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Chapters
Table of Contents
Related Manuals for Metso MP1000
Summarization of Contents
Section 0 Safety
0.1 Introduction
Provides guidance for operators on safety and operations.
0.1.1 General
Manual aims to increase knowledge and awareness of safety for all personnel.
0.1.2 Definitions
Defines terms used in the manual such as Crushing Plant, Owner, Operator.
0.2 General Safety Instructions for a Crushing Plant or Plant Environment
Outlines general safety rules for operating within a crushing plant environment.
0.2.1 Safe Products and the Crushing Plant
Addresses inherent dangers of machinery and Metso's commitment to safety.
0.2.2 Safety and You
Emphasizes that safety is everyone's responsibility and an individual's actions contribute to workplace safety.
0.2.2.1 Objective
Aims to minimize risks and prevent accidents by avoiding carelessness and following instructions.
0.2.2.2 Safety Signs, Labels And Symbols
Explains the use of alert symbols, DANGER, WARNING, CAUTION, and NOTICE.
0.2.2.3 Some General Safety Instructions
Provides specific do's and don'ts for general safety during operation and maintenance.
0.2.2.4 Safety Instructions after Start-up
Details checks and actions required after the equipment has been started.
0.2.2.5 Report a Defective Machine
Emphasizes the importance of reporting and correcting any unsafe conditions immediately.
0.2.2.6 Stopping Safely
Lists activities that require the equipment to be stopped before proceeding.
0.2.2.7 Blasting
Advises against using radio control devices during blasting and suggests moving the plant away.
0.2.2.8 Portable Plants
Covers essential footing and cribbing requirements for safe operation of portable units.
0.2.2.9 Mobile Equipment Transportation
Provides guidelines for safe transportation of mobile crushing equipment.
0.2.3 Typical Risks in Crushing Plant Working Environment
Identifies potential hazards and types of accidents common in crushing plant operations.
Typical Hazards
Lists common hazards such as pinch points, poor housekeeping, and noise.
Typical Injury Types
Categorizes common injury types encountered in the workplace.
0.2.3.1 Typical Hazards
Details specific hazards like Nips, Gaps, Pinch Points, Poor Housekeeping, and Working Locations.
Nips, Gaps, and Pinch Points
Explains the dangers of ingoing nips formed by drive devices and pinch points from moving equipment.
Poor Housekeeping
Stresses the importance of maintaining a clean and dry environment to prevent hazards.
Elevated or Narrow Working Location
Addresses safety considerations for working in elevated or confined spaces within the plant.
Lifting and Shifting Heavy Loads
Covers safe practices for handling heavy loads using cranes or other lifting equipment.
Cranes
Highlights requirements for regular maintenance and proper use of crane facilities.
Mobile cranes
Details safe operating practices for mobile cranes, including ground conditions and outrigger use.
Sharp Edges
Warns about potential sharp edges on metal structures and equipment.
High-Pressure Equipment — Hydraulic or Air
Discusses dangers associated with high-pressure hydraulic systems and the risk of fluid injection.
0.2.4 Personal Protective Equipment and Clothing
Specifies the types of personal protective equipment (PPE) required for safe operation.
0.2.4.1 Hearing Protection
Addresses noise levels and the necessity of wearing hearing protection in machinery areas.
0.2.4.2 Eye and Face Protection
Outlines requirements for eye and face protection against hazards like flying material and chemicals.
0.2.4.3 Respiratory Protection
Details the need for respiratory protection when air contains contaminants like dust, fumes, or vapors.
0.2.4.4 Foot Protection
Specifies the use of protective footwear in areas with foot injury risks from falling objects or electrical/chemical hazards.
0.2.4.5 Head Protection
Covers requirements for wearing protective helmets approved by safety authorities.
0.2.4.6 Hand Protection
Details the use of appropriate hand protection against substances, cuts, and burns.
0.2.4.7 Safety Harnesses
Mandates the use of safety harnesses when working in elevated areas or hazardous places with fall risks.
0.2.4.8 Work Clothing
Advises on appropriate clothing to protect against hazards and avoid entanglement with machinery.
