60-110 English Tech Ref 17X0501-01.0701 (New Addition)

Technical Reference Manual

Technical Reference Manual

60-110 SUPERIOR® MK II® Gyratory Crusher Installation, Operation and Maintenance Instructions

FOREWORD This Instruction Manual provides guidance to first time operators of the Crusher as well as providing technical procedures as a reference for the experienced crusher operator. Read — study — and keep for future reference. Illustrations and instructions guide the operator through correct procedures for checking, installing, operating and maintaining the Crusher and accessories. Operating techniques outlined in the book are basic. Operating skills and additional techniques will develop as the operator gains knowledge of the Crusher 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 Crusher, 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 crusher must be obtained from the installation drawings and technical data furnished for your particular Crusher.

SAFETY Operator safety and the safety of others depends upon reasonable care and judgement in the operation of this Crusher. 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 most accidents can be prevented by recognizing hazards and taking steps to avoid them 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 instructional manual to highlight these conditions.

SUPERIORR, SUPERIORR, SUPERIOR MK IIR, Mainshaft Positioning SystemR, MPSR, and Metso MineralsR are registered trademarks of Metso Corporation.

SUPERIOR MK- II Gyratory Crushers

TABLE OF CONTENTS

0.

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0

1.

Safe Equipment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2.

Safe Handling of Heavy Equipment and Machinery . . . . . . . . . . . . .

2

3.

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

4.

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

5.

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

6.

MPS Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

7.

Bottom Shell Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

8.

Eccentric Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

9.

Pinionshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

10. Mainshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

11. Top Shell Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

12. Spider Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

13. Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

14. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

15. Low Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

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TABLE OF CONTENTS

This page was purposely left blank.

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Section 0 — Index

SUPERIOR MK- II Gyratory Crushers

0. Safety

Page 0--2 0--2 0--3 0--3 0--3 0--3 0--7 0--17 0--20 0--20 0--22 0--22 0--22 0--23 0--23 0--23 0--25 0--26 0--27 0--29 0--29 0--39

0

Description Introduction — General — Definitions General Safety Instructions for a Crushing Plant or Plant Environment — Safe Products and the Crushing Plant — Safety and You — Typical Risks in Crushing Plant Working Environment — Personal Protective Equipment and Clothing Machine Safety — Protective Devices and Accessories for Machine Safety — Transport — Towing — At the work-site Safety During Maintenance and Repair — General Information and Safety Lockouts — Mechanical Safety During Maintenance and Repair — Electrical Safety During Maintenance and Repair — Hydraulic Safety During Maintenance and Repair — General Maintenance Work Safety Plates — Safety Plates — ANSI — Safety Plates — EN

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Section 0 — Safety

INTRODUCTION General This manual, together with specific instruction manuals for individual equipment, has been prepared by Metso Minerals Crushing and Screening Business Line to increase the knowledge and awareness of all persons involved in the operation, supervision, service and maintenance of crushing and 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 replace an OEM safety device with a nonOEM device. 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 for the safety of those around you.

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 Typical Risks in Crushing Plant Working Environment on page 0-7), which are related to each other. Foresee and

0-2

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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 safety! Metso Minerals, as the machinery manufacturer and supplier, regards safety as of 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. – That compliance with and adherence to this manual be mandated and supervised by the Owner. – 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 and/or systems 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 followed; 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 any amendments, additions or other changes to safety law, rules or regulations arising subsequent to the date on which this manual was drafted. 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 company safe-

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ty programs. The information contained in this manual is not intended to replace safety codes, insurance requirements, federal, state and local laws, rules and regulations.

Section 0 — Safety

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. Safety and You Safety is everyone’s responsibility; safety is your responsibility.

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.

NOTICE 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. Definitions “Crushing Plant” means a combination or part of various equipment, components, systems and parts for crushing and/or screening of rock, minerals, recycling or other crushable materials. For the purposes of this manual, the Crushing Plant also means stand-alone crushing or screening equipment as applicable. Throughout this manual, words such as “machine”, “machinery”, “equipment” and “crusher” 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, these general safety instructions, together with any specific instructions for individual equipment, as amended from time to time, provided by or on behalf of Metso Minerals.

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. 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. – operating instructions – service, trouble-shooting and maintenance instructions – automated features and motions of the machine – specific safety features and instructions

GENERAL SAFETY INSTRUCTIONS FOR A CRUSHING PLANT OR PLANT ENVIRONMENT Safe Products and the Crushing Plant All machines require human involvement. Like any other heavy machinery, a Crushing Plant has inherent

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Section 0 — Safety

Gyratory Crushers

NOTICE •

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.

•

Report any item that needs attention, repair, replacement, or adjustment.

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 can be summarized in three main themes: – MACHINE KNOWLEDGE – SAFE OPERATION AND MAINTENANCE – GOOD HOUSEKEEPING 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.

DANGER WARNING CAUTION Sign

Description

DANGER

Immediate hazards or unsafe practices that will result in severe personal injury or death.

WARNING

Hazards or unsafe practices that could result in severe personal injury or death.

CAUTION

Hazards or unsafe practices that could result in minor personal injury or equipment damage.

FIG. 0-2 — Danger, Warning, Caution Signs and their Meaning

This manual uses another convention to communicate information which, if not followed, will affect the performance of the equipment or cause damage to the equipment. This is indicated by the word NOTICE.

NOTICE Usually communicates information which, if not followed, will affect the performance of the equipment or cause damage. FIG. 0-3 — Important Notice and its Meaning

While such conditions and practices do not pose an immediate threat of personal injury, the damage that occurs over time can be hazardous. FIG. 0-1 — 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.

0-4

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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. (Warning signs are listed and their locations described in the machine safety instructions.) 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. 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. Wrist watches and rings can be dangerous. Rings should be removed or covered with tape. Keep your pockets free of loose objects.

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Section 0 — Safety

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 air flow 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, name plates or warnings.

WARNING 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! Safety Instructions after Start-up 1. After equipment has been started, check all gauges and instruments to be sure that everything is operating properly. 2. Shut down immediately if any improper readings are observed. 3. Test all controls for proper functioning. 4. Listen for and report any unusual noises. 5. Recheck alarms or other warning and safety devices. 6. Do not take a chance with a defective machine. Report it to your supervisor.

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Section 0 — Safety

Gyratory Crushers

Report a Defective Machine Inspect your machine daily. Check for loose, worn or damaged parts. Report or correct any unsafe conditions immediately, and do not operate the machine until they have been corrected. Even a minor defect can become serious. Report any machine defects to your supervisor. Stopping Safely Be sure equipment is stopped before: • cleaning •

servicing

•

lubricating

•

checking belt tension

•

removing housing covers

•

working on the hydraulic system

•

making repairs

•

or attempting to clear a plugged cavity.

NOTICE Make no checks, adjustments or repairs of any kind while the equipment is in operation. 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. 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.

0-6

Place jacks at designated jacking locations. Consult the portable plant instruction manual if these are not marked on the chassis. Typically the four corners are supported along with points in between where crusher, screen or feeder forces are concentrated. Jacks must be used in pairs directly opposed to each other. After correct height and level are achieved, adjust each jack until vibrations are reduced to a minimum. Insert locking pins if so equipped. If holes for locking pins do not align, loosen the jack and place metal shims under the jack until the holes align. Periodically recheck the trailer footing for stability. 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 tail lights are on, as applicable. Use proper traffic warning flags and signs. 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.

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Section 0 — Safety

Gyratory Crushers

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 and auxiliary equipment can create dust. Crushing 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. 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 of which everyone working at, on or around the Crushing Plant should be aware. 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 and power lines – 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 – falling material from conveyors, and from loading, unloading and feeding operations – crushing cavity

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These typical hazards are discussed more fully in the next section of this chapter. Be aware of these hazards. All personnel working on or around the machine should be properly trained in avoiding these hazards. Typical Injury Types – crushing – slipping, tripping and bumping – falling – cutting – entanglement – burns and electrical shocks – respiratory organ illnesses – asphyxiation 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.

DANGER 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. 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 hand rails 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,

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Section 0 — Safety

ladders and floors. Tidiness provides a safer working environment by preventing or reducing tripping, slipping, fire hazards and electrical shocks. Elevated or Narrow Working Location

Gyratory Crushers

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!

NOTICE

Crushing 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.

0-8

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 maximum weight load that can be handled safely. Always follow the crane manufacturer’s operational and safety instructions.

NOTICE The weight indicated on machine plates tells the weight of standard configuration. In many cases the actual weight may differ greatly from that indicated on a machine plate due to, casting variations, 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.

NOTICE When using a mobile crane, always operate within the rated capacity of the machine to avoid buckling the boom or tipping. 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.

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–

– –

– – – –

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 are properly trained. Rig the load firmly to prevent any unintended movement and assure stable and accurate positioning. Make sure nobody is below or in the path of the load and transfer routes are clear and proper protective clothing and gear are used.

Sharp Edges

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.

Section 0 — Safety

High-Pressure Equipment — Hydraulic or Air

WARNING Hydraulic oil under pressure can penetrate body tissue causing serious injury and possible death. When troubleshooting a hydraulic system for leaks, always use a mirror, cardboard wood or other appropriate techniques as a detector. DO NOT USE YOUR BARE HANDS. If you are injected with hydraulic oil or any other fluid, immediately seek treatment from a doctor trained in the treatment of penetrating fluid injuries. High pressure oil can be dangerous. Relieve all pressure before opening or removing any hydraulic or air pressure lines, valves, fittings, etc. Use a mirror, cardboard or other appropriate techniques to look for leaks. 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 state. 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 state 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.

WARNING Poorly tightened or damaged hydraulic components may create 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.

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Section 0 — Safety

WARNING 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

Gyratory Crushers

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 prevent injury or death. Follow proper procedures at all times! Maintenance, repair and installation of electrical equipment must be performed only by qualified personnel who are familiar with the machinery and equipment in question. –

Automatic Functions and Unexpected Start-Ups

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. Protect electrical devices that move as part of the machine from dirt and mechanical damage. Regularly check the operability of these devices.

DANGER 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. The lockout program, 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. – Each person working on the unit must have his own lock with only 1 key.

0-10

Unexpected start-ups during maintenance: – Lock out and tag machine controls before performing maintenance or repairs to avoid unexpected start-up. Failure to properly lock out the machine can lead to injury or death. Someone may accidentally start the machine from the control room or an unexpected occurrence may activate a control. For example, a power surge may alter the logic of the control system status causing an unexpected machine movement or sequence.

WARNING Machine parts may move unintentionally and cause a risk of injury. Absence of safety functions may cause dangerous machine movements. Do not tamper with limit switches or other safety devices included in the system.

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Section 0 — Safety

DANGER

WARNING

If danger zones are not respected during machine operation or maneuvers there is a risk of serious injury or death.

Risk of injury. Fire may break out. Never perform welding or torch cutting activities in the presence of flammable materials.

Many devices operate automatically, following certain sequences which have been programmed into the logic system (e.g., 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. When cutting or welding on a plant with gasoline or diesel units, cover fuel filler caps with several layers of wet shop cloths.

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NOTICE 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.

NOTICE 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. 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.

0-11

SUPERIOR MK- II

Section 0 — Safety

Machine Inertia

Gyratory Crushers

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. Fire Hazards

Due to the large inertial forces of the Crushing Plant and Crushing Plant components, 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.

–

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. On mobile equipment be cautious around the engine because of exhaust gases. 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.

– – –

– –

It is recommend to equip the Crushing Plant with manual fire 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

0-12

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.

Know the location of first aid kits and know how to use them. Know where to get emergency help.

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SUPERIOR MK- II

Section 0 — Safety

Gyratory Crushers

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 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

WARNING 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.

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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.

NOTICE 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.

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Section 0 — Safety

WARNING 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!

SUPERIOR MK- II Gyratory Crushers

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

Noise and Vibration

• Crushing Plant Noise A 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 ranges from 100 dB to 110 dB measured at 1 m (3 ft) from the Crushing Plant. Metso Minerals recommends wearing ear protection at, on and around Crushing Plant, particularly when the noise level exceeds 85 dB. It is recommended that the Owner develop a signalling 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 EC, OSHA, MSHA, etc. Refer to applicable safety regulations for permissible noise exposures, and take steps to ensure compliance with those regulations. • 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.

0-14

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. Crushers, 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. Do not use sheaves with damaged rims or spokes.

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SUPERIOR MK- II

Section 0 — Safety

Gyratory Crushers

Ejection of Objects from the Crushing Plant

Typical Injury Types Crushing

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 stand in front of the feed opening or look into the crushing cavity while the crusher is operating. Never attempt to clear jam on feeder, crushing cavity or conveyors when the 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 an approved safety 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.

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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 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 an approved safety helmet and other safety equipment as appropriate.

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SUPERIOR MK- II

Section 0 — Safety

Gyratory Crushers

Falling

Entanglement

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.

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. Never attempt to service, repair, or troubleshoot any moving part of the Crushing Plant while it is energized or otherwise capable of movement.

WARNING Do not operate any equipment until all guard rails and safety devices have been re-installed or returned to their proper operating condition. Failure to do this could result in serious injury or death.

WARNING 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

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

0-16

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.

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SUPERIOR MK- II

Section 0 — Safety

Gyratory Crushers

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. 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 an approved 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 stand in front of the feed opening or look into the crushing cavity while the crusher is operating. 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.

NOTICE

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.

Always use right size of protective equipment.

NOTICE 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.

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SUPERIOR MK- II

Section 0 — Safety

Gyratory Crushers

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.

Foot Protection

The Owner shall ensure that affected personnel use protective footwear when working in areas where there is a danger of foot injuries due to falling or rolling objects piercing the sole, and where feet are exposed to electrical or chemical hazards. Head Protection

NOTICE 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 Typical Hazards on page 0-8.

NOTICE The area should be well ventilated. Epoxy fumes can cause nausea or eye or skin irritation.

The Owner should ensure that affected personnel wear a protective helmet approved by OSHA, MSHA (or by other applicable authority) when working in areas where there is a potential for head injuries from falling objects or walking throughout areas with low head clearance. The Owner should ensure that a protective helmet designed to reduce electrical shock hazard is worn by personnel when near exposed electrical conductors which could contact the head. Hand Protection

NOTICE Breathing dust may be hazardous to the health of anyone working at, on, or around the Crushing Plant.

NOTICE Metso Minerals highly recommends that adequate dustprotective devices such as a respirator be worn by anyone exposed to airborne dust, particularly silica dust, to prevent its inhalation.

0-18

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 burns, and harmful temperature extremes.

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SUPERIOR MK- II

Section 0 — Safety

Gyratory Crushers

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

Safety Locks and Tags

Follow all lock-out tag procedures. Refer to appropriate standards and instructions provided by Metso Minerals.

DANGER

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.

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For maintenance work, disconnect all devices from electric power sources. Bring all hydraulic gravity or spring loaded devices to a zero-energy state. Follow lockout procedures. The lockout program, locks, tags and the blocking/restraining devices provided are designed for Operator protection. It is the Operator’s responsibility 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!

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SUPERIOR MK- II

Section 0 — Safety

Gyratory Crushers

MACHINE SAFETY Protective Devices and Accessories for Machine Safety 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. 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 Crushing Plant parts 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.

NOTICE It may be necessary to engage reset switches before movement can resume. Safety Interlocks A 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. Interlocks can also be used to prevent sudden unexpected movement of a machine function or component. During operation, the logic system (e.g., 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. 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.

WARNING 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.

CAUTION Emergency stop not only stops the machine but often it may initiate other protective sequences.

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SUPERIOR MK- II

Section 0 — Safety

Gyratory Crushers

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 to minimize the potential for hazardous situations to occur. A hose break valve functions to lock up if fluid flow is discharged too rapidly from an 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

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. Additional Warning Devices Horns and Lights

If visual contact between work places is obstructed or if communication is difficult, sound and/or light signalling 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

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 or electric limit interlock switches may cut off the drive or actuator power or initiate an emergency stop mode. For specific operation, see later sections of this manual.

WARNING Safety gates must not be opened during normal machine operation. Exceptions to this rule are defined in the operating instructions.

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 are typically safety yellow.

Safety gates may also be opened for maintenance purposes when the machine has been stopped. Follow all lockout procedures.

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0-21

Section 0 — Safety

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.

CAUTION Extreme caution must always be used on machine walkways. Transport Observe the following precautions before transporting the Crusher Plant: 1. Chock chassis tires securely whenever connecting or disconnecting chassis from tractor or dolly. 2. Check tire pressure. Use a protective cage or a clip-on type air chuck and remote in-line valve and gauge when inflating tires. Never exceed maximum inflation pressures of the tire or rim. 3. Check tightness of wheel lug nuts before transport and check frequently during transport. 4. Check that brake system operates correctly. 5. Observe maximum axle and tire loading capacities. 6. Protect components being transported using appropriate shipping braces and blocking material. 7. Travel may be limited to daylight hours only, depending on your specific plant and applicable state regulations. 8. Follow recommended limits on towing speed. 9. Make sure all lights are on and that they are operating correctly. 10.Use traffic warning flags, signs and lights as required. 11. Before moving the Crushing Plant, check all roadways and bridges on the route for weight limits. 12.Check clearance of bridges, overhead lines and other overhead obstructions. 13.Follow all applicable laws and regulations.

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SUPERIOR MK- II Gyratory Crushers

Towing Observe the following precautions before towing the Crusher Plant or its components: – Check if towing is allowed for each individual equipment. At the Work-site Precautions Observe the following minimum precautions at the work-site: 1. Know the locations of underground and overhead powerlines and other potential hazards. 2. Select the work-site with care. The ground must be firm, level and able to support the weight of the entire plant. Make sure there is enough room for loading ramps, loaders, conveyors, etc., and for safe maneuvering of trucks and loaders. 3. Check that cribbing is secure and that plant has not shifted or settled. 4. Make sure that electrical cables are protected from wear and traffic. 5. Follow pre-operation checks and start-up procedure covered in the individual manual supplied with your specific unit equipment. Check that all fluid and lubrication systems are at the correct level and that there are no leaks. Low fluid levels can lead to serious hydraulic failures. Low oil or grease can lead to machine seizure, damage to other components, and to human injury. 6. Check equipment for warning tags which indicate that maintenance is being carried out and/or that an unsafe condition exists. Tag out conditions must be cleared before operation. 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 a 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 specific crusher.

