.2.3 Preventive Maintenance ............................................................................................. 35
4.2.4 Confined Spaces ........................................................................................................ 35
4.3 Electrical safety during maintenance and repair ................................................................ 36
4.3.1 General ...................................................................................................................... 36
4.3.2 Electrical Fault Situations .......................................................................................... 37
4.3.3 Program Changes ....................................................................................................... 37
4.4 Hydraulic safety during maintenance and repair ............................................................... 38
4.5 General maintenance work ............................................................................................... 39

SAFETY PROCEDURES – N11479516 / Rev. 00 3-35

SAFETY PROCEDURES
1 INTRODUCTION
1.1 General
This manual has been prepared by Metso
Minerals Mining Screening Business Line
to increase the knowledge and
awareness of all persons involved in the
operation, supervision, service and
maintenance of screening equipment with
regard to safety and operations. A copy of
this manual must be provided to and
studied by each person entering the
machine areas of the Crushing Plant, or
otherwise involved in the operation of the
Crushing Plant. It is the responsibility of
the owner to always keep this manual
and other written instructions either in the
Crushing Plant or its vicinity for Operator
reference.
Knowledge of the machines and the
potential hazards they present are
essential to a safe workplace. Knowledge
of and compliance with all state,
provincial, and federal safety laws, safety
regulations, and Crushing Plant safety
procedures, warnings and instructions
also are essential to a safe workplace.
Failure to do so can result in serious
injury or death.
When in doubt - don’t! Never bypass
instructions or procedures to save time.
Never place foreign items, tools, rods, or
any part of your body into an operating
machine. Never reach over, around or
beyond safety devices. Never operate a
machine if safety devices are missing or
disabled. Never service equipment until
all potentially moving parts are secured
and power has been locked out and
tagged out to prevent unexpected
movement.
The Operator is responsible for using
care and common sense at all times.
Remember, safety is everyone’s
business. You are responsible not only
for your safety, but also for the safety of
those around you.
Please read this manual carefully. Know
its contents. If you have any questions,
contact your Metso Minerals
representative without delay for advice.
Keep in mind that there are different
types of risks, hazards and injury types
(see section 2.3 – Typical risks in
crushing plant working environment),
which are related to each other. Foresee
and prevent such risks and hazards as
well as resulting injuries and other
consequences from occurring by all
available means. Never compromise
when the question is about safety!
Metso Minerals, as the machinery
manufacturer and supplier, regards safety
as of the utmost importance, and deems
the following as essential prerequisites to
the safe operation of the Crushing Plant:
– That the owner makes available this
manual, before using the machinery, to
each person involved with the operation,
supervision, service, or maintenance of
the Crushing Plant;
SAFETY PROCEDURES – N11479516 / Rev. 00 4-35
SAFETY PROCEDURES

– That compliance with and adherence to any amendments, additions or other

this manual be mandated and supervised changes to safety law, rules or
by the owner. regulations arising subsequent to the date
on which this manual was drafted.
– That all personnel involved in the
operation, supervision, service, or
maintenance of the Crushing Plant
become familiar with the contents of this
manual prior to such involvement.

– That every person involved in the

operation, supervision, service, or
maintenance of the Crushing Plant be
properly trained and have adequate
professional skills as required for the
performance of the respective tasks.

– That all visitors to the Crushing Plant be

properly informed of applicable safety
precautions and risks, and that safety
precautions be adequately maintained
and in connection with any such visits,
including, but not limited to, adherence to
this manual.
No changes shall be made in the
operation of the machinery supplied by
Metso Minerals or the contents of this
manual without express written approval
of Metso Minerals. All operation, service,
maintenance, handling, modifications, or
other use of Crushing Plant equipment is
the responsibility of the owner. Metso
Minerals shall not be liable for any injury,
death, damage or cost caused by any act
or omission on the part of the Owner,
Operator or other personnel, agents,
contractors, vendors, or others. All
applicable safety rules, regulations,
standards, instructions, and procedures
must be complied with; as must be those
of this manual as well as any other
instructions, specifications, and
recommendations by Metso Minerals.
This manual is based upon the safety
laws, rules and regulations in effect on
the date hereof. The owner and operator
bear sole responsibility for complying with
Although these instructions are intended
to be as comprehensive as possible,
there may be hazards that cannot be
anticipated, hazards associated with a
particular work-site or hazards covered by
special comany safety programs. The
information may also not include all
practices that must be observed, such as
insurance requirements or governmental
regulations.
If you have questions or concerns
regarding safety aspects of machinery
supplied by Metso Minerals, contact us
before using, operating, servicing or
repairing the machinery.
IMPORTANT!
Safe operation of the machine requires
alertness and safety-consciousness
on the part of all operating personnel.
It should be operated only by
knowledgeable and trained personnel.

SAFETY PROCEDURES – N11479516 / Rev. 00 5-35

SAFETY PROCEDURES

1.2 Definitions

“Crushing Plant” means a combination

or part of various equipment,
components, systems and parts for
crushing and screening of rock, minerals,
recycling or other crushable materials.
For the purposes of this manual, the
Crushing Plant means also stand-alone
crushing or screening equipment as
applicable. Throughout this manual,
words such as “machine”, “machinery”,
“equipment”, “crusher” and "screen" are
used interchangeably to refer to the
Crushing Plant and its component parts.

“Owner” means the entities or

individuals who own or lease the
Crushing Plant and/or the entities or
individuals who are in charge of operating
and/or servicing the Crushing Plant.

“Operator” means the individuals who

either operate the Crushing Plant or
perform actual maintenance, service,
repairs, supervision or any other activity
on or for it.

“This manual” means, as applicable,

this general safety instruction, together
with any specific instructions for individual
equipment, as amended from time to
time, provided by or on behalf of Metso
Minerals.

SAFETY PROCEDURES – N11479516 / Rev. 00 6-35

SAFETY PROCEDURES
2 SAFETY INSTRUCTIONS
2.1 Safe products and the crushing
plant
All machines require human involvement.
Like any other heavy machinery, a
Crushing Plant has inherent dangers that
must be identified, understood and taken
into account in order to avoid accidents
and injuries. Metso Minerals, as
machinery manufacturer and supplier, is
committed to promoting safety at the
Crushing Plant by providing safety
devices and features, and by providing
training, services, manuals and
instructions.
2.2 Safety and you
“Safety is everyone's responsibility;
safety is your responsibility.”
Safety is the concern of all personnel.
With your actions, you participate in
establishing the safety of the working
environment.
Metso Minerals products are designed
and constructed with safety in mind. The
machines incorporate high quality safety
features used.
To assure safe operation, all personnel
must be alert when operating or working
on or around the machine. Be aware of
real and potential hazards. Only properly
trained personnel should operate,
supervise, maintain, or service the
machine.
Personnel must carefully study all
aspects of the specific machine,
including:
operating instructions
service, diagnosis and maintenance
instructions
automated features and motions of
the machine
specific safety features and
instructions
_________________________
IMPORTANT!
If unsure of any procedure, check
the operation manuals and/or
contact your supervisor before
proceeding;
Follow all lockout and safety
procedures before entering the
machine;
Be constantly aware of the location
of each worker on or around the
machine;
Observe all safety instructions;
Do not remove or disable any
guard, safety device, sign or
warning.
_________________________
2.2.1 Objective
The objective of these instructions is to
minimize risks and to avoid or prevent
accidents and injuries. Accidents are
often caused by carelessness or
disregard of important instructions.
Knowledge of the machine operation and
continuous safety training are necessary
for a safe working environment.
SAFETY PROCEDURES – N11479516 / Rev. 00 7-35
SAFETY PROCEDURES
Safety can be summarized in three main
themes:
MACHINE KNOWLEDGE
SAFE OPERATION AND
MAINTENANCE
GOOD HOUSEKEEPING
2.2.2 Safety Signs, Labels And
Symbols
The following symbol is used in this
manual and on the machine to call
attention to instructions, which will help
prevent machine related injuries.
When you see this symbol on your
machine or in this manual be alert to the
potential for personal injury.
Figure 2-1 Alert Symbol
This manual uses the alert symbol, with
words such as DANGER, WARNING or
CAUTION, to alert you and other
Crushing Plant personnel of actions or
conditions that pose a potential safety
hazard, with an attending risk of personal
injury (including death) or property
damage. The machine also displays
safety signs, labels and tags at
appropriate points to show safety risks
that may exist.
Sing Description
Immediate hazards or
unsafe practices that will
result in severe personal
injury or death.
Hazards or unsafe
practices that could result
in severe personal injury
or death
Hazards or unsafe
practices that could result
in minor personal injury or
equipment damage
Figure 2-2 Danger, Warning, Caution Signs
and Their Meaning
2.2.3 Some General Safety
Instructions
1. Do not remove, cover or disable any
installed safety devices, guards,
warning signs or tags. They are
attached to equipment to warn
personnel of possible danger and
prevent injury. Use OEM
replacements in the event any safety
devices, warning signs or tags
become damaged or unreadable.
Observe all instructions. Keep
warnings signs and tags clean, visible
and readable.
2. Make sure that all required walkways,
handrails, barriers, safety devices,
and guards are in place before
starting the machine. Do not use non-
OEM walkways, handrails, barriers,
safety devices or guards, when such
items are available from OEM.
3. Keep the machine itself and the area
around the machine clean and clear of
obstructions. Be aware of dust, smoke
or fog, which may obscure your vision.
SAFETY PROCEDURES – N11479516 / Rev. 00 8-35
SAFETY PROCEDURES
4. Wipe up any substance, such as
spilled oil, grease, water or ice, which
may cause a person to slip or fall.
Good housekeeping practices prevent
injuries. Be a good housekeeper.
Keep the machine environment and
walkways clean and free from oil,
grease, rags, cables, chains, buckets,
rocks and other obstructions. Keep
loose parts in a toolbox or return them
there promptly.
5. Keep clothing and all parts of the body
away from nip points and rotating or
moving equipment. Be especially alert
to avoid contact with parts that move
intermittently.
6. Know the weight limitations of lifting
devices and their loads. Never detach
a lifting device from a load until the
load is stable and secured from
unintended movement.
7. Do not climb or stand on equipment
other than in areas, which are
designed for that purpose. Do not
overreach.
8. Emergency-Stop buttons should be
tested on a regular schedule for
proper operation, as should electrical
interlocks and related limit switches.
Safety defects should be repaired
prior to continuing operation, and
thereafter tested and certified for
appropriate operation by skilled
personnel.
9. Personal protective equipment and
safety uniforms, safety shoes,
helmets, safety glasses, heavy gloves,
ear protection devices etc. should be
used at all times. Safety shoes should
be used by all personnel entering into
the Crushing Plant. Persons with
loose clothing, neck ties, necklaces,
unprotected long beard or long hair
should not go near the machine.
Wristwatches and rings can be
dangerous. Rings should be removed
or covered with tape. Keep your
pockets free of loose objects.
10. Keep all non-operating and non-
trained personnel clear of the
Crushing Plant at all times. Injury or
death may result if this is not done.
11. The equipment at the control panel
should be handled with care. Do not
place objects on the keyboard, color
display or other equipment. All
equipment can fail if put in contact
with liquids, or excessive heat or
excessive humidity. Allow good airflow
around the equipment at all times.
Keep magnets away from computer
components, particularly hard drives
and PLC cabinets.
12. A knowledgeable and properly trained
Operator familiar with this manual,
safety requirements, and automatic
operation of the machine should be
stationed at the controls whenever the
machine is operating.
13. Do not consume any alcoholic
beverages or other intoxicants before
coming to work or while on the job. Do
not operate the Crushing Plant after
taking any medicines, tranquilizers or
other drugs, which can impair the
senses.
14. Familiarize yourself with the safety
signs on the Crushing Plant. Never
remove or damage any safety signs,
nameplates or other safety-related
warnings, symbols or components.
Replace them as necessary with OEM
equipment.
15. Do not paint over safety signs,
nameplates or warnings.
SAFETY PROCEDURES – N11479516 / Rev. 00 9-35
SAFETY PROCEDURES
Only qualified and properly trained
operators and servicemen should
operate or service the machine.
Everyone else should stay clear of the
machine when it is operating, or under
service or maintenance!
2.2.4 Blasting
The use of the Crusher Plant’s radio
control device is strictly forbidden during
blasting operations, as it may cause a
premature explosion. Move the mobile
Crushing Plant far enough away from
dangerous area when blasting. Do not
store or transport explosives on mobile
crushing plant or screening plants.
2.2.5 Portable Plants
If the Crushing Plant includes of portable
equipment (i.e. crushing and screening
equipment mounted on trailers), trailer
footing or cribbing is extremely important
for safe operation. Your machine must be
on as solid and level footing as possible.
If the ground is not naturally level, it must
be leveled so that the unit will operate
safely and effectively. The ground must
support the weight of entire unit and keep
it from sinking or shifting. Use heavy
timber mats as needed. Trailers must be
raised so that trailer wheels do not touch
the ground.
Place jacks at each corner of the trailer or
as near the corner as possible and to
other suggested support points at mid-
frame. All corner jacks must be at an
equal distance from each end. Adjust
each jack until the unsupported portion of
the trailer beams stops vibrating or until
vibrations are reduced to a minimum.
Lock jacks and adjustable support legs
mechanically with locking pins when
applicable. Periodically recheck trailer
footing for stability.
2.2.6 Mobile Equipment
Transportation
Use only appropriate transportation and
lifting equipment with adequate capacity.
Provide a supervisor to direct lifting
operations. Follow all disassembly and
assembly instructions carefully.
Disconnect all external power supplies
before moving any part of the equipment.
Transport or hoist components and
handle any parts in accordance with the
instructions and advice provided. Fasten
the lifting equipment only to the points
meant for lifting. Use only proper means
of transport with adequate transporting
capacity. Fasten the load carefully. For
lifting use only the fastenings shown in
instructions. Secure all component parts
of the equipment immediately after
loading to avoid any accidental shifting.
Attach required warning signs to the load.
When moving your trailer, check bridges
before crossing. Make sure they will
support the weight of the machine. Check
clearances under bridges, for overhead
lines or any overhead obstruction. Never
travel with near capacity loads. Check
local laws, especially on weight
limitations. When travelling on the
highway make sure all headlights;
clearance lights and taillights are on, as
applicable. Use proper traffic warning
flags and signs.
SAFETY PROCEDURES – N11479516 / Rev. 00 10-35
SAFETY PROCEDURES
Remove all shipping brackets before re-
starting the Crushing Plant. Carefully
assemble all of the parts previously
disassembled. Perform any start up in
accordance with the instruction manual.
After the system is running, check all
gauges and instruments to see that they
are working correctly. Check that all
controls function normally and properly.
Listen for unusual noises. Shut system
down immediately if any component of
the system does not operate normally.
2.3 TYPICAL RISKS IN CRUSHING
PLANT WORKING
ENVIRONMENT
Even though every Metso Minerals
machine is designed with many safety
features, it is impossible to design out all
safety risks. There are potential hazards,
that must be recognized and avoided.
Noise levels may interfere with normal
discussion when the machine is
operating. By their nature, Crushing
Plant, Screening Plant and auxiliary
equipment can create dust. Screening
itself and some other machine processes
may momentarily obstruct the view of
some machine parts. In general, high
levels of respirable silica and other dust in
the air may expose Operator to health
risks for lung disease depending upon the
length and amount of exposure and type
of material being crushed and screened.
In addition, there are some risks or
hazards, which cannot be completely
guarded or avoided because of
interference with machine operations.
Accordingly, working on the Crushing
Plant requires constant alertness by all
personnel in the area. Accidents happen
unexpectedly. Below are some typical
hazards and types of accidents that
everyone working at, on or around the
Crushing Plant should be aware 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 unexpected
start-ups;
toxic and corroding agents;
machine inertia;
hot surfaces and fires;
zinc;
conveyor belts;
dust;
noise and vibration;
improper work methods;
rotating equipment and moving
components;
ejection of material from the crusher /
screen;
falling material from conveyors, and
from loading, unloading and feeding
operations;
Crushing cavity.
These typical hazards are discussed
more fully in section 2.3.1 - Typical
hazards - of this chapter. Be aware of
these hazards. All personnel working on
or around the machine should be properly
trained in avoiding these hazards.
SAFETY PROCEDURES – N11479516 / Rev. 00 11-35
SAFETY PROCEDURES
Typical Injury Types:
crushing;
slipping, tripping and bumping;
falling;
cutting;
entanglement;
burns and electrical shocks;
respiratory organ illnesses;
Asphyxiation.
2.3.1 Typical hazards
NIPS, GAPS, AND PINCH POINTS
An ingoing nip is formed by drive devices
such as belt and pulley, chain, and
sprocket or gears. Similarly, a pinch point
may be formed by rotating or moving
equipment.
Nips and gaps are serious hazards in a
Crushing Plant. They are usually
guarded by nip guards, railings, or
location. In all cases, extreme care
must be taken to avoid nips, gaps, and
pinch points or serious injury or even
death may occur.
Be extremely careful when moving
near steel coil spring because there is
risk due to pinch points between the
spring coils.
POOR HOUSEKEEPING
Promote good housekeeping. Keep
machine environment, walkways,
platforms etc. clean and dry and free of
debris. Oily or wet machine environment,
walkways, platforms, steps and handrails
are slippery. In cold weather, watch out
for ice and snow. Wet spots, especially
near electrical equipment, are dangerous.
Return tools to their proper place after
use. Even then extreme caution should
be used. Follow established Crushing
Plant safety procedures. Clean slippery
deposits from walkways, ladders and
floors. Tidiness provides a safer working
environment by preventing or helping
reduce tripping, slipping, fire hazards and
electrical shocks.
ELEVATED OR NARROW WORKING
LOCATION
SAFETY PROCEDURES – N11479516 / Rev. 00 12-35
SAFETY PROCEDURES
Crushing Plants / Screening plants are
tall structures. The walkways and
platforms, designed to be used during
machine operation, are furnished with
railings to help prevent falling. When
working on an elevated surface be aware
of machine movements and other
activities in the area. Do not run on the
walkways. Do not reach over or beyond
walkway railings while the machine is
running. Do not stand on railings or toe
plates. There may be narrow access
routes for maintenance purposes. Do not
use these routes while the machine is
operating. Do not enter any close
quarters within the Crushing Plant when
the machine is operating.
LIFTING AND SHIFTING HEAVY LOADS
Cranes
Crushing Plants, like any other type of
mechanical equipment, require regular
periodic maintenance. One of the most
flagrant Crushing Plant safety violations is
the use of inadequate and unsafe lifting
equipment.
Although a Crushing Plant is a finely
tuned piece of equipment, the internal
parts of a Crushing Plant should be
assembled and disassembled with crane
facilities that have the capability of gently
and slowly lifting and lowering the various
parts that make up a Crushing Plant.
Do not use chain hoists (chain blocks) to
assemble or disassemble a Crushing
Plant. These lifting devices lack the
stability and robustness required in lifting
and positioning heavy components.
Do not use impact hammer boom or any
other equipment, 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
until the load is stable and secured from
unintended movement.
When it comes to safety, don't
compromise!
IMPORTANT!
When using a crane, always operate
within the rated capacity of the crane.
The safe rated capacity includes
weight of hook, block and any
materials handling devices such as
cables, slings, spreader bars, etc.
Subtract the weight of all these items
from the rated capacity to find the true
weight of the load that can be handled
safely. Always follow the crane
manufacturer's operational and safety
instructions.
SEE THE CORRECT LIFTING WEIGHT
OF THE SCREEN OR PARTS IN THE
INSTALLATION DRAWING.
IMPORTANT!
SAFETY PROCEDURES – N11479516 / Rev. 00 13-35
SAFETY PROCEDURES
The weight indicated in machine plates
tells the weight of standard
configuration. In many cases the
actual weight may differ greatly from
that indicated in machine plate due to,
e.g., options or ancillary equipment.
Always verify the weight of the object
you are lifting before attempting to lift
it.
Mobile cranes
Safe ratings are based on operating the
crane on firm, level ground; outriggers
must be properly extended and/or
lowered whenever required. Avoid fast
swings, hoists or sudden braking; these
can cause overloads. Do not handle
large, heavy loads in strong winds. When
moving your crane, check bridges before
crossing, make sure they will support the
total weight in question. Check
clearances under bridges for overhead
electrical lines and any overhead
obstruction. Be sure your hitcher is clear
before starting lift. Make sure the load is
securely attached.
IMPORTANT!
When using a mobile crane, always
operate within the rated capacity of the
machine to avoid buckling the boom
or tipping.
SEE THE CORRECT LIFTING WEIGHT
OF THE SCREEN OR SCREEN PARTS
IN THE INSTALLATION DRAWING.
Always handling the screen by the
lifting lugs to avoid accidents and
consequentily personnal injuries.
Take the following precautions when
lifting heavy loads:
Follow all established Crushing Plant
procedures.
Follow all instructions and safety
procedures recommended by the
crane manufacturer.
Plan the lifting and maintenance
procedures in advance. Read and
understand specific instructions for
proper use of lifting equipment prior to
using (e.g instructions of the machine,
lifting device and local regulations).
Clean the working environment
beforehand to prevent slipping and
tripping hazards.
Make sure that the crane and other
lifting devices such as chains and
slings have sufficient capacity and are
in good working order.
Do not attempt to ride or sit on moving
loads.
Be sure that crane operators, riggers
and other personnel have been
properly trained.
Rig the load firmly to prevent any
unintened movement and assure
stable and accurate positioning.
Make sure nobody is below or on the
path of the load and that the transfer
routes are clear and proper protective
clothing and gear are used.
SHARP EDGES
SAFETY PROCEDURES – N11479516 / Rev. 00 14-35
SAFETY PROCEDURES
Sharp edges may occur on any metal
structures. Equipment damage may
uncover or produce unexpected sharp
edges. Sharp edges may inflict deep and
serious cuts. Wear protective gloves
when handling materials, parts, etc. with
sharp edges. Repair or guard detected
sharp edges immediately.
HIGH-PRESSURE EQUIPMENT -
HYDRAULIC OR AIR
High-pressure oil can be dangerous.
Relieve all pressure before opening or
removing any hydraulic or air pressure
lines, valves, fittings, etc. Do not touch
pressurized components since the
pressure from a pin hole leak is so strong
that it can easily penetrate the skin or
eyes. Always exercise caution when
handling hydraulic devices.
Regularly check the condition of hoses,
pipes, valves and various connections.
Replace them as necessary. Before
starting any maintenance work, stop all
hydraulic pumps, lock out pump motors,
and depressurize the system, bringing all
components to a zero energy status.
Remember to also depressurize the
accumulators through the bleed valve for
each accumulator. Do not disconnect any
hoses until the actuator has been brought
to a zero energy status and properly
secured.
Bleed the hydraulic system regularly to
remove entrapped air that may interfere
with normal expected machine operation
or cause a hazard during maintenance.
Poorly tightened or damaged hydraulic
components may inject dangerous jets
of fluid. Before restarting the machine,
be sure that the hydraulic system is
ready for operation, and personnel are
clear of affected areas.
Machine parts may move
unintentionally and cause a risk of
injury. Before restarting the machine,
make sure that all personnel are clear
of affected areas where machine
movement may occur.
ELECTRICAL EQUIPMENT
Be especially cautious when working with
or near electrical equipment. An electric
shock can be fatal. Crushing Plant
electrical outlets must be grounded and
have ground fault interruption protection.
Tools plugged into the outlets must be
double insulated. Never expose electrical
equipment to mechanical damage or
humidity. Protect all electrical equipment
from direct contact with water or high
humidity.
SAFETY PROCEDURES – N11479516 / Rev. 00 15-35
SAFETY PROCEDURES

Protect electrical devices that move as

part of the machine from dirt and
mechanical damage.
Regularly check the operability of these
devices.
Only qualified personnel who are familiar
with the machinery and equipment in
question must perform maintenance,
repair and installation of electrical
equipment.

