Professional Documents
Culture Documents
MPS Rebuild
313-01-01-005
Gyratory Crusher
Superior MK-II 42-65
LEGEND
DANGER
Definition: Indicates a hazardous situation which, if not avoided, will result in death or serious
injury. This signal word is limited to the most extreme situations.
WARNING
Definition: Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Definition: Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
NOTICE
Definition: Notice is the preferred signal word to address practices not related to personal in-
jury. Used when misuse or failure to follow specific directions will lead to equipment damage.
WEIGHTS
ASSEMBLIES
kg lbs
Mainshaft Assembly 23,130 51,000
Balance Cylinder & Piping 450 1,000
MPS Cylinder Assembly 4,040 8,900
Piston 748 1,650
Since various assembly combinations are available in each crusher size and because of manufacturing variations,
the weights shown above are approximate and they can vary 5 to 10%.
CAUTION
Check the weight of all loads before lifting. Make sure the lifting device and other components
that will support the weight of the load are in good condition and are rated for the weight of
the load.
See “Safe Handling of Heavy Equipment and Machinery” procedure from Metso.
See customer’s site specific procedure to operate the customer’s particular crane.
Metso Metso
Tools QTY Special Tools QTY
Number Number
Tool box (Hand tools) Maintenance cart
Snap ring pliers - piston 00-673-247-160 1 Lowering rods - MPS 17-105-881-512 3
Snap ring pliers - 00-673-247-087 1 Lowering rods - piston 17-105-881-504 3
mainshaft Lowering rod - mainshaft 17-202-513-801 1
Eyebolt - 0.375" 00-691-525-095 2 step
Eyebolt - 0.5" 00-691-531-184 3 Inside micrometer 23.5" -
Eyebolt - 0.75" 00-691-531-302 4 26" Bushing ID and
Cylinder Bore
Eyebolt - 1" 00-691-531-412 4
Outside micrometer 23.5"
Eyebolt - 1.25" 00-691-531-517 1 - 26" piston OD, Bushing
2.75" boxsocket sledging 17-103-757-006 1 OD
wrench Hydraulic Jacks 10 ton 4" 3
2.625" boxsocket sledging 17-103-757-017 1 stroke
wrench Piston stop plate 17-200-005-501 1
Sledgehammer 10 lbs Piston stop plate bolt 00-611-271-736 2
Shackles Piston stop plate nut 00-631-001-116 2
Slings
Steel blocks - Mainshaft
support
Wrench Set 1/4 to 1 5/8 17-107-059-001 1
Adjustable Wrenches 8-12 17-107-059-002 1
Hex Key Wrench Set 5/16- 17-107-059-003 1
3/4
Heating Torch
Metso Metso
Spare Parts QTY Wear Parts QTY
Number Number
MPS Cylinder 2005-0 1
Lower MPS cyl. bushing 2050-1 1
Upper MPS cyl. bushing 2050-2 1
Lower MPS cyl. bsh’g bolt 2055-0 2
Upper MPS cyl. bsh’g bolt 2060-0 12
MPS cylinder dowel 2090-0 1
Bottom shell drain plug 2120-0 1
MPS cylinder O-ring 2140-0 1
Piston 2205-0 1
Piston plug 2205-1 1
Piston plug capscrew 2205-2 6
Plug 2217-0 2
Piston dowel 2225-0 1
Piston wearing plate 2260-0 1
Step washer retainer 2275-0 1
Step washer retaining ring 2276-0 1
Step washer 2280-0 1
Oil seal 2305-0 1
Clamp plate 2325-0 1
Clamp plate retaining ring 2325-1 1
Bolt 2325-2 8
Washer 2325-4 8
MPS cylinder cover 2505-0 1
MPS cylinder cover O-ring 2506-0 1
MPS cylinder cover bolt 2515-0 22
MPS cylinder cover nut 2515-1 22
MPS cyl. cover locknut 2515-3 22
Capscrew 2520-0 2
MPS cylinder drain plug 2530-0 1
Balance cylinder 8075-0 2
Seal kit 8075-4 2
Piston kit 8075-8 2
These catalog numbers have been used as a
typical example only. Use the part number
indicated in the parts manual provided with your
specific equipment
Anti-seize compound/paste
Site specific Crushing Chamber Work platform(s)
Cleaning rags (Bags)
Varsol (Cleaning lotion)
Dry Ice
Light Oil
Tarpaulins
Locktite #242
Buckets
NOTICE
Prior to starting the work, check that all PPE and Tools are in good and safe condition and
working properly. Check that all spare parts are correct for the equipment to be worked on.
2.4 Mobilization
▪ Ensure adequate lay-down area exists close to the crusher
▪ Ensure safe access to the equipment.
▪ Obtain site specific work permits: Hot work, Confined space
WARNING
When working on equipment with lubrication and/or Hydraulic systems, precautions must be
taken to ensure that any stored energy has been eliminated. Escaping fluid under pressure
can penetrate the skin, causing serious injury.
