Metso HP4 Assembly And Disassembly

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ASSEMBLY

New Generation

CONE CRUSHERS

DISASSEMBLY

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Summary of Contents for Metso HP4

Page 1 ASSEMBLY ASSEMBLY DISASSEMBLY DISASSEMBLY New Generation New Generation of of CONE CRUSHERS CONE CRUSHERS...
Page 4 Main frame is partly welded on top as arm guards Main frame is partly welded on top as arm guards lay on arms, locked by angle- lay on arms, locked by angle- bars welded. bars welded. & & © Metso © Metso...
Page 5 *orn Main Frame  Main Frame Liners should be checked at ever liner change  Neglected Main Frame Liners will lead to very costly damage! © Metso...
Page 6 " #n the event that the crusher e$%eriences ring movement& the seat liner %rotects the main 'rame seating sur'ace 'rom damage (orn in )ushing *eat Liner +amage Note: Fre,uent 'orce overloads -ad.ustment ring movement/ will result in %in wear& %in bushing wear& and seat liner wear" © Metso...
Page 8 NOTE: The distance between the ad.ustment ring and main 'rame should be %eriodically measured to determine i' there is any noticeable main 'rame seating sur'ace wear" 0e%lace the seat liners when the initial measurement is reduced by 1mm" © Metso...
Page 11 3lean bottom o' seal using coarse sand %a%er to remove 4shine4 be'ore a%%lying activator and adhesive to bottom o' groove in 'rame Main Frame NOTE: Thoroughly clean groove in main frame with an oil free solvent and allow to dry. Use alcohol or acetone. © Metso...
Page 12 On new s& it is bolted on the main 'rame& and the counterweight turns inside it" #t is also used as a su%%ort 'or the antis%in ring" *hort animation showing the counterweight and its 'i$ed guard : © Metso...
Page 13 3lam%ing 0ing #nstallation 3lam%ing 0ing Oil 3hamber 2d.ustment 0ing 3onnector ose )etween Oil 3hamber and ydraulic ower 7nit © Metso...
Page 14 3lam%ing 0ing #nstallation The ring assembly is com%osed o' : 2d.ustment ring& with the hydraulic motor assembly 3lam%ing ring& with the clam%ing system This 'irst one is very similar to 899 " 5& © Metso...
Page 15 +ismantling the oil chamber : • remove the drain %lug and remove the nuts 'rom the valves" 0emove the s%rings 0emove the seat and the oil chamber 'rom the clam%ing ring housing" 3hange the oil chamber i' necessary" © Metso...
Page 16 3lam%ing 0ing #nstallation +ust M atch M ark  ol e *hell in 3lam%ing 0ing 3lam%ing Oil 3hamber 0ing )ladder M atch M ark ole 2d. ustment in 2d. us tm ent 0ing 0ing © Metso...
Page 17 3lean the clam%ing ring housing& wi%e the oil chamber" Engage the < valves through the clam%ing ring holes& %osition the oil chamber on the bottom o' the housing" lace the s%rings and a thin nut on the each valve& tighten hard by hand © Metso...
Page 18 Turn over the clam%ing ring assembly and lower it on wooden blocks" Tighten the thin nut o' the valve and ad.ust the s%ring length to 8@ mm" Lock the thin nut with the locking nut" 0e%eat the above ste%s 'or the second valve" © Metso...
Page 19 Tram% release asssembly *%herical Nut 2d.ustment 0ing ressuriAing 3ircuit 2ccumulator 3learing 3ircuit HP & ' + 9 & main a//(m("ator for , /#"inder HP ) 9 2 main a//(m("ator for , /#"inder © Metso...
Page 21 )ottom out the %iston rod in the cylinder C measure distance 'rom the to% o' the ad.ustment ring to the end o' the %iston rod" Turn the s%herical nut on the %iston rod several turns and %ull the rod out o' the cylinder the distance shown in the table on the right" © Metso...
Page 22 A < 5+ mm for new HP 2d.ustment 0ing e$ Nut Tram% 0elease iston 0od 3ylinder NOTE: Loctite 242 must be used to loc the s!herical nut and the he" nut into the correct !osition on the !iston rod. © Metso...
