New Generation of

Main Frame

2 © Metso

Main Frame Liner & Arm Guards

The main frame liner and arm guards installed at begining.
Main frame is partly welded on top as arm guards lay on arms, locked by angle-
bars welded.

3 © Metso

Worn Main Frame  Main Frame Liners should be checked at ever liner change  Neglected Main Frame Liners will lead to very costly damage! 4 © Metso .

Seat Liners NOTE: Main Frame seat liners are standard on all HP. pin bushing wear. 5 © Metso . Worn Pin Bushing Seat Liner Damage Note: Frequent force overloads (adjustment ring movement) will result in pin wear. and seat liner wear. the seat liner protects the main frame seating surface from damage. In the event that the crusher experiences ring movement.

Result of Worn Main Frame Pins Bent Piston Rod Leaking Seals 6 © Metso .

C. 7 © Metso . Determining Seating Surface Wear Adjustment Ring Mark A. Replace the seat liners when the initial measurement is reduced by 8mm. B. etc. Measure and Record This Dimension Main Frame NOTE: The distance between the adjustment ring and main frame should be periodically measured to determine if there is any noticeable main frame seating surface wear.

INTERNAL Main Frame Assembly 8 © Metso Date Author Title .

Replacing Lower Thrust Bearing 9 © Metso .

10 © Metso . Use alcohol or acetone. Main frame “U” Seal Clean bottom of seal using coarse sand paper to remove "shine" before applying activator and adhesive to bottom of groove in frame Main Frame NOTE: Thoroughly clean groove in main frame with an oil free solvent and allow to dry.

On new HPs. It is also used as a support for the antispin ring. and the counterweight turns inside it. • Short animation showing the counterweight and its fixed guard : 11 © Metso . it is bolted on the main frame.HP main frame assembly • The only significant difference vs the previous HP machines is the counterweight guard: .

•Clamping Ring Installation Clamping Ring Oil Chamber Adjustment Ring Connector Hose Between Oil Chamber and Hydraulic Power Unit 12 © Metso .

Adjustment ring.Clamping Ring Installation • The ring assembly is composed of : . Clamping ring. 13 © Metso . with the hydraulic motor assembly . with the clamping system • This first one is very similar to HP100 .

Clamping Ring Installation • The clamping is not done by 8 cylinders but by a single ‘oil chamber’ made of polyurethane. Remove the seat and the oil chamber from the clamping ring housing. . remove the drain plug and remove the nuts from the valves. . • Dismantling the oil chamber : . Change the oil chamber if necessary. 14 © Metso . Remove the springs . working at low pressure (25 bar).

•Clamping Ring Installation M atch M ark Hol e Dust in Clamping Ring Shell Clamping Ring Oil Chamber Bl adder M atch M ark Hole Adjustment in Adjus tm ent Ring Ring 15 © Metso .

position the oil chamber on the bottom of the housing.Clamping Ring Installation • The clamping ring assembly (up side down) : • Installation of the clamping ring assembly : . wipe the oil chamber. tighten hard by hand 16 © Metso . . Place the springs and a thin nut on the each valve. Clean the clamping ring housing. . Engage the 2 valves through the clamping ring holes.

Maintain these parts into position with 3 clamps. . Apply lithium NLG1 grease to the oil chamber. Turn over the clamping ring assembly and lower it on wooden blocks. clean the plastic seat and position it on the oil chamber in the housing. . .Clamping Ring Installation • Installation (continued) : . Repeat the above steps for the second valve. Do not place the bevelled joint of the plastic seat in front of a valve. . . Tighten the thin nut of the valve and adjust the spring length to 17 mm. . 17 © Metso . Lock the thin nut with the locking nut.

Tramp release asssembly Spherical Nut Nut Adjustment Ring Pressurizing Circuit Accumulator Clearing Circuit HP 3 & 5 : 3 main accumulators for 6 cylinders HP 4 : 2 main accumulators for 6 cylinders 18 © Metso .

INTERNAL Tramp release assembly HP4 HP3&5 19 © Metso Date Author Title .

Turn the spherical nut on the piston rod several turns and pull the rod out of the cylinder the distance shown in the table on the right. 20 © Metso .Tramp release assembly Cylinders installation Spherical Nut ROD PULL-OUT DISTANCE Crusher Size Setting HP3 21 mm HP4 21 mm HP5 35 mm NOTE: Bottom out the piston rod in the cylinder & measure distance from the top of the adjustment ring to the end of the piston rod.