“AUTOMATIC FUNCTIONS AND

UNEXPECTED START-UPS”
There is a risk of an electric shock, if
sufficient precautions are not taken.
An electric shock can be fatal. For
maintenance work, disconnect all
devices from electric and hydraulic
power sources and follow Crushing
Plant lockout procedures.
Unexpected start-ups during maintenance:

Lock out and tag machine controls before

The lockout program, locks, tags and the
performing maintenance or repairs to
blocking/restraining devices provided are
avoid unexpected start-up. Failure to
designed for your protection. Your
properly lock out the machine can lead to
responsibility is to follow the program and
injury or death. Someone may
use the proper equipment.
accidentally start the machine from the
control room or an unexpected
Remember:
occurrence may activate a control. For
example, a power surge may alter the
Follow procedures.
logic of the control system status causing
an unexpected machine movement or
Stay alert.
sequence.
Do not take anything for granted.

Verify lockout.
Machine parts may move
Each person working on the unit must unintentionally and cause a risk of
have his own lock with only 1 key. injury. Absence of safety functions
may cause dangerous machine
Tag must identify the work being done movements. Do not tamper with limit
and the person(s) who locked and switches or other safety devices
tagged the control. included in the system.
Locks and tags are changed with each
shift that comes on.

Work to prevent injury or death. Follow

proper procedures at all times!

SAFETY PROCEDURES – N11479516 / Rev. 00 16-35

SAFETY PROCEDURES
If danger zones are not respected
during machine operation or
maneuvers there is a risk of serious
injury or death.
Many devices operate automatically,
following certain sequences which
have been programmed into the logic
system (i.e. programmable logic
controller, microcontroller, relay
system or similar). The danger zone is
any area within the confines of moving
machine elements, feed material or
beneath any objects being lifted. Do
not enter these danger zones unless
the machine has been properly
safeguarded according to the
Crushing Plant lockout procedure and
manufacturer's instructions.
WELDING EQUIPMENT
Weld repairs are to be performed only by
qualified personnel. Welders and welder’s
helpers must wear protective clothing and
equipment.
Precautions must be taken when torch
cutting and/or welding due to the health
hazards posed by many metals. Anyone
performing these types of procedures
should avoid breathing the fumes. Such
procedures should be done outdoors or in
a well ventilated area with either a
separate clean air supply provided to the
mechanic or with local exhaust of fumes.
Please refer to EU, OSHA, MSHA or
other applicable standards as
appropriate. One of the most frequently
used tools around the Crushing Plant is
the cutting torch.
Crushing Plants which are equipped with
hydraulic components and/or conveyor
belts and/or v-belts should have these
components depressurized and
adequately covered with flame-proof
material so that sparks, weld spatter, etc.,
cannot reach theses areas.
Ruptured high-pressure hydraulic lines
will quickly vaporize the hydraulic fluid as
it reaches the atmosphere. This
vaporized fluid can quickly become a
mass of flames, resulting in severe burns
for personnel in the immediate area.
Adequate precautions should be made to
avoid contact with these components.
Never perform welding or torch cutting
activities in the presence of flammable
materials.
Risk of injury. Fire may break out.
Never perform welding or torch cutting
activities in the presence of flammable
materials.
IMPORTANT!
All maintenance personnel who use
cutting and/or welding torches should
be advised if there are hydraulic
components in the immediate area in
which they are working.
IMPORTANT!
SAFETY PROCEDURES – N11479516 / Rev. 00 17-35
SAFETY PROCEDURES
Contact Metso Minerals or its
authorized representative prior to any
welding of major Crushing Plant
components such as main frame,
adjustment ring, bowl, etc.
Performing welding on the Crushing
Plant components can be detrimental.
Before welding, always verify that
material is weldable! Failure to do so
may result in weldment failure and
present a risk of injury and/or property
damage.
Screening surface and coatings may
burn. Gases could be toxic. Check
before burning or welding for special
precautions.
TOXIC, CORRODING AND IRRITATING
AGENTS
Before handling chemicals, carefully read
the safety instructions from the supplier of
the respective chemical. Hazardous
chemicals may be in use. Wear protective
clothing, gloves, boots, glasses, and
respirator when necessary.
Refer to the MSDS (Material Safety Data
Sheets) and Crushing Plant procedures
for handling of these materials.
Avoid prolonged contact with fluids, such
as gasoline, diesel fuel, hydraulic oil and
cleaning solvents, which may cause skin
irritation or other reactions.
MACHINE INERTIA
Due to the large inertial forces of the
Crushing Plant and Screening Plant, the
machine can not be stopped abruptly.
This is potentially hazardous to
personnel. All personnel must stay clear
of rotating elements and other moving
parts until the machine has come to a
complete stop. Regularly inspect the
structural elements to maintain safe
operation.
Be extremely careful when moving
around the screen in the start-up or
stopping. The equipment pass through
the critical frequency, increasing
momentarily your stroke.
HOT SURFACES AND FIRES
There are hot surfaces on Crushing
Plants. Protective gloves and coveralls
help protect against burns. Be aware of
hydraulic system, hoses, fittings, and
pipes. Regularly inspect and observe high
temperature lines, and fluid lines for leaks
or damage.
When in contact with hot temperatures, or
when heated themselves, some hydraulic
oils may ignite at around 392°F (200°C).
Attention must be paid to the condition of
hydraulic hoses and couplings. Remove
immediately oil spills from floor,
walkways, and pits. Fix all sources of oil
leaks and clean up spills.
In case of fire it is recommend to equip
the Crushing Plant with manual
SAFETY PROCEDURES – N11479516 / Rev. 00 18-35
SAFETY PROCEDURES
extinguishing equipment. Legislation and
regulations about suitable equipment may
vary by country. Familiarize yourself with
applicable standards. Personnel must
also be trained properly to be able to use
fire-extinguishing equipment.
A trained person with sufficient fire
extinguishing equipment must be present
during welding maintenance work. Cold
water on hot metal surfaces may cause a
violent explosion. Monitoring after welding
must be arranged as required by laws
and regulations. If no other regulations
apply, monitoring time is a minimum of
one half-hour.
Never touch the vibrator mechanism
after working period to avoid serious
injury, as burn. HIGH TEMPERATURE!
"FIRE HAZARDS”
Do not smoke while refueling, or when
handling fuel containers.
Shut off engine when refueling and
use extra caution if engine is hot.
When pouring fuel into the tank,
ground the funnel or spout against the
filler neck to avoid static electric spark.
Do not use gasoline or diesel fuel for
cleaning parts. Good commercial,
nonflammable solvents should be
used.
Do not smoke while using flammable
cleaning solvents. Whenever possible,
use non-flammable cleaning solvents.
Do not let greasy, oily rags
accumulate in a poorly ventilated
area. Store oily rags and other
combustible material in a safe place.
Never use an open flame to check
fuel, battery electrolyte or coolant
levels, or to look for hydraulic leaks
anywhere on the equipment. Use a
flashlight. Know where fire
extinguishers are kept, how they
operate, and for what type of fire.
Check regularly, at least monthly, to
be sure they are in the working area.
Do not weld or cause open flame in
the presence of flammable materials.
In the event of a fire, shut down the
Crushing Plant, hydraulic power unit
and lubrication system if this can be
safely done. Warn other people in the
area and commence fire-fighting
activities according to applicable rules.
It is the responsibility of the Owner to
maintain proper training and
instructions in these respects.
"EPOXY VERSUS ZINC"
Many Crushing Plants require some type
of backing when replacing the crushing
members. Epoxy resin backing
compounds have almost completely
eliminated the possibility of workers being
accidentally burned due to molten zinc
SAFETY PROCEDURES – N11479516 / Rev. 00 19-35
SAFETY PROCEDURES
either spilling or exploding when it comes
in contact with wet surfaces. When epoxy
backings are used, care should also be
taken when removing the liners with a
cutting torch. Do not use molten zinc as
backing material. Use epoxy only
according to specific instructions from the
manufacturer.
"CONVEYOR BELTS"
Do not use conveyor belts as
walkways. Do not climb on them.
Always stay clear of any falling or
dropping materials or components.
Never attempt to stand on, walk on, or
step across a conveyor. Never stand
below a running conveyor. Do not use
loose clothing, neck ties, necklaces or
other loose items when near
conveyors or other moving or rotating
equipment. Emergency pull cords
should be used only in case of
emergency - do not use them for
routine stoppage of conveyor. Never
attempt to service the conveyor while
it is energized. Keep in mind
hazardous nip points.
"CRUSHING PLANT DUST"
By their nature, Crushing Plant and
auxiliary equipment such as chutes,
transfer stations, screens, etc. can create
dust and, if not contained, the dust can
escape into the air. In general, high levels
of dust (particularly, respirable silica) in
the air can create a hazard of lung
disease, depending upon the
concentrations of dust, the length of
exposure, and the type of material being
crushed. Dust protective devices and dust
warnings may be required by OSHA,
MSHA or local laws.
The Owner and Operator of the Crushing
Plant must identify the material being
crushed and ascertain whether respirable
dust from the application poses a health
hazard to personnel in the vicinity of the
Crushing Plant. If the material presents
such a hazard the Owner and Operator
must take all necessary measures to
ensure that personnel are protected from
the dust. Such measures include, but are
not limited to providing dust collection
system, using water spray bars at the
feed and discharge points, crusher
transfer points and screens and providing
adequate personal respiratory protection
devices to workers.
Crushing with a choke level may also
reduce the amount of dust issuing from
the Crushing Plant itself. Because the
configuration of each rock crushing
installation is different, Metso Minerals
recommends that the Owner and
Operator consult Metso Minerals or a
dust consultant about possible alternative
means of dust reduction.
IMPORTANT!
Metso Minerals highly recommends
that dust protective devices such as
an appropriate respirator be worn by
anyone exposed to airborne dust to
prevent its inhalation.
SAFETY PROCEDURES – N11479516 / Rev. 00 20-35
SAFETY PROCEDURES
Breathing dust may be hazardous to
the health of anyone working at, on, or
around the Crushing Plant. It can
cause serious or fatal respiratory
diseases including silicosis! It is the
responsibility of the Owner and
Operator to determine the necessity
and adequacy of protective devices
and warnings, to provide them, and to
ensure that they are used and
followed!
IMPORTANT!
Screens can be fully enclosed. This
will not only eliminate dust and reduce
noise emissions, but also provide the
operator protection from eject stones.
WITHOUT DUST PROTECTION
WITH DUST PROTECTION
“NOISE AND VIBRATION"
Crushing Plant Noise
Crushing Plant by its very nature is noisy
and the auxiliary equipment found at, on
or around the Crushing Plant such as
chutes, transfer stations, screens, etc.,
can at times be noisier than the Crushing
Plant itself. Typical Crushing Plant noise
level while crushing range from 100 - 110
dB measured at 1 m (3ft) from the
equipments.
Metso Minerals recommends wearing ear
protection at, on and around Crushing
Plant, particularly when the noise level
exceeds 85dB. It is recommended that
the Owner develop a signaling
communication system in noisy
environments to reduce the risk of
accidents. Proper machine maintenance
and replacement of worn parts can help
reduce noise.
The most commonly applied noise
reduction procedures are:
use of isolation techniques;
equipment enclosures;
operator enclosures;
Silencers.
Allowable noise levels and exposure
limits are regulated by various agencies
such as ISO, OSHA, MSHA, etc. Refer to
applicable safety regulations for
permissible noise exposures, and take
steps to ensure compliance with those
regulations.
SAFETY PROCEDURES – N11479516 / Rev. 00 21-35
SAFETY PROCEDURES
Vibration
Long term exposure of Operator to
vibration may result in detrimental health
effects. There is an increased risk of
falling on a vibrating platform. Avoid
standing on a vibrating Operator's
platform or walkway.
Unexpected or excessive vibrations may
be a sign of wear and/or maintenance
needs. Excessive vibrations associated
with a portable crushing or screening
plant is frequently caused by improper
cribbing.
It is recommended to regularly monitor
vibration levels of machine components
including, but not limited to:
bearings;
shafts;
rollers;
Structural members (including
conveyor frames, walkways,
platforms, hoppers, chutes, etc.).
IMPROPER WORK METHODS
Improper work methods and motions may
cause physical injuries. Use suitable
tools, cranes or jacks for moving large
and heavy objects. Overreaching and
improper support for loads may lead to
injuries to the back or other parts of the
body. If you are unsure of proper work
methods, contact your safety director or
other person responsible for ensuring the
safety at your work place.
When lifting equipment by hand, protect
your back by lifting close to your body
and using your legs without twisting. Use
hoists whenever possible. Stand clear of
hoisted loads and lifting cables.
ROTATING EQUIPMENT AND MOVING
COMPONENTS
Rotating and moving components provide
pinch points, snagging possibilities and
other potential hazards. Keep clear of all
moving parts until they come to a
complete stop. Do not use any body part,
tool or other foreign object to attempt to
stop, adjust, clear, or clean any area in
proximity to moving equipment such as
vibrating feeder, conveyor belts, drives or
other rotating parts of the crusher.
Engaging in such activities can result in
severe personal injury, including death.
Screens, designed to operate within a
specific RPM range for maximum
efficiency, are typically checked with a
tachometer. Make sure that any access
openings have a protective cover in place
at all times except when RPM readings
are being taken.
Never change sheave combinations
without first consulting your Metso
Minerals representative.
EJECTION OF OBJECTS FROM THE
CRUSHING PLANT
SAFETY PROCEDURES – N11479516 / Rev. 00 22-35
SAFETY PROCEDURES
Ejected objects from the Crushing Plant
may cause bodily injury. For example
rock can be thrown several meters
(several yards) into the air out of the
crushing cavity during operation.
Ejected materials may include rock, tramp
metal, metal rods and work implements.
Do not look into crushing cavity while
crusher is in operation or near the
screening surface when the screen is
operating. Never attempt to clear jam on
feeder, crushing cavity or conveyors
when system is energized.
FALLING MATERIAL FROM
CONVEYORS, LOADING, UNLOADING
AND FEEDING OPERATIONS
Rocks or other objects may fall from
conveyors during loading, unloading and
feeding operations. Impact of falling
material may cause serious bodily injury.
To assure safe operation, all personnel
must be alert when operating or working
at or around the machine.
Wear proper protective clothing (including
also helmet) and protective devices. Keep
all non-operating and non-trained
personnel clear of the Crushing Plant at
all times. Never walk under any
equipment included in loading, feeding,
crushing, conveying, discharging or
stockpiling material.
2.3.2 Typical injury types
CRUSHING
In general, avoid areas where you may
be exposed to expected or unexpected
machine movements. Crushing injuries
typically occur either between two rotating
or moving parts, or between a moving
component and a stationary object.
Keep all body parts, clothing and tools
away from areas where they may get
trapped, pinched, or crushed, or
otherwise come into contact with moving
parts on the Crushing Plant. When
moving equipment, be sure the path is
clear. Horns and lights, where provided,
are for your safety to alert you of moving
objects. Pay attention to all such devices.
SLIPPING, TRIPPING, AND BUMPING
Items such as hoses, tools, etc., on
walkways and Crushing Plant floors
impede movement and create a tripping
and slipping hazard. Good housekeeping
reduces the risks considerably.
Personnel should wear safety shoes that
reduce the risk of slipping and provide
protection against falling objects or
crushing. Hydraulic oil leaked or spilled
on the floor must be cleaned up
immediately.
To help avoid injury, be aware of parts
positioned close to the floor level or
SAFETY PROCEDURES – N11479516 / Rev. 00 23-35
SAFETY PROCEDURES
protruding machine components,
changes in elevation of platforms,
walkways, and narrow access points. It is
recommended that safety shoes be worn
at all times. Wear safety helmets and
other safety equipment as appropriate.
FALLING
Use only designated access routes
designed for the purpose, for example
walkways and platforms. Walkways and
platforms are furnished with railings
designed to meet applicable standards.
However, in some work phases, railings
or platforms may have to be temporarily
shifted aside. In those cases, special
caution signs or temporary barriers must
be used when working on the machine.
Use personal fall protection gear,
temporary barriers, interlocks, or other
warning devices where appropriate.
Never attempt to operate, service, or
repair the Crushing Plant without first
ensuring proper protection against falling.
Guards that are moved aside must be
installed immediately after maintenance
work and before the machine is returned
to operation. Never climb or stand on
areas of the Crushing Plant not
specifically designated for that purpose.
Do not operate any equipment until all
guard rails and safety devices have
been re-installed or returned to their
Failure to do this
proper operating could result in
condition.
serious injury or death.
KEEP THE AREA CLEAN!
CUTTING
Do not reach in or enter:
the movement paths of cutting
equipment;
between moving machine
components;
between moving loads and machine
structures.
ENTANGLEMENT
To avoid entanglement, avoid wearing
loose clothing that could be caught by
rotating shafts, conveyors, and other
moving parts and materials. Remove
neckties, necklaces, rings, and other
jewelry before performing work
assignments. Also protect a long beard or
hair from entanglement.
Do not touch a rotating roller, sheave,
pulley, idler or moving conveyor belts with
any body part or work implement, as you
may become entangled and pulled into a
hazardous area.
SAFETY PROCEDURES – N11479516 / Rev. 00 24-35
SAFETY PROCEDURES
Never attempt to service, repair, or
troubleshoot any moving part of the
Crushing Plant while it is energized or
otherwise capable of movement.
Keep safety gates, shrouds, guards,
and other protective devices in place
and in good working condition at all
times. Test emergency stop, electrical
interlocks, and related limit switches
frequently.
BURNS AND ELECTRICAL SHOCKS
Protective gloves and coveralls help
protect against burns. Be cautious around
and near hydraulic system hoses, fittings
and pipes. Regularly inspect and repair
leaking or damaged high temperature
lines and fluid lines.
To avoid electrical shocks:
Power must be shut off and locked out
before any servicing or maintenance
work is done. Unplug or disconnect all
auxiliary motors and equipment.
DO NOT drill blindly into beams,
electrical cabinets or other enclosures.
Avoid any contact between moisture or
other fluid and electrical equipment.
IMPACT FROM EJECTED MATERIALS
There are several hazards related to
falling, flying or otherwise ejected
materials when the Crushing Plant is
being operated or serviced. For example,
rock can be thrown several meters
(several yards) into air out of crushing
cavity during operation or when it is
screening. Ejected materials may include
rock, tramp metal, metal rods and work
implements. Keep the safety grate down
during the operation. Wear proper
protective clothing (including helmet) and
protective devices. Always use properly
maintained and approved tools and work
methods. Stay clear from the path of
ejected materials, also during lifting,
assembly and disassembly operations.
Removal of tramp iron jammed between
the crushing members is extremely
dangerous. Follow the instructions in the
instruction manual.
Do not look into crushing cavity while
crusher is in operation.
Do not look direct to the screening
surface when the material is classified.
2.4 Personal protective equipment
and clothing
Personal protective equipment and
clothing such as foot protection, helmet,
hearing protection, dust protective
devices, safety glasses or other personal
protective clothing and equipment should
be worn at all times. All equipment should
be maintained in accordance with
applicable standards. Respirators,
goggles, protective masks, gloves, boots,
and other such equipment shall be
cleaned and disinfected before being
used by another employee. The Owner
and Operator are responsible for ensuring
that all eye, head, respiratory, and ear
protection conforms to applicable
standards.
IMPORTANT!
SAFETY PROCEDURES – N11479516 / Rev. 00 25-35
SAFETY PROCEDURES
Always use right size of protective
equipment.
IMPORTANT!
It is the responsibility of the Owner
and Operator to determine the
necessity and adequacy of protective
devices and warnings, to provide
them, and to ensure that they are used
and followed.
Hearing Protection
Noise level in the machinery area may
exceed 85 dB, and exposure to the
machinery area in such circumstances
without adequate hearing protection may
lead to hearing loss.
Therefore, users must be provided with
appropriate hearing protection of the type
and to the extent required by law.
Eye and Face Protection
General requirements should include:
The Owner should ensure that
personnel for the machine area use
appropriate eye or face protection
when exposed to eye or face hazards
such as flying material, molten metal,
liquid chemicals, acids or caustic
liquids, chemical gases or vapors.
The Owner should ensure that
affected personnel use eye protection
that includes side protection from
flying objects.
The Owner should ensure that
affected personnel who wear
prescription lenses while engaged in
operations that involve possible eye
hazards wear eye protection that
incorporates the prescription in its
design, or wear eye protection that
can be worn over the prescription
lenses without disturbing the proper
position of the prescription lenses or
the protective lenses.
Respiratory Protection
Respiratory protection is required when
the air contains contamination such as
harmful dusts, fogs, fumes, mists, gases,
smokes, sprays, or vapors. The primary
objective is to protect the health of
workers.
Respiratory protection must be provided
by the Owner when such equipment is
necessary to protect the health of
personnel. The Owner shall provide the
respiratory protection and training
programs, which are applicable and
suitable for the purpose intended and
comply with the latest requirements and
recommendations of health authorities
and regulatory agencies.
IMPORTANT!
When working around the screen
without dust enclosure, the respiratory
protection must be used.
IMPORTANT!
SAFETY PROCEDURES – N11479516 / Rev. 00 26-35
SAFETY PROCEDURES

The enormous degree of convenience

as well as the high safety factor
involved when using plastic backing
agents has made the use of molten
zinc for Crushing Plant liner backing
obsolete. See section 2.3.1 «Typical
hazards».
The Owner should ensure that affected
personnel wear a protective helmet
IMPORTANT! approved by OSHA, MSHA (or by other
The area should be well ventilated. applicable authority) when working in
Epoxy fumes can cause nausea or eye areas where there is a potential for head
or skin irritation. injuries from falling objects or walking
throughout areas with low head
clearance.
IMPORTANT!
The Owner should ensure that a
Breathing dust may be hazardous to
protective helmet designed to reduce
the health of anyone working at, on, or
electrical shock hazard is worn by
around the Crushing Plant
personnel when near exposed electrical
conductors which could contact the head.
IMPORTANT!
Metso Minerals highly recommends Hand Protection
that adequate dust-protective devices
such as a respirator be worn by
anyone exposed to airborne dust,
particularly silica dust, to prevent its
inhalation.