Page 25 3ounter6sha't assembly inion 0emoval Gap Here NOTE: The capscrews holding the lock plate to the pinion must be loosened. These capscrews must be heated to approximately 200 ° to break the !octite. Pinion Retainer Plate Threads Pinion © Metso...
Page 26 inion 0emoval inion Lock (rench 3ountersha't (rench inion 3ountersha't Note: The countersha"t can be disassembled "rom the pinion by use o" the pinion and countersha"t wrenches. The pinion is threaded to the countersha"t with a right handed thread. © Metso...
Page 29 Outer 3ountersha't )ushing )ushing NOTE: The bushings must be cooled in ice "or a minimum o" 2 hours prior to installing them in the countersha"t box. #pproximately 2$ kg o" ice will be re%uired& minus '0°elcius "rom ambient temperature. © Metso...
Page 30 3ounter6sha't assembly Location o' Oil >rooves #nner )o$ )ushing #lways at $2:%% o&cloc 3ountersha't )o$ 'osition © Metso...
Page 31 3ounter6sha't assembly Location o' Oil >rooves Outer )o$ )ushing Normal H:99 oclock osition 8<:99 oclock osition For Gertical +rive ulling +own &6 © Metso...
Page 32 3ounter6sha't assembly *etting End Float Cr(4er Si;e End F"oat $C"earan/e% A"" new HP 9"1 mm J 8"H mm End Float Outer 3ountersha't )o$ )ushing Oil Flinger TIGHT! &5 © Metso...
Page 33 *etting End Float edge between frame and pignon #n order to establish the %ro%er end 'loat& the %inion 3ountersha't must be tight against the 'lange o' the inner countersha't bo$ bushing" inion #nner 3ountersha't T()*T+ )o$ )ushing &2 © Metso...
Page 34 3ounter6sha't assembly *etting End Float Feeler >auge Flinger Ne=t> 4eat t4e oi" f"in.er to aro=imate"# 2+?C a!o@e am!ient and "ide into oition (nti" it i ti.4t a.aint t4e fee"er .a(.e && © Metso...
Page 36 Eccentric assembly !ccentric !ccentric "ushing %#& 'eal %T& 'eal $ounterweight !ccentric Gear #pper Thrust "earing &+ © Metso...
Page 38 Eccentric *teel late (ooden Eccentric )locking )ushing NOTE: The bore of the eccentric must be checked before installing a new eccentric bushing. The entire length of the bore must be checked for scoring, rough sots, and concentricit. &- © Metso...
Page 39 possibility that this excessi+e temperature has damaged the bore behind bron)e bushing. this reason, the bore must be checked "or dimensional accuracy and "or cracks be"ore bron)e bushing is installed. &0 © Metso...
Page 40 (" the dimensions show that ther (" the dimensions show that there e is distortion in the bore, make certain to call is distortion in the bore, make certain to call etso inerals "or +eri"ication. etso inerals "or +eri"ication. &1 &1 © Metso © Metso...
Page 42 Eccentric assembly Eccentric assembly 7%%er Thrust )earing 7%%er Thrust )earing Gear Gear !ccentric "ushing !ccentric "ushing #pper Thrust "earing #pper Thrust "earing © Metso © Metso...
Page 43 Eccentric assembly 7%%er Thrust )earing wear Cr(4er Si;e Ori.ina" Minim(m Groo@e Det4 Groo@e Det4 ? 1 mm H"@ mm B 89 mm 1"@ mm = 89 mm 1"@ mm Minimum Original >roove >roove +e%th +e%th © Metso...
Page 44 Ne=t> r(n t4e /r(4er for ) 4o(r wit4 (ffi/ient materia" in t4e /r(4in. /a@it# to rea/4 -+ of rated ower of t4e dri@e motor  After /om"etin. t4e ) te a!o@e> /r(4er /an !e r(n at f("" "oad $566 of rated ower of t4e dri@e motor% )& © Metso...
Page 45 Eccentric assembly 3ounter6weight removal 3ounterweight Eccentric Eccentric to >ear 3a%screw 2lignment +owel >ear (ooden Timber © Metso...
Page 46 Older counterweights had plastic T1 and 1 seals that were glued into position much the same as the 1 seal that4s glued into the main "rame or the T1 seal that4s glued into the head. %T& 'eal © Metso...
Page 47 <"= B 9"HB to 8"8B <"1H Main *ha't = 9"1 to 8"H= ?"H To check the clearance& always %ush the thick side o' the Eccentric )acklash towards the Main *ha't" >ear inion 0oot 3learance >ear inion Main Frame © Metso...
Page 49 *ocket assembly *ocket is in one %iece without bronAe liner" The oil grooves have similar design than %revious inside bronAe& and must be controlled at every liner change" © Metso...