Tramp release assembly Cylinders installation A = 15 mm for new HP Spherical Nut Adjustment Ring A Hex Nut Piston Rod Tramp Release Cylinder NOTE: Loctite 242 must be used to lock the spherical nut and the hex nut into the correct position on the piston rod. 21 © Metso .

Countershaft Assembly 22 © Metso .

Counter-shaft assembly 23 © Metso .

These capscrews must be heated to approximately 200 °C to break the Loctite.Counter-shaft assembly Pinion Removal Gap Here NOTE: The capscrews holding the lock plate to the pinion must be loosened. Pinion Retainer Plate Threads 24 © Metso Pinion .

Counter-shaft assembly Pinion Removal Pinion Lock Wrench Key Countershaft Wrench Pinion Countershaft Note: The countershaft can be disassembled from the pinion by use of the pinion and countershaft wrenches. The pinion is threaded to the countershaft with a right handed thread. 25 © Metso .

Counter-shaft assembly Outer Bushing Removal Jacking Arrangement Centering Plate Threaded Rod 26 © Metso .

Counter-shaft assembly Inner Bushing Removal Set-screw Bar Centering Plate 27 © Metso .

minus 40°Celcius from ambient temperature.Counter-shaft assembly Bushing Installation Set-screw Guide Rod Inner Countershaft Bushing Outer Countershaft Bushing NOTE: The bushings must be cooled in ice for a minimum of 2 hours prior to installing them in the countershaft box. 28 © Metso . Approximately 25 kg of ice will be required.

Counter-shaft assembly Location of Oil Grooves Inner Box Bushing Always at 12:00 o'clock Countershaft Box Position 29 © Metso .

Counter-shaft assembly Location of Oil Grooves Outer Box Bushing Normal 6:00 o'clock Position 12:00 o'clock Position For Vertical Drive Pulling Down 45º 45º 30 © Metso .

8 mm – 1.6 mm Outer Countershaft End Float Box Bushing Oil Flinger TIGHT! 31 © Metso .Counter-shaft assembly Setting End Float Crusher Size End Float (Clearance) All new HPs 0.

Pinion Inner Countershaft TIGHT! Box Bushing 32 © Metso .Counter-shaft assembly Setting End Float Wedge between frame and pignon In order to establish the proper end float. the pinion must be tight against the Countershaft flange of the inner countershaft box bushing.

Counter-shaft assembly Setting End Float Feeler Gauge Flinger Next. heat the oil flinger to approximately 25ºC above ambient and slide into position until it is tight against the feeler gauge 33 © Metso .

Eccentric Assembly 34 © Metso .

Eccentric assembly Eccentric Eccentric Bushing “U” Seal “T” Seal Counterweight Eccentric Gear Upper Thrust Bearing 35 © Metso .

Eccentric assembly Bushing Removal Locking Material Eccentric Bushing Eccentric Drill out locks 36 © Metso .

37 © Metso . and concentricity. rough spots. The entire length of the bore must be checked for scoring.Eccentric assembly Bushing Removal Wooden Timber Eccentric Steel Plate Wooden Eccentric Blocking Bushing NOTE: The bore of the eccentric must be checked before installing a new eccentric bushing.

Eccentric assembly Failed Eccentric bushing Note: It takes a tremendous amount of heat to turn a bronze bushing black. For this reason. 38 © Metso . there is a definite possibility that this excessive temperature has damaged the bore behind the bronze bushing. Whenever a bushing overheats to this extent. the bore must be checked for dimensional accuracy and for cracks before a new bronze bushing is installed.

Eccentric assembly
Failed Eccentric bushing

Measure Here and at 90°

Note: Measure the eccentric bore with micrometers. If the dimensions show that there
is distortion in the bore, make certain to call Metso Minerals for verification.

39 © Metso

Eccentric assembly
Eccentric bushing installation
 Pack the bore of the
bushing with dry ice Eccentric
Lifting Eye
for approximately 2
hours prior to
installation. Wrap the
outside of the FLUSH HERE
bushing with
insulation or burlap
to prevent frost Flat Washer
 Using the ring bolts Epoxy
Eccentric Bushing Locking
and washers will
assure that the Compound
bushing will seat
flush with the top of
the eccentric.

NOTE: It is more important to precisely line up the oil holes in the bushing and
eccentric than it is to line up the cored pockets!
40 © Metso

Eccentric assembly
Upper Thrust Bearing


Upper Thrust Bearing Eccentric Bushing

41 © Metso

7 mm HP5 10 mm 8.Eccentric assembly Upper Thrust Bearing wear Crusher Size Original Minimum Groove Depth Groove Depth HP3 8 mm 6.7 mm HP4 10 mm 8.7 mm Minimum Original Groove Groove Depth Depth 42 © Metso .