Foot Protection
The Owner should ensure that personnel
use properly sized appropriate hand
protection when hands are exposed to
hazards such as those from skin
absorption of harmful substances, cuts or
lacerations, abrasions, punctures,
chemical burns, thermal and electrical
The Owner shall ensure that affected
personnel use protective footwear when burns, and harmful temperature
working in areas where there is a danger extremes.
of foot injuries due to falling or rolling
objects piercing the sole, and where feet
are exposed to electrical or chemical
hazards.

Head Protection

SAFETY PROCEDURES – N11479516 / Rev. 00 27-35

SAFETY PROCEDURES
Safety Harnesses
The Owner should ensure that any
person working on elevated areas not
protected by railings or on hazardous
places must wear suitable safety
equipment, including safety harnesses, if
there is a risk of falling. Confined spaces
may also require safety harnesses.
Work Clothing
The Owner should ensure that personnel
wear appropriate clothing to help protect
against hazardous material and hot
surfaces. Loose clothing can get caught
in a nip, shaft, or other moving machine
components.
Tools
The Owner should ensure that personnel
use appropriate tools for the job. Use
tools that are specially designed to break
away or are easily released to help avoid
certain accident situations such as
unexpected movement at a nip point or a
rotating shaft. Under no circumstances
must tools be allowed to come into
contact with moving parts while the
Crushing Plant is energized.
When working in humid or damp
environments, use hydraulic tools or
electrical tools that are suitably grounded,
double insulated, or have ground fault
interruption circuits.
Safety Locks and Tags
Follow all lockout tag procedures. Refer
to appropriate standards and instructions
provided by Metso Minerals.
For maintenance work, disconnect all
devices from electric power sources.
Bring all hydraulic gravity or spring-
loaded devices to a zero-energy
status. Follow lockout procedures.
The lockout program, locks, tags and the
blocking/restraining devices provided are
designed for Operator’s protection.
Operator’s responsibility is to follow the
program and use the proper equipment.
Remember:
Follow procedures;
Stay alert;
Do not take anything for granted;
Verify lockout;
Tag must identify the work being done
and the person(s) who locked and
tagged the control;
SAFETY PROCEDURES – N11479516 / Rev. 00 28-35
SAFETY PROCEDURES
Locks and tags are changed with each
shift that comes on.
Work to eliminate injury and death. Follow
proper procedures at all times!
3 MACHINERY SAFETY
3.1 Protective devices and
accessories for machine safety
3.1.1 Overview
The machine system has many built-in
safety features. Owners and Operators
should make themselves familiar with the
function and purpose of each feature and
make sure all of the features are enabled.
Owners and operators should never
attempt to defeat, bypass or disable any
safety features. If any of the features are
defeated or become disabled, the
machine should not be operated until
corrective action is taken and all safety
features are restored.
3.1.2 Emergency-Stop (E-Stop)
Use the emergency stop when injury may
occur or human life is in danger from
continued operation of the machine. This
provides the quickest, most sure way to
stop the machine. Due to the large inertial
forces of the Crushing Plant and
Screening Plant and components, the
machine can not be stopped abruptly.
Large red emergency stop buttons are
typically located in control panels near the
vicinity of danger points.
Emergency stops can be, and often are,
in the form of pull cords that run parallel
to conveyors and surround hazards.
On large complex systems, the E-stop
may control only those components
that are in the immediate area.
The location of local E-stop buttons may
vary on different machines; therefore the
locations of these buttons must be
verified from the operating and
maintenance manuals specific to the
equipment and/or from proper training.
In emergency stop situations, the
objective is to stop the machine as soon
as possible to minimize potential injuries
while maintaining the structural integrity
of the machine.
Emergency stop not only stops the
machine but often it may initiate other
protective sequences.
Note: It may be necessary to engage reset
switches before movement can resume.
3.1.3 Safety interlocks
Safety interlock is a device that will
interrupt the supply of electricity,
hydraulic oil or compressed air to an
actuator or motor. A machine already in
operation may need to stop quickly due to
Operator error, safety violations, or an
unexpected machine event. For example,
a safety gate may be interlocked to stop a
machine if the gate is opened while the
machine is running.
SAFETY PROCEDURES – N11479516 / Rev. 00 29-35
SAFETY PROCEDURES
Interlocks can also be used to prevent
sudden unexpected movement of a
machine function or component.
During operation, the logic system (i.e.
programmable logic controller,
microcontroller, relay system or similar
device) controls the functions of the
machine. Interlocks built into the system
employ limit switches and other sensors
to help assure proper machine operation.
THEREFORE IT IS IMPORTANT THAT
INTERLOCKING ARRANGEMENTS
ARE NOT REMOVED, MODIFIED OR
BYPASSED, AND THAT THEY ARE
CORRECTLY ADJUSTED. LIMIT
SWITCHES, AND OTHER SENSORS
MUST BE KEPT IN GOOD WORKING
ORDER.
Electric Motors
Electric drives and motors may be
controlled to stop or reduce speeds, as
determined by the safety interlocks at a
particular location.
Hydraulic System
Components that help protect the
hydraulic system include certain valves,
such as hose burst valves, pressure relief
valves, counterbalance valves and pilot-
controlled throttle valves as well as
pressure transducers and drain valves for
pressure accumulators. Metso Minerals
uses these components where applicable
in the hydraulic systems minimize the
potential for hazardous situations to
occur.
A hose break valve functions to lock up if
fluid flow is discharged too rapidly from
actuating cylinder, as happens if a hose
breaks and the loads react to gravity.
The pressure relief valve prevents the
system pressure from rising beyond
system capabilities. It helps protect the
entire fluid system and any operators in
the vicinity from bursting hoses and
components.
The pilot-controlled throttle valve helps
prevent uncontrolled actuator
movements.
Pressure transducers monitor the system
pressure for information or control
purposes.
Safety Gates
Some safety gates are designed so that
opening or closing of the gates will
prevent or stop a specific machine
function in that area. Hydraulic, hydraulic
or electric limit interlock switches may cut
off the drive or actuators power or initiate
an emergency stop mode.
For specific operation, see later sections
of this manual.
SAFETY PROCEDURES – N11479516 / Rev. 00 30-35
SAFETY PROCEDURES
Safety gates must not be opened
during normal machine operation.
Exceptions to this rule are defined in
the operating instructions.
Safety gates may also be opened for
maintenance purposes when the machine
has been stopped. Follow all lockout
procedures.
Cable Switches
Cables or ropes connected to the
electrical switches can be used as
interlocks also. They may stop machine
function in areas where control panels
cannot be closely located but where
Operators may be working. Know the
locations of e-stop pull cords for
conveyors.
3.1.4 Additional warning devices
Horns and Lights
If visual contact between work places is
obstructed or if communication is difficult,
sound and/or light signaling devices may
be used before starting the machine or a
machine function. The warning device for
start-up should operate so that personnel
are given sufficient time to move to a safe
distance from the machine. It is the
responsibility of the Owner to ensure that
the Crushing Plant is always equipped
with required horns and lights.
Safety Signs and Labels
Safety signs have colors to determine the
degree of hazard in particular areas.
These signs must not be removed.
Temporary placement of safety signs and
danger tags should also be used on the
control panels to warn of maintenance
work and lockout situations.
Obey all warning and safety signs on the
machine and in the manual.
Safety Warning Colors: Color of safety
warnings is typically safety yellow.
3.1.5 Walkways, service platforms,
ladders and railings
The design of walkways, ladders and
railings follow standards and regulations
for the application. The walkways provide
access to the machine. Safe operating
procedures must be followed when on
walkways. Never stand, walk or climb in
or on any area of the Crushing Plant not
designated for such activity. If an area of
the Crushing Plant must be accessed and
cannot be reached by designated
walkways, ladders, or platforms, then the
Owner and Operator must make all
necessary arrangements for safe access
to the area, including but not limited to
safe lifting devices and fall protection.
Extreme caution must always be used
on machine walkways.
3.2 TRANSPORT
SAFETY PROCEDURES – N11479516 / Rev. 00 31-35
SAFETY PROCEDURES

Observe the following precautions before 13. Follow all applicable laws and
transporting the Crusher Plant: regulations.

1. Chock chassis tires securely

whenever connecting or disconnecting 3.3 TOWING
chassis from tractor or dolly.
Observe the following precautions before
2. Check tire pressure. Use a protective
towing the Crusher Plant or its
cage or a clip-on type air chuck and
components:
remote in-line valve and gauge when
inflating tires. Never exceed maximum
inflation pressures of the tire or rim. Check if towing is allowed for each
individual equipment;
3. Check tightness of wheel lug nuts
before transport and check frequently 3.4 AT THE WORK-SITE
during transport.

4. Check that brake system operates 3.4.1 Precautions

correctly.

5. Observe maximum axle and tire Observe the following minimum

loading capacities. precautions at the work-site:

6. Protect components being transported 1. Know the locations of

using appropriate shipping braces and underground and overhead
blocking material. powerlines and other potential
hazards.
7. Travel may be limited to daylight
hours only, depending on your specific 2. Select the work-site with care.
plant and applicable status The ground must be firm, level
regulations. and able to support the weight of
the entire plant. Make sure there
8. Follow recommended limits on towing is enough room for loading
speed. ramps, loaders, conveyors, etc.
and for safe maneuvering of
9. Make sure all lights are on and that trucks and loaders.
they are operating correctly.
3. Check that cribbing is secure
10. Use traffic warning flags, signs and and that plant has not shifted or
lights as required. settled.

11. Before moving the Crushing Plant, 4. Make sure that electrical cables
check all roadways and bridges on the are protected from wear and
route for weight limits. traffic.

12. Check clearance of bridges, overhead 5. Follow pre-operation checks and

lines and other overhead obstructions. start-up procedure covered in
the individual manual supplied

SAFETY PROCEDURES – N11479516 / Rev. 00 32-35

SAFETY PROCEDURES
with your specific unit
equipment.
3.4.2 During operation
Keep watch
Do not rely too much on automated
systems. Observe Crushing Plant
equipment while the system is running.
Pay attention to unauthorized persons
approaching the site as well as any
unusual behavior of the equipment
(uncommon noise, vibration, smell,
reduced output, etc.).
Clearing
Crushers Plant equipment can become
plugged and stall because of power
failures, surges of material or other
unplanned events. Clearing Crusher is
potentially very hazardous. Shut down the
system completely, lock and tag out all
applicable controls and follow all
instructions in the instruction manual of
your screen.
4 SAFETY DURING MAINTANANCE
REPAIR
4.1 GENERAL INFORMATION AND
SAFETY LOCKOUTS
Detailed instructions for the operation of
the machine can be found in following
sections of the manual. Because each
machine section may incorporate unique
functions, some of which may be
automated, maintenance personnel
should be knowledgeable of the operation
of the machine sections in order to
perform the maintenance and repair work
as safely as possible.
DO NOT COMPROMISE SAFETY DUE
TO TIME PRESSURES.
FOLLOW ALL CRUSHING PLANT
SAFETY AND FIRE PREVENTION
PROCEDURES.
Before starting any repair, maintenance
or troubleshooting work on the machine,
ensure the following:
If you have not been trained to
perform the required repairs,
maintenance or troubleshooting, or
you are unsure how to safely
perform the activity - STOP! Never
attempt to repair, maintain or
troubleshoot any aspect of the
Crushing Plant unless you are
thoroughly trained for the activity
and understand how to perform the
activity in a safe manner.
Be sure to coordinate all repair and
maintenance work with other
Crushing Plant operations.
Use lockout and warning signs to
inform others that maintenance and
repair work are in progress. These
signs should only be removed (after
all work has been completed) by the
person who has placed them there.
Transmit all knowledge of the
maintenance work to the
succeeding shift.
Know the whereabouts of all
personnel in, on, at and around the
machine.
Never service any machine or
component without first referencing
its maintenance manual.
Before handling chemicals, refer to
the MSDS (Material Safety Data
SAFETY PROCEDURES – N11479516 / Rev. 00 33-35
SAFETY PROCEDURES

Sheets) and Crushing Plant Be sure all mechanical components

procedures for handling of these are brought to a zero energy status
materials. including all spring driven devices,
cylinders, accumulators, drive shafts,
pulleys, rollers, gears, etc., prior to
4.2 MECHANICAL SAFETY DURING entering the machine and performing
MAINTENANCE AND REPAIR
the work. Never attempt to perform
repair, maintenance, or
4.2.1 General troubleshooting work on or in
proximity to energized mechanical
components.

IMPORTANT!
FOLLOW ALL ESTABLISHED Block up and support parts as
LOCKOUT PROCEDURES. REFER TO necessary to prevent any unexpected
THE APPROPRIATE STANDARDS. motion when performing maintenance.
For repair, maintenance or
troubleshooting work, disconnect all
devices from electric, pneumatic and 4.2.2 Fire Safety During Maintenance
hydraulic power sources and follow and Repair
lockout procedures.
The lockout instructions, locks, tags
and the blocking/restraining devices
provided are designed for your
protection. Your responsibility is to
follow the instructions and use the
proper equipment. Observe all regulations on fire safety.
Remember: Sources for fires include, but are not
Follow procedures; limited to the following:
Stay alert;
Do not take anything for granted; sparks from grinding;
Verify lockout;
Tag must identify the work being flames and molten metal from welding
done and the person(s) who locked or torching;
and tagged the control; electrical arcing;
Locks and tags are changed with
each shift that comes on. spontaneous combustion;
Work to eliminate injury and death.
Follow proper procedures at all times! Smoking.

Before starting any work take the

following steps to prevent a fire hazard:

Properly dispose of rags with

combustible material to avoid
IMPORTANT! spontaneous combustion.

SAFETY PROCEDURES – N11479516 / Rev. 00 34-35

SAFETY PROCEDURES

Move flammable materials 10m (33ft)

or more away from any fire hazard. observing the maintenance and
lubrication instructions of the machine
Clean up all debris. and equipment suppliers;

Clean up all oil spills and leaks;
Remove any source of flammable
gases, liquids or solids.
Use proper electrical grounding
techniques for welding.
Provide adequate fire extinguishing
equipment; inspect such fire
equipment regularly.
Arrange for qualified personnel to
guard against fire while welding,
cutting, or heating operations are
being performed, as well as a
sufficient period of time after the work
is completed.
keeping the machine and surrounding
area clean and orderly;
monitoring the vibration levels of the
machine and to help predict bearing
failures;
monitoring the power consumption of
motors to help detect early failures;
repairing all leaks as soon as possible
to prevent more serious conditions
that eventually may occur;
monitoring the condition of pipes and
tubes enclosed in ducts; repairing
possible leaks.

Protect yourself and others from sparks 4.2.4 Confined Spaces

with proper personal protective
equipment and clothing.

4.2.3 Preventive Maintenance

Preventive maintenance will both

increase safety and be economically
beneficial. It is more safe and economical
to replace a worn part during a scheduled
shut-down than to repair a broken device
A confined space means a space that:
in the middle of a production cycle. A
machine or device that is not in proper
1. is large enough and so
condition, and that has been left without
configured that a person can
regular maintenance and inspections, is a
enter and perform assigned
safety risk for its user. For instance,
work; and
without lubrication a bearing may fail,
bringing a production line down.
2. has limited or restricted means
Furthermore, the hot bearing may present
for entry or exit (for example, the
a fire hazard or cause skin burns.
crushing cavity, tanks, vessels,
silos, storage bins, hoppers,
Some preventive maintenance
vaults, and pits are spaces that
suggestions for a machine include:

SAFETY PROCEDURES – N11479516 / Rev. 00 35-35

SAFETY PROCEDURES
may have limited means of
entry.); and
3. Is not designed for continuous
employee occupancy.
Certain confined spaces may require an
entry permit program to allow entry. Be
sure that all applicable procedures are
followed. If you have questions contact
your Crushing Plant supervisor for more
information.
Confined spaces may contain high
concentrations of gases, which may
cause injury or death. Follow all
established safety procedures.
4.3 ELECTRICAL SAFETY DURING
MAINTENANCE AND REPAIR
4.3.1 General
Follow all established lockout
procedures.
For maintenance work, disconnect all
devices from electric, pneumatic and
hydraulic power sources and follow
lockout procedures.
The lockout instructions, locks, tags
and the blocking/restraining devices
provided are designed for your
protection. Your responsibility is to
follow the program and use the proper
equipment.
Remember:
Follow procedures;
Stay alert;
Do not take anything for granted;
Verify lockout;
Tag must identify the work being
done and the person(s) who locked
and tagged the control;
Locks and tags are changed with
each shift that comes on.
WORK TO ELIMINATE INJURY AND
DEATH. FOLLOW PROPER
PROCEDURES AT ALL TIMES!
Be sure all electrical components are
brought to a zero energy status including
capacitors and similar electrical devices.
Before maintenance work:
Be sure all control power supplies are
turned off, disconnected, and lock out
procedures have been followed;
Confirm that ALL power sources are
disconnected. Some electrical devices
may be supplied by more than one
power source;
Be aware that multiple voltage levels
may exist in some junction boxes.
Ensure that during lockout
procedures, locks and signs are
appropriately attached, and
subsequently removed only by the
person who installed them after all
SAFETY PROCEDURES – N11479516 / Rev. 00 36-35
SAFETY PROCEDURES
work is completed. Follow Crushing
Plant lockout instructions for
placement and removal.
For testing and troubleshooting, clear
all personnel from the machine just as
though the machine were being
returned to production mode.
Reactivate the necessary power
supplies and perform the tests. Then
again disconnect all power supplies
and follow lockout instructions before
further maintenance work is
performed.
Be sure electrical supply voltage is
disconnected before drilling into any
structural frame members. Electrical
cables may be inside.
Verify that electric motors are
disconnected before starting any
maintenance work, thereby
preventing the supply of electricity to
the motor. Generally the disconnects
are located in the drive control room.
Each person performing maintenance
work should install their lock and sign
the lockout tag.
4.3.2 Electrical Fault Situations
Electrical faults may be caused by
component failures such as loose or
damaged wiring. Diagnostics are
provided through pilot lights, alarms, and
help messages.
IMPORTANT!
Electrical connections can and do
loosen due to vibration in transit and
thermal expansion of the wires and
lugs in operation. This is especially
true after initial delivery, break in and
after major relocation. Loose
connections increase current draw,
which can result in false trips,
intermittent circuits, and burned-out
components. As part of the start-up,
check and retighten as necessary all
electrical connections in the electrical
enclosure. Repeat after the first forty
to fifty hours of operation. This work
must be performed by properly trained
personnel.
IMPORTANT!
Improper phasing will damage
backstops in conveyor drive reducers
and may damage hydraulic system
components.
4.3.3 Program Changes
Changes to Metso Minerals' supplied
control program should be made only
by Metso Minerals personnel. Faulty
program code may cause the machine
to behave unexpectedly. Any changes
to interlock circuitry must be made
with extreme caution and be reviewed
and approved in writing by Metso
Minerals before implementation.
An electric outlet may be supplied in the
logic center and control cabinet for
programming purposes only. Do not
connect any electrical tools to this outlet.
The tool may cause electrical
disturbances in the machine control
system. This could alter the machine
SAFETY PROCEDURES – N11479516 / Rev. 00 37-35
SAFETY PROCEDURES

control program and cause unpredictable

machine operation. Mineral and other oils and additives
can cause skin irritation. Inhaled oil
REMARQUE: Do not use the logic center mist can also cause internal irritation,
or control cabinet’s outlet for anything headache or nausea. Avoid repeated
other than a programming device! exposure to these materials. Use
appropriate personal protective
equipment.
4.4 HYDRAULIC SAFETY DURING Purge entrapped air from the hydraulic
MAINTENANCE AND REPAIR system. Entrapped air in the hydraulic
system can cause erratic and
unexpected movements.
Oil mist in the work area or oil leaking
onto floors and walkways will cause a
Follow all established lockout serious risk of slipping. Clean up all
procedures. spills and repair leaks immediately.
For maintenance work, disconnect all Hydraulic oil temperature may be
devices from electric, pneumatic and extremely high.
hydraulic power sources and follow
lockout procedures.
The lockout instructions, locks, tags
and the blocking/restraining devices
provided are designed for your
Elevated temperatures levels can be
protection. Your responsibility is to
hazardous and may cause severe
follow the program and use the proper
burns. Wait until machine cools down
equipment.
before doing maintenance or repair.
Remember:
Follow procedures;
Stay alert; A mixture of air and oil mist may
Do not take anything for granted; explode at higher temperatures.
Verify lockout; Hydraulic oil spilled on hot machine
Tag must identify the work being surfaces may start a fire.
done and the person(s) who locked
and tagged the control; Pressurized hydraulic hoses should
Locks and tags are changed with not be handled with bare hands since
each shift that comes on. high-pressure leaks may easily
WORK TO ELIMINATE INJURY AND penetrate the skin. Hydraulic fluid
DEATH. FOLLOW PROPER pressure in the hoses may exceed
PROCEDURES AT ALL TIMES! 3000 PSI/210 bar/21MPa.