0.2.4.9 Tools
Emphasizes the use of appropriate tools and safe practices when working with them.
0.2.4.10 Safety Locks and Tags
Explains the importance and procedures for using lockout and tagout systems for safety.
0.3 MACHINE SAFETY
Covers built-in safety features and general machine safety principles.
0.3.1 Protective Devices and Accessories for Machine Safety
Discusses the function and importance of built-in safety features and their proper use.
0.3.1.1 Overview
Highlights the presence of safety features and the responsibility to keep them enabled.
0.3.1.2 Emergency-Stop (E-Stop)
Explains the function and location of emergency stop buttons for immediate machine shutdown.
0.3.1.3 Safety Interlocks
Describes safety interlocks that interrupt machine functions for safety reasons.
0.3.1.4 Additional Warning Devices
Covers warning devices like horns and lights used for communication and alerts.
Horns and Lights
Advises on the use of sound and light signals to warn personnel before starting the machine.
0.3.1.5 Safety Signs and Labels
Explains the meaning of safety signs and labels used to indicate hazard degrees.
Safety Warning Colors
Mentions that safety warning colors are typically safety yellow.
0.3.1.5 Walkways, Service Platforms, Ladders and Railings
Outlines design standards and safe operating procedures for walkways and platforms.
0.3.2 Transport
Provides precautions for transporting the Crusher Plant, including tire checks and weight limits.
0.3.3 Towing
Lists precautions to observe before towing the Crusher Plant or its components.
0.3.4 At the work-site
Details minimum safety precautions to be taken at the work-site.
0.3.4.1 Precautions
Lists essential precautions for site selection, powerlines, and equipment checks.
0.3.4.2 During operation
Emphasizes monitoring equipment and personnel during operation and safe clearing procedures.
Clearing
Advises on safe procedures for clearing plugged crushers, stressing system shutdown.
0.4 SAFETY DURING MAINTENANCE AND REPAIR
Covers crucial safety procedures and lockouts required before performing maintenance or repair work.
0.4.1 General Information and Safety Lockouts
Emphasizes not compromising safety due to time pressure and following all safety procedures.
0.4.2 Mechanical Safety During Maintenance and Repair
Details safety measures for mechanical components during maintenance and repair.
0.4.2.1 General
Outlines do's and don'ts for working safely around machinery and components.
0.4.2.2 Fire Safety During Maintenance and Repair
Lists fire sources and preventive steps to take before starting work involving fire hazards.
0.4.2.3 Preventive Maintenance
Explains the benefits of preventive maintenance for safety and operational efficiency.
0.4.2.4 Confined Spaces
Defines confined spaces and mentions the need for entry permit programs and following procedures.
0.4.3 Electrical Safety During Maintenance and Repair
Stresses extreme caution when working with electrical equipment and following lockout procedures.
0.4.3.1 General
Details procedures for ensuring all electrical components are at a zero energy state before maintenance.
0.4.3.2 Electrical Fault Situations
Mentions that electrical faults can be caused by component failures and diagnostics are provided.
0.4.3.3 Program Changes
Warns against connecting electrical tools to control cabinet outlets as it may affect the program.
0.4.4 Hydraulic Safety During Maintenance and Repair
Covers safety procedures for working with hydraulic systems, emphasizing depressurization.
0.4.5 General Maintenance Work
Provides do's and don'ts for normal Crushing Plant maintenance procedures.
0.5 SAFETY PLATES
Shows examples of safety plates used on the machine and in the manual.
0.5.1 Safety Plates — ANSI
Displays various ANSI safety plates with warnings and dangers related to machine operation.
0.5.2 Safety Plates — EN
Displays various EN safety plates with warnings and cautions related to machine operation.
Section 1 General Crusher Information
1.1 Introduction
Introduces the Instruction Book and its purpose for users and operators.
1.2 Initial Inspection
Recommends a careful check for transit damage and inventory verification upon receipt.
1.3 Information Furnished
Lists the installation drawings and data provided for the specific Crusher.
1.4 Repair Parts
Advises on providing specific information when ordering spare parts to ensure accuracy.