 Next. the following break-in procedure must be followed:  The lube oil drain line temperature must be 16ºC before starting the crusher  Start the crusher and operate for 2 hours WITHOUT material. run the crusher for 4 hours with sufficient material in the crushing cavity to reach 75% of rated power of the drive motor. run the crusher for 2 hours with sufficient material in the crushing cavity to reach 50% of rated power of the drive motor.Eccentric assembly Bushing Break-in Procedure After installation of new head bushings or eccentric bushing.  After completing the 4 steps above.  Next. crusher can be run at full load (100% of rated power of the drive motor) 43 © Metso .

Eccentric assembly Counter-weight removal Counterweight Eccentric Eccentric to Gear Capscrew Alignment Dowel Gear Wooden Timber 44 © Metso .

“T” Seal 45 © Metso . Eccentric assembly Counter-weight “U” and “T” seals Note: The “T” and “U” seals of the counterweight of the current design are an integral part of the “U” Seal counterweight . Older counterweights had plastic “T” and “U” seals that were glued into position much the same as the “U” seal that’s glued into the main frame or the “T” seal that’s glued into the head.they are machined into the counterweight.

02 2.5 HP4 0.14 2.51 to 1. Eccentric assembly Backlash & Root Clearance Crusher Backlash in Theoretical Root Size milimeter Clearance HP3 0. Gear Pinion Root Clearance Gear Main Frame Pinion 46 © Metso . always push the thick Backlash side of the Eccentric towards the Main Shaft.64 to 1.6 Shaft To check the clearance.65 3.89 to 1.86 Main HP5 0.

Socket Assembly 47 © Metso .

The oil grooves have similar design than previous inside bronze.Socket assembly Socket is in one piece without bronze liner. and must be controlled at every liner change. 48 © Metso .

New socket oil grooves are approximately 6mm. The oil groove depth should be measured at every liner change.Socket assembly Determining the wear New Socket Contour Worn Out Socket Contour Note: The socket is considered worn out when the oil groove depth measures 2.5mm. 49 © Metso .

Socket assembly Removal Jackscrew Heat here around Socket entire circumference to 145ºF (80ºC) over ambient Main Shaft 50 © Metso .

• Screw the 3 eye bolts. screw them in the threaded holes of the socket. 20mm) from the tool kit. • Quickly slide down the socket on the shaft top. Make sure the socket is properly seated (check with feeler gauges). torque 200 N. length 90mm. and use the fixation bolts (dia 16mm.Socket assembly Installation • Use the 3 centering bolts (dia. Oil the socket spherical surface (ISO CC150). 51 © Metso .m). check again the torque. • Remove the centering bolts. • Once the socket has cooled down. Gently heat the bottom of the socket until the temperature is 80°C above ambiant.

No clearance should exist.Socket assembly Checking Socket Contact NOTE: The contact between the socket bottom and mainshaft top needs to be checked after the socket has been installed. 52 © Metso .

Head Assembly 53 © Metso .

New HP Head Assembly : • Head ball in bronze • Head bushing in one part • Spherical ring for antispin Item Description 1 Mantle 2 Spacer ring 3 Locking bolt 4 Cone feed plate 5 Head ball 6 Head bushing 7 Seal 8 Spherical ring 54 © Metso .

MAXIMUM MINIMUM  Center Head on Socket and continue CLEARANCE CLEARANCE lifting. Head Assembly removal Head  Lift assembly upward until Head Bushing clears Eccentric outside diameter. Socket Thick Side of Eccentric 55 © Metso .

Head Assembly installation Center Head on Socket. Move Head toward thick side of Eccentric and continue lowering. 56 © Metso .

This minimizes the risk of damaging the7-4threads directly behind the torch ring. 57 © Metso .Head Assembly Cutting the Torch Ring Torch Ring Be careful not to damage Locking Bolt the locking bolt or head Cutting Torch Head Note: The torch should be held at an angle.

and mantle should be stitch welded together with this design. 58 © Metso . torch ring. The locking bolt.Head Assembly Locking Bolt Arrangement Feed Plate Silicone Feed Plate Bolt Locking Bolt Note: The single piece locking bolt is the current design.

Head assembly Tightening the Mantle TIGHTEN Locking Bolt Wrench Lock NOTE: The Lock Bolt is left-hand thread. Bolt 59 © Metso .