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SUPERIOR MK- II

Section 0 — Safety

Gyratory Crushers

SAFETY DURING MAINTENANCE AND REPAIR

Mechanical Safety During Maintenance and Repair

NOTICE Never tamper with safety devices or attempt to modify or eliminate safety devices installed at the factory. 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 Sheets) and Crushing Plant procedures for handling of these materials.

General

DANGER FOLLOW ALL ESTABLISHED LOCKOUT PROCEDURES. REFER TO THE APPROPRIATE STANDARDS. For repair, maintenance or troubleshooting 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 instructions 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!

NOTICE Be sure all mechanical components are brought to a zero energy state including all spring driven devices, cylinders, accumulators, drive shafts, pulleys, rollers, gears, etc., prior to entering the machine and performing the work. Never attempt to perform repair, maintenance, or troubleshooting work on or in proximity to energized mechanical components.

NOTICE Block up and support parts as necessary to prevent any unexpected motion when performing maintenance.

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0-23

SUPERIOR MK- II

Section 0 — Safety

A certain amount of work must be done in the immediate area of the crushing equipment during the normal course of operations on a day-to-day basis. The following are some of the do’s and don’ts to be followed as part of normal equipment operating procedures. • Do not perform maintenance on moving machinery. This includes such items as adding lubricating oil or greasing parts of the equipment while it is in operation. •

Do not put hands or feet on the release cylinders which protect the equipment from tramp iron overloads while the equipment 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 avoid harm to the operator as well.

•

Do avoid spillage around the equipment. Plant operators should make it a habit to keep the area immediately adjacent to the equipment free from this type of spillage which could cause unsuspecting personnel to trip and fall.

•

Never stand in front of the feed opening or look into the crushing cavity while the crusher is operating.

•

When using a crane to raise or lower a load keep all personnel clear of the area.

•

Never walk, stand, crawl or lay under any load hanging from a crane.

Fire Safety During Maintenance and Repair

Observe all regulations on fire safety. Sources for fires include, but are not limited to the following: – Sparks from grinding. – Flames and molten metal from welding or torching. – Electrical arcing. – Spontaneous combustion. – Smoking. Before starting any work take the following steps to prevent a fire hazard: – Properly dispose of rags with combustible material to avoid spontaneous combustion. – Move flammable materials 10 m (33 ft) or more away from any fire hazard. – Clean up all debris. – Clean up all oil spills and leaks.

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Gyratory Crushers

– – – –

–

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. Protect yourself and others from sparks with proper personal protective equipment and clothing.

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 in the middle of a production cycle. A machine or device that is not in proper condition, and that has been left without regular maintenance and inspections, is a safety risk to its user. For instance, without lubrication a bearing may fail, bringing a production line down. Furthermore, the hot bearing may present a fire hazard or cause skin burns. Some preventive maintenance suggestions for a machine include: – Observe the maintenance and lubrication instructions of the machine and equipment suppliers. – Keep the machine and surrounding area clean and orderly. – Monitor the vibration levels of the machine to help detect loose or worn parts or impending bearing failure. – Monitor the power consumption of motors to help detect early failures. – Repair all leaks as soon as possible to prevent more serious conditions. Repair fuel leaks immediately. – Monitor the condition of pipes and tubes enclosed in ducts; repairing possible leaks. Confined Spaces

A confined space means a space that: – is large enough and so configured that a person can enter and perform assigned work; and – has limited or restricted means for entry or exit (for example, the crushing cavity, tanks, vessels, silos, storage bins, hoppers, vaults, and pits are spaces that may have limited means of entry); and

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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. –

DANGER Confined spaces may contain high concentrations of gases which may cause injury or death. Follow all established safety procedures. Electrical Safety During Maintenance and Repair

General

DANGER 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.

•

Tags must identify the work being done and the person(s) who locked and tagged the control.

•

Locks and tags are changed with each work shift.

Section 0 — Safety

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 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 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. – Always turn off electrical power before disconnecting electrical cables. 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.

Work to eliminate injury and death. Follow proper procedures at all times! Be sure all electrical components are brought to a zero energy state including capacitors and similar electrical devices.

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Section 0 — Safety

Gyratory Crushers

NOTICE 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.

NOTICE Improper phasing will damage backstops in conveyor drive reducers and may damage hydraulic system components. Program Changes

WARNING 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 control program and cause unpredictable machine operation.

NOTICE Do not use the logic center or control cabinet’s outlet for anything other than a programming device!

0-26

Hydraulic Safety During Maintenance and Repair

DANGER 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! Before proceeding with any repair, maintenance or diagnostic procedures on the hydraulic system, bring all components to a zero energy state, including cylinders, accumulators, spring loaded hydraulic devices, circuitry between valves and actuators, etc. – Mineral and other oils and additives can cause skin irritation. Inhaled oil mist can also cause internal irritation, headache or nausea. Avoid repeated exposure to these materials. Use appropriate personal protective equipment. – Purge entrapped air from the hydraulic 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 serious risk of slipping. Clean up all spills and repair leaks immediately. – Hydraulic oil temperature may be extremely high;

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SUPERIOR MK- II Gyratory Crushers

WARNING Elevated temperatures levels can be hazardous and may cause severe burns. Wait until machine cools down before doing maintenance or repair. – –

A mixture of air and oil mist may explode at higher temperatures. Hydraulic oil spilled on hot machine surfaces may start a fire. Pressurized hydraulic hoses should not be handled with bare hands since high-pressure leaks may easily penetrate the skin. Hydraulic fluid pressure in the hoses may exceed 3000 PSI/210 bar/21MPa.

WARNING Hydraulic oil under pressure can penetrate body tissue causing serious injury and possible death. When troubleshooting a hydraulic system for leaks, always use a mirror, cardboard wood or other appropriate techniques as a detector. DO NOT USE YOUR BARE HANDS. If you are injected with hydraulic oil or any other fluid, immediately seek treatment from a doctor trained in the treatment of penetrating fluid injuries. 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

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Section 0 — Safety

the machine, since pressurization of the system may cause machine motion. – Once the system is in the pressurized state, 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. Use a mirror, cardboard or other appropriate techniques.

NOTICE Never adjust pressure relief valves higher than settings specified. 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 crusher is in operation. – Never clear a jam on or in the feeder, 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. – Do avoid spillage around the crusher. Operator should make it a habit to keep the area immediately adjacent to the crusher free from spillage, which could cause people to trip and fall. – Never stand in front of the feed opening or look into the crushing cavity while the crusher is operating. – When using a crane or other lifting device to raise or lower a load keep all personnel clear of the area. – 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. – Store and secure hazardous materials in restricted areas. Mark materials clearly and

0-27

Section 0 — Safety

–

–

–

SUPERIOR MK- II Gyratory Crushers

make sure any federal or other labelling regulations are followed. Store gasoline, diesel fuel, hydraulic oil, cleaning solvent and any other flammable material in a cool, dry, ventilated and secure location. Avoid spills of fuels, oils, lubricants, or antifreeze. If spills occur, contain and neutralize them with an approved agent and dispose of them properly. Use only quality Metso replacement parts. Handle parts carefully to prevent damage to machined surfaces. Machined surfaces may have sharp edges. Replace fasteners with the same type, size and quality as the original parts.

WARNING Never start and run a diesel or gasoline engine in an enclosed area that is not ventilated. Although carbon monoxide is odorless and colorless, it is deadly.

0-28

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Section 0 — Safety

SAFETY PLATES Safety Plates — ANSI

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Section 0 — Safety

0-30

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Section 0 — Safety

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Section 0 — Safety

0-32

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Section 0 — Safety

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Section 0 — Safety

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Section 0 — Safety

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Section 0 — Safety

0-36

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Section 0 — Safety

0-37

Section 0 — Safety

0-38

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Section 0 — Safety

Safety Plates — EN

Do not stand in the vicinity of the crusher when the engine is running.

Do not stand on the machine.

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Do not stand in the vicinity of the crusher when the engine is running.

There are moving parts behind the protecting cover. Do not open the cover when the engine is running.

0-39

Section 0 — Safety

SUPERIOR MK- II Gyratory Crushers

Do not go near the feeder when the engine is running.

Do not go under the machine when the engine is running.

Mind the hot surface.

Mind the high-pressure liquid.

0-40

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Section 0 — Safety

Stay away from the powerful magnet.

Read the user instructions.

Do not open the hatch when the rotor is moving.

Lock the rotor before entering the crusher.

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0-41

Section 0 — Safety

0-42

SUPERIOR MK- II Gyratory Crushers

Watch out for material dropping from the conveyor.

Watch out for material dropping from the bucket.

Rotation direction of the vibrator.

Switch off the radio control before blasting.

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Section 0 — Safety

Emergency stop.

Conveyor emergency stop.

Conveyor emergency stop wire.

Do not open the main current switch when the engine is running.

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0-43

Section 0 — Safety

0-44

SUPERIOR MK- II Gyratory Crushers

Close the hatch before lowering the conveyor.

Stay away from the crusher cavity.

Do not step under the conveyor.

Use a safety rod to prevent the crusher from closing.

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Do not insert tools in the crusher cavity when the engine is running.

Section 0 — Safety

Pressure accumulator.

Do not open the hatch when the engine is running.

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0-45

Section 0 — Safety

SUPERIOR MK- II Gyratory Crushers

Do not attach or detach hydraulic connection when the engine is running.

Keep the door closed when the engine is running.

Tighten the wheel nuts to the specified torque when changing tires. Check the tightness of the nuts after 50 km (30 miles) and 150 km (93 miles).

Use the pin to lock the conveyor before moving the machine.

0-46

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Section 0 — Safety

Gyratory Crushers

Use the pin to lock the conveyor before starting the crushing.

Oil.

Oil recommendation.

Use of respirators required.

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0-47

Section 0 — Safety

0-48

SUPERIOR MK- II Gyratory Crushers

Inspect every 8 hours and tighten every 40 hours.

Lock the catch.

Use of hearing protectors required.

Use of helmet required.

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Section 0 — Safety

Greasing point.

Check every 8 hours.

Fuel tank.

Use of eye shields required.

0-49

SUPERIOR MK- II

Section 0 — Safety

Gyratory Crushers

Engine oil. Valve.

Hydraulic oil. Oil recommendation.

Coolant.

0-50

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Section 0 — Safety

Gyratory Crushers

DANGER! Electric shock.

CE mark.

Fastening flat bar.

Conveyor safety switch.

People using pacemakers must not go near the magnet.

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Section 0 — Safety

SUPERIOR MK- II Gyratory Crushers

This page was purposely left blank.

0-52

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Section 1 — Index

SUPERIOR MK- II Gyratory Crushers

1. Safe Equipment Operation

Page 1-1 1-2 1-3

Description Index Crusher Safety Precautions General Safety Precautions for Crushing Plants

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1

1-1

SUPERIOR MK- II

Section 1 — Safe Equipment Operation CRUSHER SAFETY PRECAUTIONS It is important that “Section 0 -- Safety” is read in its entirety. This section provides additional Safety Precautions specific to the SUPERIOR Gyratory Crusher. All personnel operating and maintaining a SUPERIOR crusher should be aware of the following safety precautions. 1. Always install lifting gear so that the installation and removal of consumable parts can be carried out in a safe way. 2. When the crusher is fed by a dump hopper and a feeder, an access platform shall be built around the crusher feed opening to allow the operator a clear view of the material being fed to the crusher.

WARNING Suitable guard rails and kicking boards must be provided around the platform and other open areas around the top of the crusher to prevent any personnel from falling into the feed opening. 3. The dump pocket around the top opening of the crusher is dangerous. Personnel should not be in the dump pocket when the crusher is in operation. Being struck by falling material from trucks when dumping, or falling into the crushing chamber could be fatal. It is the customer’s responsibility to provide visual warnings of dump pocket dangers, visual / acoustic warnings of trucks dumping material, and acoustic warning of crusher start up. 4. When crushing in a SUPERIOR gyratory crusher it is inevitable that sooner or later a large stone will jam in the feed opening. It is also possible that a material blockage can occur inside the crushing chamber. To correct such a situation in a quick and safe way for plant personnel, we recommend that a hydraulic hammer, overhead crane, or a suitable hydraulic arm with a grab or a pick is included in the installation at the planning stage.

WARNING Metso Minerals does not recommend blasting. The use of explosives is at the customer’s risk. Metso Minerals will not take responsibility for damage to personnel or to the crusher.

1-2

Gyratory Crushers

5.

DANGER If it is necessary for personnel to go into the crushing zone, first switch off the machine then lock and tag electrical controls. it is very important that anchor points are provided where a safety harness can be attached. 6.

CAUTION The sides of the dump hopper must be high enough to prevent rocks from bounding over the edge and causing damage. 7. When looking towards the crusher, the crusher pinionshaft must rotate clockwise. This is necessary for the self-tightening action of the head nut. 8. The crusher drive motor must be interlocked so that it cannot be started until the lubrication system is operating correctly -- i.e. the oil pump is running, oil returns from the crusher and the oil is not too hot. The oil pump must not be stopped until after the crusher has stopped. 9. After running-in is completed, re-tighten all bolts. 10. Do not stand inside the top shell when removing the concaves.

WARNING Metso Minerals does not recommend that explosives be used to remove the concaves. 11. Special precautions must be taken when using manganese concaves on crushers that crush hard but less abrasive material. A hard material which is not abrasive will peen the manganese faster than it will wear out the concaves. See Fig. 4-13.

CAUTION The gaps between the concaves can disappear completely and this can lead to cracks in the top shell. The gaps between the concaves should be checked daily. When the gaps decrease below 6 mm, the corners of the concaves must be burnt off. Refer to Section 4 -- “Installing Concaves” and Fig. 4-13.

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12.

GENERAL SAFETY PRECAUTIONS FOR CRUSHING PLANTS

CAUTION Several liners on the crusher are manganese steel. In particular the spider rim and arm liners and crusher mainshaft liner (mantle). Torch cutting, welding, and grinding on manganese steel produces toxic fumes and dust. Approved respirators should be worn for personnel protection. 13. The crusher main drive must be guarded to prevent serious injury. If the guard is supplied by the customer, it is their responsibility to design it to meet all national and local regulations.

CAUTION A fixed guard should always be installed over the crusher drive unit. If the crusher is driven by a V-belt transmission there must be a provision to check the belt tension designed into the guard. Guards must be designed so that they comply with the applicable safety regulations. 14. Crushing equipment by its very nature is noisy and the auxiliary equipment found in and around crushing equipment such as chutes, transfer stations, screens, etc., can at times be noisier than the Crusher itself. Noise levels at one meter distance from the crusher when crushing rock range from 90 to 110 dB(A). Ear protection should be used when working near and around the crusher when it is in operation. Signs should be posted to advise personnel to wear ear protection.

CAUTION Ear protection should be worn by all plant operators. Values are equivalent continuous sound levels (Leq) measured during a period of 60 seconds with an integrating sound level meter. All readings are taken at a distance of approximately 1 m from the machine and at a height of approximately 1.6 m from the floor level (or platform where applicable). Values are approximate. Noise levels vary depending on whether dust encapsulation is fitted or not, installation and feeding arrangements, size and Work Index of feed material, motor size, etc.

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Section 1 — Safe Equipment Operation

WARNING A hard hat, eye protection, and hearing protection are required at most crushing and screening installations. Hard hats and safety goggles can prevent injury. Wear hearing protection when noise levels exceed 85 dBA and breathing protection when dust levels exceed acceptable limits. 1. In a crushing plant, the environment can be dusty, noisy, and exposed to bad weather conditions.

NOTICE An operator’s tower should be provided to give protection for the operators.

NOTICE There should always be visual access to the material that is being fed to the primary section of the crusher plant, either directly from a platform or cabin near the crusher, or from a remote observation facility within a control room. 2. In cases where feeders or crushers are proceeded by a dump hopper there is always a risk of vehicles reversing into the hopper.

NOTICE Always install stop blocks across the full width of the access road. The height or these stop blocks must be a least 50 percent of the diameter of the rear wheels of the largest vehicle used. Additional safety devices such as guard rails must be provided around the rest of the hopper. 3. All controls furnished by the customer must be designed, constructed, and equipped so that all electrical hazards are or can be prevented. 4. Machine Maintenance: Several areas of the crusher require access for maintenance. Access to areas such as the main drive assembly, spider bearing assembly, mainshaft position system cylinder assembly (underneath the crusher), and the lubrication system is not provided by the manufacturer. It is the customer’s responsibility to provide a safe means for servicing these areas. The design and building of access for maintenance are the customer’s responsibility. 1-3

Section 1 — Safe Equipment Operation 5. One of the most flagrant crusher safety violations is the use of inadequate and unsafe lifting equipment. The internal parts of a Crusher 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 Crusher.

SUPERIOR MK- II Gyratory Crushers

6. When using a crane to raise or lower a load keep all personnel clear of the area. Never walk, stand, crawl or lay under any load hanging from a crane. 7. It is important that “Section 0 -- Safety” is read in its entirety.

NOTICE 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 to find the true weight of the load that can be handled safely.

1-4

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2.

Page 2-1 2-2 2-2 2-3 2-4 2-4 2-4 2-5 2-5 2-5 2-5 2-6 2-6 2-6 2-7 2-7 2-7 2-8 2-8 2-9 2-9 2-10 2-11 2-11 2-12 2-13 2-13 2-14 2-15

Safe Handling of Heavy Equipment and Machinery

Description Index Introduction Making a Safe Hitch Factors Affecting the Use of Slings Sling and Load Protection Blocking Loads Hooks Eyebolts — Inspection — Application — Cautions — Definition of Rated Capacity — Capacity Table for Type 1 Eyebolt — Capacity Table for Type 2 Eyebolt Shackles — Safe Rigging Practices — Safe Loading Table for Standard Shackles Wire Rope Slings — Safe Rigging Practices — Wire Rope Clip Installation — Clips Required for Fastening Wire Rope Ends — Safe Loading Table for FC or IWRC Wire Rope Slings Braided Wire Rope Slings — Safe Rigging Practices — Safe Loading Table for 8-Part Braided Rope Slings Alloy Steel Chain Slings — Safe Rigging Practices — Safe Loading Table for Alloy Steel Chain Slings Hand Signals for Cranes and other Lifting Devices

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2

2--1

Section 2 — Safe Handling of Heavy Equipment and Machinery INTRODUCTION Hoisting devices are the most frequently used type of equipment for handling heavy machinery. Slings and related equipment provide the critical link between the load and the lifting device. They often determine the difference between a safe effective lift and a disaster. The following information is provided to assist personnel responsible for the unloading, handling and installation of heavy machinery. The primary consideration in providing this information is the safety of personnel working with or near the machinery while it is being handled. The secondary concern is the avoidance of damage to the machinery itself.