Before proceeding with any repair,

maintenance or diagnostic procedures on
the hydraulic system, bring all
components to a zero energy status, Risk of personal injury due to high-
including cylinders, accumulators, spring pressure fluid jets. Do not check for
loaded hydraulic devices, circuitry pressurized leaks with bare hands.
between valves and actuators, etc.

SAFETY PROCEDURES – N11479516 / Rev. 00 38-35

SAFETY PROCEDURES
Use cardboard or other appropriate
techniques.
Hydraulic hoses are subject to wear and
tear. Pressurized hoses tend to straighten
up, bend or twist due to reaction forces.
Replace all weakened or deteriorated
hoses promptly. Keep hoses properly
clamped and secured to help prevent
being whipped by broken hoses.
Avoid letting dirt and other impurities
into the system while doing
maintenance work. Use lint free cloths
for cleaning the hydraulic components
system.
When changing a cylinder, or other
hydraulic device, plug all open ports
and hose ends. Catch spilled oil in a
suitable storage device and avoid
introducing dirt into the system.
Dispose of all waste fluids as
presented by law.
Tighten disconnected pipe and hose
couplings immediately after
reinstallation. Before finishing the
work, check all parts and connections
that have been serviced or repaired.
Before starting up the pumps, make
sure that maintenance work is
completely finished in all work areas.
When starting up the pumps, stay at a
distance from the areas, which were
repaired.
Before opening the main valves, make
sure that there is no one working
between any parts of the machine,
since pressurization of the system
may cause machine motion.
Once the system is in the pressurized
status, test repaired system for proper
operation before putting system back
into production.
Check the system for possible leaks after
repair. Leaking fittings must not be
tightened when under pressure. To seal
threaded fittings, use appropriate sealing
rings or a sealing compound suitable for
hydraulics.
4.5 GENERAL MAINTENANCE WORK
The following are some of the do's and
don'ts to be followed as part of normal
Crushing Plant procedures:
Do not perform any maintenance on
moving machinery. This includes such
items as adding lubricating oil or
greasing parts while the screen is in
operation.
Never clear a jam on or in the feeder,
screening media, crushing cavity or
conveyors when system is energized.
Do not put hands or feet on the
release cylinders, which protect the
crusher from tramp iron overloads
while the crusher is in operation.
Do check the manufacturer's
recommendations for periodic
maintenance procedures. These
maintenance procedures are designed
to not only avoid damage to the
equipment but also to avoid harm to
the Operator.
Never look into the crushing cavity or
screening surface while equipment is
in operation.
When using a crane or other lifting
device to raise or lower a load keep all
personnel clear of the area.
SAFETY PROCEDURES – N11479516 / Rev. 00 39-35
SAFETY PROCEDURES

Never detach a lifting device from its

load until the load is securely affixed
at its designation, or steps have been
implemented to prevent the load from
unintended shifting or falling.

Never walk, stand, crawl or lay under

any load hanging from a crane or
other lifting device.

Do not put hands or fingers between

spring coil, when the screen is in
operation.

SAFETY PROCEDURES – N11479516 / Rev. 00 40-35

 GENERAL INFORMATION – Mining Screens

GENERAL
1 SCREEN TERMINOLOGY ............................................................................................................................................ 3

2 SHIPPING, RECEIVING AND HANDLING ..................................................................................................................... 6

2.1 Checks, reviews of damages or loss during Shipment .......................................................................................... 6

2.2 Recommendations for lifting .............................................................................................................................. 6

3 STORAGE CONSIDERATIONS ..................................................................................................................................... 8

3.1 Mechanism Storage ........................................................................................................................................... 8

4 SPARE PARTS ............................................................................................................................................................ 8

4.1 Recommended Spare Parts ................................................................................................................................ 9

4.2 Spare Parts Request ........................................................................................................................................... 9
4.3 General Maintenance and Repairs ..................................................................................................................... 9
 GENERAL INFORMATION – Mining Screens

1 SCREEN TERMINOLOGY

Certain terms are used throughout this manual to

describe the screen, its correct operation and
maintenance procedures. These terms are defined to
avoid the possibility of confusion or misunderstanding,
and to ensure proper communication between users of
this equipment and the factory.

Screen base mounted: screen supported on a

support structure (support base) may be of steel or
concrete.
Deck example – Panelcord media
Side protection liners (side liners) liners located
above the screening surface, assembled on the side
plates. Its function: Discharge chute: not vibranting extension of
screen deck, responsible for material transfer from
1. Fix the side screens; vibrating equipment to the conveyor or next
equipment;
2. Perform the sealing between the side plate, media
and frame (when present); Dynamic loads: forces applied to the support
structure of the screen due to the vibrating forces
3. Prevent premature wear on the side plates of the of the equipment. They are usually expressed in
equipment. terms of load (Newton force). The dynamic loads
are caused by the deflection and extension of the
springs that support the equipment due to the
screen body movement. Metso specifies the values
of the load in the Installation drawings (Outline
drawings).

Feed: material fed into the screen to be processed

(sorted).

Feed Box: steel structure, with liners at the back

Side protection liners for poliurethane or rubber media
of the equipment, responsible for receive the
material and hence its transfer to the screening
Cross members: profiles or rectangular hollow
surface.
section steel, with flanges at its ends. In addition to
ensuring the structural rigidity of the equipment, it
is intended to fix the longitudinal stringers that are
responsible for supporting the screens;

Slope: shape of the screen deck. Represents the

difference in angle between the screening surface
and the support springs (horizontal position).

Deck: Set formed by cross beams, stringers, deck

(if present), media and accessories.

GENERAL INFORMATION – Mining Screens – N11481555 / Rev. 00 3-9

 GENERAL INFORMATION – Mining Screens

Feed rate: Volume of material fed into the screen
to be processed. It is usually expressed in tons per
hour (t/h) or cubic meters per hour. (m3/h).
Acceleration - "G’s": number of times the
acceleration of the screen exceeds the force of
gravity. Its value can be calculated by the
equation:
2 transport.
a RPM
G' s
894617.5
Where:
a = vibrating amplitude of the equipment in mm;
RPM = vibrating speed of themechanism expressed in
revolutions per minute.
Drive side: location of the drive motor to the body
of the screen viewing in the material flow
direction, from the feed end to the discharge end
of the equipment.
Live weight: sum of the weight of all vibrating
components of the screen fixed to the equipment.
Are not included springs, drive (motor, cardan
shaft, pulleys, etc.), lower spring guides, etc.
Shipping weight: total weight of the equipment
(weight coupled with vibrant springs, drive guides,
springs below) plus the weight of packaging and
boxes used for storage of components for
Total weight: weight of transport boxes and other
containers used for packaging of components.
Vibrating mechanism: the screen element
responsible for inducing the movement of
equipment to vibrational excitation. The
movement of the screen is expressed in Stroke, a
value which corresponds to twice the value of the
amplitude. This excitation force is generated by
the unbalance of counter weights fixed to a shaft
supported on bearings.

Right Hand Left Hand

Box Mechanism ML

Material flow
Isolation base (opcional): it is a steel frame that
the screen will be mounted. Provided by own
springs, it is a dynamic system of two springs that
intends to reduce the level of vibration transmitted
through the screen to the support bases.

Isolation base example

GENERAL INFORMATION – Mining Screens – N11481555 / Rev. 00 4-9

GENERAL INFORMATION – Mining Screens

Mech. Beam: steel structure extremely rigid and
reinforced that extends transversely across the
width of the screen. It has flanges at its end to fix
to the side plates. Its function is to transmit the
movement generated by the mechanisms to the
other components of the screen.
structure of the screen must stand. This value is
expressed in the equipment installation drawing;
Frame: component of the deck, responsible to
support the screening surface and to increase the
structural rigidity of the body of the screen.
Includes: cross beams, side plates and stringers to
support the media.

Speed: rotational speed of the mechanism,

expressed in RPM or vibrating frequency of the
screen.

Ressonance frequency: frequency at which the

screen operation speed corresponds to the natural
frequency of the mass system mass spring / screen
expressed in RPM.
Screening surface: correspond to the media and
are usually manufactured in rubber or
polyurethane. Provides openings for passing the
classified material.
Stroke: total movement of the vibrating body of
the equipment at operating speed. Corresponds to
twice the value of the amplitude.
Amplitude: half of the course of the vibrating
body at the speed of operation. It is theoretically
calculated by the formula:

m r
a
M
Where:
a = vibrating amplitude of the equipment in mm;
mxr = counter weight mass times the distance between
the center of rotation and center of gravity of the piece.
M = mass of vibrating equipment.
Side Plates: structural components of the
vibrating body of the equipment that cross beam
and mechanism beams are assembled. Vibrating body: consisting of side plates, cross
beams, mech beam, vibrating mechanism and
other parts of the screen that have vibration.

Static load: loads represented in Newtons, due to

the total mass of the screen, which the support

GENERAL INFORMATION – Mining Screens – N11481555 / Rev. 00 5-9

 GENERAL INFORMATION – Mining Screens

2 SHIPPING, RECEIVING AND HANDLING

Metso equipment is assembled as completely as

possible for delivery, unless the transport in these
conditions is not possible, if it is illegal or may cause
damage to equipment. Items that are packaged
separately for installation on site include:
Srings and spring guides;
Make sure the screen is not subject to falls or
inapropritate handling. Metso will not assume
responsibility for damage caused by improper
handling after the screen left the factory.

Screen media;

Motors e auxiliary drive equipment (if provided);

Water spray system (if provided);

Dust enclosure (if provided).

2.1 Checks, reviews of damages or loss during

Shipment

The equipment is thoroughly inspected and carefully

prepared for shipment. However, it can cause damage
or loss of some components of the machine during
transport.

Check each item carefully with the cargo document,

bill of freight or bill of lading.

Metso requests to notify the carrier, immediately, if

there is any damage or discrepancies. The carrier
should receive your statement. This will assist you in
prompt resolution of your pendencies.

2.2 Recommendations for lifting

When moving equipment from one location to another,

everytime lift it through the lifting lugs, to avoid
distortions in the body or damage to the side plates.
Metso does not recommend the lifting through other
points to avoid possible distortion or deformation of
the side plates.

Lift the screen always by the four corners using the

existing lifting lugs. Whenever possible, use cables for
a vertical traction.

Always refer to the equipment installation drawing for

the correct values of the static weight, dimensions of
equipment and positions of the lifting lugs.

GENERAL INFORMATION – Mining Screens – N11481555 / Rev. 00 6-9

GENERAL INFORMATION – Mining Screens

Lifting Device
(Not Supplied)

Figure 1 – Correct points to screen lifting with lifting device

Figura 2 – Acceptable points to lift the screen

** Figures for illustration only.

GENERAL INFORMATION – Mining Screens – N11481555 / Rev. 00 7-9

 GENERAL INFORMATION – Mining Screens
3 STORAGE CONSIDERATIONS
Metso recommends storing the screens in a building
that is free from excessive moisture. If screens need
to be stored outside, exposed to the weather, protect
them with well adjusted canvas.
Periodically inspect the stored equipment for
possible damage or corrosion points, and take
the necessary preventive measures.
Remove the screen media from the body of the
screen and store them in a building to prevent
damage by corrosion, dryness or cracking by
objects placed or dropped on the parts. If the
conditions do not guarantee the removal of media,
take precautions to prevent damage.
3.1 Mechanism Storage
The vibrating mechanisms leave the factory
supplied with the correct oil level.
Oil Lubricated Mechanisms:
All vibrating mechanisms when they leave the
factory can be stored for a period of three months
without the need for interventions. If the equipment
or mechanism is stored for longer than mentioned
above, follow these instructions:
1. Drain all the oil and refill it with oil that has
properties of corrosion inhibitors, or add oil
corrosion inhibitors;
2. Close all openings of the shaft with tape to
prevent moisture penetration;
3. Replace the housing breather by a plug (closed);
4. Manually turn the engine every 2 months of
storage.
Before operation of the mechanism (after more than
60 days of storage) drain the oil used during storage
and fill the mechanism with the specified oil in this
manual checking its correct level.
GENERAL INFORMATION – Mining Screens – N11481555 / Rev. 00 8-9
The storage period of 60 days depends on storage
environmental conditions such as humidity,
temperature, dust and other contaminants. Therefore,
Metso recommends that you review the oil before
putting the equipment into operation, in order to verify
the characteristics and the contamination of the
lubricant.
4 SPARE PARTS
Metso Minerals, seeking greater flexibility and reduction
in the care of spare and wear parts, keeps a stock of the
components of vibrating screens.
Spare parts are not included in the supply of equipment
and must be requested and purchased separately.
Long life is a characteristic vibrational mechanisms
with proper maintenance. One reason for this is the use
of precision bearings in these mechanisms, built
according to specifications of Metso.
Experience has shown that commercial standard
bearings do not offer the same high level of
performance, and premature bearing failures can lead
to extensive damage to the components of the
mechanism.
Precision bearings designed specifically for your
mechanism are available only by Metso Minerals. All
components of the mechanism, including parts, O-rings
and seals should be carefully inspected whenever you
need to replace bearings.
Any damage to a mechanism or housing, resulting from
the use of commercial standard bearings, will be the
responsibility of the operator of the screen. Insist on
genuine Metso Minerals spare parts.
 GENERAL INFORMATION – Mining Screens

4.1 Recommended Spare Parts 4.3 General Maintenance and Repairs

To reduce the downtime in an emergency Metso Metso Minerals, aiming to satisfy customers, has set up the
recommends as a minimum to keep in stock the refurbishment, rebuilding and recovery of vibratory
parts listed in the list of Recommended Spare Parts equipment and its components. Due to the low cost
(attached). effective and short time to repair, in many cases, it is
advantageous to return the equipment to the factory.
If multiple units of the same size, or multiple units At Metso the equipment will be completely disassembled,
or vibrating mechanisms of the same description the parts go through a strict control of dimensional
(number and value of the counter weight) are used analysis and wear checking. The worn and damaged parts
in your facility, increase the recommended amount are replaced with original parts Metso.
of each item to best suit your situation.
Always, consult Metso Minerals for further clarification
It is characteristic of screen box mechanisms that and additional information.
these items are fully encapsulated with independent
housing body vibration (box type). Away, entaire
mechanisms can be removed as a unit and taken to
a repair shop from the area of the plant. This makes
it practical to keep available a re-conditioned
mechanism "as new" (especially where several
similar ones are used) to replace a unit for repair.
This precaution keeps to minimum the downtime
for mechanisms repair.

4.2 Spare Parts Request

When ordering spare parts, include the following

information:

Size of the screen;

Serial number of the screen - check the

identification plate affixed to the side plate of
the screen or see the ID sheet of equipment
attached to this manual;

Description of the item by name, catalog

number (where applicable) and part number;

Quantity of each item requested;

Complete instructions for delivery, stating that

the shipment should be by mail, express or
freight (surface or air).

This information should be sent to the nearest

Metso office, as listed on cover pages, in an
emergency. Metso recommends keeping at
least items of spare parts list (attached) in the
customer stock.

If multiple units of the same size, multiple

mechanisms of vibrators or units of the same
description (number of mechanisms and values
of counter weights) are used in your plan, then
it is recommended to increase the quantity of
each item in order to better adapt this situation.

GENERAL INFORMATION – Mining Screens – N11481555 / Rev. 00 9-9

 INSTALATION - Vibrating Screens

1 GENERAL CONSIDERATIONS............................................................................................................................................. 3
1.1 Foundations and structural supports ........................................................................................................................ 3
1.2 Feed Arrangement ................................................................................................................................................... 3
1.3 Chutes, Spouts and Hoppers ..................................................................................................................................... 5

2 INSTALLING BASE-MOUNTED SCREENS ............................................................................................................................ 6

3 PLACING THE SCREEN ON THE SPRINGS ........................................................................................................................... 6

4 CHECKING SPRING DEFLECTION ....................................................................................................................................... 8

5 DRIVE CONSIDERATIONS (MOTOR AND TRANSMISSIONS) ............................................................................................... 9

5.1 Motor Mounting ...................................................................................................................................................... 9

6 TAPER LOCK BUSHES:....................................................................................................................................................... 9

6.1 To install Taper-Lock bushing: .................................................................................................................................. 9
6.2 To Remove Taper lock Bushes ................................................................................................................................. 10

7 CHECKS OF DRIVE PULLEY ALIGNMENT .......................................................................................................................... 11

7.1 Mounting and Adjustment of Belt 'V' ...................................................................................................................... 11
7.2 TENSION DEFLECTION METHOD ............................................................................................................................. 13
7.3 Drive Guards .......................................................................................................................................................... 15

8 INSTALLATION CHECKS .................................................................................................................................................. 15

9 SCREW TIGHTENING PROCEDURES ................................................................................................................................ 16

9.1 General.................................................................................................................................................................. 16
9.2 Procedure for Tightening Bolts (with a torque wrench) ............................................................................................ 16
9.3 Procedure for Tightening Bolts (without a torque wrench)....................................................................................... 17

10 SCREEN MEDIA .............................................................................................................................................................. 20

10.1 Modular Panels...................................................................................................................................................... 20
10.1.1 Trellstep media:............................................................................................................................................. 20
10.1.2 LS media:....................................................................................................................................................... 20
10.1.3 Panelcord media:........................................................................................................................................... 20
10.2 Steel wire............................................................................................................................................................... 20

11 MEDIA FIXING SYSTEMS................................................................................................................................................. 21

11.1.1 Fixation System for wireless Minor than 3/8”: ................................................................................................ 21
11.1.2 Fixation System for wireless Greater than 3/8”:.............................................................................................. 21

12 DUST ENCLOSURE .......................................................................................................................................................... 21

INSTALLATION - Vibrating Screens - N11479518/ Rev. 00 1-22

 INSTALLATION - Vibrating Screens

1 GENERAL CONSIDERATIONS
1.1 Foundations and structural supports
Screen location is usually determined by the process
Vibration levels in the screen supporting structure
flow. The standard design configuration for Metso should not exceed 10mm/s (peak level), measure at
screens is for base mounting on the supporting the bottom of the spring pedestals in tri-axial
structure. direction. The Metso Minerals must authorize all
exceptions from this requirement.
The design of supporting structures and foundations
for vibrating screen installations is complicated by
the dynamic forces involved. Review the specific
conditions of your installation with an engineer who
is experienced in this field. Maintenance
requirements must also be considered during the
structural design stage.

The design of a supporting structure for the vibrating

screen should consider primarily two items:

1. The strength required to support the screen and

additional loads.

2. And avoidance of a harmonic vibrating

frequency which might coincide with the
operating speed of the vibrating screen. If the
operating speed of the screen coincides with or is
close to the natural frequency of one or more
supporting structure parts, vibration will be
imparted to those parts. This could result in
injury to personnel or damage to equipment.
Generally, the natural frequency of the support
structure should be at least twice the running speed of
the screen.
When making calculations relating to the harmonic
vibrating frequency of the structure, also consider the
operating speed of the other equipment in the vicinity
of the screen. The natural frequency of structure
should not directly coincide with or be a harmonic of
the vibrating frequency of any other piece of
equipment.
Vibrating Level
measuring point
1.2 Feed Arrangement
The success of your installation will depend upon an
efficient method of feeding process material to the
screen. In order to efficiently utilize the screen
capacity and minimize maintenance of the screening
surface and feed box liners, the following items
should be considered in the feeding installation
design.
a. The process material should enter the feed area
along a line parallel to the centerline of the
screen.
b. The process material should be fed at a uniform
rate and evenly distributed across the full width
of the screen.