Head Bushing Head Ball Note: The new HP head assembly is different than the other HP models. It’s unique design incorporates a one-piece upper and lower head bushing and a bronze head ball. The head bushing and head ball are disassembled or assembled the same as previous machines. Head “T” Seal One-piece Head Bushing 60 © Metso .

Head ball • head ball made of BRONZE (socket liner made of STEEL) • So. 61 © Metso . • Refer to instruction manual chapter 11 for the detailed head ball replacement procedure. (similar to HPX00 machines). it is now subject to wear : change the head ball when the groove 1 is no longer visible.

Ram or press the worn or damaged Heat Here head ball out of the head fit area. warm the head area just outside the head ball to approximately 55°C above ambient to relieve the interference fit. Blocking 62 © Metso . If the head ball is difficult to remove.Head Assembly Head Ball Removal Note: Remove the safety bolt.

50 lbs (22 kgs) of dry Lifting Eye ice is required. 63 © Metso . After cooling. Don’t forget to re- install the safety bolt. measure the bore of the head and the outside of the head ball to make sure that it has sufficiently cooled to drop right in. The threads of this Dowel Pin bolt should be coated Head with Loctite 277.Head Assembly Head Ball Installation Note: Cool the head ball in Lifting Cable Cooled Head Ball dry ice for a minimum of four to six hours.

8 bolts.Head bushing • Head bushing is no longer composed of Lower bushing + Upper bushing. • Fixation : bolted on a flange. but a single bushing which fulfils the functions of both (like HP100) : • The lower section insures the contact on the outer diameter of the eccentric • The upper section insures the contact on the outer diameter of the socket when the crusher is running empty. 64 © Metso . • Large holes between the two sections allows the oil flowing out from the socket to pass through the head.

Head Bushing Installation 65 © Metso .

Packing the bushing with dry ice can expedite the removal process if using the pulling arrangement. 66 © Metso .Head Assembly Head Bushing Removal Note: The lower head bushing can be removed by cutting it out but make certain that the saw blade doesn’t touch the head bore. The bushing can also be removed by pulling it out as shown to the left.

Head Assembly Head Seal Replacement Note: The new head seal is glued into position. Clean bottom of seal using coarse sand paper to remove "shine" before applying activator and adhesive to bottom of groove in head 67 © Metso . The adhesive used is Loctite Depend No: Head 20252. Dry fit the seal before gluing it in to assure proper fit up. Never force the seal into the groove.

11 for detailed procedure. 68 © Metso .Head Assembly Spherical ring • Purpose : prevents the head from spining when the crusher is empty. Refer to the specific presentation « anti-spin device ». • Below the head there is a bolted ring which rubs against polyurethane flat bars fitted on the frame. • The ring is fitted by 12 glued bolts CHC 10x30mm and positionned by 3 pins 25 x50mm. 16mm to remove the ring. • Refer to instruction manual chapter 11. • When the head is up side down. use eye bolts dia.

Bowl Assembly 69 © Metso .

Bowl Assembly 70 © Metso .

Thicker Liners • Long bowl allows to use thicker liners • Thicker Liners result in longer liner life • Thicker liners result smaller scrap rate © Metso .

Improved bowl liner fixing • Vertical bolt allows to use power tools • Bolt location not in the area where dust is building up 72 © Metso .

73 © Metso . The wooden timbers should never be placed under the bowl. Lifting Bowl Assembly NOTE: When resting the bowl assembly on blocking. always place the wooden timbers underneath the bowl liner.

Locating Helix High Points 74 © Metso .

 The wedge bolt must stay vertical during tightening.  The spring washers must 0.25mm Max. not become flat ( torque Clearance control) Bowl Liner 75 © Metso . Bowl Liner Installation Wedge Bolt Wedge  Contact between the wedge and bowl liner must be made on the thin Bowl portion of the helix..

FEED ARRANGEMENTS • Fine feed (up to 32 mm) • Segregated feed (up to 70 mm) • Coarse (Direct) Feed (up to 252 mm) 76 © Metso .

COVER ARRANGEMENT • The cover around the crusher protects employees from casual contact with adjustment and tramp release mechanisms • It also protects the workspace with reduced dust emissions • It makes it easier to install the crusher into a plant and to connect it to an existing dedusting systems 77 © Metso .