▪ With the mainshaft supported, drain oil from the crusher by removing the bottom shell drain
plug (2120-0) from the bottom of the MPS cylinder flange.
▪ Then disconnect the lubrication and hydraulic lines and drain. Open the vent at the balance
cylinder to help drain the hydraulic lines. Cap/Plug ends of lubrication and hydraulic lines to
prevent additional oil leakage or spillage.
▪ If equipped remove bin level sensor and disconnect wires.
▪ If equipped remove Mainshaft position sensor and disconnect wires.
FIGURE 1
▪ The eccentric support plate (1905-0), is held up by cap screws (1910-0), these cap screws
will retain the eccentric in position while the cylinder assembly is not in place.
▪ Locate the eccentric cart or skid under the MPS cylinder. It is recommended to use an
overhead crane to lift and lower the eccentric cart or skid with the MPS cylinder assembly.
▪ Install the 3 MPS lowering rods, pipe sleeves and nuts into the tapped holes in the bottom
shell. The lowering rods are used primarily to guide the MPS cylinder assembly into position.
WARNING
The lowering rods are to be properly threaded into the bottom shell until the thread bottoms
out inside the bottom shell. Failure to properly secure and maintain the tight fit of the guide
rods in the bottom shell could result in the component or assembly being guided to shift and
fall, causing serious injury and possible death.
▪ It is acceptable to support the weight of the MPS cylinder assembly with the lowering rods
while the primary means of lifting the MPS cylinder is being repositioned.
▪ To do this, thread the nut, washer and sleeve up each lowering rod until it contacts the
bottom side of the upper flange of the MPS cylinder.
▪ It is important that the MPS cylinder assembly is level when the weight is transferred to the
lowering rods. It is not recommended to turn the nuts on the lowering rods while the weight
of the MPS cylinder is fully supported by the rods. (See Figure 2)
CAUTION
Check the weight of all loads before lifting. Make sure the lifting device and other components
that will support the weight of the load are in good condition and are rated for the weight of
the load.
Eccentric
Bottom shell
Lowering Rods
(3 in total) with MPS Cylinder
nuts and
washers
FIGURE 2
▪ With all of the MPS flange bolts removed, slowly lower the assembly, taking care not to
damage the threaded studs.
CAUTION
When lowering the MPS cylinder with an overhead crane caution must be taken that the
rigging does not bind or catch on the crusher body or liners causing the MPS cylinder to
become unbalanced or unstable.
FIGURE 3
▪ With the cart and MPS cylinder in its lowest position with the load released from the crane,
remove rigging and lowering rods. Transport MPS assembly to service area.
FIGURE 4
Mainshaft Step Thickness 1.75 (45) 1.75 (45) 1.88 (48) 2.13 (54)
at Outer Diameter “A”
Mainshaft Step 0.375 (10) 0.375 (10) 0.375 (10) 0.375 (10)
Allowable Wear
Total Step Bearing 6.50 (165) 6.75 (172) 7.75 (197) 9.00 (229)
Thickness New “B”
Total Allowable 0.75 (19) 0.75 (19) 0.75 (19) 0.75 (19)
Step Bearing Wear
▪ To remove the step, thread the lowering rod provided into the tapped hole in the bottom of
the mainshaft. Draw the lowering bar up snugly against the bottom of the step with the
lowering rod nut. Remove the snap ring retainer 4135-0 and lower the step to a skid. (See
Figure 5)
FIGURE 5
▪ Verify that the mainshaft dowel 4035-0 is securely in place. (See Figure 5) Replace the
mainshaft step and install the snap ring retainer.
WARNING
The clamp plate (2325-0) may adhere to the bottom of the piston during removal and fall off
the piston after it has been removed from the hydraulic cylinder, causing injury or death. Be
sure the clamp plate remains in the hydraulic cylinder. While lifting the piston, a slight jar can
be used to separate the clamp plate from the bottom of the piston.
▪ Screw two 0.75" eyebolts into the clamp plate (2325-0) and hoist it out of the hydraulic
cylinder. Alternatively the MPS cylinder cover (2505-0) can be unbolted from the bottom of
the cylinder and the cylinder lifted off the MPS cylinder cover, again taking care that the
clamp plate is not lifted with the cylinder.
▪ Measure and record wear on the step washer and piston wear plate. If wear exceeds limits
in the table above, replace the part. Oil grooves on the piston wear plate are 3/8" deep when
new and must be replaced when worn smooth.
▪ Inspect and record the condition of the wearing surfaces of the bushings, piston, and clamp
plate. These surfaces should be free of wear and scratches which might cut the MPS oil
seal. Take special effort to inspect the MPS oil seal. This seal must withstand pressures up
to approximately 2000 psi (13.8 MPa) and should have no nicks or cracks.