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 3-21

 INSTALLATION - Vibrating Screens
CORRECT FEED ARRANGEMENT:
Correct feed arrangement – material is evenly
distributed over the screen width to utilize the full
screening surface area.
INCORRECT FEED ARRANGEMENT:
A feed chute extremely small compared to the width
of the equipment, and located closer to one end of the
screen, does not allow rapid distribution of material
on the screens, reducing the separation efficiency of
the material.
Not used screening
area.
INSTALLATION - Vibrating Screens - N11479518 Rev. 00 4-21
In this case, as the former, the feed chute is extremely
narrow when compared with the width of the screen,
reducing the efficiency of the equipment.
Not used screening areas.
c. Any positive feeding arrangement such as a
surge bin equipped with a vibrating feeder, is an
excellent investment when it is correctly selected
and installed. Such feeding equipment should
have controls to regulate the feed rate to the
capacity of the screen. For screens 12’ (3.6m)
wide and larger, feeders are recommended to
have at least 75% of screen width.
d. Vibrating screens are designed for the specific
process materials and feed rates required for
each application. As material conditions and
requirements change, feed rate may have to
altered. Feed rates depend upon too many
variables
Feed velocity;
Material characteristics (density, humidity,
material shape, etc.);
Material depth over the screen surface;
Conveyors or other feed mechanisms should not
introduce the feed at a higher velocity than the screen
capacity. The material speed from the feed must be
decreased in order not to impair the screening
efficiency.
e. Gravity chutes and feed boxes may be used to
deliver wet or dry process materials. These
utilize gates and baffles arranged to retard
process material flow from high velocity feeding
devices. This allows the screen to accept the
process material at the proper feed rate, also
preventing the material at high speed impact
directly on the box coatings and screens,
promoting premature wear. So whenever
possible, use power shots with deflectors. The
 INSTALLATION - Vibrating Screens
formation of stone boxes ensures to slow
material, ensuring a longer life of coatings and
fabrics.
ROCK BOX
FEED BOX
Where headroom for a baffle feed box is not
available, chain baffles can be used to retard feed
material velocity and even distribution. Chain baffles
will also help prevent coarse materials from being
projected directly onto the screening surface.
Any chute or feed box used to deliver the
process material should be six inches (154mm)
narrower than the width of the vibrating screen,
and should not come closer than two inches from
the screening surface or feed plate, if provided.
(check in this case the maximum size of feed
material, to avoid locking material between
chute and lining of feed box);
Feed and discharge chutes should be designed
with appropriate distances of vibrating
equipment and other equipment, allowing easy
intervention to carry out maintenance and
replace parts. Possible measures to be followed
in the project include: easy attachment and
removal of the discharge chutes. Provide
sufficient space to facilitate the inspection of the
body of the sieve, as well as good access
between the screen and discharge chute for a
person to get under the screen if necessary.
1.3 Chutes, Spouts and Hoppers
Follow the provisions of your company confined
space entry policy for any work under and around
the unit.
When designing the feed chute and boxes discharge
spouts and fines hoppers, take care that a three inch
(76mm) clearance is available to allow for excessive
motion while the screen is starting or stopping.
INSTALLATION - Vibrating Screens - N11479518 Rev. 00 5-21
The screen body must not touch any stationary object
under any circumstance, including any possible
accumulation of material in the corners of the fine
hopper or in a product chute.
Chutes, spouts and hoppers must not be added to
the vibrating body. Any such unauthorized
attachment of chutes, spouts or hoppers to
vibrating body will void any and all product
warranties.
A vibrating screen is carefully engineered for correct
weight distribution. Weight should not be added to
the vibrating body. As balance and bearing life will
be adversely affected and screening performance can
be impaired. The need for attachment of side
plates/rubbers skirts or extensions should be part of
installation planning as a part of the original machine
design or provided as a completely separate
component of the structure.
Discharge Chutes / Transference:
Responsible for collecting material removed from the
deck. Should be designed taking into consideration
the following factors:
1. Have an inclination sufficient to prevent or stop
the material accumulates on its surface;
2. The internal dimensions shall be not less than three
times the size of the material to be processed;
3. It should allow easy access to screening surface, if
the equipment does not have back windows for
inspection;
4. Its design should allow twisting or arranged in a
way that can be easily removed.
Fines Hopper (Under pan):
This component has the function to collect the fines
that pass through the surfaces of the last screening
deck. Should be supported and mounted
independently of the vibrating body of screen and
have a minimum 2 "(50.8 mm) clearance from the
vibrating structure. His side, where inclined, should
be steep enough that the fine material cannot stop or
accumulate. Material accumulated in taps, can cause
the reduction of minimum clearances recommended,
and allow the creation of blows between the vibrating
structure and the static, causing damage to the body
of the screen.
 INSTALLATION - Vibrating Screens
Access Platforms:
Working platforms should be provided for use by
operators so they can observe the performance of the
vibrating screen. When designing these platforms,
make sure to properly consider necessary space
requirements and ease of access for a change of
screening surface and liners.
Necessary access must be provide to properly
maintain the vibrating screens.
2 INSTALLING BASE-MOUNTED SCREENS
Standard base-mounted screens are furnished with
pedestal-type support bases, which can be mounted
on and secured to either structural steel or reinforced
concrete.
The concrete or steel supporting structure must be
leveled and plumbed. Use shims between the
supporting structure and the spring bases, if
necessary.
Use shims to level and pluming equipment. If the
equipment works uneven, the distribution of material
on the surface screening.
The figures below illustrate the spring bracket,
including the internal and external springs, spring
guides and support plates.
INSTALLATION - Vibrating Screens - N11479518 Rev. 00 6-21
Spring Guide
Internal
Spring External
Spring
Spring
Bracket
Leveled and Plumbed Surface
Pedestal-Type Support Base
3 PLACING THE SCREEN ON THE SPRINGS
1. Locate each pedestal base according to
installation drawing. Be sure that the two pedestal
bases on opposite sides of the screen at the feed and
discharge ends are level with each other. Shim
between the pedestal base and support structure to
level, if necessary.
2. Assemble the steel coil springs on the spring
guide washers located on the pedestal bases. If inner
springs are provided, locate inner springs on the
spring guide washers and then place the outer coil
springs over the inner springs.
3. Set all supporting springs vertically.
4. Fixed bracket mounts are pre-installed, so
that they are set horizontally when the screen is
located on the slope shown on the Outline Installation
drawing.
5. Lower the screen in position on the
supporting springs making sure that the bracket
spring guides are properly seated on the springs.
6. Ensure that all supporting springs are
positioned vertically on each pedestal base and
 INSTALLATION - Vibrating Screens

located by the spring guides on the bases and support

brackets.

7. Bolt pedestal bases securely to the steel or

concrete supporting structure.

If springs are not vertical, shift pedestal bases

until vertical alignment is obtained.

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 7-21

 INSTALLATION - Vibrating Screens

4 CHECKING SPRING DEFLECTION

After the screen has been installed check to ensure that supporting springs have the same “deflected length” in comparison to
the springs located on the opposite side of the screen at the same end (i.e. either feed end or discharge end). The deflected
length of the springs may vary from one end of the screen to other.

Feed end

Discharge end

x
y

The two spring sets at the feed end of the Operating the screen with uneven support springs
screen must have the same deflected length (± could result in premature failure of the screen body
3.2mm) when compressed under the static
load.
The two spring sets at the discharge end of
the screen must have the same deflected
length (± 3.2mm) when compressed under the
static load.
For future reference, these measurements
should be recorded in the Installation
Checklist provided. Never hit the spring with steel hammer. Use rubber
hammer if necessary. Cracks can occur!!!

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 8-21

 INSTALLATION - Vibrating Screens

5 DRIVE CONSIDERATIONS (MOTOR 6 TAPER LOCK BUSHES:

AND TRANSMISSIONS)
In all vibrating equipment drives, use only high-
torque industrial motors, combined with a
starting class H. If the high torque motor is not
available, can be replaced by an motor of
greater power, with a normal torque (class of
conjugate N).

(Only for indirect drive with pulley and belt)

6.1 To install Taper-Lock bushing:

1. Remove the protective coating from the bore and
outside of bush, and bore of hub. After ensuring that
the mating tapered surfaces are completely clean and
free from oil or dirt, insert bush in hub so that holes
line up.

When locating motor bases for V-belt drives,

be sure to allow for belt installation and
tension adjustment.
A shorter center distance (drive pulley to
driven pulley) is required to allow easy belt
installation.
A longer center distance is needed for belt
take-up and adjustment.

2. Sparingly oil thread and point of grub screws, or

Ventilation TEFC (Totally Enclosed, Fan thread and under head of cap screws. Place screws
loosely in holes threaded in hub, shown thus in
Cooled) is recommended. Follow the notes and
diagram:
recommendations of the manufacturers of
motors, to look on the protection requirements
3. Clean the shaft, removing possible dust particles, oil
in relation to high currents. The installation of
or other substances. If present, mount the key on the
circuit breakers is recommended.
shaft. Align the keyway in the Taper-lock bushing
with the shaft key. Check first that the bushing will
Install wiring to the motor in accordance with
the relevant Global Standards and requirements tighten the axle first and then the hub will be slightly
of any local inspection authority with attracted to the sleeve.
jurisdiction in the territory in which the motor
and starter are installed.

5.1 Motor Mounting

After the screen properly mounted in the correct
working position, install the motor in its support
/ base. Ensure that the space around this
component is suitable for possible procedures
Align the keyways
for inspection and maintenance, when required.
Spaces for assembly and tightening of the belts
should be taken into consideration in the design
of installation / drive.
The drive support must be properly leveled and
rigid, preventing possible vibrations.

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 9-21

 INSTALLATION - Vibrating Screens

4. Using a hexagon wrench tighten screws

gradually and alternately.

Bolts to lose the

bushing
1
4

3 3. 3. Tighten screws alternately until bush is loosened

in hub and assembly is free on the shaft.
2
4. Remove Taper-lock from the shaft.
5. Hammer against large end of bush, using a
block or sleeve to prevent damage. (This
will ensure that the bush is seated squarely
in the bore.) Screws will now turn a little
more.

6. Repeat this alternate hammering and screw

tightening once or twice to achieve
maximum grip on the shaft.

7. After mounting the Taper-lock bushing to

the shaft, and the final assembly of the
drive, let the it working for a brief period.
Then tighten all screws.

6.2 To Remove Taper lock Bushes

1. Loosen all the screws that hold the bushing
taper-lock hub of the pulley.

2. Apply a small amount of oil at the end of

the screws removed in the previous
procedure, and threaded holes located in the
Taper-lock bushing. Mount the screws,
threaded holes in the bushing taper-lock
and perform the grip gradually and
alternately.

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 10-21

 INSTALLATION - Vibrating Screens

• Loosen the two bolts indicated below and tighten

7 CHECKS OF DRIVE PULLEY
ALIGNMENT the others two to tension the belt.

The drive belts should be correctly aligned so

that they can transmit the power for which they
were designed to minimize possible wear. After
mounting the motor and driven pulleys, use a
ruler to check if the channels of these
components are aligned with each other.

Common types of misalignment are shown below:

Tighten the two screws evenly

7.1 Mounting and Adjustment of Belt 'V'
The most important factor in successful V-Belt
operation is proper belt tensioning. Avoid belt
slippage or whipping. Belt's squealing during
operation is an indicator of slippage, and belt
tension must be checked. Belt creaky during
operation is an indicator that the belt is not with
your correct tension and therefore should be
tensioned again.
V-belt drive tension must be sufficient to
overcome slippage under maximum peak loads.
This could be at start-up or during the work
cycle. The amount of peak load will depend on
the nature of the driven machine or drive
system. To increase total tension in the drive,
increase the center distance of the belts as
follow:
1. Loosen the four bolts that fix the motor in
the motor base rail;
Loosen and tighten the bolts per equal to avoid the
pulley misalignment.
Check belts daily during the first week of operation. Belts
are not always perfectly matched for sheave center
distance, and the tighter belts will stretch until the "as
manufactured" elasticity is reduced by operation. Tighten
belts daily until tension remains constant.
Highly tensioned belts will give when operated under load.
Avoid operating the equipment when you look at the belts
that have too tight or loose.
For the installation of belts, follow the procedure below:
2. Adjust the distance between the shafts for the
minimum, this will allow adjust of belts without the
need to use keys, levers, etc..

TOO TIGHT

SLIGHT BOW TOO LOOSE

Bolts to adjust and to fix the motor in the base.

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 11-21

 INSTALLATION - Vibrating Screens

Never use tools to roll or pry belts into the

pulley grooves. This can damage belt cords
and lead to belt roll over, short life or
breakage. It is also a difficult and unsafe
practice

3. Install the belt so that they stay fitted

around the channels of the pulleys;

4. Turn the pulley 3 / 4 laps to accommodate

the belts properly in the channels of the
pulleys. (Note: if done manually, be careful
not to pinch your fingers between the
pulley and belt channels);

5. Tighten the belts following the procedure

below;

6. Operate the transmission in low load for 15

to 20 minutes;

7. Turn on / off / the drive, check the belt

tension and re-adjust the value if necessary.

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 12-21

 INSTALLATION - Vibrating Screens

5. At the end of 2-4 hours of operation, the drive should

7.2 TENSION DEFLECTION METHOD
be re-tensioned to approximately the maximum force.
For tensioning the drive using the TENSION-
DEFLECTION method, proceed as follows: 6. After 24-48 hours, it is well to check the drive to see
if the force on the belts is between the minimum and
For tensioning the drive using the maximum force shown in Table 4-1. Re-tension if
TENSION-DEFLECTION method, necessary. Either excessively low or high tension will
proceed as follows: affect the life and operation of a V-belt.

1. Place a straight edge across the top of both EXAMPLE:

sheaves. See figure below;
Section V = Belt Conveyor Standard SPC.
2. Measure the span length (length of the
tangent); Length (distance from the center) = 1575mm (62 ")

3. Using a spring scale at right angles to the
center of the span length, apply a force to
the scale great enough to deflect one of the
belts the equivalent of .016 times
millimeters of span length (.016 times
inches of span length).
4. The force should approximate the forces
shown in Table 4-1 for a properly tensioned
drive.
Smaller pulley diameter = 280mm
Force deflection (see table) = 9.4 kg
Deflection = 1575mm (62 ") x 0016 = 25mm (1")
So in an installation with a new web standard SPC section,
length of 1575mm (62 "), the belt should deflect 1"
(25mm) with a spring force of 9.4 kg for proper voltage
transmission.

DEFLECTION 0.4mm
FOR EACH 25mm (1")
(1/64")
OF SPAN LENGTH
SPAN LENGTH STRAIGHT
EDGE
1/2 SPAN
LENGTH

PULL
MOTOR
SHEAVE
SCREEN
SPRING SHEAVE
SCALE
BELT

FORCE (PER TABLE)

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 13-21

INSTALLATION - Vibrating Screens

BELT SECTION SETTING FORCE TO DEFLECT BELT 16mm PER METRE OF SPAN

SMALL
BASIC SETTING FORCES 1,25 x SETTING FORCES
SHEAVE
Dia. (mm) Newton (N) kilogram (kgf) Newton (N) kilogram (kgf)

56 up to 71 16 1,6 20 2,0

SPZ 75 up to 90 18 1.8 22 2.2

95 up to 125 20 2.0 25 2.5

XPZ & QXPZ over 125 22 2.2 28 2.8

80 up to 100 22 2.2 28 2.8

SPA 106 up to 140 30 3.0 38 3.9

150 up to 200 36 3.7 45 4.6

XPA & QXPA over 200 40 4.0 50 5.1

112 up to 160 40 4.0 50 5.1

SPB 170 up to 224 50 5.1 62 6.3

236 up to 355 62 6.3 77 7.9

XPB & QXPB over 355 65 6.6 81 8.3

224 up to 250 70 7.1 87 8.9

SPC 265 up to 355 92 9.4 115 12.0

& QXPC over 375 115 12.0 144 15.0

8V 335 & above 150 15.0 190 19.0

Z 56 up to 100 5 up to 7.5 0.5 up to 0.8

A(& HA banded) 80 up to 140 10 up to 15 1.0 up to 1.5

B 125 up to 200 20 up to 30 2.0 up to 3.1

C 200 up to 400 40 up to 60 4.1 up to 6.1

D 355 up to 600 70 up to 105 7.1 up to 10.7

TABLE 4-1

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 14-21

 INSTALLATION - Vibrating Screens
8 INSTALLATION CHECKS
7.3 Drive Guards
The drive guards supplied with each screen are a
Metso standard design, which allow for custom fitting
on site. Metso Minerals ensures that the drive guards
are designed in accordance with relevant standards,
however, the final fitting, and approval for subsequent
use is the responsibility of site operators and
management.
Equipment users bear responsibility for the fitting of
drive guards conforming to statutory requirements and
safety rules. Guards must have no gaps or openings
allowing personnel to reach inside and get caught in
the drive.
Never operate belt-driven equipment without
adequate drive guards, properly placed and
secured. Do not be lulled into a false sense of
security by a temporary or makeshift guard.
CARDAN SHAFT GUARD
PULLEY GUARD
Always mount all guards before operating or testing
equipment.
INSTALLATION - Vibrating Screens - N11479518 Rev. 00 15-21
1. Check the occurrence of possible damage to
components during installation;
2. Make sure the screen is installed correctly by
checking the slope, leveling shoes and whether
they are upright;
3. Check the clearance between the vibrating
structure and the stationary components located
around it are greater than the minimum required
size;
4. Check the correct torque of the spring guides and
plates bolts;
5. Make sure all the liners (feed box, side plates,
discharge lip, etc.) were properly assembled;
6. Verify that the screening media have been
properly installed, tensioned (steel wire), and if
the modular panels (rubber / PU) have been
correctly set;
7. Make sure that the motors were installed
correctly and in accordance with the
manufacturer's specifications;
8. Make sure the rotation is correct, as well as its
direction of rotation;
9. Make sure all the protections of the drive are
fixed and do not interfere with the belts and
pulleys;
10. Check the drive if all screws were correctly
tighten and if the belts were correctly tensioned;
11. Check the level and quantity of lubricant in the
mechanism. The lubricant supplied by the factory
should not be used for more than 40 hours of
operation.
12. In case of automatic lubrication, make sure it is
operating properly, verifying the amount of
lubricant filled, lubrication time, etc.
13. Check in the outline drawing the correct
equipment operation speed and make sure that
the equipment is working in this rotation.
Variations of up to 2% are tolerable due to
voltage variations. If the equipment presents
rotation outside this range, please refer to Metso
or nearest dealer.
 INSTALLATION - Vibrating Screens

14. In screens belonging to the lines Low-Head,
Multi-Flo, or equipment with box mechanisms, it
is extremely important to verify that the
resonance plate was properly mounted (when
supplied). This item increases the rigidity of the
equipment, ensuring its proper operation.
RESONANCE PLATE - UPPER
1. Deburr all bolt holes be for assembly to
ensure a tight fit between parts being fastened
together.
2. Contact surface of the parts attached with
bolts must be free of dirt, oil, rust, loose scale, etc.
3. Use two hardened washers per bolt, one
under the bolt head and one under the nut. See figure
below.

4. Hands tighten bolts using a 300mm long

spanner; check the gap between the plates with a
feeler gauge. The maximum gap, which allows contact
with the shank of the bolt, is 0.1m.

5. Bolts are to be tightened with a torque

wrench.

RESONANCE PLATE - LOWER

9 SCREW TIGHTENING PROCEDURES Imperial - grade 5 SAE. or Structural Metric - grade

9.1 General 8.8
Successful operation of a machine depends upon good 6. Use the Proper size and grade of bolt for the
maintenance. job. The “Bolt Torque Value” chart lists the size,
grade and head marking of the bolt, and provides a
minimum and maximum torque value for each size
and grade of bolt in “kilogram meters” and “foot
pounds" (in parentheses).
Machinery must be inspected frequently to ensure
that all bolts are tight.

Check the tightness of all bolts after the first few

hours of initial operation of the machine.

During the first week of operation, check the bolts for

tightness daily and then periodically thereafter.

This procedure also applies to parts and components

that have been disassembled and reassembled during
normal maintenance periods.

9.2 Procedure for Tightening Bolts (with a torque

wrench)

Not to be used for bolting low head mechanisms to

mechanism support beams.

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 16-21

 INSTALLATION - Vibrating Screens

9.3 Procedure for Tightening Bolts (without a

torque wrench)
1. Install sufficient fitting-up bolts and tighten as
required to bring the parts together.

2. Install bolts in the balance of holes. Tighten the

nuts by the “turn of nut” method. This requires
that bolts be brought to a snug-tight condition to
insure at the joint material is properly compacted
before the nut is rotated through the specified
turn.

"Snug-tight" is defined as:

“The tightness attained by a few impacts of an impact

wrench or the full effort of a man using an ordinary
spud wrench”.

When using an impact wrench, snug condition is

readily noticeable as that point at which the wrench
starts impacting solidly.

3. Give nuts an additional 1/2 to 2/3 turn.

4. Tighten nuts on fitting-up bolts to “snug-tight”

condition and then give these nuts an additional
1/2 to 2/3 turn.

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 17-21

INSTALLATION - Vibrating Screens

SPECIFICATION TIGHTENING TORQUE – GRADE 5 SAE. OR STRUCTURAL

(NOT PLATED)

SIZE THREAD TIGHTENING TORQUE

MAX. MIN.

3/8" UNC 56Nm (41.5 lbs.ft) 54Nm (40 lbs.ft)

7/16" UNC 89Nm (66 lbs.ft) 86Nm (63 lbs.ft)

1/2" UNC 137Nm (101 lbs.ft) 130Nm (96 lbs.ft)

5/8" UNC 271Nm (200 lbs.ft) 258Nm (190 lbs.ft)

3/4" UNC 480Nm (354 lbs.ft) 456Nm (337 lbs.ft)

7/8" UNC 772Nm (569 lbs.ft) 734Nm (541 lbs.ft)

1" UNC 1169Nm (862 lbs.ft) 1111Nm (819 lbs.ft)

1 1/4" UNC 1871Nm (1380 lbs.ft) 1778Nm (1311 lbs.ft)

1 1/2" UNC 3954Nm (2920 lbs.ft) 3760Nm (2773 lbs.ft)

1 5/8" UNC 5450Nm (4020 lbs.ft) 5178Nm (3820 lbs.ft)

1 3/4" UNC 6890Nm (5080 lbs.ft) 6546Nm (4828 lbs.ft)

Metric Grade 8.8

SIZE TIGHTENING TORQUE

MAX. MIN.

M10 67Nm (49 lbs.ft) 64Nm (47 lbs.ft)

M12 118Nm (88 lbs.ft 112Nm (84 lbs.ft)

M16 292Nm (215 lbs.ft 277Nm (204 lbs.ft)

M20 572Nm (422 lbs.ft 544Nm (401 lbs.ft)

M24 985Nm (726 lbs.ft) 934Nm (690 lbs.ft)

M30 2020Nm (1491 lbs.ft) 1920Nm (1417 lbs.ft)

M36 3534Nm (2606 lbs.ft) 3358Nm (2476 lbs.ft)

M42 5648Nm (4156 lbs.ft) 5366Nm (3957 lbs.ft)

M48 8462Nm (6242 lbs.ft) 8039Nm (5930 lbs.ft)

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 18-21

INSTALLATION - Vibrating Screens

SPECIFICATION TIGHTENING TORQUE – GRADE 5 S.AE OR STRUCTURAL

(PLATED)

SIZE THREAD TIGHTENING TORQUE

MAX. MIN.

3/8" UNC 39Nm (29 lbs.ft) 38Nm (28 lbs.ft)

7/16" UNC 63Nm (46 lbs.ft) 60Nm (44 lbs.ft)

1/2" UNC 96Nm (71 lbs.ft) 91Nm (68 lbs.ft)

5/8" UNC 190Nm (140 lbs.ft) 180Nm (133 lbs.ft)

3/4" UNC 336Nm (248 lbs.ft) 319Nm (236 lbs.ft)

7/8" UNC 540Nm (398 lbs.ft) 513Nm (378 lbs.ft)

1" UNC 818Nm (398 lbs.ft) 777Nm (573 lbs.ft)

1 1/4" UNC 1310Nm (966 lbs.ft) 1245Nm (918 lbs.ft)

11/2" UNC 2772Nm (2042 lbs.ft) 2634Nm (1942 lbs.ft)

1 5/8" UNC 3816Nm (2814 lbs.ft) 3625Nm (2673 lbs.ft)

1 3/4" UNC 4822Nm (3556 lbs.ft) 4581Nm (3378 lbs.ft)

Metric Grade 8.8

SIZE TIGHTENING TORQUE

MAX. MIN.