1.5 Crusher Terminology
Defines key terms used throughout the manual for clarity in describing the Crusher.
1.6 Optimizing Crusher Capacity
Discusses factors influencing crusher capacity and performance, and those that detract from it.
1.7 Selection of Proper Liners
Explains the development of varied crushing members and how to determine wear contours.
Section 2 General Installation Information
2.1 Foundation
Emphasizes the importance of a solid, level foundation for successful Crusher operation.
2.2 Crusher Clearance Dimensions
Highlights the necessity of well-planned installation and provides details on crusher clearances.
2.3 Crusher and Sub-Assembly Weights
Discusses crusher weights as a factor for foundation design and overhead lifting equipment selection.
2.4 Feed Arrangement
Details the importance of controlling feed material to prevent overflowing and ensure proper crushing.
2.5 Discharge Arrangement
Provides guidance on discharge compartment design, including inspection doors and shelves.
2.6 Type of Drive
Recommends V-belt drives for their ability to prevent shock loads and handle surge loads.
2.7 Crusher Motor
Specifies requirements for the recommended electrical driving motor, including its duty type and starter.
2.8 V-belt Drive
Covers critical procedures for installing and tensioning V-belt drives to ensure proper operation.
2.8.1 Initial Installation of V-belt Drive
Outlines the steps for initial installation of V-belt drives, including cleaning sheaves and aligning shafts.
2.8.2 Tensioning the V-belt Drive
Explains the importance of proper belt tension for drive operation and longevity.
2.8.3 Tension-Deflection Method
Describes a general method for determining belt deflection based on applied force.
2.8.4 Example for New V-belts
Provides an example calculation for tensioning new V-belts using the deflection method.
2.8.5 Tensioning Procedure for Standard V-belts for a New Crusher Installation When a New Countershaft Bushing with new V-belts Has Been Installed
Details the procedure for tensioning V-belts after installing a new countershaft bushing and new belts.
2.8.6 Tensioning Procedure for Standard V-belts When a New Countershaft Bushing Has Been Installed and Using the Existing V-belts
Outlines the procedure for tensioning V-belts when a new countershaft bushing is installed with existing belts.
2.8.7 Tensioning Procedure for Standard V-belts When New V-belts Have Been Installed With Existing Countershaft Bushing
Describes tensioning procedures for new V-belts installed with an existing countershaft bushing.
2.8.8 Retensioning Procedure for Standard V-belts Using Existing V-belts
Provides a procedure for retensioning standard V-belts that are already in use.
2.8.9 Percent Elongation Method
Explains a general method for tensioning V-belt drives using the percent elongation calculation.
2.9 V-belt Precautions
Lists essential do's and don'ts for proper V-belt drive operation and maintenance.
2.10 Checking End Float
Guides on how to check the end float of the countershaft for proper operation.
2.11 Crusher Sheave Installation (V-belt Drive)
Details the procedure for installing a crusher sheave with a removable bushing.
2.12 Crusher Sheave Removal
Provides instructions on how to remove the crusher sheave from the bushing cone.
2.13 Jack Shaft Drive
Recommends jack shaft drive designs for use with V-belt drives to minimize motor costs.
2.14 Direct Drive
Covers procedures for removing and installing flexible couplings on direct drive arrangements.
Flexible Coupling Removal
Instructs on removing the flexible coupling half from the countershaft.
Flexible Coupling Installation (See Figure 2-15)
Details the steps for initial installation or reassembly of a flexible coupling.
2.15 Piping Information
Discusses proper types of oil, temperature, regulation, and piping layout for the lubrication system.
2.16 General Assembly and Disassembly Information
Explains that Nordberg MP Cone Crushers are shipped in subassemblies and provides general instructions.
2.17 General Maintenance Information
Lists general precautions to be observed when performing maintenance work on the Crusher.
2.18 Minimum Recommended Spare Parts List
Lists essential spare parts that should be kept on hand to ensure minimum downtime.
2.19 Special Tools
Identifies special tools furnished with the Crusher and how to use them for component handling.
2.20 Protecting the Crusher Against Rust Corrosion
Provides protective measures for seasonal shutdown or outdoor storage to prevent rust.