Page 50 ew 'ocket $ontour orn ut 'ocket $ontour Note: The socket is considered worn out when the oil groo+e depth measures 2.$mm. New socket oil groo+es are approximately 5mm. The oil groo+e depth should be measured at e+ery liner change. © Metso...
Page 51 *ocket assembly 0emoval ackscrew *eat here around *ocket entire circumference to $4-/ 01%3 over ambient Main *ha't © Metso...
Page 52 %ro%erly seated -check with 'eeler gauges/" 0emove the centering bolts& and use the 'i$ation bolts -dia 8Hmm& length 9mm& tor,ue <99 N"m/" Once the socket has cooled down& check again the tor,ue" Oil the socket s%herical sur'ace -#*O 338=9/" © Metso...
Page 53 *ocket assembly 3hecking *ocket 3ontact NOTE: The contact between the socet bottom and mainshaft to! needs to be checed after the socet has been installed. No clearance should e"ist. © Metso...
Page 55 New  ead 2ssembly : ead ball in bronAe ead bushing in one %art *%herical ring 'or antis%in Item De/rition Mantle < *%acer ring Locking bolt 3one 'eed %late ead ball ead bushing *eal *%herical ring © Metso...
Page 56 ead 2ssembly removal  Li't assembly u%ward until ead ead )ushing clears Eccentric outside diameter" MAIMUM MINIMUM  3enter ead on *ocket and continu CLEARANCE CLEARANCE li'ting" *ocket Thick *ide o' Eccentric © Metso...
Page 57 ead 2ssembly installation  3enter ead on *ocket"  Move ead toward thick side o' Eccentric and continue lowering" © Metso...
Page 58 Torch 0ing Be /aref(" not to dama.e Locking t4e "o/in. !o"t )olt or 4ead 3utting Torch ead Note: The torch should be held at an angle. This minimi)es the risk o" damaging the threads directly behind the torch ring. © Metso...
Page 59 ead 2ssembly Locking )olt 2rrangement +eed Plate 'ilicone +eed Plate "olt *ocking "olt Note: The single piece locking bolt is the current design. The locking bolt, torch ring, and mantle should be stitch welded together with this design. © Metso...
Page 60 ead assembly Tightening the Mantle T()*TEN Locking )olt (rench Lock NOTE: The !ock 6olt is le"t3hand thread. )olt © Metso...
Page 61 (t4s uni%ue design incorporates a one3piece upper lower head bushing and a bron)e head ball. The head bushing and head ball are disassembled or assembled the same as pre+ious machines. Head %T& 'eal ne-piece Head "ushing © Metso...
Page 62 )0ONPE -socket liner made o' *TEEL/ *o& it is now sub.ect to wear : change the head ball when the groove 8 is no longer visible" 0e'er to instruction manual cha%ter 88 'or the detailed head ball re%lacement %rocedure" -similar to Q99 machines/" © Metso...
Page 63 Heat Here head ball out o" the head "it area. (" the head ball is di""icult to remo+e, warm the head area ust outside the head ball to approximately $$° abo+e ambient to relie+e the inter"erence "it. "locking © Metso...
Page 64 =on4t "orget to re3 install the sa"ety bolt. The threads o" this bolt should be coated /owel Pin Head with !octite 2>>. ,& © Metso...
Page 65 The u%%er section insures the contact on the outer diameter o' the socket when the crusher is running em%ty" Large holes between the two sections allows the oil 'lowing out 'rom the socket to %ass through the head" Fi$ation : bolted on a 'lange& 1 bolts" © Metso...
Page 67 The bushing can also be remo+ed by pulling it out as shown to the le"t. 8acking the bushing with dry ice can expedite the remo+al process i" using the pulling arrangement. © Metso...
Page 68 %ro%er 'it u%" Never 'orce the seal into the groove" The adhesive used is Loctite +e%end No: ead <9<=<" 3lean bottom o' seal using coarse sand %a%er to remove 4shine4 be'ore a%%lying activator and adhesive to bottom o' groove in head © Metso...
Page 69 The ring is 'itted by 8< glued bolts 33 89$?9mm and %ositionned by ? %ins <= $=9mm" (hen the head is u% side down& use eye bolts dia" 8Hmm to remove the ring" 0e'er to instruction manual cha%ter 88"88 'or detailed %rocedure" © Metso...