M10 47N.m (35 lbs.ft) 45N.m (33 lbs.ft)

M12 83N.m (61 lbs.ft) 79N.m (58 lbs.ft)

M16 204N.m (150 lbs.ft) 194N.m (143 lbs.ft)

M20 400N.m (295 lbs.ft) 380N.m (280 lbs.ft)

M24 689N.m (508 lbs.ft) 655N.m (483 lbs.ft)

M30 1414N.m (1043 lbs.ft) 1344N.m (991 lbs.ft)

M36 2747N.m (1825 lbs.ft) 2351N.m (1734 lbs.ft)

M42 4536N.m (3365 lbs.ft) 4335N.m (3197 lbs.ft)

M48 5923N.m (4368 lbs.ft) 5623N.m (4150 lbs.ft)

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 19-21

 INSTALLATION - Vibrating Screens

10.1.3 Panelcord media:

10 SCREEN MEDIA
OPTIONAL ITEM

(Not included in basic equipment).

10.1 Modular Panels

The modular panels are the screening media more
applied in vibratory equipment due to cost / benefit.
These panels can be bolted directly to the girders
(Panelcord screens, etc.) or can be fixed in girders
profiles (LS media, etc.). They have the advantage of
longer life in relation to the tensioned media, in many
cases avoiding problems of clogging and blinding of 10.2 Steel wire
holes due to lamellate and humidity of the material.
Classification surface used in primary, secondary and
10.1.1 Trellstep media: tertiary materials separation. Can be used in
classification procedures in fines and also dewatering.

For screens provided with steel wires, there is a need

for adaptation of tables that will support the screening
surface. Depending on the type and size of screens steel
wire will be: simple curvature, double curvature or flat.

Are laterally tensioned and supported by longitudinal

bars, mounted on the side plates frames. For simple
curvature, the longitudinal bars have a variable height
and arranged in a way that the screening surface is
10.1.2 LS media: higher in the central region of the screen, decreasing
gradually towards the side plates. To double curvature,
the screen is divided into two halves (two surfaces with
simple curvature).

Rubber gaskets are mounted on the longitudinal bars,

avoiding hitting between the surfaces and the bars to
avoid wear.

Steel wires are usually provided with hooks at their

ends or straight parts, depending on the thickness of the
wire, to be used to tighten and fix the surface on each
end.

Modular panels are also widely used in primary and Fixation systems are located above the screening
secondary classification (Panelcord) working with surface and are designed to set the screens on the deck
materials of larger sizes and higher abrasion. frame. These components are fixed to the side plates by
bolts through holes located in the side plates.

INSTALLATION - Vibrating Screens - N11479518 Rev. 00 20-21

 INSTALLATION - Vibrating Screens

11 MEDIA FIXING SYSTEMS 12 DUST ENCLOSURE

11.1 Fixation System for wireless Minor than 3/8”: OPTIONAL ITEM

(Not included in basic equipment).

The dust enclosure is of a partial rubber design based

on complete encasing of all dust exit points. This
encasing combined with a negative pressure in the
equipment yields very low dust indexes. Separate
intermediate support legs support the dust hood frame.

To assemble the steel sections of the STM enclosure

system on the screen, use M10 screws hex head, grade
8.8 or higher.

11.2 Fixation System for wireless Greater than 3/8”:

Never weld the enclosure profiles to the reinforcement

profiles. This can generate fatigue cracks in the
structure.

The upper enclosure system is static and is connected

to screen through Trellex rubber sheets and rubber
gaskets, which are mounted to the profile of the
enclosure by rubber hammers.

Central Fixation System (double curvature):

Contact the Metso Engineering Department before

making any change of frames to adapt other types
of media.

INSTALLATION - Vibrating Screens – N11479518 / Rev. 00 21-21

 OPERATION – Vibrating Screens

OPERATION
1 Safety Considerations..................................................................................................................................... 3

2 Pre-Commissionin .......................................................................................................................................... 3

3 Commissioning ............................................................................................................................................... 3
3.1 Before Introducing Feed Material ............................................................................................................ 3
3.2 After The Screen Has Been Operating for One Hour .................................................................................. 4
3.3 After The Screen Has Been Operating for 50 Hours................................................................................... 4

4 Check Critical Speed Against Operation One .................................................................................................. 4

4.1 Rouble Shooting ...................................................................................................................................... 6
4.2 4Screen Stoppage.................................................................................................................................... 7
4.3 Unlike Movement of the Screen ............................................................................................................... 8
4.4 Spring Breakage ...................................................................................................................................... 8
4.5 Loss of Amplitude (stroke) ....................................................................................................................... 9
4.6 Loss of oil ................................................................................................................................................ 9
4.7 V-belt drive............................................................................................................................................ 10
4.8 Pre-Commissioning Checks and Records................................................................................................. 11

OPERATION –Vibrating Screens – N11479520 / Rev. 00 1-12

 OPERATION – Vibrating Screens
1 SAFETY CONSIDERATIONS
Be extremely cautious when moving near steel coil
spring because there is risk due to nip points between
the spring coils.
There should always be a suitable clearance between
the screen body and adjacent structures and
components in order to avoid nip risks and to allow
the screen body to move freely.
Always make sure that all safety guards are fitted
prior to operation.
Avoid welding work on the screen body. Such work
can increase stresses in the plates and possibly
damage the screen body.
Be extremely observant when moving around
vibrating screens in operation.
To avoid injuries, always wear a safety helmet and
protective goggles.
2 PRE-COMMISSIONIN
Check for any damage which may have
occurred during installation.
Check is the screen is installed with the correct
inclination. Spring base must be leveled and
plumbed.
Check clearance between the screen and
surrounding structure for compliance with
minimum specified, according to outline
drawings.
Minimum operating clearances: vertical: 75 mm,
longitudinal: 75 mm, transversal: 25 mm. Screen
movements will be enlarged in all directions
during starting and stopping, when the
mechanism speed coincides with the natural
frequency of the screen and its springs.
Check anchor bolt tightness (see appendix for
correct tightening torque).
Check that all replaceable liners are fitted -
especially on feed box, feed chute and side
plates.
OPERATION –Vibrating Screens – N11479520 / Rev. 00 3-12
Check that the screen deck is installed and
tensioned correctly and if modular panels are
securely fitted.
Check that motors are correctly installed and
conform to manufacturer’s specifications. Verify
that rotation checks have been signed off, and
rotation direction is correct.
Check that all guards are secure and will not
interfere with drive, belts and sheaves when
supplied.
Check drives arrangement for looses items, and
correct belt tension.
Check mechanism lubrication level. Note that
factory-supplied lubricant has not to be used for
more than 40 hours operation.
Ensure that the design operating speed is known
and that actual operating speed can be verified
on start-up and recorded.
Check that all ancillary devices are securely
installed and do not interfere with operation of
the screen.
3 COMMISSIONING
3.1 Before Introducing Feed Material
Check for abnormal noises (hitting, loose bolts,
etc.).
Check if the vibrating screen body is not hitting
the adjacent structures and components.
Check the operating speed and throw as
specified in the outline drawing
Check the stroke graphs (see item 1.4).
If an abnormal speed condition exists, contact
Metso Minerals immediately. Operation of the
screen prior to Metso review and approval of the
screen commissioning throw cards may void the
warranty and result in premature failure of the
equipment.
Check the mechanism(s) for oil leaks and losses.
 OPERATION – Vibrating Screens
Check that vibration in the surrounding structure
is not adversely influenced (increased
significantly) by operating the screen.
Do not continue operating the screen without
rectifying any abnormal conditions identified in
the pre-commissioning and commissioning checks.
3.2 After The Screen Has Been Operating for One
Hour
Check anchor bolts for tightness.
Check if compression of screen suspension
springs is consistent with measurements recorded
during screen installation (refer to check sheets
located in the appendix).
Check that all components of the screen deck are
secured / tensioned correctly (media, liners, etc.).
Check the temperature of the mechanism
bearings and lubricating oil. Check for loose
bolts.
3.3 After The Screen Has Been Operating for 50
Hours
Check the tighten torque of all bolts. Mainly,
those ones that fix the mechanisms.
4 CHECK CRITICAL SPEED AGAINST
OPERATION ONE
Critical speed (as related to vibrating screens) is
defined as the natural frequency of the screen body.
This is not the same as the natural frequency of the
screen body / suspension spring system, which can be
observed at low speeds during the starting and
stopping cycles.
Critical speed depends on screen body stiffness, mass
balance and bolt tightness. Although screen
suspension does not normally affect critical speed,
uneven compression of suspension springs can alter
the screen's motion pattern.
OPERATION –Vibrating Screens – N11479520 / Rev. 00 4-12
IMPORTANT!
Do not operate the screen above or below the
speed shown on the Installation drawing without
consulting Metso Minerals.
Make the following checks on critical speed
conditions after installation checks are completed:
Securely fasten throw cards to the screen body in
the four corner positions, using adhesive or
masking tape. A master layout for the required
throw cards is attached. Position cards on
approximately the same location on both feed
end and discharge end corners. After cards are
attached draw a true horizontal line on the top of
each card so that the true angle of motion can be
determined.
With screen operating at full speed and pencil or
fine-point pen at right angles to the side plate,
momentarily touch the card in a series of spots.
Be sure pencil or fine-point pen is held firmly
and rigidly to prevent any secondary motion.
Fill out each of the four test cards, noting where
each card was attached to the screen. List the
serial number and where, when and by whom the
test was conducted.
If the motion pattern recorded on the feed end
cards is not similar to each other, a critical speed
condition may have developed. A critical speed
condition usually exists if the amplitude of the
screen on two diagonal corners is considerably
smaller than on the other two diagonal corners.
When this condition exists, the screen body
usually has a slight side vibration. Therefore, the
full motion may not be recorded on the card
when the pencil is held at right angles to the side
plate.
OPERATION – Vibrating Screens

DISCHARGE END
RIGHT / LEFT SIDE CARS

FEED END
RIGHT / LEFT SIDE CARDS

Locate throw cards in the same position on both feed end corners and both
discharge end corners (** Figure only for illustration)

THROW CARD

OPERATION –Vibrating Screens – N11479520 / Rev. 00 5-12

 OPERATION – Vibrating Screens

If a critical speed condition does not exist, check the

following:

Compression of the suspension springs. Ensure

that springs at feed and discharge end are
compressed alike.

Screening surface and clamps. Be sure they are

tight.

If screening surface is clogged with build-up of

packed material on surface, remove packed
material and clean the surface, as well as body
parts such as support frames.

Bolts for tightness.

After all these points have been checked, make a

second test pattern on the same cards. If the motion
pattern is still uneven from side to side at each end of
the screen, forward four test cards to Metso Minerals.
Does this promptly, as continued operation of a
screen in critical speed may cause damage to the
screen body.

All test cards are to be marked with the screen serial

number and mailed to Metso Minerals for the address
presented in the cover of this manual.
4.1 Rouble Shooting
This troubleshooting section includes some of the
most common problems that may be encountered
during operation of a vibrating screen.

Troubleshooting Procedures

a) Note unusual operation trouble. Refer to table

below to determine probable cause.

b) Always check the easiest and most obvious

causes first to save time and trouble. Do not
disassemble the vibrator mechanism or
components until all other possible causes and
remedies for a specific problem have been
examined.

c) After a mechanical / electrical failure has been

corrected, locate and correct the cause of the
trouble so that the failure will not reoccur.

OPERATION –Vibrating Screens – N11479520 / Rev. 00 6-12

 OPERATION – Vibrating Screens
4.2 4Screen Stoppage

Possible cause Symptoms / Corrective action

Too much or too little lubricant will cause bearing to overheat and lose
internal diametrical clearance, resulting in seizing of bearing;
Overheating of mechanism
Check the oil level;
Correct level and allow mechanism to cool prior to restarting;
After the mechanism has cooled, rotate it by hand for indication of
bearing trouble. If the mechanism does not rotate freely, one or more
Failed bearing bearing bearings may have failed.
Replace all mechanism bearings after thoroughly cleaning out the
mechanism housing and checking of components.
Check labyrinth groove on outer face of the bearing seal plate for possible
build-up of fine material. This could cause frictional heat resulting in
bearing seizure. Clean out grooves;
Friction in labyrinth seal
Check seal plate bolts for tightness;
Check gasket thickness between seal plate and bearing housing.
Gasket thickness for all mechanisms is 0.794mm;
Belt breakage or jumping off sheave resulting in loss of speed and
bogging down of screen. If necessary to replace belts do so in matches'
V-belt drive sets to maintain uniform belt stretch.
Loss of belt tension due to motor coming loose on support and not
maintaining required belt centers or.
Power failure Check power and motor leads.
Check the condition of the cardan shaft, as well as their striatum. Make
Cardan shaft failure
sure that they are in perfect working condition.
Allow mechanisms to completely cool down, and then check for proper
Thrust loading of bearings
end float.

OPERATION –Vibrating Screens – N11479520 / Rev. 00 7-12

 OPERATION – Vibrating Screens
4.3 Unlike Movement of the Screen

Possible cause Symptoms / Corrective action

Material clinging to the screen becomes dead weight and will
affect both throw and motion;
Build-up material Inspect screen surface, support frames, boxes and discharge
spouts for material build-up;
Remove all material from body.
Inspect springs for indication of coil breakage or possible build-
up material around spring coil;
Check possible setting of building support beams. Check level
Screen support of all support points.
Uneven compression of the springs may cause distortion in the
screen body - resulting in uneven vibration.
Check the building structure rigidity.
Refer to the instructions in the previous section for checking
Critical Speed
the critical speed.
Check the feed arrangement of the screen. This should evenly
Feed arrangement distribute the feeding material on the liners of the feed box,
reducing its speed.
Check all body bolts for tightness.
Loose body parts
Inspect screen surface for possible looseness.

4.4 Spring Breakage

Possible cause Symptoms / Corrective action

It is important that loading of springs be equal to avoid possible
Uneven loading bottoming and overstressing of spring.
Check spring alignment.
Inspect springs for corrosive action;
Corrosion If necessary, spray or dip springs in corrosion preventive
mixture.
Excessive wobble will result in reduced spring life.
Wobble Refer to Metso for recommendations on eliminating spring
wobble
Material build-up around spring coils will reduce number of
Material build-up active coils and increase spring stress, causing premature
failure.
It is important that pairs of springs be of like characteristics:
Unlike springs height, wire diameter, outside diameter and spring rate.
Unlike springs can cause uneven loading and premature failure.

OPERATION –Vibrating Screens – N11479520 / Rev. 00 8-12

 OPERATION – Vibrating Screens
4.5 Loss of Amplitude (stroke)

Possible cause Symptoms / Corrective action

Material build-up on the screen will increase body weight and
Material build-up cause a decrease in throw.
Remove the build-up.
Loss of speed will result in reduce conveying capacity and
increase bed depth and body weight – resulting in decrease
Belt slippage
throw.
Replace worn belts and sheaves.
Low plant voltage can result in slower motor speed with results
Power fluctuation
similar to those stated in "belt slippage".

4.6 Loss of oil

Possible cause Symptoms / Corrective action

Loose plugs Check all plugs in housings for possible looseness.
Excessive wear in bearings results in oval motion of seal and
Worn bearing subsequent loss of oil.
Replace all bearings.
Check housing breather for possible looseness. Excessive
Housing breather dripping of oil from breather indicates too much oil in
mechanisms.
Oil seal not assembled in seal plate correctly.
Damage seal.
Damage contact area on drive shaft.
Seal leakage Remove the seal plate and inspect thoroughly.
Air pressure build-up in the housing due to a clogged housing
breather can cause oil leakage though the seal.
Clean out the breather to correct.
Damage gaskets Check all gaskets for possible leakage or damage.
Check housing for possible cracks. It may be necessary to run
Cracked housing
mechanism until housing is hot before cracks can be observed.

OPERATION –Vibrating Screens – N11479520 / Rev. 00 9-12

 OPERATION – Vibrating Screens
4.7 V-belt drive

Possible cause Symptoms / Corrective action

Grooves are shiny, not enough tension. Increase tension.
Belt slip
Overload drive. Correct overload condition.
Overload drive. Corrects overload condition.
Not enough arc of contact. Increase center distance.
Drive belts squeal
Heaving starting load. Increase belt tension. Look for ways to reduce
load.
New belts installed with old. Replace with full matched sets only.
Mismatched belts Improper groove angle – worn groove. Replace the sheave.
Non-parallel shafts. Realign drive.
Cord broken due to prying or forcing on belt and sheave.
Correctly replace new set of belts.
Overloaded drive. Correct overload.
Belt turned over
Impulses loading. Apply proper tension.
Sheave and shaft misaligned. Realign drive.
Worn sheave grooves. . Replace sheave.
Shock loading. Apply proper tension.
Recheck drive alignment.
Breaking belts Review machine installation for ways to relieve shock load
conditions.
Foreign objects in drive. Provide drive shroud.
Sheave grooves worn. Replace sheave.
Mismatched belts. Replace with matched belts!
Belts slipping. Increase tension.
Belts wear rapidly
Sheaves misalign. Realign drive arrangement.
Grease on belts. Eliminated source of grease.
Clean belts with soap and water.
Belt slipping.
Shut down drive and test sheave temperature by feel.
Loss in drive speed
Excessive heating can result from belt slippage.
Increase tension.

OPERATION –Vibrating Screens – N11479520 / Rev. 00 10-12

 OPERATION – Vibrating Screens
4.8 Pre-Commissioning Checks and Records

Pre-Commissioning Checks
Pre-commissioning checks are of vital importance to
ensure safe, effective and efficient operation of the
equipment.

Metso Minerals has a trained field service team

available to ensure that installation and
commissioning procedures are completed
satisfactorily. Make the following general checks
before operating the screen.

If installation and commissioning is not performed /

supervised by Metso Minerals field personnel, please
ensure that the Commissioning / Audit Checklist
(attached) are completed, signed and sent to Metso
Minerals for review and approval – before putting the
equipment into service.

Check sheets should be faxed to the nearest Metso

office as detailed in the covering pages of this manual

Any action taken to rectify a non-conformance

before completing and submitting the installation
/commissioning checks (for review by Metso
Engineers – see page 14) will seriously jeopardize
warranty available on the equipment and can
result in premature structural failure of the
equipment.

OPERATION –Vibrating Screens – N11479520 / Rev. 00 11-12

OPERATION – Vibrating Screens

OPERATION –Vibrating Screens – N11479520 / Rev. 00 12-12

 MAINTENANCE – Vibrating Screens

MAINTENANCE

1 Safety Considerations..................................................................................................................................... 3

2 Routine maintenance schedule ...................................................................................................................... 4

2.1. Daily checks ................................................................................................................................................. 4

2.2. Weekly Maintenance Checks ........................................................................................................................ 5

3 Screen repair .................................................................................................................................................. 6

3.1 Screen design considerations ................................................................................................................... 6

3.2 Emergency Screen Repairs ....................................................................................................................... 6
3.3 Huckbolt removal .................................................................................................................................... 7
3.4 Adding weight to body ............................................................................................................................ 8
3.5 Welding on body ..................................................................................................................................... 8

MAINTENANCE –Vibrating Screens – N11479522 / Rev. 00 1-9

 MAINTENANCE – Vibrating Screens

1 SAFETY CONSIDERATIONS

Follow a systematic pattern of regular inspection and

keep a log of the periodic inspections and
maintenance-related activities for each screen. Metso
Minerals recommends that any log of maintenance
performed on the equipment include the following:

Machine serial number;

Date and description of maintenance activity;

Operating hours and tonnage produced since

installation.

One of the best rules in screen maintenance is to keep

a record of actual operating hours. After a
predetermined operational period, give the screen a
thorough major inspection. The length of time in this
initial operating period will vary with the type of
application and can best be determined by
experience.

Examine new equipment after a relatively short

operation period. Then lengthen the time before the
next major inspection. Follow this system until you
have a pattern that best suits your installation, and
adhere to it as your operating schedule.

Systematic inspection will result in less maintenance

and consequently lower repair bills.

Maintenance checks will help detect wear and other

problem areas before they cause serious damage.

A mirror problem, as a loosen bolt, if ignored,

may rapidly result into a major problem, as a
structural failure.

MAINTENANCE –Vibrating Screens – N11479522 / Rev. 00 3-9

 MAINTENANCE – Vibrating Screens

2 ROUTINE MAINTENANCE SCHEDULE

2.1. Daily checks

Oil lubricated mechanisms: Check the oil level before starting

equipment. In the case of continuous operation, stop the screen time
enough to allow the return of all the oil to the bottom of the housing
/ connection tube.
Screen mechanism
Mechanisms grease lubricated: Make sure the bearings are properly
lubricated;
Check mechanism breathers. Clean or replace if necessary.
Check for any indication of loose mechanism bolts.
Check the belt drive for indication of looseness, turning, wear or
breakage. Replace belts in sets to maintain uniform belt stretch.
Indirect Drive Assembly Checks drive and drive pulleys for possible looseness.
Checks alignment of pulleys (visual check only).
Be sure guards are secured in place.
Make sure the cardan shaft bolts are properly tighten;
Direct Drive Assembly Check the status of the striatum of the cardan shaft. If there are signs
of wear replace them immediately.
Check for possible interference between screen body and stationary
hoppers, chutes and building beams due to material build-up or
insufficient operating clearance.
Check screen decks for blinding, or build-up of material. Remove if
present.
Check deck arrangement for possible loose, or damage surface,
Screen body clamps, bars/bolts, hold-down, bars/bolts, buffer strips. Note that top
deck wear (and damage) is usually much more severe than on lower
decks.
With screen running, check for loose bolts or parts. Stop screen prior
to tightening of bolts or parts to avoid possible personnel injury.
With screen operating, check pattern of material flow over screen
decks. Bed should be evenly distributed over full width of screen.
Check the compression of the spring if they are uniformly loaded.
Check the springs for breaks or the accumulation of material on the
Screen Assembly
coils. Remove if present!
Check the spring assembly of the isolation base (if present).

Do not continue operating the screen without rectifying any abnormal conditions identified in the daily
maintenance checks.

MAINTENANCE –Vibrating Screens – N11479522 / Rev. 00 4-9

 MAINTENANCE – Vibrating Screens

2.2. Weekly Maintenance Checks

Check oil for indication of contamination (metal particles

similar to fish scales indicates spall of bearing). If present, flush
Screen mechanism out mechanism and refill with correct amount of new oil.

Check mechanism while running for possible noise.

Check side plates for loose bolts, excessive wear, or possible
cracking. Repair per instructions.