WARNING 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. MAKING A SAFE HITCH 1. Before lifting and transporting a load, check its physical characteristics, weight, size and shape. a. The weights of major assemblies and complete machines are usually listed on installation drawings and in the respective equipment instruction manuals. Larger assemblies may have the weight marked on them. If no weight is found consult your supervisor or weigh the load. b. The size and shape of loads will indicate the type of hitch to be used — choker, basket or a hitch with special attachments. It may also indicate the type of hitching equipment to be used — wire rope, alloy chain, eyebolts, shackles, etc. 2. When the weight of the load, load angle, type of hitch and hitching equipment to be used has been determined, select the proper size hitching equipment of that type from the Safe Loading Tables in this section. 3. If the load to be lifted exceeds the safe load rating of a particular size sling or related hitching components, go to the next larger size that will carry the load safely. The safe load rating of the hitching equipment must not be exceeded. 4. If there is any doubt as to the correct type of hitch, or size and type of hitching equipment to use, contact your supervisor. 5. Hitching equipment must be carefully checked when it is removed from the storage rack. Defective equipment must be removed from service and notice given to your supervisor. 6. To assure longer life of hitching equipment and greater safety in its use, the equipment must not be overloaded and must be protected from the sharp 2--2

SUPERIOR MK- II Gyratory Crushers corner of the load by using bagging, corner irons, lagging, etc. Protect finished surfaces of the load from possible damage by the hitching equipment. Secure protecting material to the load or sling to prevent them from falling when the sling becomes slack. 7. When it is necessary to climb on the machinery to place hitching equipment, observe the following rules: a. Use ladders of the approved type whenever possible and ensure that they are held securely in place. b. Keep both hands free for climbing. Hitching equipment should be pulled up with a crane. 8. When the hitching equipment is in position, give the signal to take out the slack. Give particular attention to the position of the fingers to prevent them from getting pinched. See figures 2-1 and 2-2.

FIG. 2-1 — Position of Hand when Taking Sack Out of Sling

FIG. 2-2 — Position of Hand when Guiding Hook

9. Give standard crane signals clearly and in sight of the crane operator so he can move the load as desired. See ”Hand Signals” at the end of this section. 10. Before giving the signal to lift the load, the person making the hitch must check the following: a. Make sure no loose materials, tools, dirt, bolts, etc. are on the load. b. Make sure unused sling legs are secured by hooking them back into the master ring or by

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Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers

11.

12. 13.

14. 15.

shackling them together. Unused legs must not be allowed to dangle loose. c. Stand in the clear and be sure others in the immediate area are also in the clear before proceeding with the lift. Check the hitch at all points, when the slack has been taken out to see that it is safe, secure and in balance. Check the hitching equipment to see that it is still protected from the load and that finished surfaces are protected from the hitching equipment. When the load has been raised several inches off the ground and is completely supported by the lifting device, check the load brake and recheck the hitch at all positions. Whenever possible, transport loads over areas where no one is working. Give sufficient warning when loads will be moved over personnel occupied areas. A clear area with adequate blocking should be prepared when selecting a place for the load, avoid placing loads in aisles, roadways, tracks or heavy occupied areas. When the load is being lowered to its approximate position, keep all personnel clear of the area. Stop the load just before contact with the ground and adjust the blocking to the loads final position.

CAUTION Keep hands and feet away from the pinch point areas between the blocking and the load. See figure 2-7. 16. Properly place blocking to assure that the load will be level and stable when lowered to the ground. Consider the following guidelines when placing blocking: a. Weight of the load — blocking must provide a stable resting surface capable of supporting the complete weight of the load. b. Finish of the load — protect finished surfaces by padding the blocking and hitching equipment with bagging, pressed cardboard, belting, etc. See figure 2-4. c. Size and shape of the load — wedge and block round shafts, forging and rings. See figure 2-6. Use blocking of equal dimensions to ensure that the load will rest level. Be sure adequate blocking is used when off-balance loads are encountered. d. Working surfaces — compensate for flaws in floor and yard surfaces when using blocking. Use extra care when blocking on frozen ground to assure the load will not shift when the ground thaws. e. Condition of blocking — use blocking that is in good condition and of uniform size. Do not use defective blocking that is rounded, rotted, broken, containing large knots, etc. See figure 2-5. 17. Slowly lower the load until its full weight is supported by the ground or blocking. 17X0501-01.0701

CAUTION Hitching equipment protection such as corner irons, belting and lagging may fall when sling is slack. Keep personnel away from area until hitching equipment protection is removed. 18. When the hitch has been completed, remove and check the hitching equipment for damage. If no longer needed, place the hitching equipment back on the storage rack. FACTORS AFFECTING THE USE OF SLINGS The Safe Load Tables in this section give the maximum safe load for each size of hitching equipment when used as shown in the illustrations above each table. The illustrations cover most of the common applications of hitching equipment. See your supervisor for applications not covered in the Safe Load Tables. The Safe Load Tables take into account the following factors: NUMBER OF LEGS — the number of sling legs connecting the crane hook with the load. LOAD ANGLE — the angle between the load (horizontal surface) and the sling. The smaller the load angle the smaller is the safe load capacity or efficiency of the hitching equipment as shown in the table below and in figure 2-3. Load Angle Degrees 30o 45o 60o 90o

ANGLE EFFICIENCY TABLE Lifting Safe Working Load for Efficiency One Leg Based on Percent 500 Lb. (227 kg) Load 50.0% 250 lbs. (113 kg) 70.7% 354 lbs. (161 kg) 86.6% 433 lbs. (196 kg) 100.0%. 500 lbs. (227 kg)

FIG. 2-3 — Sling Angle

2--3

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers

SPLICE EFFICIENCY — the reduction in strength of wire rope due to eye splices or endless splice. CORNER EFFICIENCY — the reduction in strength of slings when bent around reasonable corners. The Safe Load Tables are not set up for sharp corners. CHOKER EFFICIENCY — the reduction in strength of slings when used for choker hitches. LOADING — the reduction in strength of hitching equipment due to shock or impact loading and acceleration loading by the crane or hoist. WEAR — the reduction in strength of hitching equipment due to normal wear. The Safe Load Tables do not take into account such unusual factors as high temperatures, sub-zero temperatures, excessive vibration and corrosive or solvent exposures. SLING AND LOAD PROTECTION Protect slings with materials designed to increase the radius of corners, such as burlap bagging, sheet metal lagging ,corner irons, belting or wood blocking. See figure 2-4.

Correct

FIG. 2-6 — Wedging and Blocking a Round Load

Figure 2-7 shows the proper position for the hand when moving blocking so the hand will not be pinched if the load should shift.

Wrong

FIG. 2-4 — Increasing Radius of Sharp Corner with Sling Protection

Protect finished surfaces of loads from slings and hitching equipment by using soft sling protection materials. BLOCKING LOADS Always use good hardwood timber whenever blocking is required. Place blocking under loads so that they will be stable and level. This will also allow space under the load to get slings on and off easily. See figure 2-5.

Correct

Blocking should be approximately square in cross section and in good condition. Wedge and block loads that may roll or move. See figure 2-6. When blocking loads on frozen ground, make allowances for the possibility of thawing which can cause loads to sink or shift.

FIG. 2-7 — Position of Hand when Placing Blocking

HOOKS Hooks that are permanently fastened to the ends of wire rope or chain slings must not be point loaded or wedged on a load. The load rating for hooks is usually stamped somewhere on the hook. Check with your supervisor if no load rating is given for the hooks. Secure each leg of a wire rope sling at the hook to prevent reeving of the sling on the hook. Figure 2-8 shows the correct method of rigging wire rope slings to a hoist hook. Do not use single leg wire rope slings alone because of the possibility of load rotation unlaying the rope.

Wrong

FIG. 2-5 — Use of Blocking

Correct

Wrong

FIG. 2-8 — Rigging Wire Rope to the Hook

2--4

17X0501-01.0701

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers Use spring latch hooks for the hoist hook whenever possible. If spring latch hooks are not available, mouse the hook as shown in figure 2-9.

Load

Load

FIG. 2-9 — Mouse Hook if Load is Liable to Slip Off

EYEBOLTS (ANSI/ASME B18.15--1985) Type 1, plain pattern (straight shank) and Type 2, shoulder pattern eyebolts are furnished by Metso Minerals for use on specific parts or assemblies. The material and mechanical property requirements for these general purpose forged carbon steel eyebolts are covered by ASTM A489. Inspection Eyebolts shall be free from visible defects that might affect serviceability. Eyebolts should be routinely visually inspected for such defects as: a. Bent or distorted eye or shank. b. Nicks and gouges. c. Obvious wear. d. Worn and/or distorted threads. e. Cracks. If any of these defects are visible, the eyebolt should be removed from service and destroyed. Application 1. Capacities shown in the following tables are for carbon steel ASTM A489 eyebolts, at temperatures between 30o F (--1o C) and 275o F (135o C). Carbon steel is subject to failure from shock loading at temperatures below 30o F (--1o C) and loses strength at temperatures above 275o F (135o C). 2. Refer to tables for reduced loads on angular lift capacities. 3. Loads must always be applied to eyebolts in the plane of the eye, not at some angle to this plane. See figure 2-10.

17X0501-01.0701

Correct (Front View)

Wrong (End View)

FIG. 2-10 — Load applied in the plane of the eye, not at some angle to the plane.

4. Type 1 plain eyebolts must be engaged to within one-half turn from the eye end of the threads to obtain rated capacities. 5. Type 2 shoulder eyebolts should bear firmly against the mating part; otherwise the rated capacity must be reduced to those indicated for Type 1 eyebolts. A steel washer or spacer, not to exceed one thread pitch, may be required to put the plane of the eye in the direction of the load when the shoulder is seated. Cautions 1. Eyebolts should never be ground, notched, undercut or welded. Such alterations will weaken the eyebolt. Eyebolts showing signs of having been so altered should be immediately destroyed. 2. Eyebolts that are being removed from service should be rendered unusable. Crushing or cutting clear across the eye is recommended. 3. Never stand, work or crawl under the load. If the load could swing, or if pieces could scatter in the event of a drop, allow for this possibility by establishing a safe distance from the load. 4. Any visible rending or elongation of the eyebolt is a danger signal and indicates that it has been stressed beyond rated capacity. The bolt should be removed and destroyed, and the application investigated.

2--5

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers

DEFINITION OF RATED CAPACITY Rated capacity is the maximum recommended load that should be exerted on the item. All rated capacities are for in-line pull with respect to the centerline of the item. RATED CAPACITY OF TYPE 1, PLAIN PATTERN (STRAIGHT SHANK) EYEBOLTS (ANSI/ASME B18.15--1985) 0 deg.

30 deg.

60 deg. 90 deg.

SHANK Dia. Inches 1/4 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2

MM 6.4 12.7 19.1 25.4 31.8 38.1 50.8 63.5

0 Degree Per Bolt Pounds Kg 400 181 1,840 834 4,340 1,968 7,880 3,574 12,600 5,715 18,260 8,282 32,500 14,741 52,000 23,586

30 Degree

60 Degree

90 Degree

IN ORDER TO MAINTAIN A 5 TO 1 SAFETY FACTOR,, ALL LIFTS USING TYPE 1 PLAIN PATTERN EYEBOLTS MUST BE LIFTED IN A 00 -DEGREE DEGREE CONFIGURATION. CONFIGURATION READ AND UNDERSTAND THE EYEBOLT APPLICATION SECTION OF THIS MANUAL FOR ADDITIONAL PRECAUTIONS.

RATED CAPACITY OF TYPE 2, SHOULDER PATTERN EYEBOLTS (ANSI/ASME B18.15--1985) 0 deg.

30 deg. 60 deg. 90 deg.

SHANK Dia. Inches 1/4 1/2 3/4 1 1-1/4 1-1/2 2

2--6

MM 6.4 12.7 19.1 25.4 31.8 38.1 50.8

0 Degree 30 Degree 60 Degree 90 Degree Per Bolt Per Bolt IN ORDER TO MAINTAIN A 5 TO 1 Pounds Kg Pounds Kg SAFETY FACTOR, ALL LIFTS USING 400 181 75 34 TYPE 2 SHOULDER PATTERN EYEBOLTS MUST NOT BE GREATER 1,840 834 850 385 THAN 30 DEGREES FROM THE 4,340 1,968 2,230 1,011 VERTICAL AXIS OF THE SHANK OF THE 7,880 3,574 3,850 1,746 EYEBOLT. READ AND UNDERSTAND 12,600 5,715 6,200 2,812 THE EYEBOLT APPLICATION SECTION OF THIS MANUAL FOR ADDITIONAL 18,260 8,282 9,010 4,086 PRECAUTIONS PRECAUTIONS. 32,500 14,741 15,970 7,243

17X0501-01.0701

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers SHACKLES Shackles are made of drop forged steel and bent into shape. Shackles are strong, closed attachments which won’t come unhooked and are recommended for hitching. The size is determined by the diameter of the body — not the pin. See figure 2-11. Safe Rigging Practices 1. Side pull on the shackle body may cause bending and should be avoided. 2. Shackle pins should fit free without binding. 3. Safe loads on larger size shackles are stamped on the shackle body. The safe load of anchor or chain shackles, screw pin or slip pin, are the same. 4. Never substitute a bolt for the shackle pin. Common bolts are weaker than shackle pins. 5. When shackles are used at load angles other than 90o reduce safe load rating according to Angle Efficiency Table, in the section on “Factors Affecting The Use Of Slings”, page no. 2-3.

Diameter Size

Anchor Shackle Screw Pin

Chain Shackle Screw Pin

FIG. 2-11 — Shackles

SAFE LOADING TABLE FOR STANDARD SHACKLES

Diameter Inches 1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 4

17X0501-01.0701

MM 6.4 7.9 9.5 11.1 12.7 15.9 19.1 22.2 25.4 28.6 31.8 34.9 38.1 44.5 50.8 57.2 63.5 69.9 76.2 101.6

One Shackle Vertical Short Metric Tons Tons 1/3 .3 1/2 .5 3/4 .7 1 .9 1-1/2 1.4 2 1.8 3 2.7 4 3.6 5-1/2 5 6-1/2 5.9 8 7.2 10 9 12 10.8 16 14.5 21 19 27 24.5 34 31 40 36.2 80 45.3 100 90.7

2 Shackles 60o Short Metric Tons Tons 3/4 .7 1 .9 1-1/4 1.1 1-3/4 1.6 2-1/2 2.3 3-3/4 3.4 5-1/2 5 7 6.3 10 9 11-1/2 10.5 14 12.7 17 15.4 20 18.1 28 25.4 36 32.6 46 41.7 58 52.6 69 62.9 87 78.8 173 156.9

2 Shackles 45o Short Metric Tons Tons 1/2 5 3/4 .7 1 .9 1-1/2 1.4 2 1.8 3 2.7 4-1/2 4.1 6 5.4 8 7.2 9-1/2 8.5 12 10.8 14 12.7 17 15.4 23 20.9 30 27.1 38 34.5 48 44 57 51.9 71 64.4 142 128.7

2 Shackles 30o Short Metric Tons Tons 1/3 .3 1/2 .5 3/4 .7 1 .9 1-1/2 1.4 2 1.8 3 2.7 4 3.6 5-1/2 5 6-1/2 5.9 8 7.2 10 9 12 10.8 16 14.5 21 19 27 24.5 34 31 40 36.2 50 45.3 100 90.7

2--7

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers

WIRE ROPE SLINGS Wire rope slings are made from the best quality tempered steel wire. Wires are laid into strands. Six strands are laid around a fiber core (FC) or an independent wire rope core (IWRC) to form the complete rope. The fiber core acts as a cushion and oil reservoir, while the independent wire rope core gives greater resistance to crushing and heat. Use the Safe Load Table For Wire Rope slings for both types of cores. Wire rope slings are very strong for their weight, are lighter than chain, but are inclined to be stiff to handle. Wire rope slings are best used in straight hitches or around large radius corners. Wire rope is made up into slings by hand splicing or by swaged fittings. Size of the wire rope is obtained by measuring its overall diameter. See figure 2-12. Diameter Size

5. Figure 2-14 shows proper methods of rigging wire rope slings to the hook. a. Secure each leg of a wire rope sling at the hook to prevent reeving of the sling on the hook. b. Do not use single leg wire rope slings alone because the load might spin, unlaying the wire rope and allowing the splice to pull out. 6. Do not make a complete turn of wire rope around a crane hook. The sharp radius will damage the sling. 7. Check wire rope slings for: a. Broken or cut wires or strands. b. Rust and corrosion. c. Kinks and doglegs. d. Broken seizing wire. e. Damage to swaged fittings. f. Other signs of damage or abuse.

Core

Strand Wire

FIG. 2-12 — Wire Rope

Safe Rigging Practices 1. Protect wire rope slings against weather, solvents, high temperatures, and chemicals. 2. Do not exceed the following temperatures when using wire rope slings: Fibre core -- 212o F (100o C). Higher temperatures damage the core. Independent wire rope core -- 400o F (210o C). Higher temperatures damage the steel. 3. Knots permanently damage wire rope slings and must not be used. 4. Protect rope slings from sharp corners by increasing the corner radius with corner irons or blocks. See figure 2-13. Bagging and lagging in sufficient amounts may also be used.

Correct

Wrong

FIG. 2-14 — Rigging Wire Rope to the Hook

8. Protect finished surfaces from wire rope slings with bagging and lagging. 9. Avoid bending the eye sections of wire rope slings around corners because the splice or swaging may be weakened.

FIG. 2-15 — Use Shackles for Wire Rope Choker Hitches

10. Use a shackle when making choker hitches with wire rope slings. See figure 2-15. 11. Use the larger end of pear shaped master links on the crane hook so as to prevent the master links from binding. The smaller end is used for the wire rope sling.