2.21 Storage of a Crusher
Offers recommendations for preparing components and subassemblies for extended storage.
2.22 Long Term Storage of a Crusher
Provides Metso Minerals' recommendations for long-term storage of a crusher (up to two years).
Section 3 Main Frame, Adjustment Ring, Tramp Release & Clearing Jack Assemblies
3.1 Description
Covers the main frame, adjustment ring, tramp release, and clearing jack assemblies.
3.2 Assembly Instructions
Provides procedures for assembling main frame components.
3.2.1 General
States that components are shipped disassembled and maintenance procedures should be followed.
3.2.2 Crusher Installation
Details installation procedures for concrete foundations and steel structures.
3.2.3 Oil Temperature RTDs
Explains the mounting and location of eccentric bushing oil temperature RTDs.
3.3 Maintenance
Covers maintenance procedures for various parts of the main frame assembly.
3.3.1 Main Frame Liner and Arm Guards
Advises on inspecting main frame liners and arm guards for wear and replacement.
3.3.2 Main Shaft Replacement
States that main shaft replacement is rare and should be done by factory representatives.
3.3.3 Lower Thrust Bearing and Shim Replacement
Details how to replace the lower thrust bearing or add shims for backlash adjustment.
3.3.4 Seal Replacement
Provides instructions for replacing the U-shaped seal that prevents oil leakage and protects surfaces.
3.3.5 Main Frame Pins and Pin Bushings
Explains how to check for and replace main frame pins and pin bushings due to wear.
3.4 Main Frame Seat Liner and Fulcrum Bar
Discusses the inspection and replacement of the main frame seat liner and fulcrum bar.
3.4.1 General Information
Covers periodic inspection of the seat liner and fulcrum bar for wear.
3.4.2 Main Frame Seat Liner Wear
Describes how to determine wear on the main frame by measuring distances and comparing them to original dimensions.
3.4.3 Main Frame Seat and Fulcrum Bar Installation
Details the procedure for installing new seat liners and fulcrum bars, including welding and gap maintenance.
3.4.4 Tramp Release Cylinder and Accumulator Removal
Provides instructions for removing the tramp release cylinder and accumulator assembly.
3.4.5 Tramp Release Cylinder and Accumulator Installation
Outlines the steps for installing a new or repaired tramp release cylinder and accumulator assembly.
3.4.6 Clearing Jack Removal
Provides procedures for removing a leaking clearing jack cylinder for replacement or repair.
3.4.7 Clearing Jack Installation
Details the steps for installing a new or repaired clearing jack cylinder.
3.4.8 Accumulator Replacement
Addresses the serious condition of a faulty accumulator and the procedure for replacement.
3.4.9 Accumulator Bladder Replacement
Refers to another section for accumulator bladder replacement procedures.
3.4.10 Main Frame Ring Replacement
Explains the purpose and procedure for replacing the frame ring in the main frame.
3.4.11 Adjustment Ring Installation
Guides on assembling the adjustment ring assembly onto the main frame.
3.4.11.1 Adjustment Ring Vibration Detection
Describes how vibration sensors monitor ring bounce and indicate problems requiring correction.
3.4.12 Adjustment Ring Disassembly
Details the process of detaching and removing sealing and clamping components from the adjustment ring.
3.4.13 Clamping Cylinder Removal
Provides steps for removing a faulty clamping cylinder.
3.4.14 Clamping Cylinder Disassembly and Repair
Refers to another section for clamping cylinder disassembly and repair.
3.4.15 Clamping Cylinder Installation
Guides on installing a new or rebuilt clamping cylinder into the clamping ring.
3.4.16 Adjustment Ring Assembly
Outlines the procedure for placing the adjustment ring assembly back on the main frame.
Section 4 Countershaft, Countershaft Box & Sheave Assemblies
4.1 Description
Covers the countershaft, countershaft box, and sheave assemblies.
4.2 Assembly Instructions
Provides procedures for assembling the countershaft box assembly.
4.2.1 Countershaft Box Assembly Installation
Details the steps for installing the countershaft box assembly into the main frame.