FIGURE 6
▪ To replace the oil seal (2305-0), remove the screws (2325-2) which hold the seal retainer
ring (2325-1) to the clamp plate. Remove the clamp plate and oil seal. Install the new oil seal
into the clamp plate such that the pressure side will be toward the retainer ring. Install the
retainer ring with screws and washers. Use Loctite #242 on screw threads and torque the
0.375" screws to 24 ft-lbs (32.5 N-m).
FIGURE 7
▪ To re-assemble the cylinder (2005-0), start by applying a light coat of oil on the upper and
lower cylinder bushings. Place two 0.75" eyebolts in the top of the clamp plate assembly
(2325-0) and lower it into the cylinder until it rests on the cover plate (2505-0). Next, insert a
lifting eyebolt into the top of the piston (2205-0). Lift and lower the piston into the cylinder
until it rests on top of the clamp plate.
▪ Replace the piston wearing plate (2260-0) being sure the dowel (2225-0) enters the hole in
the bottom of the wearing plate so that the plate is flat on the top of the piston.
▪ Place the step washer (2280-0) on top of the piston wearing plate with the concave side up.
Install the step washer retainer (2275-0) on top of the step washer. Then install retaining ring
(2276-0) to hold the parts to the piston.
WARNING
When working on equipment with lubrication and/or Hydraulic systems, precautions must be
taken to ensure that any stored energy has been eliminated. Escaping fluid under pressure
can penetrate the skin, causing serious injury.
▪ With the mainshaft supported, drain oil from the crusher by removing the bottom shell drain
plug (2120-0) from the bottom of the MPS cylinder flange.
▪ Then disconnect the lubrication and hydraulic lines and drain. Open the vent at the balance
cylinder to help drain the hydraulic lines. Cap/Plug ends of lubrication and hydraulic lines to
prevent additional oil leakage or spillage.
▪ If equipped remove bin level sensor and disconnect wires.
▪ If equipped remove mainshaft position sensor and disconnect wires.
FIGURE 8
▪ Remove the cover plate bolts (2515-0) and slowly lower the cover plate. The piston and
clamp plate will also descend, but they are not attached to the cover plate.
▪ When the piston is about 1" below the flange, a groove in the piston will be seen. Insert the
piston stop plate and bolt it to the MPS cylinder flange.
▪ The cover plate will have to be lowered and removed from the lowering rods to remove the
clamp plate.
▪ To replace the oil seal (2305-0), remove the screws (2325-2) whichand/or hold the seal
retainer ring (2325-1) to the clamp plate. Remove the clamp plate and oil seal. Install the
new oil seal into the clamp plate such that the pressure side will be toward the retainer ring.
Install the retainer ring with screws and washers. Use Loctite #242 on screw threads and
torque the 0.375" screws to 24 ft-lbs (32.5 N-m).
▪ To assemble the cover (2505-0), first place the O-ring (2506-0) into the cover groove. Next,
install 0.5" diameter roll pin (2090-0) into the cover roll pin hole and then raise the cover up
to the cylinder with the three piston lowering rods (see Figure 8). Be sure the roll pin seats
into the corresponding cylinder roll pin hole. Install bolts (2515-0) with nuts (2515-1 and
2515-3) and socket head screws. Torque to 1400 ft-lbs (1898 N-m).
▪ Replace the lubrication and hydraulic piping.
▪ If equipped install the bin level sensor and reconnect wires.
▪ If equipped install the MPS level sensor and reconnect wires.
▪ Install the lubrication and hydraulic fluid.
▪ Raise the piston to lift the mainshaft and remove the blocking under the mainshaft.
FIGURE 9
▪ Inspect the bore of the piston and report condition in Section 4.
▪ Replace the seals, piston, guide or rod as required (Seal kit 8075-4, piston repair kit
8075-8).
▪ Reassemble the cylinder with new o-rings and torque the tie rod nuts to 135-145 ft-lbs (183-
197 N-m).
▪ Install the cylinder on the crusher and connect pipe line.
▪ Pressurize oil circuit. Bleed the air from the lube and hydraulic lines.
▪ Charge the balance cylinder to 90 psi (620 kPa) with nitrogen after the mainshaft is
supported on a column of oil (i.e. raised 10%).
▪ Recheck gas pressure under load and top up as required.
5.1 Reviewing
Revision N° A
GENERIC
Written by Signature:
Date: / / LCS Specialist
Reviewed by Signature:
Date: / / Field Service Specialist
Approved by Signature:
Date: / / Product Line Manager
SITE SPECIFIC
Released by Signature:
Date: / / Regional LCS Manager
This procedure should be reviewed every 2 years or at any time that significant changes take
place in the Maintenance development.
5.2 References
Metso Technical Reference Manual
SUPERIOR® MK II® Gyratory Crushers
42-65, 50-65, 54-75, 62-75, 60-89
Installation, Operation and
Maintenance Instructions (17X0500-03.0908)
Risk Assessment
H.S.E.
Lifting Procedure