FIG. 2-13 — Corner Iron Protection for Wire Rope Sling

2--8

17X0501-01.0701

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers Wire Rope Clip Installation There is only one correct method of attaching wire rope clips. Attach clips to the rope ends as shown in figure 2-16. The base of each clip must bear against the live end of the rope and the U--bolt of the clip must bear against the dead end. The proper number of clips and the spacing between clips to use with various sizes of wire rope are listed in the table below. Tighten clip nuts to the recommended torque. Wire rope Clip U-Bolt thimble

Clip base or saddle

Spacing between clips

After the rope has been placed in service and is under tension, tighten the clip nuts again to compensate for any decrease in rope diameter caused by the load. Check the clip nuts and tighten periodically to compensate for rope stretch and diameter shrinkage.

Dead End

Live End

FIG. 2-16 — Proper Wire Rope Clip Installation

CLIPS REQUIRED FOR FASTENING WIRE ROPE ENDS U-Bolt Diameter Clip Spacing Minimum Number Rope Diameter Inches MM Inches MM Inches MM of Clips Required 3/16 4.76 11/32 8.73 3 76 2 1/4 6.35 7/16 11.11 3-1/4 83 2 5/16 7.94 1/2 12.70 3-1/4 83 2 3/8 9.53 9/16 14.29 4 102 2 7/16 11.11 5/8 15.88 4-1/2 114 2 1/2 12.70 11/16 17.46 5 127 3 5/8 15.88 3/4 19.05 5-3/4 146 3 3/4 19.05 7/8 22.23 6-3/4 172 4 7/8 22.23 1 25.40 8 203 4 1 25.40 1-1/8 28.58 8-3/4 222 4 1-1/8 28.58 1-1/4 31.75 9-3/4 248 5 1-1/4 31.75 1-7/16 36.51 10-3/4 273 5 1-3/8 34.93 1-1/2 38.10 11-1/2 292 6 1-1/2 38.10 1-23/32 43.66 12-1/2 318 6 1-5/8 41.28 1-3/4 44.45 13-1/4 337 6 1-3/4 44.45 1-15/16 49.21 14-1/2 368 7 2 50.80 2-1/8 53.98 16-1/2 419 8 2-1/4 57.15 2-5/8 66.68 16-1/2 419 8 2-1/2 63.50 2-7/8 69.85 17-3/4 451 8

17X0501-01.0701

2--9

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers SAFE LOADING TABLE FOR FC OR IWRC WIRE ROPE SLINGS

Wire Rope Diameter Inches 1/4 3/8 1/2 5/8 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2

MM 6.4 9.5 12.7 15.9 19.1 25.4 31.8 38.1 50.8 63.5 76.2 88.9

Wire Rope Diameter Inches

3/4 3/8 1/2 5/8 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 2--10

MM

6.4 9.5 12.7 15.9 19.1 25.4 31.8 38.1 50.8 63.5 76.2 88.9

Straight 1 Leg Short Metric Tons Tons 1/2 .5 1 .9 2 1.8 3 2.7 4 3.6 7 6.3 10 9 13 11.8 21 1.9 28 25.4 38 32.6 40 36.2

60o Basket 2 Leg Short Tons

Metric Tons

2/3 1-1/2 2-1/2 4 5 9 13 17 27 38 49 59

.6 1.4 2.3 3.6 4.5 8.2 11.8 15.4 24.5 34.5 44.5 53.5

Choker 1 Leg Short Metric Tons Tons 1/3 .3 3/4 .7 1-1/2 1.4 2 1.8 3 2.7 5 4.5 7 6.3 9 8.2 15 13.6 22 20 28 25.4 34 31

45o Basket 2 Leg Short Tons

1/2 1 2 3 4 7 11 14 22 31 40 49

60o Choker 2 Leg Short Metric Tons Tons 2/3 .6 1-1/4 1.1 2-1/2 2.3 4 3.6 5 4.5 8 7.2 12 10.8 16 14.5 27 24.5 38 34.5 49 44.5 59 53.5

30o Basket 2 Leg

Metric Tons

Short Tons

Metric Tons

.5 .9 1.8 2.7 3.6 6.3 1.0 12.7 20 28 36.2 44.5

1/3 3/4 1-1/2 2 3 5 7 10 15 22 29 34

.3 .7 1.4 1.8 2.7 4.5 6.3 9 13.6 20 26.3 31

45o Choker 2 Leg Short Metric Tons Tons 1/2 .5 1 .9 2 1.8 3 2.7 4 3.6 7 6.3 9 8.2 13 11.8 22 20 31 28 40 36.2 48 43.5

60o Basket 4 Leg Short Tons

1 3 5 7 11 18 26 35 53 75 97 118

Metric Tons

.9 2.7 4.5 6.3 1.0 16.3 23.6 31.7 48 68 88 107

30o Choker 2 Leg Short Metric Tons Tons 1/3 .3 3/4 .7 1-1/2 1.4 2 1.8 3 2.7 5 4.5 7 6.3 9 8.2 15 13.6 22 20 28 25.4 34 31

45o Basket 4 Leg Short Tons

1 2 4 6 9 15 21 28 44 61 80 97

30o Basket 4 Leg

Metric Tons

Short Tons

Metric Tons

.9 1.8 3.6 5.4 8.2 13.6 1.9 25.4 40 .3 72.5 88

3/4 1-1/2 3 4 6 10 15 20 31 43 56 68

.7 1.4 2.7 3.6 5.4 9 13.6 18.1 28 39 51 62

17X0501-01.0701

SUPERIOR MK- II Gyratory Crushers BRAIDED WIRE ROPE SLINGS Braided slings are made by braiding wire ropes together. An 8-part braided sling has a cross section of 8 wire ropes. The size of a braided sling is determined by the diameter of one wire rope or part, together with the number of parts in the cross section of the sling. See figure 2-17. Example: 1/4” x 8 part braided sling. Braided slings have greater flexibility than wire rope slings, which makes for easier handling in the larger sizes. They also have a better grip on the job than wire rope slings.

Section 2 — Safe Handling of Heavy Equipment and Machinery 5. Check braided slings for: a. Broken or cut wires, strands or parts. b. Rust and corrosion. c. Kinks and doglegs. d. Excessive slack in any of the parts. e. Broken seizing wire. f. Other signs of damage or abuse. 6. Protect braided slings from sharp corners by increasing the radius of the corner with bagging, lagging, and corner irons. See figure 2-18.

Size: Diameter of one part and number of parts.

FIG. 2-17 — Braided Wire Rope Sling

FIG. 2-18 — Lagging Protection for Braided Sling

Safe Rigging Practices 1. Protect braided slings from weather, solvents, high temperatures, and chemicals. 2. Do not use braided slings at temperatures above 212o F (100o C) if made with a fiber core or above 400o F (210o C) if made with an independent wire rope core. 3. Knots must not be used -- they will permanently damage braided slings. 4. Rig braided slings to a hook similar to methods used for wire rope.

7. Protect finished surfaces from braided slings by bagging and lagging. 8. Avoid bending the eye sections of braided slings. It may cause the seizing wire to break and damage splices. 9. When making choker hitches with braided slings, use shackles similar to wire rope. See figure 2-15.

17X0501-01.0701

2--11

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers SAFE LOADING TABLE FOR 8--PART BRAIDED ROPE SLINGS

Diameter of One Part Inches 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/4

MM 6.4 7.9 9.5 11.1 12.7 14.3 15.9 19.1 22.2 25.4 31.8

Diameter of One Part Inches

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/4

2--12

MM

6.4 7.9 9.5 11.1 12.7 14.3 15.9 19.1 22.2 25.4 31.8

Straight 1 Leg Short Metric Tons Tons 3 2.7 5 4.5 7 6.3 9 8.2 12 10.8 15 13.6 19 17.2 27 24.5 36 32.6 47 42.6 74 67.1

60o Basket 2 Leg Short Tons

5-1/2 8 12 16 21 26 32 46 63 81 128

Metric Tons

5 7.2 10.8 14.5 1.9 23.6 29 41.7 57.1 73.5 116

Choker 1 Leg Short Metric Tons Tons 2-1/2 2.3 3-1/2 3.2 5 4.5 7 6.3 9 8.2 11 10 14 12.7 20 18.1 27 24.5 35 31.7 55 50

45o Basket 2 Leg Short Tons

4-1/2 7 10 12 17 21 26 38 52 66 104

Metric Tons

4 6.3 9 11.8 15.4 1.9 23.6 34.5 47.1 60 94.3

60o Choker 2 Leg Short Metric Tons Tons 4 3.6 6 5.4 9 8.2 12 10.8 16 14.5 20 18.1 24 21.7 35 31.7 47 42.6 61 55.3 95 86.2

30o Basket 2 Leg Short Tons

3 5 7 9 12 15 19 27 36 47 74

Metric Tons

2.7 4.5 6.3 8.2 10.8 13.6 17.2 24.5 32.6 42.6 67.1

45o Choker 2 Leg Short Metric Tons Tons 3-1/4 2.9 5 4.5 7 6.3 10 9 13 11.8 16 14.5 20 18.1 28 25.4 39 35.4 50 45.3 77 69.8

60o Basket 4 Leg Short Tons

11 16 24 32 42 52 64 92 126 162 256

Metric Tons

10 14.5 21.7 29 38 47.1 58 83.4 114 147 232

45o Basket 4 Leg Short Tons

9 14 20 26 34 42 52 76 104 132 208

30o Choker 2 Leg Short Metric Tons Tons 2-1/2 2.3 3-1/2 3.2 5 4.5 7 6.3 9 8.2 11 10 14 12.7 20 18.1 27 24.5 35 31.7 55 50

30o Basket 4 Leg

Metric Tons

Short Tons

Metric Tons

8.2 12.7 18.1 23.6 31 38 47.1 69 94.3 120 189

6 10 14 18 24 30 38 54 72 94 148

5.4 9 12.7 16.3 21.7 27.2 34.5 49 65.3 85.2 134

17X0501-01.0701

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers ALLOY STEEL CHAIN SLINGS Alloy chain slings are made by bending, electric welding and heat--treating alloy steel rods into chain links. Alloy chain slings are more rugged and flexible, but less shock resistant than wire rope or braided slings. The size is measured by the diameter of the link stock. See figure 2-19.

4. Alloy chain slings may be shortened by hooking back into the chain, into the master link, or with grab hooks. See figure 2-20. Never shorten a chain by twisting, knotting or by use of bolts. 5. Protect alloy chain slings from sharp corners which can bend the links. Use lagging, corner irons, etc. for this purpose. See figure 2-21.

Diameter Size

FIG. 2-19 — Alloy Steel Chain Sling

Safe Rigging Practices 1. Protect alloy chain slings against chemicals, rust and corrosion. Extremely low temperatures, below 0o F (--18o C), will cause brittle fractures and it is advisable to reduce the safe load rating under those conditions by 50%. 2. Reduce safe loads of alloy chain slings by the following percentages when the chain is heated. Temperatures Up To

Reduce % Of Load

500o F (260o C) . . . . . . . . . . . . . . . . .

None

600o

F

(315o

C) . . . . . . . . . . . . . . . . .

10%

F

(370o

C) . . . . . . . . . . . . . . . . .

20%

800o F (425o C) . . . . . . . . . . . . . . . . .

30%

700o

Above 800o F (425o C) -- red heat visible in the dark -- there is a permanent reduction in strength when the chain cools to room temperature. After such exposure, take alloy chain slings out of service and notify your supervisor. 3. Knots must not be used. They weaken alloy chain slings and may cause chain links to bend or otherwise fail.

Correct

FIG. 2-21 — Corner Iron Protection for Alloy Chain Sling

6. When making choker hitches with alloy chain slings always face the hook opening out and away from the pull of the sling so the hooks will not slip out when slack is taken out of the sling. See figure 2-22. 7. Check alloy chain slings for: a. Nicks, cracks, gouges and wear. b. Bent links, lifted weld fins, bent or opened hooks, and stretch. c. Rust and corrosion. d. Uneven lengths when sling legs are hanging free. 8. If all the legs of an alloy steel chain sling are hooked back into the master link, the safe load capacity of the whole sling may be increased 50%. 9. Finished surfaces must be protected from alloy chain slings by bagging, lagging, etc. 10. Sling hooks should not be point loaded. 11. Use the larger end of pear shaped master links on the crane hook so as to prevent the master links from binding. The smaller end is used for the alloy sling chain.

Correct

FIG. 2-20 — Shortening Alloy Chain Sling

17X0501-01.0701

Wrong

Wrong

FIG. 2-22 — Face Hooks Out From Pull of Sling

2--13

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers SAFE LOADING TABLE FOR ALLOY STEEL CHAIN SLINGS

Alloy Chain Diameter Inches MM 1/4 3/8 1/2 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2 1-3/4

6.4 9.5 12.7 15.9 19.1 22.2 25.4 28.6 31.8 38.1 44.5

Alloy Chain Diameter Inches

1/4 3/8 1/2 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2 1-3/4

2--14

MM

6.4 9.5 12.7 15.9 19.1 22.2 25.4 28.6 31.8 38.1 44.5

Straight 1 Leg Short Metric Tons Tons 1 .9 2 1.8 3-1/2 3.2 5-1/2 5 8 7.2 10 9 14 12.7 16 14.5 21 1.9 27 24.5 36 32.6

60o Basket 2 Leg Short Tons

1-1/2 3 5 7-1/2 11 14 19 22 28 37 50

Metric Tons

1.4 2.7 4.5 6.8 1.0 12.7 17.2 20 25.4 33.5 45.3

Choker 1 Leg Short Metric Tons Tons 3/4 .7 1-1/2 1.4 3 2.7 4 3.6 6 5.4 8 7.2 11 1.0 13 11.8 16 14.5 21 19 30 27.2

45o Basket 2 Leg Short Tons

1-1/4 2-1/2 4 6 9 12 15 18 23 30 41

Metric Tons

1.1 2.3 3.6 5.4 8.2 10.8 13.6 16.3 20.8 27.2 37.2

60o Choker 2 Leg Short Metric Tons Tons 1-1/2 1.4 3 2.7 5 4.5 7-1/2 6.8 11 1.0 14 12.7 19 17.2 22 20 28 25.4 7 33.5 50 45.3

30o Basket 2 Leg Short Tons

3/4 1-1/2 3 4 6 8 11 13 16 21 30

45o Choker 2 Leg Short Metric Tons Tons 1-1/4 1.1 2-1/2 2.3 4 3.6 6 5.4 9 8.2 12 10.8 15 13.6 18 16.3 23 20.8 30 27.2 41 37.2

60o Basket 4 Leg

Metric Tons

Short Tons

Metric Tons

.7 1.4 2.7 3.6 5.4 7.2 10 11.8 14.5 19 27.2

3 6 10 15 22 28 38 44 56 74 100

2.7 5.4 9 13.6 20 25.4 34.5 40 50.8 67.1 90.7

30o Choker 2 Leg Short Metric Tons Tons 3/4 .7 1-1/2 1.4 3 2.7 4 3.6 6 5.4 8 7.2 11 1.0 13 11.8 16 14.5 21 19 30 27.2

45o Basket 4 Leg Short Tons

2-1/2 5 8 12 18 24 30 36 46 60 82

30o Basket 4 Leg

Metric Tons

2.3 4.5 7.2 10.8 16.3 21.7 27.2 32.6 41.7 54 74.4

Short Tons

1-1/2 3 6 8 12 16 22 26 32 42 60

Metric Tons

1.4 2.7 5.4 7.2 10.8 14.5 20 23.6 29 38 54

17X0501-01.0701

SUPERIOR MK- II Gyratory Crushers

HOIST. With forearm vertical, forefinger pointing up, move hand in small horizontal circle.

USE MAIN HOIST. Tap fist on head; then use regular signals.

17X0501--01.0701

Section 2 — Safe Handling of Heavy Equipment and Machinery

LOWER. With arm extended downward, forefinger pointing down, move hand in small horizontal circles.

USE WHIPLINE (Auxiliary Hoist). Tap elbow with one hand; then use regular signals.

2--15

Section 2 — Safe Handling of Heavy Equipment and Machinery

2--16

SUPERIOR MK- II Gyratory Crushers

RAISE BOOM. Arm extended, fingers closed, thumb pointing upward.

LOWER BOOM. Arm extended, fingers closed, thumb pointing downward.

MOVE SLOWLY. Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist slowly shown as example).

RAISE THE BOOM AND LOWER THE LOAD. With arm extended, thumb pointing up, flex fingers in and out as long as load movement is desired.

17X0501--01.0701

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers

LOWER THE BOOM AND RAISE THE LOAD. With thumb extended, thumb pointing down, flex fingers in and out as long as load movement is desired.

STOP. Arm extended, palm down, hold position rigidly.

17X0501--01.0701

SWING. Arm extended point with finger in direction of swing of boom.

EMERGENCY STOP. Arm extended, palm down, move hand rapidly right and left.

2--17

Section 2 — Safe Handling of Heavy Equipment and Machinery

TRAVEL. Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel.

TRAVEL (Both Tracks). Use both fists in front of body, making a circular motion about each other, indicating direction of travel; forward or backward. (For crawler cranes only.)

2--18

SUPERIOR MK- II Gyratory Crushers

DOG EVERYTHING. Clasp hands in front of body.

TRAVEL (One Track). Lock the track on side indicated by raised fist. Travel opposite track in direction indicated by circular motion of other fist, rotated vertically in front of body. (For crawler cranes only.)

17X0501--01.0701

SUPERIOR MK- II Gyratory Crushers

Section 2 — Safe Handling of Heavy Equipment and Machinery

EXTENDED BOOM. (Telescoping Booms). Both fists in front of body with thumbs pointing outward.

RETRACT BOOM. (Telescoping Booms). Both fists in front of body with thumbs pointing toward each other.

EXTEND BOOM (Telescoping Boom). One hand signal. One fist in front of chest with thumb tapping chest.

RETRACT BOOM (Telescoping Boom). One Hand Signal. One fist in front of chest, thumb pointing outward and heel of fist tapping chest.

REPRINTED BY PERMISSION OF THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS, B30 COMMITTEE.

17X0501--01.0701

2--19

Section 2 — Safe Handling of Heavy Equipment and Machinery

SUPERIOR MK- II Gyratory Crushers

This page was purposely left blank.