HP100 & HP200 70-4660 0100 . 78 © Metso . Template part numbers: 70-4660 0101 .All others. Then measure and record the gap (if any) that exists between the tapered portion of the template to the tapered portion of the threads. and clamping ring threads can be inspected for wear by use of a checking template. Checking Thread Wear Note: The bowl. adjustment ring. Hold the template flats tight to the thread flats and push in as far as it will go.

Greasing Threads and cam followers NOTE: Grease the bowl and adjustment ring threads weekly. 79 © Metso . and with the bowl unclamped. Threads must be greased with bowl clamped.

Crusher Sensor Package .

5 : Terminal box 3 : Proximity sensors 2 : Pressure Sensor 4 : Temperature sensor 1 : Pressure Switch 4 : Temperature sensor 81 © Metso . • The HP4 crusher is equiped with several SENSORS which are gathered in the Sensor Package.

8 bar measured at the countershaft is the minimum pressure which guarantees a sufficient pressure and lubrication in the whole crusher ). 82 © Metso . 1. • A pressure switch controls permanently the pressure and triggers when P < 0.8 bars • Insufficient pressure will lead to inadequate lubrication and will damage the crusher. • It must be interlocked so that the crusher and the pump stop when the pressure drops down to a dangerous level.Pressure Switch • Used to control the minimum lubrication pressure at 0.8 bar • (0.

Turn the green screw (2) to read the differential value 0. if really needed : .1 bar on the red scale. .1 bar • The pressure switch is pre-set. This sets the minimum pressure at 0. normally 0. If below. Open the top cover . it must lead to a crusher emergency stop.3 bar there is no need to adjust it.8 bar safety device for the crusher.3 bar on the green scale. Turn the red screw (1) to read the value 1. 83 © Metso . don’t play with the settings !!! • However. • This pressure switch is the most important 0.8 bar. . 1.Pressure Switch Pressure Pressure Switch : setting procedure 1.

1. • Contact opens when P < 0.1 bar.Pressure Switch Pressure Switch : connection • The pressure switch has 2 electrical contacts • Only the « open contact » is used (labels 13 & 14) • Contact remains closed if P > 1. • The pressure switch is connected in the on-board electrical cabinet in terminals 10 & 11.8 bar. • Contact rating : . 0. 1 Amp at 24 Volts DC 84 © Metso .5 Amp at 230 Volts AC .

s/n N02495342 (reference HYDAC HDA4445-A-400-000) 85 © Metso . • 0 bar  4 mA 400 bar  20 mA • For the time being the automation only displays the pressure value. converting the pressure to a 4-20mA signal sent to the automation. • This information will be further used to control the crusher.Pressure transmitter • Measures the pressure in the tramp release circuit • 0 – 400 bar sensor. 2.

2.Pressure transmitter • Supply : 24V DC • connection in the terminal box : 86 © Metso .

Proximity Switch • Used to count the number of teeth the pignon has turned (in relation with the crusher setting). the number of teeth is displayed on the remote control box. • The direction of rotation is given by the status of solenoid n° 5 (activated means openning the setting) 87 © Metso .3. • One sensor is connected to the lubrication unit. • One sensor is connected to the PLC (optional feature) which displays directly the setting.

3.Proximity Switch • Supply : 24V DC • Connection in the terminal box To the lubrication To the PLC (if any) & hydraulic unit 88 © Metso .

INTERNAL 3. 89 © Metso .Proximity Switch • The switches must be fitted at 4 or 5 mm from the top of a tooth.

• The other the oil temperature in the return line. • Both sensor cables pass through a collar 90 © Metso .Temperature sensors • The crusher is equiped with 2 temperature sensors. Pt100 probes with platinum resistor are electrical conductors whose resistance varies according to the temperature.4. • One measures the temperature in the lower thrust bearing.

4.Temperature sensors For the thrust bearing For the oil return line 91 © Metso .

Temperature sensors / converter • The sensors are connected in the terminal box to converters sending a 4-20 mA signal. Temperature sensors • Temp = -100°C  4 mA • Temp = +100°C  20 mA 92 © Metso .4.

4.Temperature sensors / converter • Make sure this selector is switched on «3W» position (Pt100 probes with 3 wires) • Make sure this selector is switched on «4-20 mA » position • Converter power supply 24V DC • Wiring : 93 © Metso .

5- Terminal Box
• The

94 © Metso

5- Terminal Box

95 © Metso

MAY 2005

Crusher Tools

96 © Metso

Countershaf t Wrench Flat Washers Eye Bolts Head Lifting Plate Safety Blocks Jacking Bolts Dowel Pins Chargin g Kit Locking Bolt Wrench 97 © Metso .