4.2.2 Crusher Sheave Installation (V-Belt Drive)
Guides on installing a crusher sheave with a removable bushing.
4.2.3 Crusher Sheave Removal
Provides instructions for removing the crusher sheave.
4.2.4 Flexible Coupling Removal
Instructs on removing the flexible coupling half from the countershaft.
4.3 Maintenance
Covers maintenance procedures for the countershaft box and its components.
4.3.1 Countershaft Box Disassembly
Details the process of disassembling the countershaft box and countershaft assembly.
4.3.2 Pinion Replacement
Explains how to replace a worn pinion gear, recommending replacing the gear and pinion together.
4.3.3 Countershaft Bushing Removal
Outlines methods for removing countershaft bushings, including ramming and jacking procedures.
4.3.4 Inspection Prior to Bushing Installation
Advises on checking bore and shaft dimensions and tolerances before installing new bushings.
4.3.5 Countershaft Bushing Installation
Guides on installing new countershaft bushings, including positioning oil grooves and using dry ice for shrinkage.
4.3.6 Countershaft Box Assembly
Details the assembly process of the countershaft box, including exceptions and checks.
4.3.7 Oil Leakage from Drive End of Countershaft Box
Discusses potential causes of oil leakage from the drive end of the countershaft box.
4.3.8 Oil Leakage from Pinion End of Countershaft Box
Explains how to address oil leakage from the pinion end of the countershaft box by replacing seals and wear strips.
Section 5 Eccentric Assembly
5.1 Description
Covers the eccentric assembly, including the eccentric, bushing, gear, and counterweight.
5.2 Assembly Instructions
Provides procedures for installing the eccentric assembly.
5.2.1 Eccentric Assembly Installation
Details the steps for installing the eccentric assembly over the main shaft.
5.2.2 Checking or Adjusting Backlash and Root Clearance
Explains methods for determining and adjusting backlash and root clearance between gears.
5.2.2.1 For Spiral Bevel Gear Sets
Describes measuring backlash for spiral bevel gear sets using circumferential motion.
5.2.2.2 For Straight Bevel Gear Sets (Circumferential Measurement Method)
Details checking backlash for straight bevel gear sets using circumferential measurement.
5.2.2.3 For Straight Bevel Gear Sets (Direct Backlash Measurement Method)
Explains how to measure backlash directly using feeler gauges for straight bevel gear sets.
5.3 Maintenance
Covers maintenance procedures for the eccentric assembly and its components.
5.3.1 Removing Eccentric Assembly
Provides steps to remove the entire eccentric assembly.
5.3.2 Counterweight
Discusses the counterweight's role in reducing unbalanced forces and its positioning.
5.3.3 Upper Thrust Bearing
Covers the upper thrust bearing and its function within the eccentric assembly.
5.3.4 Upper Thrust Bearing Replacement
Details the procedure for replacing the upper thrust bearing.
5.3.5 Seal Replacement
Provides instructions for replacing seals related to the eccentric assembly.
5.3.6 Eccentric Bushing
Describes the eccentric bushing and its role as a bearing surface.
5.3.7 Eccentric Bushing Removal
Outlines methods for removing the eccentric bushing.
5.3.8 Inspection of Eccentric Bore
Advises on inspecting the eccentric bore for wear or damage.
5.3.9 Inspection of Mainshaft
Guides on inspecting the mainshaft for straightness and run-out.
5.3.10 Installing the Eccentric Bushing
Details the process of installing the eccentric bushing.
5.3.11 Repouring Bushing Lock
Covers procedures related to repouring the bushing lock.
5.3.12 Adjusting Gear Backlash for Wear
Explains how to adjust gear backlash for wear compensation.
5.3.13 Replacing Gear
Provides instructions for replacing the gear.
5.3.14 Counterweight and Gear Removal
Details the process of removing the counterweight and gear.
5.3.15 Gear and Counterweight Assembly
Guides on assembling the gear and counterweight.
5.3.16 Counterweight Guard
Covers the counterweight guard and its purpose.
5.3.17 Optional Counterweight Guard Components (MP1000 only)
Mentions optional counterweight guard components specifically for the MP1000 model.
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