2--20

17X0501--01.0701

SUPERIOR MK- II

Section 3 — Index

Gyratory Crushers

3. General information

Page 3-1 3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-3 3-3 3-3 3-3 3-4 3-4 3-5 3-6

Description Index Introduction Shipping Check for Loss or Damage in Shipment Types of Damage to Watch for If Damage Occurs from Shipment or Handling Use of Drawings and Parts Manual Service Parts Recommended Spare Parts SUPERIOR Crusher Size Designation Recommended Feed Size Recommendations for Handling Parts Protecting Crusher Parts in Storage Removal from Storage Storing Completely Assembled Crushers General Specifications -- 60-110

17X0501-01.0701

3-1

Section 3 — General Information INTRODUCTION We welcome you as a user of a Metso Minerals product. With reasonable care and attention, it will give long and trouble free service. A combination of high quality materials and engineering skills make this a simple machine to install and operate. Parts arrangements facilitate care and inspection, so that any good mechanic can operate and maintain the crusher, once he is familiar with it. This instruction book will acquaint you with the easiest and most practical way to install, operate and maintain your crusher. Read it carefully before installing or operating the crusher and keep it on hand for future reference. For assistance in any processing problem, please contact your area Metso Minerals distributor or company representative, or call or write direct to Metso Minerals Industries, Inc. SHIPPING SUPERIOR gyratory crushers are shipped partially in sub-assemblies, plus separately packaged parts which cannot be secured to a sub-assembly during shipment. The degree of assembly depends on shipping restrictions and equipment available for handling at the job site. The usual breakdown of assemblies includes the spider, top shell, concaves, mainshaft, bottom shell, eccentric, bevel gear and eccentric sleeve, pinionshaft and external lubrication system. CHECK FOR DAMAGE OR LOSS IN SHIPMENT The crusher was thoroughly inspected and carefully prepared for shipment before it was turned over to the carrier. However, it is possible for machinery to be damaged or lost in shipment. Check each item carefully with the shipping manifest, freight bill or bill of lading. Call any damage or shortage to the carrier’s immediate attention. Be sure that he makes a full statement of the problem on the appropriate shipping document. This will help avoid controversy where a claim is made and facilitate prompt and satisfactory adjustment. TYPES OF DAMAGE TO WATCH FOR 1. Bearing surfaces damaged by chains or slings on upper or lower mainshaft journals. 2. Bruises in critical fits or bearing surface damage from dropping the part or dropping an object on the part. 3. Railroad damage from bumping cars or trucking damage from improper or inadequate tie-downs.

3-2

SUPERIOR MK- II Gyratory Crushers 4. Removal of or damage to protective covering, allowing rust to attack the bare metal in critical bearing or fit areas. IF DAMAGE OCCURS FROM SHIPMENT OR HANDLING 1. For damage in shipment, the settlement is between the shipper and the distributor or customer. 2. If handling damage occurs, notify the Metso Minerals distributor or sales office to determine if a repair or a new part is required. USE OF DRAWINGS AND PARTS MANUAL Number references, associated with part names in copy and illustrations throughout this instruction book, are termed “catalog numbers.” A parts list, with catalog numbers and reference drawings, is included in Section 4 of this book. In addition, a parts manual is supplied with each crusher. The parts manual is forwarded separately, after the crusher has been shipped. It is broken down by assemblies and subassemblies and lists the quantities and specific “part numbers” of each item used in the crusher assembly. Catalog and part numbers, reference drawings, parts lists and the parts manual are provided for your use when ordering spare or replacement parts. SERVICE PARTS Wearing and replacement parts for SUPERIOR gyratory crushers are carried in stock by Metso Minerals Industries, Inc. In addition, local stocking distributors associated with Metso Minerals carry major parts in stock. Order replacement parts through your local Metso Minerals distributor, or direct from Metso Minerals Industries, Inc. When ordering service parts, include the following information: 1. crusher size; 2. crusher serial number — look for the serial number plate affixed on the crusher bottom shell near the pinionshaft — the serial number is also listed on the parts manual cover sheet; 3. parts description by name, along with catalog and part numbers; 4. quantity of each part required; and 5. complete shipping instructions, including whether shipment should be via mail, express, surface or air freight.

17X0501-01.0701

SUPERIOR MK- II

Section 3 — General Information

Gyratory Crushers RECOMMENDED SPARE PARTS Wearing parts for crushers are carried in stock at Metso Minerals Industries, Inc. However, we suggest that you carry the following parts in your own stock to eliminate down-time in an emergency. Spider Bushing . . . . . . . . . . . . . . . . . . . . . . . . Spider Bearing Oil Seal . . . . . . . . . . . . . . . . . Mainshaft Sleeve . . . . . . . . . . . . . . . . . . . . . . Head Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dust Seal Ring . . . . . . . . . . . . . . . . . . . . . . . . Bottom Shell Bushing . . . . . . . . . . . . . . . . . . Eccentric Bushing . . . . . . . . . . . . . . . . . . . . . Concaves (Bottom Tier) . . . . . . . . . . . . . . . . (Second Tier) . . . . . . . . . . . . . . . . . . . . . . . . . (Third Tier) . . . . . . . . . . . . . . . . . . . . . . . . . . . (Fourth Tier) . . . . . . . . . . . . . . . . . . . . . . . . . . (Fifth Tier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Sixth Tier) . . . . . . . . . . . . . . . . . . . . . . . . . . . Mainshaft Step Bearing . . . . . . . . . . . . . . . . . Step Washer . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Wearing Plate . . . . . . . . . . . . . . . . . . . MPS Cylinder Bushing . . . . . . . . . . . . . . . . . MPS Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . Pinionshaft Oil Seal — Pinion End . . . . . . . Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasket Stock for all Gaskets Filter Cartridges

5675-0 5705-0 4025-0 4205-0 4175-1, 3 4305-0 1200-0 1810-0 6305-0 & -1 6325-0 & -1 6345-0 & -1 6365-0 & -1 6385-0 & -1 6395-0 & -1 4075-0 2280-0 2260-0 2050-1, 2 2305-0 3170-1 3170-2

SUPERIOR CRUSHER SIZE DESIGNATION The size and model number of a SUPERIOR crusher is designated in terms of the feed opening at its widest point and the mantle diameter at its largest point, in inches. For example, on a model 60-110 SUPERIOR crusher, the distance from the top of the mantle to the top of the concave assembly is nominally 60 inches (152 cm). The crushing head diameter is nominally 110 inches (279 cm) at the bottom of the mantle. See Fig. 3-1. If the approximate feed opening were 60 inches (152 cm), and the crushing head measured 89 inches (226 cm) at the largest diameter, the crusher would be designated as a 60-89. RECOMMENDED FEED SIZE Vertical adjustment of the crushing head allows compensation for wear at the discharge point. We recommend that 80% of the feed to a SUPERIOR gyratory crusher be less than two-thirds of the feed opening in size. This applies to both secondary and primary SUPERIOR gyratory crushers. This size distribution helps to prevent blockage of the spider openings and permits a well-filled crushing chamber that evenly distributes bearing pressures between the spider and eccentric bearing surfaces. Scalping of the feed ahead of a primary crusher can be advantageous when there is an excessive quantity of fines in the feed, or if the material is extremely abrasive and could wear the manganese excessively.

NOTICE

RECOMMENDATIONS FOR HANDLING PARTS When handling crusher parts, observe these precautions:

Spare parts are not included as standard equipment on regular machine purchases, but ordered separately.

General • When lifting or removing parts, use equipment of sufficient size to make the parts handling easy. • Assembly weights are tabulated in “General Specifications,” in the Appendix to this section, for use in selecting hoists, jacks, etc. • Handle bronze parts carefully. Driving or hammering on soft bronze may cause it to flow and destroy the fit with mating parts. • Clean and lubricate parts carefully, and check for any damage or imperfections that should be removed before assembling.

60” 152 cm

110” 279 cm

Machined and Bearing Surfaces • Take special care to prevent damaging parts with machined or bearing surfaces. • Protect machined and bearing surfaces with oil or rust preventive if the part is to be exposed to atmosphere for any extended time period. • Place machined surfaces on timbers or padded supports NOT on the ground. • Never assemble a bearing surface without first eliminating any imperfections and applying lubricant.

FIG. 3-1 — Method of Designating Crusher Size (60-110) 17X0501-01.0701

3-3

Section 3 — General Information PROTECTING CRUSHER PARTS IN STORAGE Special protective measures are required to prevent deterioration of crusher parts stored for extended time periods. Here are general recommendations on parts storage. 1. Large castings (bottom shell, top shell, spider, dust seal retaining rings, dust collar) — items of this type may be stored out of doors if properly protected. Do not place parts directly on the ground; set them on timbers or some type of support. Coat all machined surfaces with a rust preventive, such as Rust Veto 344 (E.F. Houghton & Co.). For added protection, fill the spider and bottom shell hubs, and the bottom shell pinionshaft arm, with crumpled VPI treated wrapping paper such as Nox Rust Vapor Wrapper VW35D (Daubert Coated Products, Inc.) and cover openings with plywood. Plug all pipe tapped holes to prevent entry of dirt and moisture. Then cover the entire piece with a tarpaulin, properly positioned and securely fastened to protect the parts from weather and ultraviolet exposure. 2. Small castings (spider bushing, step bearings, eccentric assembly) — items of this type are best stored indoors, with machined surfaces coated with rust preventive. If possible, store parts in boxes filled with crumpled VPI treated paper. It is extremely important to protect polished bearing surfaces against corrosion and physical damage. 3. Mainshaft assembly — Coat machined surfaces with a rust preventive such as Rust Veto 344. If the shaft is to be stored in shipping saddles, use a double saddle arrangement and place felt, saturated with rust preventive, between the shaft and the saddles. If stored out of doors, cover the entire assembly with a tarpaulin. 4. Pinionshaft and MPS cylinder assembly — Store these assemblies indoors at all times. Fill the pinionshaft assembly to the proper level with a rust preventive oil such as Nox Rust VPI 10 (Daubert Chemical Co.). Coat all external machined surfaces with rust preventive. To assure that bearings are always coated with oil, rotate the shaft one complete revolution at least once a month. Avoid damage to the small breather which should remain generally on the “up” side. Remove the oil seal from the cylinder assembly before storing. After plugging all open holes in the cylinder assembly, pour about two gallons of rust preventive oil such as Nox Rust VPI 10 into the cylinder. Cover the open end of the cylinder with plywood and coat all exposed machined surfaces with a rust preventive. Once a year, pour a quart of oil around the edges of the piston so it flows down all the sides. 5. MPS control and lubrication system piping — Pour several gallons of rust preventive oil such as Nox Rust VPI 10 into the MPS control and oil tank. Fill the oil piping with the same rust preventive oil, breaking lines open at convenient locations such as the pressure gauges. Make sure a small quantity of oil enters the oil 3-4

SUPERIOR MK- II Gyratory Crushers pumps in order to prevent internal pump corrosion. Plug all open oil pipes and securely fasten cover to prevent entrance of air and moisture into the system. If the lubrication pump is equipped with a gear reducer, fill it with Nox Rust VPI 10 or other rust preventive oil. If the lubrication system is stored outside, cover it with a tarpaulin. Tightly cover the ends of the MPS oil piping after pouring several gallons of rust preventive oil into it. Do not store anything with seals near a high voltage source like a welder or transmitter. 6. Seals and gaskets — Seals and gaskets may harden and lose their sealing efficiency if they were not fully protected against heat and oxidation. We recommend replacement of such parts after eight months. If seals and gaskets are to be stored, coat them with a preservative oil and keep them in a cool, dry area. 7. Round and cylindrical shapes — Avoid distorting critical dimensions of round and cylindrical component shapes. Always use spreaders when lifting bronze cylinders (unless on a skid). Store dust seals and collars flat — across the larger dimension and not on edge. Store cylindrical shapes such as bottom shell bushings or eccentric sleeves on end. For protection, store components in the shipping container indoors. Be extremely careful to prevent physical damage to parts during handling and storage. Because climatic conditions vary, it is best to contact a local supplier of protective coatings for recommendations of products best suited for the conditions which will be encountered. Periodically inspect stored parts to insure that protective measures are intact and that parts are undamaged. Metso Minerals assumes no responsibility for the success of protective measures during storage. REMOVAL FROM STORAGE Before reassembling the crusher, remove the rust preventive from all surfaces using a suitable solvent. Completely drain preservative oil from all components which had been previously filled. Complete flushing should not be required. Nox Rust VPI 10 is generally compatible with the type of lubricating oil used in crushers. Thoroughly inspect all components for corrosion or damage which could be detrimental to machine operation. Correct any such conditions discovered.

17X0501-01.0701

SUPERIOR MK- II Gyratory Crushers STORING COMPLETELY ASSEMBLED CRUSHERS If the crusher assembly is complete but anticipated start-up is delayed in excess of thirty (30) days, use the following procedure: 1. Fill the bottom shell cavity with the recommended lubrication oil until it slightly overflows the dust collar, using the lubrication pump. Valve or blank off the drain line to retain the oil in the bottom shell. Close the valve from the tank to the pump to prevent oil flow back to the tank through pump clearances, etc.

17X0501-01.0701

Section 3 — General Information 2. Fill the spider bearing cavity with oil to prevent condensation in the bearing area. 3. Turn the pinionshaft by hand at least four (4) complete revolutions every two (2) weeks. The pinionshaft assembly is shipped with a rust inhibitor. 4. Coat the mainshaft sleeve on the upper journal with grease in the exposed area between the spider hub and mainshaft head nut. 5. If the lubrication and MPS pumps are exposed to the weather, cover them with a waterproof cover or shield.

3-5

General Specifications

SUPERIOR MK- II Gyratory Crushers

60-110 SUPERIOR GYRATORY CRUSHER — GENERAL SPECIFICATIONS Approximate Weight with Standard Configuration -- Pounds (Kilograms) Crusher Size

60--110

Bottom Shell Assembly

MPS Assembly

Eccentric Assembly

Pinionshaft Assembly

Lube Assembly w/o Oil

Balance Cylinder & Piping

1,305,000 22,200 229,200 408,000 229,000 314,000 (591,944) (10,070) (103,964) (185,070) (103,874) (142,430)

46,900 (21,275)

36,900 (16,740)

7,300 (3,311)

8,100 (3,675)

3,000 (1,360)

Total Crusher

Spider Cap

Top Shell Assembly

Spider Assembly

Mainshaft Assembly

NOTE: Top Shell Assembly and Mainshaft Assembly Weights using Epoxy Backing. Pinionshaft Crusher Size

60--110

Standard Eccentric Throws Inches (mm)

1.0, 1.25, 1.5, 1.75, 2.0 (25, 32, 38, 44, 51)

Maximum Power at Maximum Eccentricity HP (kW)

Gyrations Per Minute

Wk2 at Pinionshaft Lb.-Ft.2 (Kg-m2)

Speed (RPM)

Diameter at Drive End Inches (mm)

1400 (1044)

127 152

9,600 (404.6)

500 600

7.5 (190.5)

Keyway WxD Inches (mm)

1.750 x 0.73 (44.5 x 18.5)

Shaft Ext. For Drive Inches (mm)

Pitch Line Backlash Inches (mm)

Pinion Gear Pitch Dia. Inches (mm)

Approx. Oil Required Quarts (Liters)

8.8 (223.5)

0.083 -0.100 (2.11 -2.54)

21.591 (548.4)

5.0 (4.7)

Mainshaft Step Bearings Inches (mm)

MPS Gear Pump Crusher Size

Approx. Feed Opening Inches (Meters)

Largest Open Side Setting Inches (mm)

For Wear Mainshaft Travel Inches (mm)

Mainshaft Travel Rate* In./Min. (mm/Min.) 50HZ 60HZ

60--110

60x 150 (1.52 x 3.81)

12.0 (304.8)

1.54 11.4 (39) (289.6) 1.86 (47)

Setting Change for 1” (25mm) Mainshaft Travel Inches (mm)

Min. Oil Under Piston (Inches (mm)

0.468 (11.89)

1.0 (25)

Capacity GPM (LPM)

Motor RPM

Motor HP (KW)

50HZ

50HZ

60HZ

60HZ

10.0 (38.0)

Pinionshaft Housing

Pinion & Gear

1500

7.4 (5.5)

12.0 (45.4)

MPS Relief Valve Setting PSIG (kPa)

Thickness at O.D. New

Allowable M.S. Step Wear

750 (5171)

2.13 (54.1)

0.88 (22.35)

Step Bearings Thickness New

Step Bearings Total Wear

9.0

2.50 (63.5)

(228.6)

(1)

1800

NOTE: (1)Maximum allowable wear on mainshaft step, washer, and piston wearing plate. Lubrication Gear Pump

Tank Capacity Gallons (Liters)

Crusher Size

60--110

Lube Oil

MPS Oil

Immersion Heater (KW)

Capacity GPM (LPM)

Motor HP (KW)

500

200 (757)

12

50 & 40

10.0 & 7.4 (7.5 & 5.5)

(1,893)

(189.3 & 151.4)

Water Cooler

Motor RPM 50HZ 60HZ

Oil Filter Retention Size (Microns)

1500

20

Water Required GPM (LPM)

Water Pipe Fitting

Air Radiator

Air Flow SCFM SCMM

60--110

50HZ 60HZ

12.8 (48)

1800

Spider Bushing

Crusher Size

Gallons (Liters)

Fan RPM

Dependent on Site Conditions

Backing Material

Clearance(1) Inches (mm)

Balance Cylinder

Fan Motor HP (KW)

Spider Oil Reservoir

Bore x Stroke Inches (mm)

Oil Capacity Gallons (liters)

Standard Charging PSIG (kPa)

New

Maximum

8 x 30 (203 x 762) (4 Units)

6.75 (25.5)

125 (862)

0.035 -- 0.057 (0.89 -- 1.45)

0.184 (4.67)

Concaves Zinc Lbs. (Kg)

Epoxy 22 lb. Kits (10 Kg Kits)

Mantle Zinc Lbs. (Kg)

Epoxy 22 lb. Kits (10 Kg Kits)

See “Backing Quantity Requirements” in Section 4.