Check screen surfaces for wear, looseness or breakage.

Check clamping bars for looseness and excessive wear.

Check support frames thoroughly for wear cracking or

Screen body breakage. Repair if necessary per instructions. Check buffer
strips for wear.

Worn buffer strips will reduce deck camber, resulting in loss of

screen surface support and premature failure of deck cloth.

Check the compressed length of the screen suspension springs

and record any variation from the measurements recorded when
the springs were initially installed.

Do not continue operating the screen without rectifying any abnormal conditions identified in the weekly
maintenance checks.

MAINTENANCE –Vibrating Screens – N11479522 / Rev. 00 5-9

 MAINTENANCE – Vibrating Screens
3 SCREEN REPAIR
On-site repairs are an integral part of successful
operation and maintenance of the screen. It should be
noted however that, when carried out by the operator,
certain on-site repair work should only be performed
by skilled and trained, or supervised by a Metso
service coaching.
Metso Minerals will provide supervision for on-site
repair works if requested, and can also offer training
for site maintenance staff, thus ensuring that the most
effective methods are employed in future repair
work.
Major repairs may require replacement of parts and
components quickly. Therefore, always keep critical
items in stock.
3.1 Screen design considerations
The projects of Metso screens are continually
improved in order to facilitate technical interventions
to repair and maximizing the life of components.
Examples of improvement include replaceable wear
liners (feed box, side plates, etc.).
For all options to maximize maintenance advantages
on Metso Minerals screens please consult Metso
Minerals at any time.
Friction grip bolts are usually employed to secure
components, which will be dismantled for
maintenance purposes (Eg. mechanism, side
protection liners, etc.).
In the most of applications, Metso Minerals has
permitted the use of Huck-bolts on its equipment.
Unless a replacement bolt is being used where
originally installed, please contact Metso Minerals to
establish whether huck bolting is appropriate.
MAINTENANCE –Vibrating Screens – N11479522 / Rev. 00 6-9
If (without any clear reason) huck bolts breakage
occurs, contact Metso Minerals for advice
immediately - the performance / integrity of the
screen may be adversely affected if the cause of
the breakage is not identified, or the bolt is not
replaced, as soon as possible.
3.2 Emergency Screen Repairs
In the event that site personnel elect to repair any
Metso screen without consulting Metso Minerals the
following recommendations apply:
Adding holes to the screen body
Do not cut holes in the vibrating body with an oxy-
torch - it will induce stresses around the cut area.
When it is necessary to add holes to the vibrating
body in the field, DRILL THEM.
Flame cutting on the vibrating body in field will
be done at the operator's responsibility.
If holes are inadvertently cut in the body with a torch,
file or grind the edges of the hole smooth. Failure to
remove indentations may cause cracking due to the
stress concentration.
Items that should not be welded (due to stress relief):
All Metso screens wider than 3.0 meters are
subjected to stress relieving in critical welded
components, including cross beams and mechanism
beams.
On no account must these items be weld repaired
before consultation with Metso Minerals
personnel - to establish a suitable procedure for
rectifying the problem.
 MAINTENANCE – Vibrating Screens

Items that should not be welded (due to the condition

of critical components): In all the Metso screens side
plates are produced without any welding in critical
areas. In screens wider than 3.0 meters, no welding is
permitted, and all adjacent components bolted to the
side panels. So, first, repairs on the side plates should
be an operation of drilling and screwing. If any
welding is absolutely necessary, seek advice from
Metso Engineering before starting work. Also, a drill may be used on opposing sides of the
collar as seen in the picture below:
3.3 Huckbolt removal

Huck-bolts are widely used in the joint and assembly

of components of vibratory equipment. They are
fixed for a high life cycle and require no
maintenance.

Once installed, they can only be removed by

mechanical methods.
The correct way to remove the Huck-bolts is using a
hydraulic or pneumatic tool developed exclusively
for this purpose and provided by the manufacturer of
this element of the joint.
The use of torches is allowed, but can cause damage
to equipment if not used correctly. An alternated method of opening the collar is to
Other, simple concept, mechanical removal is chisel the collar walls out to free up the pin as
described below, and it is recommended when the seen.
hydraulic and pneumatic tools are not available.

The HuckBolt fastener is clamped at a very high

rate. Proper caution should be exercised when
remove this bolts, as they may release their clamp
suddenly. Wear proper eye protection and keep
your face at least 0.6 meters away from the collar
as you work on the removal process.

An installed fastener (as shown in the figure below)

has a collar that is cold-worked or "swage" over the
grooved CL50 pin.
Once the collar has been opened over the length of
the swage portion on two opposite sides, as shown
below, the pin may become free, or be may required
additional force to hammer or punch the pin out of
the collar.

No amounts of twisting or hammering dislodge the

pin from the collar. The collar must be cut
longitudinally to the extent of the swaged section.
This may best be accomplished with a small wheel
grinder.

MAINTENANCE –Vibrating Screens – N11479522 / Rev. 00 7-9

 MAINTENANCE – Vibrating Screens
If the pin doesn't come loose, use a chisel, or vice-
grid type pliers, to peel the collar sections back as
shown:
The pin will come free when sufficient collar
material has been pulled away from the swaged
section of collar:
If a Huck-bolt is substituted for conventional bolts
use only SAE Grade 5 (ISO 8.8).
In addition, conventional fasteners are used on
connections, which may require dismantling, and in
locations not accessible for the Huck bolt fastening
tools.
Conventional fasteners need to be retighten after the
first 50 hours of operation, and checked every 750
hours thereafter.
The tightness of bolts for the vibrator and for the
media hold down bolts is particularly critical and
requires verification at smaller intervals.
MAINTENANCE –Vibrating Screens – N11479522 / Rev. 00 8-9
3.4 Adding weight to body
The vibrator location in any screen body is
determined by the body center of gravity. Field
addition of skirt plates, baffle plates, feed boxes,
discharge spouts, or any other additional equipment
to the screen body will alter the location of the center
of gravity and directly affect screen motion, which
could lead to body failures. The added weight will
reduce screen throw and directly affect the screen
capacity and efficiency and could cause screen
blinding. Additional weight could alter the natural
frequency of the screen causing a resonant condition,
which may lead to rapid structural damage.
Any field modifications of the screen without
Metso approval will be done at the operator's risk.
3.5 Welding on body
Welding on vibrating bodies is another source of
stress concentration, which lowers the fatigue
resistance and can result in cracking. For this reason,
welding is recommended only as a temporary and
expedient repair to hold together a cracked body
until replacement parts can be obtained.
If it be necessary to weld cracks on screens for
temporary repairs, use this procedure.
Locate end of crack and drill one 1/4” (6 mm) hole at
each end of crack to prevent crack from progressing.
1. Gouge, chip, or grind out cracks as shown in
Figure 1.
2. Locally preheat to approximately 302F (150ºC),
if possible.
3. Weld with 1/8” (3.2 mm) diameter AWS E-7018
(tension: 20V-30V, current: 140A-195A,
positive polarity). Back chip and back weld to
insure full penetration weld if possible.
4. Grind weld flush (see Figure 1).
5. Reinforce with patch plate (see Figure 2).
MAINTENANCE – Vibrating Screens

2 [0.08]
3 [0.12] MAX.

Figure 1. Procedure to Obtain Full

Figure 2: Grind surface smooth and add patch

plate

MAINTENANCE –Vibrating Screens – N11479522 / Rev. 00 9-9

 METSO LINEAR VIBRATOR MECHANISM – ML

METSO LINEAR VIBRATOR MECHANISM – ML

1 LIFTING ...................................................................................................................................................................3

2 OPERATION ............................................................................................................................................................3

3 PERFORMANCE .......................................................................................................................................................3

4 ADJUSTMENTS ........................................................................................................................................................4
4.1 Calculation of Acceleration ........................................................................................................................... 4
4.1.1 Bearing Design Life................................................................................................................................ 4
4.1.2 Speed Adjustment................................................................................................................................. 4
4.1.3 Amplitude Adjustment .......................................................................................................................... 4

5 COUNTERWEIGHT ASSEMBLY PROCEDURE .............................................................................................................7

6 COUNTERWEIGHT DISMANTLING PROCEDURE .......................................................................................................8

7 GENERAL PRECAUTIONS - MAINTENANCE OF ML MECHANISMS ............................................................................8

8 VIBRATOR MAINTENANCE ......................................................................................................................................9

8.1 Lubrication of Mechanisms ........................................................................................................................... 9
8.1.1 Oil Selection .......................................................................................................................................... 9
8.1.2 Maximum Operating Temperature ........................................................................................................ 9
8.1.3 Frequency of Oil Change-out ................................................................................................................. 9
8.2 Oil Level ...................................................................................................................................................... 10
8.3 Breather ..................................................................................................................................................... 10

9 DISMANTLING / ASSEMBLY ..................................................................................................................................10

9.1 Cleaning and Inspection of Parts ................................................................................................................. 10
9.2 Assembly Preparations................................................................................................................................ 11
9.2.1 Preparation of the Gears ..................................................................................................................... 11
9.2.2 Preparation of the Casing .................................................................................................................... 12
9.2.3 Preparation of the Bearings................................................................................................................. 12
9.2.4 Preparation of the Shafts .................................................................................................................... 12
9.2.5 Preparation of the Counterweights ..................................................................................................... 13
9.3 Assembly .................................................................................................................................................... 13
9.4 Dismantling ................................................................................................................................................ 23

10 MAINTENANCE SCHEDULE OF ML MECHANISM ....................................................................................................24

10.1 Maintenance Programme ........................................................................................................................... 24

11 PROBLEM RESOLUTION IN THE ML MECHANISM ..................................................................................................25

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 1-25

METSO LINEAR VIBRATOR MECHANISM – ML

1 LIFTING

Lifting eyes in the front and rear extremities of the
ML mechanism casing, have been provide for the
purpose of lifting one mechanism at a time. The
use of appropriate hooks, shackles, slings or other
approved lifting apparatus is recommended.
Do not hoist the vibrator from the counterweights
due to the risk of damage or personal injury.
Be sure to mount the cardan shafts in accordance
with the instructions “Installation and maintenance of
Cardan shafts”.
Be sure to mount all guarding and safety equipment
in accordance with the legal requirements of the
location of installation.

During the lifting process, all precautions should

be taken to avoid contact between the vibrator and Breather
other structures to prevent damage in the bearings
and / or others parts of the vibrator mechanism. Casting
housing
Lifting
eyes Direction
of rotation

Lifting
eyes

Figure 1: Provision for Lifting the Vibrator Figure 2 - Metso Linear Vibrator Mechanism – ML

2 OPERATION 3 PERFORMANCE

The correct direction of vibration is when; the
counterweights come together at the upper most
point of rotation (at the top cover), and separate at
the lowest point (toward the mechanism foot);
There are two locations for the positioning of the
mechanism breather. Care should be taken to
locate the breather in the highest possible location
to prevent oil from being expelled during operation
(see Figure 12);
Hardware for fixing the mechanism to its support
beam should only be to ISO Class 10.9 (SAE
Grade 8) or higher. Care should be taken to ensure
all hardware is tensioned to the correct value. Re-
check all mechanism hardware torque settings after
the first 40 hours of operation. Ensure all mating
areas of contact are flat, clean, and dry before the
installation of mechanisms.
The Metso - ML linear motion vibratory mechanism is
composed basically of two axles supported on angular
compensating spherical roller bearings, on which
eccentric masses are mounted. The shafts are
synchronised through helical gears which cause the shaft
assemblies to counter-rotate with the same speed. By
running this way, the centrifugal force components
generated from the eccentric mass of counterweights F1
and F2, are added to form the force of excitement of the
equipment along the line of action (Fr), and the
components that act perpendicularly to it are cancelled
(See figure 3).

Consult the General Arrangement drawing to

obtain the correct speed of operation, motor speed,
and drive configuration.
Figure 3 – Unbalanced masses

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 3-25

 MECANISMO VIBRATÓRIO METSO LINEAR - ML
4 ADJUSTMENTS
4.1 Calculation of Acceleration
The metric and imperial formulas for acceleration follow:
2
rotation in RPM stroke mm
G strict balance requirements to prevent distortions to
1788500
rotation in RPM
2
stroke in
G damage to the equipment.
70400
4.1.1 Bearing Design Life
The useful life of the bearings depends basically on the
bearings selected for the vibrators (manufacturer,
tolerance class, etc.) and on acceleration “G” at which the
equipment is operated. It is necessary to take special care
in the assembly of the bearings to ensure the quality of
the machining of its bore, verifying its correct location
and use of the correct lubrication.
The total live mass of the vibrating equipment, the drive
speed of the mechanisms, and the eccentric mass of the
counterweights determine acceleration “G”. An increase
of acceleration “G” will reduce the useful life of the
vibrator’s bearings significantly, and a reduction in
acceleration will consequently increase the useful life of
the bearings. It is strongly recommended that the
equipment be run at the lowest possible acceleration
without adversely affecting acceptable efficiencies.
All the measures that can affect the acceleration of the
equipment (alteration of the equipment mass, increase in
counterweight setting and/or the modification of the
speed of operation) must only be undertaken after
consultation with your local Metso Minerals
representative.
4.1.2 Speed Adjustment
IMPORTANT
DO NOT OPERATE EQUIPMENT AT ANY
OTHER SPEED THAN THAT SPECIFIED BY
METSO. Any change in the speed must only be
undertaken after consulation with your Metso
Minerals representative.
METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 4- 25
4.1.3 Amplitude Adjustment
4.1.3.1 Arrangement of Adjustable Counterweights
NOTE
All of the counterweights are shaft matched to meet
the motion of the equipment. Always use original
counterweights in the correct location. Modification to
the counterweights in the field poses a high risk of
If the adjustable counterweights require adjustment to
correct the amplitude of vibration, proceed as per section
4.1.3.4 “Setting of Adjustable Counterweight”. The
adjustable counterweights must be set such that they are
symmetrical about the centreline of the mechanism in
order to avoid eccentric distortion of the motion of the
equipment. Under no circumstances are variations
permitted.
NOTE
ENSURE THAT COUNTERWEIGHT SETTINGS IN
ALL VIBRATORS ON ANY ONE PIECE OF
EQUIPMENT TAKE EXACTLY THE SAME FORM
TO PREVENT DAMAGE TO EQUIPMENT.
4.1.3.2 Eccentric Mass
An important characteristic of the ML vibratory
mechanism is called eccentric mass. The eccentric mass is
the sum of the masses of all the counterweights
multiplied by the distance between their centre of gravity
and their axis of rotation (centreline of shaft), usually
defined in kg.m (or lbs.in). The eccentric mass and
consequently the force of excitation generated by the
vibratory mechanism can gradually be adjusted by the
angular imbalance between the fixed counterweight and
the adjustable counterweight (for details see section
4.1.3.4 “Setting of Adjustable Counterweights”). The
magnitude of eccentric mass as a function of
counterweight setting can be referenced in Table 1.
“Eccentric Moment of Vibratory Mechanism
Counterweights”
METSO LINEAR VIBRATOR MECHANISM – ML

Example: This arrangement of adjustable counterweights indicates the static moment of the set to be 56kg.m.

Adjustable Counterweights

Fixed Counterweights
Static Moment as Showing
Static Moment as Showing
on the fixed counterweights
on the fixed counterweights

Figure 4 – Static Moment

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 5-25

 METSO LINEAR VIBRATOR MECHANISM – ML

Table 1 – Eccentric Moment of Vibratory Mechanism Counterweights

ADJUSTMENT ECCENTRIC MASS

CONFIGURATION OF THE COUNTERWEIGHTS
[%] Kg.m Lb.in

100 80,7 7004

98,2 79,2 6874

87,6 70,7 6136

76,8 62,0 5381

69,7 56,2 4878

60,4 48,75 4231

55,1 44,5 3862

49,2 39,7 3446

42,8 34,5 2994

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 6- 25

METSO LINEAR VIBRATOR MECHANISM – ML

4.1.3.3 Calculation of Amplitude 5 COUNTERWEIGHT ASSEMBLY PROCEDURE

The amplitude of vibratory equipment is defined through 1. After assembly of the mechanism box with shafts,
the relationship between the eccentric mass developed by gears, bearings, labyrinths and seals, place the key on
the counterweights, and the total live mass of the the shaft and locate the hub of the fixed
vibratory equipment. counterweight.

In industry it is common to hear the term ‘stroke’ in place

of ‘amplitude’. Stroke is simply the total path length
developed by the equipment from peak to trough of a
cycle, and is simply the amplitude multiplied by a factor
of 2.

Static Moment
AMPLITUDE
Live Mass of Equipment

Static Moment
STROKE 2
Live Mass of Equipment
Figure 6 – Fixed counterweight assembly

4.1.3.4 Setting of Adjustable Counterweights
All of the counterweights of the vibratory mechanisms
mounted on any one piece of equipment, must possess the
same counterweight setting.
2. Clean contact surfaces of fixed and adjustable
counterweights and apply a thin film of molybdenum
grease. This will assist in the assembly process and
prevent possible corrosion.

There are tapped holes in each fixed counterweight such

that the adjustable counterweight can be set in angular
increments to represent the static moment visible adjacent
to the adjustable counterweight when set.

Fixed
Counterweight
Figure 7 – Cleaning faces between counterweights

3. Position the adjustable counterweight with the

imbalance required relative to the fixed
counterweight. This static moment value will be
visible on the fixed counterweight adjacent to the
adjustable counterweight’s position.

Adjustable
Counterweight
Figure 5 – Static Moment

Figure 8 – Position the adjustable counterweights

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 7-25

 METSO LINEAR VIBRATOR MECHANISM – ML
4. Place the fixing screws in position to set the
counterweight.
Figure 9 – Assembly the bolts
5. Locate the spacer ring over the shaft and fix in place
with the lock washer and nut.
Figure 10 – Lock washer and nut
6. Tighten the nut and then bend the washer's lock.
6 COUNTERWEIGHT DISMANTLING
PROCEDURE
1. Remove the lock nut and washer.
2. Remove the two fixing screws that locate the
adjustable counterweight to the fixed counterweight
taking measures to ensure that sudden shearing
action between the counterweights does not result in
personal injury (i.e. chock or sling adjustable
counterweights).
3. Remove the counterweights with the use of
appropriate lifting devices and procedures.
NOTE
LOOSENING OF FIXING SCREWS CAN BE
ASSISTED WITH THE USE OF A PENETRATING
OIL OR RUST SOLVENT.
METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 8- 25
Counterweight
Fixing Screws
Figure 11 – Counterweights
NOTE
IT IS NOT NECESSARY TO COMPLETELY
REMOVE LOCK NUT AND WASHER TO ADJUST
THE COUNTERWEIGHT SETTING. LOSEN THE
LOCK NUT TO FREE THE ADJUSTABLE
COUNTERWEIGHTS, FOR ADJUSTMENT TO
THE DESIRED SETTING USING THE FIXING
SCREWS. ENSURE BOTH MATING FACES ARE
VERY CLEAN BEFORE CHANGING THE
SETTING OF COUNTERWEIGHTS.
7 GENERAL PRECAUTIONS - MAINTENANCE
OF ML MECHANISMS
Observe the following general precautions when
performing repairs and maintenance on the ML
mechanism:
Handle parts with machined surfaces with care to
prevent damage;
Protect all machined and exposed parts with suitable
protective oil to prevent corrosion. If any bare items
are to be stored for any period of time, cover with
suitable protective oil to prevent corrosion no matter
how short a time;
When dismantling machined or exposed components,
locate timber packing or other protection where items
are to be place to prevent contact with hard surfaces
resulting in damage;
Carefully clean and inspect parts before re-assembly
of mechanism components;
Replace any consumable or damaged components
before re-assembly;
METSO LINEAR VIBRATOR MECHANISM – ML

DO NOT force components into the casing of the - Greater fluidity in low temperatures, resulting in
vibratory mechanism. This can cause damage faster oil flow under equipment starts conditions.
resulting in failure that is only evident upon
operation; The selection of the correct lubrication viscosity is a
function of the geometry and operating conditions of
Replace all bearings and all oil seals in a the bearings: rotation and temperature band. Use the
mechanism if a fault is detected in any one following table to select the correct viscosity grade:
bearing. Carefully inspect components for signs of AMBIENT TEMPERATURE
-25ºC to +5ºC +5ºC to +35ºC > +35 ºC
damage and replace where necessary whenever
Maximum oil temperature
bearing exchange is taking place; < 60ºC 60ºC to 80ºC 80ºC to 90ºC 90ºC to 100ºC
SHC626 SHC629 SHC630 SHC632
When mounting ‘O’ rings in the flanges of the
mechanism labyrinth, be sure to slide or roll to 8.1.2 Maximum Operating Temperature
assure perfect positioning. DO NOT FORCE
THEM AND ALWAYS USE SYNTHETIC The temperature limit of the vibratory mechanism is
GREASE FOR LUBRICATION; 100ºC (210º F).

Ensure contact surfaces for oil seals are a polished In the event that operating temperatures are expected to
finish and lubricated prior to fitment; exceed this value, consult your local Metso Minerals
representative for advice on available oil cooling
8 VIBRATOR MAINTENANCE measures.