Page 72 Thicker Liners Long bowl allows to use thicker liners Thicker Liners result in longer liner li'e Thicker liners result smaller scra% rate © Metso...
Page 73 #m%roved bowl liner 'i$ing Gertical bolt allows to use • %ower tools )olt location not in the area • where dust is building u% © Metso...
Page 74 Liftin. Bow" Aem!"# NOTE: *hen resting the bowl assembly on blocking, always place the wooden timbers underneath the bowl liner. The wooden timbers should ne+er be placed under the bowl. -& © Metso...
Page 76 )owl %ortion o' the heli$"  The wedge bolt must stay vertical during tightening"  The s%ring washers must 62+mm Ma= not become 'lat - tor,ue C"earan/e control/ )owl Liner © Metso...
Page 77 FEE+ 2002N>EMENT* Fine 'eed -u% to ?< mm/ *egregated 'eed -u% to @9 mm/ 3oarse -+irect/ Feed -u% to <=< mm/ © Metso...
Page 78 %rotects em%loyees 'rom casual contact with ad.ustment and tram% release mechanisms #t also %rotects the works%ace with reduced dust emissions #t makes it easier to install the crusher into a %lant and to connect it to an e$isting dedusting systems © Metso...
Page 79 Then measure and record the gap ;i" any< that exists between the tapered portion o" the template to the tapered portion o" the threads. Template part numbers: >03'550 0?0? 3 78?00 @ 78200 >03'550 0?00 3 #ll others. © Metso...
Page 80 Greain. 34read and /am fo""ower NOTE: Arease the bowl and adustment ring threads weekly. Threads must be greased with bowl clamped, and with the bowl unclamped. © Metso...
Page 81 3rusher *ensor ackage...
Page 82 The B crusher is e,ui%ed with several *EN*O0* which are gathered in the *ensor ackage" = : Terminal bo$ ? : ro$imity sensors < : ressure *ensor B : Tem%erature sensor 8 : ressure *witch B : Tem%erature sensor © Metso...
Page 83 %ressure which guarantees a su''icient %ressure and lubrication in the whole crusher /" #t must be interlocked so that the crusher and the %um% sto% • when the %ressure dro%s down to a dangerous level" © Metso...
Page 84 8"8 bar on the red scale" Turn the green screw -</ to read the di''erential value 9"? bar on the green scale" This sets the minimum %ressure at 9"1 bar& #' below& it must lead to a crusher emergency sto%" 0& © Metso...
Page 85 3ontact o%ens when  V 9"1 bar" • The %ressure switch is connected in the on6board • electrical cabinet in terminals 89 C 88" 3ontact rating : • 9"= 2m% at <?9 Golts 23 8 2m% at <B Golts +3 © Metso...
Page 86 9 bar  B m2 B99 bar  <9 m2 • For the time being the automation only dis%lays the • %ressure value" This in'ormation will be 'urther used to control the crusher" • sWn N9<B=?B< -re'erence X+23 +2BBB=626B996999 © Metso...
Page 88 One sensor is connected to the L3 -o%tional 'eature/ which dis%lays directly the setting" The direction o' rotation is given by the status o' solenoid n = -activated means o%enning the setting/ © Metso...
Page 89 ?6 ro$imity *witch *u%%ly : <BG +3 3onnection in the terminal bo$ To the lubrication To the L3 -i' any/ C hydraulic unit © Metso...
Page 91 %robes with %latinum resistor are electrical conductors whose resistance varies according to the tem%erature" One measures the tem%erature in the • lower thrust bearing" The other the oil tem%erature in the return line" • )oth sensor cables %ass through a collar • © Metso...
Page 93 B6 Tem%erature sensors W converter The sensors are connected in the terminal bo$ to converters • sending a B6<9 m2 signal" Tem%erature sensors Tem% Y 68993  B m2 • Tem% Y R8993  <9 m2 • © Metso...
Page 94 B6 Tem%erature sensors W converter Make sure this selector is switched on • S?( %osition -t899 %robes with ? wires/ Make sure this selector is switched on • SB6<9 m2  %osition 3onverter %ower su%%ly <BG +3 • (iring : • 1& © Metso...

Metso HP4 Assembly And Disassembly

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