NOTE: (1)Clearance at fulcrum

3-6

17X0500-01.0401

SUPERIOR MK- II

Section 4 — Index

Gyratory Crushers

4. Installation

Page 4-1 4-2 4-2 4-2 4-2 4-3 4-3 4-3 4-3 4-3 4-4 4-4 4-4 4-5 4-9 4-9 4-9 4-9 4-11 4-14 4-16 4-16 4-16 4-17 4-19 4-20 4-20 4-23 4-23 4-24 4-24 Appendix 4-28 4-29 4-30 4-30 4-34 4-36 4-39 4-41 4-42 4-43 4-44

Description Index Preliminary Considerations — Foundation Requirements — Feed Arrangement to Crusher — Arrangements for Proper Feeding — Effect of Change to Larger Haul Trucks — Discharge Arrangement for Crusher — Pressurized Air Provision — Crusher Drives Erecting the Crusher — Bottom Shell Placement — Bottom Shell Hub, Arm and Side Liners — Hub Liners — Pinionshaft Arm Liners — Narrow Arm Liners — Bottom Shell Side Liners — Bottom Shell Bushing Assembly — Eccentric Assembly — Main Shaft Position (MPS) Cylinder Assembly — Pinionshaft Assembly — Dust Collar — Mainshaft Assembly — Top Shell Assembly — Installing Concaves — Spider Assembly — Spider Rim Liner Installation — Spider Arm Shield Installation — Drive — Lubrication and MPS Control Piping — Bottom Shell Vent System — Over Pressure Dust Sealing Unit

4

Weights and Dimensions Tool List Parts List — Instructions for Ordering Parts — 60-110 SUPERIOR Crusher Sectional Elevation — Catalog Numbers and Descriptions Epoxy Backing — Directions for Use Backing Quantity Requirements Mainshaft Lifting Eye Dimensions Procedure for Tightening Bolts SUPERIOR Crusher Bolt Torques

17X0501-01.0701

4-1

Section 4 — Installation

PRELIMINARY CONSIDERATIONS Foundation Requirements An installation drawing showing clearances and approximate weights of main parts and assemblies is furnished with each crusher. In addition, approximate weights and dimensions are tabulated in the Appendix to this section. The transmittal drawings provided by Metso Minerals should be available for reference during installation. Locate the crusher where it can be serviced with a crane or trolley and hoist to save erection time and speed parts replacement. In building the foundation, allow ample clearance for removing the MPS cylinder, eccentric and pinionshaft assemblies. Foundation requirements are usually designed by the customer, contractor or Metso Minerals, who are usually familiar with soil conditions for footings. Metso Minerals is responsible for crusher design and function only, but is available for comments on overall layout and clearances required for maintenance, method of feeding the crusher, etc. An installation outline drawing is furnished by Metso Minerals for suggested minimum clearances and general arrangements. Generally, these criteria have been followed with success: For solid mounted crushers: 1. Footing on bedrock or footing of appropriate area to suit soil conditions. 2. Concrete mass ratio to crusher weight of four to one. 3. The footing doweled into bedrock whenever possible to prevent slippage from vibration. 4. The mounting piers for the crusher tied into the footing steel with reinforcing steel so that piers and footing are integral. The concrete of the piers and footing should be a monolithic pour so that if settlement does occur it will be as a unit and prevent crusher mounting misalignment. Feed Arrangement to Crusher The need for an effective means of feeding into the crushing chamber cannot be over-stressed. Long service life of mechanical components as well as optimized crusher capacity are dependent upon an even, well-distributed feed, entering the chamber with a minimum of impact on the spider cap, mantle and concaves. Uneven feed may be defined as a greater quantity of feed in one portion of the crushing chamber than in the balance of the 360o of the crushing chamber, and/or coarse and fine feed segregation into separate portions of the chamber. Either of the above conditions may cause: 1. High hydraulic surges in the MPS control with subsequent high impact bearing pressures, excessive wear, and even failure of components. 2. Uneven and accelerated concave wear in localized areas resulting in uneven product sizing and shortened crushing surface life. 4-2

SUPERIOR MK- II Gyratory Crushers

3. Lower crusher throughput due to the crushing chamber not crushing to capacity in the full 360o of the chamber. It is important that feed be evenly distributed to maintain a round crushing chamber with a minimum of shock loading. It is equally important that trucks dump from two sides of the stone box around the spider, over the spider arms. Arrangements for Proper Feeding Spider arms must be positioned to be in line with the truck discharge, with trucks dumping at both sides. See Fig. 4-1. The heavy arm will split material flow into the crusher chamber for more even feed distribution to each quadrant of the chamber. The stone box around the spider must permit material discharge from the truck dump to fall on a dead bed of stone and fines, and roll - not fall - into the chamber. Dumped material must not be allowed to impact directly on the spider cap or mainshaft assembly. High impact loading of crusher components results when large pieces of stone are dropped directly into the crushing chamber. The mainshaft assembly usually is the component that suffers from bad dump pit design or improper barricade locations for stopping the truck when backing up to the pit for the load discharge.

FIG. 4-1 — Proper Feed Arrangement for SUPERIOR Crushers Spider arms are in line with truck dump. Dumped material falls on dead bed — not directly on crusher.

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

Increased crushing chamber wear life and bearing life are other benefits of correct feeding. Truck dumping from only one side of the crusher can cause excessive concave wear in a localized area. It can also accelerate bearing deterioration, especially in the spider bushing, which may wear elliptically due to the absorption of impact from one side only. When designing a dump pit for a primary crusher, it is imperative that it be designed for the largest truck that will be used in the hauling fleet. This will allow for the stone to impinge on the pit dead bed on the free fall and then slide or roll into the crushing chamber. This holds the impact on the crusher to a minimum. Effect of Change to Larger Haul Trucks A scale-up in truck size and capacity in an existing crushing plant operation can significantly alter the material discharge angle and the relationship between the truck dump point and the impact point of heavy pieces. In recent years, pit economies have resulted in larger trucks being procured to replace smaller and less efficient units. This has, in some instances, resulted in component failures and excessive down-time, sometimes serious in consequences. Ways to avoid the problem include: 1. Move the truck stop location on both sides of the crusher far enough to keep the dump impact away from the crusher feed opening. This is especially true if the entire truck fleet has been changed to larger units. 2. If the fleet contains both smaller and larger trucks, set up dumping cycles so that the smaller trucks dump at one side, with the stop located accordingly, and larger trucks at the other side, with the stop farther from the crusher. The effectiveness of any change can be readily observed when new trucks go into service. Discharge Arrangement for Crusher Provide a discharge storage chamber beneath the crusher that is spacious enough to contain at least two truck or quarry car dump loads. This would permit emptying the crushing chamber in the event that the under-crusher discharge conveying system shuts down during operations. Using a feeder between the discharge storage chamber and discharge conveyor will regulate the discharge rate and eliminate surging.

Crusher Drives SUPERIOR gyratory crushers are driven by a spiral-toothed bevel gear and pinion through a pinionshaft mounted in a housing extending through the side of the bottom shell. The driving force is usually provided by an electric motor. See “General Specifications,” in Section 3 for pinionshaft rpm, as well as maximum recommended horsepower. Direct drives should include a floating shaft between the motor and pinionshaft to permit removal of the pinionshaft assembly without moving the motor. Motors should have 180% starting and 250% breakdown torque. When calculated horsepower requirements indicate that power draw is close to rated horsepower, specify a 1.15 service factor. Wound rotor induction motors are recommended because of their inherently high starting torque characteristics. Squirrel cage induction motors may be specified when the power system can supply high starting currents. ERECTING THE CRUSHER

WARNING A hard hat, eye protection, and hearing protection are required at most crushing and screening installations. Hard hats and safety goggles can prevent injury. Wear hearing protection when noise levels exceed 85 dBA and breathing protection when dust levels exceed acceptable limits. Crusher parts are subjected to severe strains in operation with high unit pressure on bearings. Take care during assembly to assure proper alignment and an ample supply of clean, uncontaminated lubricant to wearing parts. Bearing surfaces are provided with means for excluding dirt and dust when the machine is properly assembled and cared for during operation. Thoroughly clean all joints and fittings before closing. Carefully examine all oil passages and remove any rust or dirt before installation. Clean bright or finished parts, covered with protective coating, with solvent. Slight damage to finished parts should be smoothed and trued to insure proper fits when assembled.

Pressurized Air Provision Crushers are equipped with an air inlet connector (1675-0) for connecting a source of pressurized air to the lubrication oil chamber. The connector is located in the bottom shell at one of the arms. Positive air pressure in the chamber helps to exclude dust-laden air and prevent oil contamination. The pressurized air source can be from either the air blower supplied with the crusher or from compressed air, if available. See “Over Pressure Dust Sealing Unit” in this section. 17X0501-01.0701

4-3

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

Bottom Shell Placement If the Gyratory crusher is to placed on a concrete foundation, the bottom shell should be grouted into place. Typically this is accomplished by first grouting in leveling blocks at each of the four corners adjacent to the foundation bolts. These blocks, as thick and large as practical, should be leveled in both directions and allowed to set. These blocks provide a foundation that is level and smooth. Use a high performance water resistant epoxy grout. Steel shims or blocks can be used to assist in leveling the crusher bottom shell and setting it at its proper elevation no more than 2” (50.8 mm) above grade. Follow the grout manufacturer’s recommendation during preparation and installation using expansion joints and multiple pours as required. It is important that the crusher be mounted level in both directions. The foundation requirements and design are to be established by a qualified civil engineer. Figure 4-2 shows a typical bottom shell assembly being placed on a concrete foundation. Customer provided foundation bolts of a through bolt arrangement should have a minimum grip length of 48” (1220 mm). These studs should have sufficient thread length on each end for a hard washer and double nuts as well as a lower bearing plate. The lower bearing plate should be a minimum of 10” (254 mm) by 10” (254 mm) x 2” (50 mm) thick and grouted into place. Tighten the foundation bolts after the grout has set.

NOTICE Torque all bolts to their recommended torque values. Prior to beginning assembly, refer to the sections titled “Procedure for Tightening Bolts” and “Bolt Torques” located later in Section 4.

FIG. 4-2 — Placing Bottom Shell on Foundation

Bottom Shell Hub, Arm and Side Liners Bottom shell side, arm and hub liners are provided to minimize wear. Liners are not factory installed, but are shipped separately, and must be assembled in the bottom shell at the job site. Place the hub liners first, then the arm liners, and finally, the side liners. See Figs. 4-2a, 4-2b, and 4-2c. For convenient handling and assembly, side liners are made up in sections. Each of the four bottom shell quadrants must be fitted with a section adjacent to the pinionshaft arm, left (1320-1) or right (1320-2) hand, four intermediate sections (1324-1, 2, 4, 5) and a section adjacent to the narrow arm, left (1326-2) or right (1326-1) hand. In addition, liner segments are provided for the pinionshaft arm, left (1010-7) or right (1010-8) hand, and the narrow arms (1010-2) with extension pieces (1010-3). Hub Liners Hub liners have been pre-fitted by the Factory, and match marked before removal for separate shipment. Upper (1305-1 and -3) and lower (1305-4 and -6) hub liner sections must be assembled over holding lugs which have been welded to the bottom shell at the factory. Sections are retained on the bottom shell by holding pates (1310-0), with two 1-1/4 inch (31.75 mm) by 2 inch (50.8 mm) long hex socket-head capscrews for each plate. Insert capscrews in the tapped holes provided and torque them to 1,350 foot pounds (186.7 Kg-m).

4-4

17X0501-01.0701

SUPERIOR MK- II Gyratory Crushers

Pinionshaft Arm Liners The two pinionshaft arm liners are each shipped in two sections (1010-7 and 1010-8). The sections must be joined, during assembly, by fitting together a dovetail join where the two sections meet on top of the pinionshaft arm. The dovetail tenon is cast on the right hand section (1010-8) and the mortise on the left hand section (1010-7). Each section is fitted with lifting lugs for handling. The lifting devices for handling sections must be capable of handling at least 1800 pounds (815 Kilograms). Place the left-hand section (1010-7) on the pinionshaft arm, with the curved back surface against the bottom shell. Lift the right-hand section in the same manner, and assemble the mortise and tenon joint to lock the two sections together. Repeat the operation when installing the other pinionshaft arm liner. Four steel, 2”x3”x3” (51x76x76 mm), blocks (1020-1) are provided for permanently locating the arm liners on the pinionshaft arms. A 3”x4” (76x102 mm) notch is cast into the bottom edge of each left and right hand pinionshaft

17X0501-01.0701

Section 4 — Installation

arm liner section. With the liner in place, seated firmly against the bottom shell, locate one of the blocks in the notch and tack weld it to the pinionshaft arm. repeat the operation for all of the four blocks.

NOTICE Provide enough clearance between the block and the arm liner so that the arm liner can be removed without first removing the block. Cored 2.6 inch (67 mm) diameter holes are located in each arm liner — two on each surface next to the bottom shell and four on each surface next to the pinionshaft arm. After locating the arm liners as previously instructed, insert 2.25 inch (57 mm) diameter by 2 inch (51 mm) long bars (1020-1, 1020-2) (provided with the liner shipment) into the 2.6 inch (67 mm) diameter holes. Rap each bar to obtain solid contact with the bottom shell, or pinionshaft arm, then weld it to the liner.

4-5

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

ARM C/L

PINION C/L

A

1310--0 1305--4

1305--6

1305--1

1305--3

A

1305--3

1310--0 1306--0 1306--1 1330--0

1306--0 1306--1

1330--0

1310--0 1305--6 SECTION A--A M--013007--TAW--01

Fig. 4-2A — Hub Liners Catalog Number

Description

Catalog Number

Description

1305-1 1305-3 1305-4 1305-6

Upper Hub Liner L.H. Upper Hub Liner R.H. Lower Hub Liner L.H. Lower Hub Liner R.H.

1306-0 1306-1 1310-0 1330-0

Hub Liner Capscrew Hub Liner Washer Hub Liner Plate Hub Liner Support Bar

4-6

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

PINIONSHAFT C/L

A 1010--8

1010--7

1030--2

1030--2

1010--2

1010--2

NARROW ARM C/L

1030--2

1030--2 1010--8 1010--2

A

PINIONSHAFT C/L 1010--8 1010--7

1010--7

1010--8 1010--7

1010--2 1020--2

1020--2

1010--3 1010--3 1030--3

1030--2

1030--2

PINIONSHAFT C/L 1030--1 1010--7 1010--8 1020--2

1030--3

1030--1 NARROW ARM C/L 1020--2

1010--7 1010--8

1020--1

1020--1

1030--1

1030--1 PINIONSHAFT C/L

1010--3 1030--3

VIEW A--A

1010--3 1030--3 M--13007--TAW--02

Fig. 4-2B — Arm Liners Catalog Number

Description

1010-2 1010-3 1010-7 1010-8 1020-1

Narrow Arm Liner Narrow Arm Liner Extension Pinion Shaft Arm Liner (L.H.) Pinion Shaft Arm Liner (R.H.) Adjusting Pin — Pinionshaft Arm Liner

17X0501-01.0701

Catalog Number

Description

1020-2 1030-1 1030-2 1030-3

Adjusting Pin — Narrow Arm Liner Pinionshaft Arm Retaining Block Narrow Arm Retaining Block Narrow Arm Holding Lug

4-7

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

PINIONSHAFT 1320--2

1320--1

1324--5

1324--4 1324--1

UPPER BOTTOMSHELL

1324--2

”B”

”A” 1326--2

1365--0 1365--1 1365--2 1365--3

1326--1 1365--0 1365--1 ”A” 1365--2 1365--3

”B”

1324--5

1324--2

NARROW ARM 1326--2 LOWER BOTTOMSHELL

1326--1 1326--2

1324--4

SECTION VIEW ”B--B”

1324--5

1320--2

1320--1

NARROW ARM

1365--0 1365--1 1365--2 1365--3

1326--1

”C”

1326--2

1326--1

1365--0 1365--1 1365--2 1365--3

NARROW ARM LINER (REF) ”C”

1324--1

1324--2

PINIONSHAFT

SECTION VIEW ”A--A”

VIEW ”C--C”

PINIONSHAFT ARM LINER (REF) M--013007--TAW--03

Fig. 4-2C — Side Liners Catalog Number

Description

Catalog Number

Description

1320-1 1320-2 1324-1 1324-2 1324-4 1324-5

Bottomshell Side Liner--LH Adjacent Pinionshaft Bottomshell Side Liner--RH Adjacent Pinionshaft Bottomshell Side Liner -- LH Intermediate Lower Tier Bottomshell Side Liner --RH Intermediate Lower Tier Bottomshell Side Liner --LH Intermediate Upper Tier Bottomshell Side Liner --RH Intermediate Upper Tier

1326-1 1326-2 1365-0 1365-1 1365-2 1365-3

Bottomshell Side Liner--LH Adjacent Narrow Arm Bottomshell Side Liner--RH Adjacent Narrow Arm Capscrew Nut Washer Hex Jamnut

4-8

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SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

Narrow Arm Liners The narrow arm liners (1010-2) are cast in one piece, each with a lifting lug on top. Each liner weighs approximately 1350 pounds (612 Kilograms). Place the arm liner onto the narrow arm with the curbed back surface against the bottom shell. Seat it firmly on the arm and against the bottom shell. Repeat operation for second arm. Four arm liner extensions (1010-3) are provided for mounting on each side of the narrow arms, below the liner (1010-2). Each extension has a lifting lug and weighs 320 pounds (145 Kilograms). With arm liners in place, locate an extension with the longer surface toward the arm, and the 2.8 inch (71 mm) lip pushed upward into the notch cast in the arm liner. Allow 0.7 inch (20 mm) clearance between the extension and the arm liner. Weld two holding lugs (1030-3) up against the bottom of the extension near each end, with the taper bearing on the narrow arm. Then, tack weld a 2”x2”x6” (51x51x152 mm) bar (1030-2) which is furnished, to the narrow arm, next to the joint between the arm liner and extension, centering the bar on the joint.

4.

5.

6. 7.