Long mechanism life strongly depends on a regular 8.1.3 Frequency of Oil Change-out
maintenance regime, correct maintenance procedures
and lubrication. Upon initial start-up of a new machine, the oil MUST
BE changed after the first forty (40) hours of operation.
8.1 Lubrication of Mechanisms This must also be done in the event that a machine
remains idle for a period greater than 4 months.
ML vibratory mechanisms are lubricated with synthetic
oil. Correct lubrication and quantity is the single Regular lubrication change-outs must be set according
greatest contributing factor in life expectancy of the to the programme below.
mechanism. To ensure the greatest life possible, follow Operating
up to1500 1500, 2000, 2500
3000
these lubrication instructions rigorously. Many hours or 180 days
Acc. to item 10.1 - Oil analysis Change oil
premature mechanism failures can be attributed to Action Maintenance - Change oil if one of the (whichever
inadequate or incorrect lubrication. Lubrication Agenda criteria below is reached comes first)
inspection must form part of the daily maintenance
Oil Solid Content Viscosity Total Acid
programme. Property
Humidity (Fe, Cr, Cu, Si, etc.) Range Number
0.1 % of ISO 4406:99 Acc. to oil
Max. ± 15 %
8.1.1 Oil Selection the weight Class 17/14/12 manufacturer

To increase the life expectancy of the mechanism,
consider increasing the frequency of oil change-out.
Metso Minerals has worked extensively with Exxon
Mobil to carry out exhaustive tests with their SHC630
series of lubricants to ensure the best maximisation of
gear and bearing lubrication requirements. Among
other benefits are:
- High chemical stability under high temperatures and
mechanical loads.
- High resistance to oxidation and therefore high
resistance to the degradation of the oil.
- Temperature stable viscosity characteristics.
- Greater resistance to the formation of sludge and
deposits, resulting in better internal cleanliness and
operation.
- Contributes to less heat generation in functioning
components.
Regular oil change will purge the mechanism of any
condensation contamination that would adversely
affect operation. Extreme operating conditions may
demand a more frequent maintenance programme.
The oil is best drained immediately after machine shut-
down, while contaminants are still in suspension to
ensure that the greatest amounts of contaminants are
removed. TAKE EXTREME CARE HANDLING
HOT OIL.
Additional to the regular oil changes, it is highly
recommended to periodically flush the mechanism with
oil SAE 10. The flushing procedure involves filling the
mechanism to the normal level with SAE 10 oil and
operating the machine for approximately fifteen (15)
minutes. Drain the oil immediately after shut-down.
This process will remove contaminants that would
otherwise remain in the system.

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 9-25

 METSO LINEAR VIBRATOR MECHANISM – ML

8.2 Oil Level

The quantity of oil required for the ML mechanism is approximately seven (7) litres.

Breather
Mechanism
Foot
Top Side

Oil Level in the

Cover
Mechanism
Foot

Oil Level in the

Casting Housing

Vibrator Mechanism Assembled In Grizzlies And Feeders Vibrator Mechanism Assembled In Screens

Figure 12 – Oil level

Remove the drain plug as indicated. A uniform trickle of oil indicates the correct level has been reached.

8.3 Breather After cleaning, all components must be carefully

inspected.
The breather controls the internal pressure of the
vibrator mechanism and it must be exchanged at least All teeth of the gears must not have cracks, wear,
together with each oil change. pitting and scratches.

If the bearings are not to be changed out, a thorough

NOTE integrity check of all of the components of each
bearing should be performed. If pitting, spalling or
SEVERE AMBIENT CONDITIONS COULD wear are evident in any one element of a bearing, all
REQUIRE MORE FREQUENT EXCHANGE OF bearings are considered to have reached their
THIS COMPONENT. serviceable life and all bearings should be changed-out
accordingly.

9 DISMANTLING / ASSEMBLY
9.1 Cleaning and Inspection of Parts
Prior to mechanism assembly, all components must be
thoroughly washed, degreased and dried with
compressed air.
The housing casting must not have cracks and / or
damage areas.
Inspect the Mechanism Casing for correct bore
dimensions in the bearing bore (see item 9.2.2).
In the event that evidence of damage exists in any
mechanism components, they should be replaced.
Always demand genuine Metso Minerals parts.

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 10- 25

METSO LINEAR VIBRATOR MECHANISM – ML

Cover the inspected parts with low viscosity oil to

assist in the assembly and protect exposed parts.

Following this, initiate preparation of the assembly as

follows, ensuring consumable parts (including
retainers, breather and rings) are new. These items
represent a small cost relative to the complete
assembly; however failure or poor performance of
these components can significantly diminish the
serviceable life of the mechanism by causing oil leaks
leading to overheated bearings and other potential
damage.

9.2 Assembly Preparations

9.2.1 Preparation of the Gears

Preparation of the gears for assembly consists of the

Figure 14 - Marks in the gears
following procedure:

1. Verify that the two gears form a matched pair and

possess the same manufacturing code. Gears that
are not adequately matched may generate
performance imperfections leading to excessive
noise and overheating.

2. Carefully place the gear pair on a clean flat

workbench with teeth engaged and ‘X’ marks
coincident (as per Figure 13). With the aid of a
straight edge ruler and the gear keyways, mark the
opposite sides to the ‘X’ mark on the gears with a
pen (Figure 14). Carry this marking down the top
land of the opposing gear tooth as per Figure 15.
This represents the assembly position of the gears Figure 15 - Marking of the teeth
in the casing.
3. Verify that the key is correctly fitted in the key
seating of the gears. If necessary adjust the key
seating using a smooth file until a tight sliding fit
is achieved (figure 16).

Figure 13 - “X” Marks

Figure 16 – Adjustment of the key

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 11-25

 METSO LINEAR VIBRATOR MECHANISM – ML

9.2.2 Preparation of the Casing

NOTE
Preparation of the casing consists of the following
procedure: When substituting bearings, only use those
constructed in accordance with metso minerals
1. Dress sharp edges and fettle any remaining specifications.
imperfections on the casting, paying particular
attention to areas that may inhibit assembly (Figure
17). If necessary use for this propose a small grinder 1. New bearings: remove excessive protective oil with
or a bastard file. absorbent paper.

2. New and used bearings: Measure the internal

clearance of the bearings (figure 18). This
measurement must be between 200 m & 240 m.
Document the measured dimension according to the
assembly report.

NOTE

When substituting bearings, never use “generic”

bearings. These will not offer satisfactory
performance, and can cause damage to other
mechanism components.

Figure 17 - Removal of barbs and other imperfections

2. Inspect the bearing housing diameter (Ø 300 mm p6;

300 mm – 0.047/ -0.079).

3. Inspect all threads, and if necessary, recondition

them. Also verify that lubrication holes are opened
and clean.

NOTE
Figure 18 – Measure of the bearing clearance
When heating the mechanism casing for assembly,
never use the direct flame of a torch or similar 9.2.4 Preparation of the Shafts
devices. It is recommended to use an oven or oil bath
to reach a temperature of approximately 120ºc. Preparation of the shafts for assembly consists of the
following procedure:

1. Verify the dimensional correctness of the shaft

9.2.3 Preparation of the Bearings particularly at the bearing journal (Ø 140 mm f6;
140 mm -0.043/-0.068).
The preparation of the bearings for assembly consists of
the following procedure:
2. Inspect all threads, and if necessary, recondition
them. Apply a thin layer of low viscosity oil on the
1. Used bearings: carefully wash bearings, and inspect
shafts.
before re-use. Coat bearings in a fine layer of
protective oil. If necessary change-out all bearings.

Figure 19 - Shafts

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 12- 25

METSO LINEAR VIBRATOR MECHANISM – ML

9.3 Assembly
9.2.5 Preparation of the Counterweights

Preparation of the counterweights for assembly consists IMPORTANT

of the following procedure:
Before assembling, observe the housing “top side”
1. Verify all counterweights, checking for damage on and “bottom side” that determine the correct
mating surfaces, in the screw threads and in key positioning of the gears and the shafts.
seats.

2. The fixed counterweight and the adjustable
counterweight are matched and balanced in the
factory. Therefore it is important to always make use
of counterweights recommended by Metso Minerals
(Figure 20).
For assembly, a pressing capacity of approximately 40 t
[400KN] is required.
1. Heat the casing and the gears in their assembly
position (Figure 22), for 1.5 hours at 120ºC. For
this process it is preferential to use an oven or oil
bath (Figure 23).

CAUTION!

To reduce the risk of burns, use appropriate gloves

and apron for protection when manipulating hot
parts.

Top Bottom
Side Side

Figure 20 - Counterweights

3. If new counterweights will be used, adjust the key

seating using a smooth file until a tight sliding fit is
achieved (figure 21).

Figure 22 - Initial position of the gears for heating

Figure 21 – Key adjustment

Figure 23 – Oven

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 13-25

 METSO LINEAR VIBRATOR MECHANISM – ML

2. Remove the casing and gears from the oven or oil

bath, placing the parts on a stable trestle and install
the two (2) bearings of one of the sides of the
mechanism.

3. Using two very clean pin punches with a diameter of

approximately 8,5 mm in the holes of the external
bearing race (Figure 24), assembly individually the
bearings into its bore in the housing (Figure 25).

Figure 26 - Bearing identification markings

4. Install the static labyrinths on the upper face with

three off screws M12 x 50 (Figure 27), and carefully
turn the casing to enable assembly of the other side
(Figure 28).

Figure 24 - Utilisation of the pin punches

Figure 27 - Support of the bearings

Top
Bottom Side
Side

Figure 25 - Assembly of the bearings

NOTE

The identification numbers of the bearings must face

toward the outside of the casing (visible externally
after assembly as per Figure 26).

Figure 28 - Reverse face of the casing

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 14- 25

METSO LINEAR VIBRATOR MECHANISM – ML

5. Verify and reposition if necessary, the position of
the gears in the casing in preparation for the
installation of the shafts. Use the gear markings as
per section 9.2.1 – Preparation of the gears (Figure
29).
7. Install the key into the shaft before complete
installation of shaft into the gear. The installation
finishes when the shoulder of the shaft contacts the
gear (Figure 31).

Bottom
Side
Figure 29 - Position of the key seating of the gears

NOTE

Check if the key seating of the gears are on opposite

sides and turned out of the casing.

6. Using an eye bolt assembled in the end of the shaft

and an appropriate lifting device, install the lower
shaft in the gear and in the bearing located in the left
side of the casing, taking as reference the mark
“BOTTOM SIDE” in the casing (figure 30).

Shoulder of
the Shaft
Figure 31 – Installing the shaft in the gear

Key Seating

Bottom
Top
Side
Side

Figure 30 - Installation Of shafts

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 15-25

 METSO LINEAR VIBRATOR MECHANISM – ML

8. Install the second shaft in the adjacent gear and

bearing of the opposite side (Figure 32). 10. Install the other two bearings using the same method
as previously used (Figure 34). Confirm that the
bearings are correctly installed (Figure 35).

Figure 34 – Installation of bearings

Bottom side Top side

Figure 32 - Installation of the second shaft

9. Install the key into the shaft before complete

installation of shaft into the gear. Finish the
installation until the shoulder of the shaft contacts
the gear (Figure 33).

Figure 35 - Bearing assembly

NOTE

Due to the tendency for heat to transfer into adjacent

components, often the last two bearings can be more
difficult to locate than the first. If necessary the outer
ring may be gently tapped with a copper faced
hammer or bearing locating tool until bearings are
fully located.

11. Carefully turn the mechanism from its assembly

position (Figures 36 & 37), position the mechanism
on trestles (Figure 38) to continue the assembly
procedure.

Figure 33 - Installation of shafts

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 16- 25

METSO LINEAR VIBRATOR MECHANISM – ML
Figure 36 -Mechanism assembly position
Figure 37 - Turning of mechanism
Figure 38 - Location of mechanism on trestles
METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 17-25
12. Remove the static labyrinths that had been
provisionally installed before (Figure 39).
Figure 39 - Removal of the labyrinth
13. On the radial side of the bearing rollers, measure the
internal clearance (Figure 40). Notate the
dimensions recorded in the assembly report. After
assembly of the bearings, the radial internal
clearance should not exceed 110 m.
Figure 40 - Measurement of the internal clearance
14. Measure the internal end float of each shaft
assembly by gently levering the assembly in one
axial direction with a podger as shown in (Figure
41). Using a depth gauge, measure the distance
between the inner race of the bearing and its
adjacent shaft step (Figure 42). Record this
dimension in the assembly report.
Figure 41 - Movement of shaft assembly for end float
measurement
 METSO LINEAR VIBRATOR MECHANISM – ML

Figure 42 - Measuring the distance

15. Relocate the assembly to its full extent back toward

the fixed end (Figure 43) and measure the depth
again (Figure 44). Record the dimensions in the Figure 45 - Deflector plates (Slinger)
assembly report. Deduct the second measurement
from the first one obtained to get the internal 17. On the table, install the seal in the static labyrinth
assembly float (between fixed and free end). The (Figure 46).
internal float must be between 4.0 and 5.5mm.
Repeat the process for the second shaft assembly.

Figure 46 – Seal of the labyrinth

18. Apply thread seal tape (Teflon®) on the 1” NPT

magnetic plug and on the breather, tighten them
(Figure 47 and 48).
Figure 43 - Relocation of shaft assembly for second
measurement

Figure 47 - Installation of the 1” NPT plugs

Figure 44 - Measuring the distance

16. Mount the deflector plates (slingers) as per (Figure

45). The correct orientation is with the shoulder
directed toward the bearings.

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 18- 25

METSO LINEAR VIBRATOR MECHANISM – ML

Figure 51 - Assembly of the gasket to the cover

Figure 48 - Installation of the breather (see note in the section
2, page 3, about the correct position and Figure 12)
21. Apply two parallel ribbons of diesel engine gasket
former or similar to the top face of the mechanism,
19. Apply thread seal tape (Teflon®) on the 3/8” NPT
mount the cover on the casing (Figure 52) and install
plug and tighten them (Figure 49).
eighteen screws M12 X 20 (class DIN ISO 898 8.8),
with smooth washers DN 12. Apply a torque of 78
N.m (Figure 53) to the screws. The oil level plug
must always be mounted on the “BOTTOM SIDE”
of the casing.

Figure 49 – Installation of the 3/8” NPT plug

20. Apply two parallel ribbons of diesel engine gasket

former or similar to the inside face of the
mechanism cover plate and spread over the
assembly contact area (Figure 50). Install the gasket
to the cover (Figure 51) and moisten it with grease. Figure 52 - Mounting the cover

Figure 53 - Tensioning the screws

Figure 50 - Adhesive application

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 19-25

 METSO LINEAR VIBRATOR MECHANISM – ML

22. Install the gaskets to the static labyrinths by 25. Install the ‘O-rings’ to the dynamic labyrinth (Figure
smearing a fine layer of grease to both sides prior to 57). Smear a fine layer of synthetic grease on the
fitment (Figure 54). rings and grooves prior to assembly. Dow Corning
(Molykote) 111 or equivalent.

Figure 54 - Application of grease

23. Carefully mount the labyrinths to the casing and
install the 8 Hex. head screws M12 x 50 with
smooth washers DN12. Apply a torque of 78 N.m
(Figure 55) to the screws.
Figure 57 – Installation of the “o-rings”
26. Mount the dynamic labyrinths to the assembly
taking particular care with fitment to the shafts
(Figure 58).

Figure 55 - Tension the screws Figure 58 - Mounting the dynamic labyrinths

24. Install the ¼” NPT plug (Figure 56). 27. Install the spacer tube to the “Bottom shaft” Figure
59.

Bottom
Side

Threads

Figure 56- Installation of plug

Figure 59 - Installation of spacer tubes

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 20- 25

METSO LINEAR VIBRATOR MECHANISM – ML

28. Apply Molybdenum Disulfide based grease to the

shoulders of the shaft that will receive the
counterweights. (Figure 60).

Figure 62 - Installation of counterweights

Figure 60 - Application of grease to the shafts 31. In the same way, install the other counterweight to
the opposite end of the shaft (Figure 63).
29. Install the counterweight keys to the shafts (Figure
61).

Figure 63 - Installation of the other counterweight

Figure 61 - Installation of the keys
32. Install the adjustable counterweights on the top side
NOTE shaft (Figure 64) to both sides.

The keys must first be adjusted so that they fit neatly

in the shaft keyway without interference.

30. Using adequate lifting apparatus, locate the first

fixed counterweight in the side of the casing marked
“TOP SIDE”, taking care that the “INNER SIDE”
tab is facing the adjacent shaft (Figure 62).

Figure 64 - Installation of the adjustable counterweight

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 21-25

 METSO LINEAR VIBRATOR MECHANISM – ML
33. Install the counterweight lock washer MB21 with
the tabs facing out from the casing of the
mechanism, and locate the lock nut KM21. Tighten
the nut until all parts are pressed together. Lock the
washer bending the clamps (figure 65). Perform this
operation on both ends of the shaft beginning with
the fixed bearing side.
Figure 65 - Installation of the lock nut and washer
34. Set the position of the adjustable counterweight
ensuring all are set to the same configuration (Figure
66 shown as 76.8%). Install the two socket head cap
screws M16 x 50 without washers. Tighten the
screws to a torque of 197 N.m.
Figure 66 - Tighten the screws of the adjustable counterweight
35. Next install the two remaining fixed counterweights
to the “BOTTOM SIDE” of the assembly, again
with the “INNER SIDE” tab facing the
counterweights in the “TOP SIDE” of the casing
(Figure 67).
METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 22- 25
Figure 67 - Installation of the remaining counterweights
36. Install the counterweight lock washer MB21 with
the tabs facing out from the casing of the
mechanism, and locate the lock nut KM21. Tighten
the nut until all parts are pressed together. Lock the
washer bending the clamps (Figure 65). Perform this
operation on both ends of the shaft beginning with
the fixed bearing side.
37. Set the position of the adjustable counterweight
ensuring all are set to the same configuration (Figure
68 shown as 76.8%). Install the two hexagon Socket
head cap screws M16 x 50 without washers. Tighten
the screws to a torque of 197 N.m.
Figure 68 - Installation of the lock nut and washer
38. Fill the mechanism with synthetic oil MOBIL
GEAR SHC 630 until excess can be seen as a
constant trickle through the 3/8” NPT plug hole
(Figure 69). Re-torque the plug.
NOTE
Oil level according to the Figure 12.
METSO LINEAR VIBRATOR MECHANISM – ML

Floating
Fixed
Bearing
Bearing

Shoulder Of
Pressure The Shaft

Figure 69 - Plug 3/8” NPT

39. Torque all 1” plugs and the breather.

Figure 70 – Identifying fixed and floating bearing
9.4 Dismantling
7. Dismantle the fixed bearing.
For dismantling, a pressing capacity of approximately 40
t [400KN] is required. 8. Repeat this procedure for the opposing shaft.

The dismantling procedure is the reverse of the assembly

procedure, however some points must be observed:

1. Firstly, all lubricant must be drained;

2. Remove the washers and the lock nut that fix the
counterweights in the shafts;

3. Remove all counterweights from one end, starting

with the counterweights that are at the "Bottom
Side" and then counterweights that are at the "Top
Side".

4. Remove the dynamic labyrinths followed by the

static labyrinths;

5. Removing the top cover of the casing can assist in

the identification of the fixed and floating bearings.
Keep in mind that the bearing on the side of the gear
with a retaining step on the shaft, will be the floating
bearing, and the opposite bearing will be the fixed.

6. To remove the shaft from the casing the bearings

and gear must be pressed off the shaft
simultaneously. The shaft must be pressed through
the housing in a direction towards the floating
bearing. The floating bearing should be the first
bearing to emerge from the housing, then the gear
will come loose, then the shaft will be free and
loose.

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 23-25

 METSO LINEAR VIBRATOR MECHANISM – ML

10 MAINTENANCE SCHEDULE OF ML MECHANISM

10.1 Maintenance Programme

ML vibratory mechanisms require periodic maintenance. A Metso Minerals recommendation is that this maintenance is
programmed and conducted at regular intervals. A suggested programme is as follows:

MAINTENANCE AGENDA

As a one off check after 1000 hrs of operation, verify the torque setting on all mechanism
ONE OFF hardware. Re-tighten if necessary.

Check possible oil leakages.

Verify the temperature of the machine. In the event that the temperature is above average, it
DAILY is possible that there are bearing issues.

Ensure that breathers are not damaged.

Visually inspect the oil for evidence of contamination (particularly in fish scale type form as
this indicates spalling of the bearings).

Verify the temperature of the oil as soon as possible after machine shut-down. The vibrator
should operate between 20º C (70º F) and 50º C (122º F) above the ambient temperature.
WEEKLY The maximum temperature should not exceed 100º C (210º F).

The oil level plug verifies the correct oil level (3/8” NPT). If necessary correct the oil level
(CAUTION: Allow enough time for any incidental oil in the plug bore to drain – failure to
do this could result in a false reading).

4 to 6
Replace the oil in accordance with the lubrication instructions within this manual.
MONTHLY

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 24- 25

METSO LINEAR VIBRATOR MECHANISM – ML

11 PROBLEM RESOLUTION IN THE ML MECHANISM

FAULT DETECTED CORRECTIVE ACTION

Overheating of the Check the lubrication. An excess or a lack of lubrication can be responsible for heat
mechanism generation within the bearings due to a breakdown of the boundary film. Correct the
oil level and allow mechanism to cool before re-starting.

Allow mechanism to cool and turn shaft manually with care to verify the existence of
Damaged bearings bearing problems. If the mechanism does not turn freely, one or more bearings could
be damaged. Replace all bearings after meticulously cleaning contaminants from the
casing.

Check to determine if there is an accumulation of fine particles between the static and
Excessive wear in the
dynamic labyrinth. This situation can generate frictional heating, and consequently
dynamic labyrinth face that
bearing failure. Clean the grooves.
stays in contact with the lip
of the seal
Check the torque on the static labyrinth retaining screws.

Check that all counterweights are set to the same eccentric moment.
Cracks in the casing
Verify that the mechanism hold-down hardware is tensioned correctly.

Loose plugs. Check all plugs in the casing for possible looseness.

Worn bearing or seal: excessive bearing wear can result in an oval movement of
the shaft causing oil leaks from the seals. Replace the bearings and the oil seals.

Breather: Check to see if the breather is fitted correctly or if there is any

obstruction. A blocked breather can result in higher internal pressures of the
casing resulting in oil leaks from seals.

Oil Leaks Lip seals: Check to see that lip seals are fitted correctly. Analysing the oil path,
oil must pass through this seal in order to enter the dynamic labyrinth.

Mating faces: Where leaks exist at mating faces between the casing, cover, or
static labyrinth, check for the possibility of incorrect assembly.

Casing: cracks in the component will generate leakage. Check that all
counterweights are set to the same eccentric moment, and that all hardware on
the casing is installed and tensioned correctly.

METSO LINEAR VIBRATOR MECHANISM – ML – N11481148 / Rev. 01 25-25

 Metso Outotec Germany GmbH

The document is the exclusive intellectual property of Metso

Outotec Germany GmbH. Its use is reserved to the buyer of the
product in question; each use by third parties has to be authorised
in writing by Metso Outotec Germany GmbH. For all information
and servicing, please consult:

Metso Outotec Germany GmbH

Harrlachweg 6
68163 Mannheim
Tel.: 0049/621-727 00-0
Fax: 0049/621-727 00-777