NOTICE Provide enough clearance between the bar and arm liner so that the arm liner can be replaced without removing the bar. Finally, insert one of the 2.25 inch (57 mm) diameter by 2 inch (51 mm) long bars in each of the 2.6 inch (67 mm) diameter holes in the curved surfaces, bearing on the bottom shell. Rap each bar firmly to obtain solid contact with the bottom shell, then weld it to the arm liner. Bottom Shell Side Liners The suggested assembly procedure is as follows: 1. Use the pinionshaft location as a starting point. Progress clockwise, with the assembly, looking inward from the pinionshaft. See Fig. 4-2b. 2. A series of 16 upper holding bars (1350-2) have been installed in the bottom shell at the factory. Two of these bars are used to wedge the upper lip of each side liner, adjacent the arms (1320-1 and -2; 1321-1 and -2), against the bottom shell. See Fig. 4-2b for locations. 3. A series of 16 lower support blocks, 2”x3”x5” (51x76x127 mm) (1350-1), are to be welded to the bottom shell. Two of these blocks are used to support the lower lip of each side liner segment, adjacent the four arms in the bottom shell. See Fig. 4-2b for locations. An additional 16 lower support blocks, 2” x 3” x 4” (51x76x102 mm) (1320-5), are to be welded to the

17X0501-01.0701

8.

9.

10.

bottom shell. One of these blocks is used to support the lower lip of each side liner (1320-0) in the bottom shell. Place the side liner for the left hand of the pinionshaft (1320-1) in position against the bottom shell side wall, allowing .8 inch (20 mm) clearance between the top of the liner and the holding bars (1350-2). Finished weight of the side liner is 853.6 pounds (387.5 Kg). A lifting lug is welded to the outer flat surface for handling, and for holding the piece while securing it to the lower holding block (1350-1). Place the 2” x 3” x 4” (51x76x102 mm) clamp block (1360-0) in position over the lower support block (1350-1) and bottom edge of the side liner, and weld the clamp block (1360-0) to the support block (1350-1). Maintain 0.5” (13 mm) clearance between the clamp block (1360-0) and the shoulder on the side liner. See Fig. 4-2b. Place wedges (1352-0) between lips of upper holding bars (1350-2) and the side liner and drive them up firmly. When secure, tack weld wedges in place. Each side liner adjacent the arms (1320-1, -2 and 1321-1, -2) has five 2.6 inch (67 mm) diameter holes for installation of 2.25 inch (57 mm) diameter bars by 1.5 inch long (1365-0). In all cases, rap the 2.25 inch (57 mm) diameter bars to obtain solid contact with the bottom shell, then weld them to the liners, using a 0.38 inch (10 mm) fillet weld. Side liners (1320-0) are secured to the bottom shell by welding. Each is supported at the bottom by support block (1320-5) and is to be welded to the shell at the top, using a 0.38” (10 mm) skip fillet weld, 3.0 inch (76 mm) long on 10 inch (254 mm) centers. Welding slots are provided, two each side. Use 0.38” (10 mm) fillet welds in these slots. Each liner (1320-0) has two 2.5 inch (64 mm) diameter holes for installation of 2.25 inch (57 mm) diameter bars by 1.5 inch (38 mm) See Step 7 for bar installation. Proceed with installation, as detailed above, around the bottom shell. Refer to Fig. 4-2b for locating data.

Bottom Shell Bushing Assembly Directions for assembling the bottom shell bushing int he bottom shell are provided in Section 7, “Bottom Shell Bushing Assembly.” Eccentric Assembly The eccentric assembly, which is covered in detail in Section 8, is to be installed into the bottom shell. The eccentric assembly (1800-1) sets on the eccentric wearing plate (1880-0) and is held in place by the eccentric support plate (1905-0). An o-ring (1920-0) is used to seal the joint between the bottom shell and the eccentric support plate. See Fig. 4-3 for details.

4-9

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

8955--0

1800--1

1910--0 1910--4 1920--0

1880--0 1905--0

M--012207--TAW--02

FIG. 4-3 — Eccentric Assembly, Showing Location in Bottom Shell, with Support and Wearing Plates Catalog Number

Description

1800-1 1880-0 1905-0 1910-0

Eccentric assembly Eccentric wearing plate Eccentric support plate Bolt - eccentric support plate

Proceed with installation as follows: 1. Position the eccentric support plate (1905-0) on a skid or eccentric cart so that the oil drain hole lines up with the hole in the MPS cylinder flange. Place the wearing plate (1880-0) and support plate O-ring (1920-0) on the support plate. Place the eccentric assembly (1800-1) on the wearing plate. 2. Move the skid or cart with the assembly under the bottom shell. 3. Insert the three guide rods (8955-0) into the bottom shell. The guide rods are used to guide the eccentric assembly into position so that securing the eccentric support plate (1905-0) to the bottom shell is made easier (see Fig. 4-3). Raise the eccentric into place on the eccentric cart using cables from the main overhead crane.

4-10

Catalog Number

Description

1910-4 1920-0 8955-0

Lockwasher O-ring Guide rod

WARNING The guide 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. 4. Secure the support plate to the bottom shell with the support plate bolts (1910-0) and lock washers (1910-4). Tighten bolts per table 4-11.

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

Main Shaft Position (MPS) Cylinder Assembly The MPS cylinder assembly, which is covered in detail in Section 6, is to be bolted to the bottom shell. See Fig. 4-4 and 4-5 for installation.

2140--0

2280--0

2260--0

2120--0

2005--0

2606--0

2606--1 2606--2

M--012307--TAW--01

FIG. 4-4 — MPS Cylinder Assembly Catalog Number

Description

Catalog Number

Description

2005-0 2120-0 2140-0 2260-0

MPS cylinder Bottom plate drain plug MPS cylinder O-ring Piston wearing plate

2280-0 2606-0 2606-1 2606-2

Stepwasher Cover plate guard Capscrew Washer

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4-11

SUPERIOR MK- II

Section 4 — Installation

Proceed with installation as follows. 1. Place the MPS cylinder assembly on the eccentric cart or skid and move it into place beneath the bottom shell. Be sure that the bottom plate drain plug (2120-0) is lined up with the drain hole in the bottom shell. Check that the piston wearing plate (2260-0) and stepwasher (2280-0) are installed. Clean the o-ring groove and the top surface of the cylinder. Install the MPS cylinder o-ring (2140-0) into the groove. 2. Insert the three guide rods (8955-0) into the bottom shell (see Fig. 4-5). The guide rods are used to guide the MPS cylinder into position until it can be secured to the bottom shell. Raise the MPS cylinder into place with the eccentric cart or skid using cables from the main overhead crane.

Gyratory Crushers

3. Install MPS stud (2020-0), nut (2020-1) and locknut (2020-3) and tighten each stud evenly per table 4-11 to insure there are no leaks. See Fig. 4-5. 4. Remove cover plate guard (2606-0) and install under crusher bin level sensor using the existing capscrews (2606-1) and lockwashers (2606-2). Connect wiring before mounting sensor. See Fig. 4-6.

2020--0 2020--1 2020--3

WARNING The guide 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.

4-12

GUIDE ROD M--041007--JRK--01

FIG. 4-5 - MPS Cylinder Removal and Installation

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

2606--1 2606--2 2660--2 2661--0 2661--4 2606--0 20_ MAX

2660--1 M--012307--TAW--02

FIG. 4-6 — Under Crusher Bin Level Sensor (Typical) Catalog Number 2606-0 2606-1 2606-2 2660-1 2660-2 2661-0 2661-4

17X0501-01.0701

Description Guard - Level Sensor Capscrew Lockwasher Transducer Aiming Kit Capscrew Lockwasher

4-13

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

Pinionshaft Assembly The pinionshaft assembly is shipped fully assembled for installation into the bottom shell. See Fig. 4-7 for location of threaded holes for use of eyebolts during installation. For the method of installation refer to Section 9, Pinionshaft Assembly under the heading “Replacement in Crusher”.

NOTICE On a new machine, backlash and tooth contact must be set and checked. See “Gear and Pinion Backlash Adjustment” and “Bevel Gear Installation and Maintenance” in Section 9.

(INCH) 1.000--8UNC--2B

(INCH) 1.000--8UNC--2B

M--012307--TAW--03

FIG. 4-7 — Pinionshaft Assembly

SK021392-JJB-4 FIG. 4-8 — Inserting Pinionshaft Assembly in Bottom Shell

4-14

FIG. 4-9 — Pinionshaft and Housing Assembly with Bottom Shell

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SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

4050--0 4025--3 4025--4 4025--0

4205--0

4175--3 4005--0

4175--9

4175--1

CONCRETE PROVIDED BY CUSTOMER

4405--0

4350--0 4305--0

4075--0

4135--0

M--012307--TAW--04

FIG. 4-10 — Mainshaft Assembly Catalog Number 4005-0 4025-0 4025-3 4025-4 4050-0 4075-0 4135-0

Description Mainshaft Mainshaft sleeve Locknut Lockwasher Eyebolt Mainshaft step Mainshaft step retainer

17X0501-01.0701

Catalog Number 4175-1 4175-3 4175-9 4205-0 4305-0 4350-0 4405-0

Description Lower mantle Upper mantle Std backing Head nut Dust seal Lower dust seal retaining ring Splash curtain

4-15

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

Dust Collar Assemble dust collar (1400-0) with gasket (1430-0), using the locating roll pin (1408-0), and the provided hardware to secure to the bottom shell. Be sure the over-flow oil passages are open. Install the upper counterweight splash ring (1420-0), (Fig. 7-1) to the dust collar lifting eyebolt holes with (3) bolts (1421-0). Use Loctite No. 242 on the capscrew threads and torque to 123 ft-lbs. (167 N-m). See the Sectional Elevation Figure 4-25 and Table 4-6 for part identification. Mainshaft Assembly Major components of the mainshaft assembly include the mainshaft (4005-0), mainshaft sleeve (4025-0), lower mantle (4175-1), upper mantle (4175-3), head nut (4205-0), mainshaft step (4075-0), step retainer (4135-0), dust seal (4305-0), dust seal retainer (4350-0), splash curtain (4405-0) and the lifting eyebolt (4050-0). See Fig. 4-10 for assembly and Section 10 for more detailed assembly information. Before installing the mainshaft assembly, remove the dust seal assembly. Carefully inspect and clean the dust seal and its retainer. Make sure that the dust seal ring moves freely in the retainer after reassembly. The lifting eyebolt is installed at the Factory and should not be removed in the field. Check to make sure that the eyebolt is fully shouldered before lifting. On the 60-110 crusher, a shackle is required between the shaft eyebolt and crane hook. See Appendix, ”Mainshaft Lifting Eye Dimensions” for eyebolt dimensions.

Top Shell Assembly (FIG. 4-11) The top shell is horizontally split into an upper and a lower section. Inspect the taper fits of the lower top shell (5005-1), the upper top shell (5005-2) and the upper bottom shell (1006-0). Remove any burrs, bruises or interfering accumulation of rust or dirt. Coat the taper fit and horizontal surfaces of the top shell sections with oil. Do not use white lead; it will harden and make it difficult to remove the top shell. Make sure that the concave support ring (6050-0) is in place on the bottom shell. Make a level hitch on the top shell assembly and lower it into the matching taper fits. Position it as level as possible so that the bolting flanges are as close to parallel as possible. The joint has a slight interference fit, and will remain open about 1/8 inch (3 mm) or slightly less until it is drawn tight. Tighten down two bolts, 180 apart, making sure that the gap between the sections remains equal. Then install two bolts 90 from the first two, again making sure the gap is equal. Install the balance of the bolts at approximately the same tightness as the first four. Continue to tighten bolts in the same sequence, approximately the same number of turns, until a 0.004-inch (0.10-mm) feeler gauge cannot be inserted between the bolting flanges at any point on the circumference. If there is any clearance between the upper and lower top shells or the top and bottom shells after tightening, it is an indication that the joint has not been pulled up tightly enough or that something in the joint is holding it open. KEEP THESE JOINTS TIGHT TO PREVENT JOINT BOLT BREAKAGE.

NOTICE For crushers with large throws and small settings, it may be required to install the mainshaft assembly before installing the concaves.

4-16

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SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

SPIDER ASSEMBLY 6395--0 6385--0 5005--2 6365--0 6345--0 5340--0 5340--1 5340--3 5005--1 6325--0 6305--0 6050--0 M--12307--TAW--05

FIG. 4-11 — Top Shell Assembly Catalog Number 5005-1 5005-2 5340-0 5340-1 5340-3 6050-0

Description Lower top shell Upper top shell Stud w/nut Heavy hex nut Heavy hex jamnut Concave support ring

Catalog Number 6305-0 6325-0 6345-0 6365-0 6385-0 6395-0

Description Concave-first tier Concave-second tier Concave-third tier Concave-fourth tier Concave-fifth tier Concave-sixth tier

Installing Concaves Lower tier concaves are generally supplied with a pocket in their back side. To save on zinc or epoxy backing, fill the backs of lower row concaves with a grout of three parts sand to one part cement. Weld reinforcing rod hairpins to the backs and pockets of the concaves to retain the grout. Always allow grout to cure in a dry atmosphere to eliminate moisture. Excess water may negatively impact epoxy backing cure and strength development.

WARNING Molten zinc coming in contact with moisture can cause explosions and endanger personnel. Molten zinc is poured at 1000 o to 1100 oF. (540 o to 590 oC.) Thoroughly clean the inside of the top shell and backs of concaves, and make sure they are dry. FIG 4-12 — Top Shell to Bottom Shell Installation Note interference taper fit machined in bottom face of top shell. Size 42-65 crusher shown. 17X0501-01.0701

4-17

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

NOTICE

WARNING

Coat top shell surfaces with oil, when using zinc backing. It will help prevent explosions. Do not use oil or any parting agent when backing the concaves with epoxy backing.

Do not use water-based putty, where zinc is used. Molten zinc coming in contact with moisture can cause explosions and endanger personnel.

When epoxy backing is to be used, do not coat the backs of concaves or inside of the top shell with a parting agent of any type. It is impossible to control coating thickness, and this could result in looseness and movement of concaves during crushing. For lifting concaves into place, the manganese concaves have a lifting lug that is cast into the concave. Prior to running the crusher this lifting lug must be removed. Cut off the lifting eyes with an oxyacetylene torch as close to the wear surface as possible. The flame should be directed parallel to the wear surface of the casting. At no time during the cutting should the flame be directed at any area of the wear surface of the casting. Set the bottom row of concaves with 3/8 inch (9.5 mm) vertical spacing between concaves. Place wooden strips in each joint to about half the depth of the joint. If 3/8 inch (9.5 mm) is not sufficient to space out the full row of concaves, alternately increase spacing, but do not exceed 5/8 inch (16 mm) between concaves. See Fig. 4-13. One method of holding concaves in place before pouring backing material is to install a ring, behind which wedges can be driven, as shown in Fig. 4-14. Another is to block the row in place with wooden props or dry sand. Next, stop off the joints between and below the concaves to prevent the escape of hot zinc or epoxy backing when poured in at the top. If zinc is to be used, seal the wood strips and bottom area of the concaves against the concave support ring with Babbittrite or equivalent oil-based putty.

If epoxy backing is used, plaster of paris can be substituted — do not use oil-based putty. It is best to set and back up one row of concaves at a time. Pour the backing up about three-fourths of the height of the row. This will prevent having a coinciding joint at the same place for a compound separation. This is especially true when using zinc, which will not bond to a previous joint. Pour zinc backing as quickly as facilities will permit, proceeding all the way around. Avoid the possibility of voids being left due to cooling of the zinc. Continue setting concaves and pouring backing in the same manner until all succeeding rows are set and backed. Particular precautions must be taken in the setting and maintenance of the manganese concaves when the crusher is to be used to reduce hard non-abrasive material. A hard material which is not abrasive will peen the manganese faster than it will wear it off, thus causing the metal to flow. See View A, Fig. 4-13. IF ALLOWED TO CONTINUE, THE FLOWING OF METAL WILL TIGHTEN THE ROW OF CONCAVES TO SUCH AN EXTENT THAT THE TOP SHELL CAN CRACK. In order to help combat these conditions, the width of the vertical joint between the concaves can be increased to 5/8 inch (16 mm). Cut 5/8 inch (16 mm) thick wooden slats of a length equal to the height of the concave and width equal to about half of the thickness of the concave and place them in the vertical joints when setting the next set of concaves. See View B of Fig. 4-13. 5/8 inch (16 mm) is generally the maximum practical spacing between concaves because of their tendency to loosen and fall out. When increasing the space width it may become necessary to trim the sides of the key concave to fit the available space. When starting a new operation, if the operator suspects the material being crushed is of the type to cause manganese flow, we recommend that he check the concave joints daily for manganese flow. Most of the peening occurs on the face of the concaves and closes the joint between, as shown in View A. This may be remedied sufficiently by cutting back the edges of the vertical and horizontal joint with an acetylene torch periodically, as shown in View C. In this way the top shell is relieved from the stress caused by the peening. Use care in determining this period, as under adverse conditions top shells have been known to burst from peening within one month of operation.

Concaves

Wood Slat

A

B

C

Backing

07-146-350

FIG. 4-13 — Precautionary Steps when Placing Manganese Concaves

4-18

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

Spider Assembly The spider must be installed after the top shell and mainshaft are in place. Main components include the spider (5605-0), spider bushing (5675-0), spider bearing oil seal (5705-0), spider cap (5650-0), arm shields (5150-0) and rim liners. See Fig. 4-15 and 4-16 for detail. Thoroughly clean the mainshaft sleeve and top end of the mainshaft, as well as the bore of the spider hub. Inspect the taper fits of both the spider and top shell. Remove burrs, dents and any rust and dirt. Coat both taper fits with oil. Do not use white lead — it will harden and make removal of the spider assembly difficult.

NOTICE FIG. 4-14 — Method of Backing Manganese Steel Concaves in the Top Shell

Install the spider - top shell jackscrew separator collars (5007-2) or optional spider - top shell hydraulic separator collars (5008-2) into the counterbored holes in the top flange of the top shell before installing the spider assembly. See Section 12 for details.

5675--0 5650--0

5705--0

5150--0

5605--0

M--012307--TAW--06

FIG. 4-15 — Spider Assembly

17X0501-01.0701

Catalog Number

Description

5150-0 5605-0 5650-0 5675-0 5705-0

Spider Arm Shield Spider Spider Cap Spider Bushing Spider Bushing Oil Seal 4-19

Section 4 — Installation

Make a level hitch on the spider assembly and lower over the mainshaft into the matching taper fits of the spider and top shell. Position as level as possible so that the bolting flanges are as close to parallel as possible. The joint has a slight interference fit, and will remain open about 1/8 inch (3 mm) or slightly less until it is drawn tight. Tighten down two bolts, 180o apart, making sure that the gap between the spider and top shell is equal. Then install two bolts 90o from the first two, again making sure of an equal gap between the two shells. Install the balance of the bolts at approximately the same tightness as the first four. Continue to tightenthe boltsin sequenceapproximately the same number of turns until a .004 inch (0.10 mm) feeler gauge cannot be inserted between the bolting flanges at any point in the circumference. Check the spider bearing oil seals (5705-0) which are pressed into a counterbore in the bottom of the spider bushing (Fig. 4-15). Note that the shaft scraper (5706-0) must be installed in the spider (5605-0) before the spider bushing (5675-0). Install the Spider Bushing When the bushing is placed in the spider hub, there will be a gap of approximately 1/16” (1.6 mm) between the bottom of the bushing flange and the top face of the spider. The flange must be pulled down tightly on the spider with the spider bushing bolts. Tighten bolts evenly to prevent the bushing from becoming cocked in the spider hub. Spider Rim Liner Installation After installing the spider on the top shell, it is necessary to mount two spacer filler blocks (5625-0) on the outer circumference of the spider rim, on opposite sides at 90_ each from the spider arm centerline. The filler blocks must be added to round out the spider rim circumference for mounting the spider rim liners. Filler blocks weigh 4,050 pounds (1,837 kilograms) each. They are secured to the spider by filler block capscrews (5635-0), fitted into tapped holes in the spider. Capscrews must be torqued to 14,800 ft.-lbs. (2,047 Kg-m) during assembly. Holes are drilled around the periphery of the spider rim for securing the spider rim liner segments (5110-1, -2 and -3). See Fig. 4-15a for the rim liner arrangement. Rim liner segments weigh approximately 2,500 pounds (1,135 Kilograms) each.

4-20

SUPERIOR MK- II Gyratory Crushers

Rim liner segments are secured to the spider by springloaded rim liner bolts (5125-0). Spring loading is necessary to prevent bolt breakage due to over-tightening of bolts or liner warpage. Springs (5125-5) must be well seated against the spider when installed. With the spring and retainer washer (5125-2) on the bolt, install a nut (5125-1) and pull it up sufficiently tight to compress the spring to a length of 4.8 inches (121.9 mm) as shown in Fig 4-15b. Add a lock nut (5125-3) to lock the installation securely. Periodically check the spring dimension, all around, to make sure springs have not compressed or opened up during operation. Spider Arm Shield Installation Two spider arm shields are furnished to protect the arms from damage and erosion. Each arm shield weighs approximately 8,200 pounds (3,719 kilograms). Two cored holes are provided for mounting lifting bars when handling arm shields. Each arm shield is secured to a spider arm with springloaded bolts (See Fig 4-15c). Locate the arm shield on the spider arm so that it cannot rock or move in place. With the shield in place on the arm, assemble the bolt (5160-0), spring (5160-5 and spring cage (5160-6), as illustrated by view A on Fig. 4-15c. Turn the nut (5160-1) on to the bolt, enough to snug up the assembly without compressing the spring. Measure and record the exact distance (dimension “A”) that the bolt projects beyond the nut. Slide the spring retainer (5160-9) over the spring cage (5160-6) until it seats on the stop collar on the spring cage. Weld the spring retainer to the spider arm per AWS Class E-60XX. Remove the nut (5160-1) and bolt (5160-0), leaving the spring, spring cage and spring retainer in place. Measure the distance “A”, previously determined, plus 0.62 inch (15.75 mm), from the end of the bolt’s threaded portion to locate the center of the cotter pin hole (see view “B”, fig. 4-15c). Drill a 0.438 inch (11.13 mm) hole, on center, through the bolt (5160-0). Reinstall the bolt (5160-0) through the spring and spring retainer, and put the nut (5160-1) in place. Turn the nut until it clears the hole you have drilled in the bolt. This will compress the spring (5160-5) by approximately 0.81 inch (17.8 mm). Install a cotter pin (5160-7) through the hole and secure it.

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

5110--3

5110--1

A

5112--0

5112--0 B

5110--3

5125--0

5110--1 5110--2 5112--0

5110--2

5125--5

B 5110--2

5150--0

5605--0

5110--2

5125--2 5125--1 5125--3

5112--0 5150--0

5160--0

5112--0

SECTION B--B

5160--5

5160--6 5160--9

5635--0 5636--0

5110--3

5160--1 5160--7

5625--0

SECTION A

M--030807--JRK--01

FIG. 4-15a — Layout of Spider Rim Liners Catalog Number

Description

Catalog Number

Description

5110--1 5110--2 5110--3 5112--0 5125--0 5125--1 5125--2 5125--3 5125--5 5150--0

Spider Rim Liner L.H. Spider Rim Liner Center Spider Rim Liner R.H. Spider Liner Locating Pins Rim Liner Bolt Rim Liner Nut Spring Retainer Washer Locknut Rim Liner Bolt Spring Spider Arm Shield

5160--0 5160--1 5160--5 5160--6 5160--7 5160--9 5605--0 5625--0 5635--0 5636--0

Spider Arm Shield Bolt Spider Arm Shield Nut Spider Arm Shield Bolt Spring Spring Case Cotter Pin Spring Retainer Spider Spider Filler Block Spider Filler Block Bolts Spider Filler Bolts

17X0501-01.0701

4-21

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

5110--1, 2, 3

5125--0

5125--5

121.9 [4.80] 5125--2 5125--1 5125--3

M--030807--JRK--03

FIG. 4-15b — Spider Rim Liner Bolt and Spring Assembly

5160--0

5160--0 5160--5

5160--5

5160--6

5160--6

STOP COLLAR 5160--9

5160--9

5160--0

11.11 [Ø0.438] THRU HOLE

”A”

”A” PLUS 15.7 [0.62]

5160--1 6.4 [0.25]

51 @ 90_ [2.0]

VIEW ”A”

5160--1 VIEW ”B”

VIEW ”C”

5160--7

M--030807--JRK--02

FIG. 4-15c — Spring Loaded Bolt Assembly for Spider Arm Shield

4-22

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

Drive Align the motor and put the floating shaft in place.

NOTICE Set gear - pinion alignment and backlash prior to setting the drive. Refer to “Gear and Pinion Backlash Adjustment” and “Curved Tooth Spiral Bevel Gear Installation and Maintenance” in Section 9.

NOTICE Drive must be arranged so that the pinionshaft rotates clockwise, viewed from the outboard end, making the crusher’s direction of gyration such that the self-tightening head nut functions properly. Lubrication and MPS Control Piping The external lubrication package includes the tank, pumps, motors, piping, etc., for both the MPS control and crusher lubricating systems. Locate the package as close to the crusher as practical, to keep piping to a minimum. You will have to supply pipes and fittings for carrying oil between the crusher and tank. See Fig. 4-17 for piping lubri-

cation systems with the oil-to-air heat exchanger. See Fig. 4-18 for piping arrangement where optional oil-to-water heat exchanger is used. Two pipes carry the lubricating oil to connections on the crusher; another larger pipe carries return oil to the tank. A separate pipe connects the crusher with the pump for the MPS control. Be sure all piping is properly supported and braced to prevent “springing” of joints and possible leakage. Two sediment separators are supplied with each crusher for installation, one each, in the two oil lines to the crusher. Install each separator as close to the crusher as is practical, with the open end of the “Y” toward the crusher. Separators are provided to reduce the possibility of particles in the oil stream getting into bearing areas. See Section 5 under “Sediment Separators” for details.

NOTICE Before assembling the piping, be sure it is free of such foreign matter as chips, dirt, slag and scale that can be picked up in the lubricating oil and damage bearing surfaces. Remove burrs from inside and outside of tubes or pipes and make all joints oil tight.

5675-0

5705-0

SK021892JJB7A FIG. 4-16 — Spider Bushing (5675-0) with Dual Oil Seals (5705-0) Lip Upwards

17X0501-01.0701

4-23

Section 4 — Installation

SUPERIOR MK- II Gyratory Crushers

Lubrication System Either pipe, tubing or hose may be used for connections between the crusher and lubrication system. Keep the number of bends at a minimum to avoid unnecessary line resistance. Install adequate supports and protection to guard pipe or tubing against mechanical loading and wear.

to be connected, by means of a 1” minimum diameter line, to the lube oil reservoir in order to provide a closed vent system for the bottom shell. A low pressure air or exhaust hose is adequate for this line. The connection to the lube tank is to be made at the tee located beneath the pressure relief/breather on top of the tank. See Fig. 4-17.

CAUTION

NOTICE

Fittings suitable for 150 psi (10.54 kg per sq.. cm) oil pressure and higher must be used. Higher than normal operating pressures occur when the crusher and oil are cold.

This closed vent system must be installed in order to provide proper breathing of the bottom shell and prevent dust ingression and lube oil contamination.

Use as large a diameter no smaller than return port on bottom shell and as steep a slope as possible for the return oil line to insure free gravity oil flow from the crusher to the oil tank. The minimum recommended slope is one inch (2.54 cm) per foot (30.48 cm) of pipe. Keep bends and elbows to a minimum. There is no pressure involved. MPS System A separate pipe connects the crusher with the MPS control modular valve assembly.

CAUTION Use high pressure pipe, suitable for 3,000 psi (210.0 kg per sq. cm) for all piping between the pump in the MPS control and the crusher. This type of pipe is usually designated by the term “Schedule No. 80.” Most components used with MPS control are mounted on the lubrication system base. See “Lubrication System Components” in the appendix to this section. These include the MPS oil tank, pump assembly (8104-0), control valve assembly (8608-0) and filter (8609-1). These components are pre-piped. In addition, two relief valves (8645-0), balance cylinders (8075-0), check valve (8525-0) and piping (8405-0, 8555-0 and 8558-0) are provided for mounting to the crusher. See Fig. 4-19 See Sections 5, “Lubrication System,” and 6, “MPS Control System,” of this manual for details. Details on the balance cylinder (8075-0) supplied with primary gyratory crushers are also included in Section 6, “MPS Control System.” Bottom Shell Vent System An air inlet connector (1675-0) is located in the bottom shell at one of the arms. This connector has a 1” NPT port

4-24

NOTICE A sight gauge and drain plug are located at the bottom of the air inlet connector (1675-0, Fig. 4-17). When oil or water appears in the sight gauge it should be drained to prevent it from entering the crusher or plugging the closed vent system or the over pressure dust sealing line. Over Pressure Dust Sealing Unit (8896-0) In addition to the closed vent system, pressurized air should be supplied into the bottom shell via the air inlet connector (1675-0, Fig. 4-17) to maintain a positive pressure inside the crusher and prevent dust ingression. Pressurized air can be supplied from either the air blower (8896-0, Fig. 4-17), which is supplied with the crusher, or from a compressed air source. If the blower that was supplied with the crusher is used, it should be installed in a dust free area, at least 8 inches (200 mm) above the inlet to the crusher. Piping between the blower, which has a 1.0” NPT male pipe thread outlet, and the air inlet connector (1675-0) located on the bottom shell at one of the arms, should be 1.0” SCH 40 pipe or equivalent hose (not furnished). When connecting the blower motor, check that the direction of rotation corresponds to the arrow on the blower housing and that it starts and stops with the crusher drive motor. If compressed air is to be used, piping should be 1.0” SCH 40 pipe or equivalent hose, valved to admit approximately 6 CFM to the crusher. The compressed air should be filtered and dry.

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

8896--3 8896--0

8075--0 8525--0 LUBE LINE TO BOTTOM SHELL

1675--0

MPS PIPING

7000--0

LUBE LINE T O MPS CYLINDER

7705--1

7705--2

40 GPM (151.4 LPM) LUBE SUPPLY LINE 50 GPM (189.3 LPM) LUBE SUPPLY LINE M--12307--TAW--07

7850--2 7850--1

FIG. 4-17 — General Arrangement of Lubrication and MPS Systems with Oil-to-Air Cooler Catalog Number 1675-0 7000-0 7705-1 7705-2 7850-1

Description Air inlet connector Lubrication and MPS system Oil-air cooler (Lower Lube Line) Oil-air cooler (Upper Lube Line) Flow Monitor (Lower Lube Line)

17X0501-01.0701

Catalog Number 7850-2 8075-0 8525-0 8896-0 8896-3

Description Flow Monitor (Upper Lube Line) Balance cylinder MPS check valve Air blower Air blower filter element

4-25

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

8896--3 8896--0

8075--0 8525--0 LUBE LINE TO BOTTOM SHELL

1675--0

7000--0

MPS PIPING

LUBE LINE TO MPS CYLINDER

WATER INLET 7705--2

WATER OUTLET

7705--1

40 GPM (151.4 LPM) LUBE SUPPLY LINE 50 GPM (189.3 LPM) LUBE SUPPLY LINE

7850--2 7850--1

M--012407--TAW--01

FIG. 4-18 — General Piping Arrangement for Lubrication System with Oil-to-Water Cooler Catalog Number 1675-0 7000-0 7705-1 7705-2 7850-1

4-26

Description Air inlet connector Lubrication and MPS system Oil-air cooler (Lower Lube Line) Oil-air cooler (Upper Lube Line) Flow Monitor (Lower Lube Line)

Catalog Number 7850-2 8075-0 8525-0 8896-0 8896-3

Description Flow Monitor (Upper Lube Line) Balance cylinder MPS check valve Air blower Air blower filter element 17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

(INCH) 1” NPT (FEMALE) MPS OIL INLET PORT 8645--0

8525--0

8555--0

8075--0

TO MPS PRESSURE TRANSDUCER

8558--0

M--012407--TAW--02

FIG. 4-19 — Balance Cylinders and MPS Piping

17X0501-01.0701

Catalog Number

Description

8075-0 8525-0 8555-0 8558-0 8645-0

Balance Cylinders MPS Check Valve Pipe Assembly Flange to Check Valve Lower Pipe Assembly Relief Valve

4-27

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

WEIGHTS AND DIMENSIONS

D D

E

E

’N’ for mainshaft

N assembly removal

F

K

L

G J

End of shaft

M

P O

Minimum for removing eccentric

H

Recommended discharge chamber size minimum two truckloads live storage

FIG. 4-20 — Weights and Dimensions TABLE 4-1 — Approximate Dimensions - ft. in. (cm)

ft.-in. cm

D

E

F

G

H

J

K

L

M

N

O

P

8-0 243.8

7-2 218.4

20-8 629.9

37-11 3/8 1156.7

12-0 1/8 366.1

18-11 576.6

7-0 1/4 214.9

9-4 284.5

0-9 22.9

26-0 3/16 793.0

6-9 205.7

15-8 477.5

TABLE 4-2 — Approximate weight of major lifts - Lbs (Kgs) *

Bottom Shell with Side Liners

288,000 (130,636)

Top Shell - Upper, without Concaves

163,200 (74,027)

Eccentric Assembly

36,900 (16,738)

Mainshaft Assembly

229,000 (103,874)

MPS Assembly

46,900 (21,274)

Spider with Bushing only

183,000 (83,008)

Top Shell - Lower, without Concaves

155,000 (70,308)

Total Crusher Weight

1,305,000 (591,944)

* NOTE: See General Specification in Section 3 for additional weight information including assembly weights and see transmittal drawings provided by Metso Minerals for additional component weights.

4-28

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

TABLE 4-3 — 60-110 Tool List Description

Quantity

Part Number

2

3.00” x 11.25” bolt for piston stop plate

07-146-694-009

2

3.00-4 UNC nut for piston stop plate

00-631-041-148

2

1.00” x 9.00” long plain eyebolt for lifting eccentric gear

00-691-525-436

3

0.50” x 1.50” long plain eyebolt for lifting piston wearing plate and joint bolt assemblies

00-691-525-184

3

0.75” x 2.00” long shouldered eyebolt for lifting mainshaft sleeve, eccentric wearing ring, step washer, bottom shell bushing, pinion, and dust collar

00-691-531-302

3

1.00” x 2.50” long shouldered eyebolt for lifting MPS cylinder upper bushing, MPS cylinder lower bushing, mainshaft step, headnut and eccentric bushing

00-691-531-412

3

1.00-8 UNC Heavy Duty Hoist Ring for lifting pinionshaft housing

17-107-642-001

3

1.50-6 UNC Heavy Duty Hoist Ring for lifting eccentric and eccentric assembly

17-107-642-002

3

1.25” x 3.00” long shouldered eyebolt for lifting lower dust seat retaining ring and spider bushing

00-691-531-517

3

1.50” x 3.50” long shouldered eyebolt for lifting piston clamp plate and upper counterweight

00-691-531-618

3

2.00” x 4.00” long shouldered eyebolt for lifting piston assembly, MPS cylinder cover, MPS cylinder cover with piston clamp plate, pinion shaft and lower counterweight

00-691-531-709

1

0.63” Hex head wrench for MPS cylinder bushing and centering ring bolts

17-106-407-010

1

0.75” Hex head wrench for gear key bolt

17-106-407-009

1

0.88” x 12.75” Hex key for spider joint nut, lower dust seal retainer and other bolts

00-935-039-196

1

1.00” x 14.25” Hex key for spider bushing bolt

00-935-039-200

1

3.88”, 6 point, 1.50” drive impact socket for spider arm shield nuts

00-935-147-253

1

2.25”, 6 point, 1.00” drive impact socket for upper dust seal retainer bolt

00-935-141-236

1

1.88” open end wrench for pinionshaft housing and rim liner nuts

00-935-045-060

1

4.63” open end wrench for spider jack bolts

00-935-045-148

1

6.13” open end wrench for bottom shell joint and spider joint nuts and others

00-935-045-196

1

4.63” boxsocket sledging wrench for MPS cylinder and cover nuts

17-103-757-005

1

4.50” boxsocket sledging wrench for spider filler block bolt

17-103-757-015

1

Spanner wrench for pinionshaft spacer

07-249-918-501

1

Piston stop plate

07-249-913-501

3

2.00-4.5 UNC x 42.00” lowering rod assembly for piston

17-105-881-513

1

0.75” x 24.00” lowering rod assembly for mainshaft step

17-202-513-804

3

3.00-4.0 UNC x 90.5” guide rod for eccentric and MPS cylinder assembly

07-249-921-001

4

Shell splitting wedge

17-201-978-001

1

2.25” Hex head wrench for MPS cylinder cover plate bolts

00-935-039-310

1

0.38” Hex head wrench for MPS cylinder

00-935-039-151

1

0.50” Hex head wrench

00-935-039-161

1

0.63” Hex head wrench

00-935-039-181

1

Open end wrench set, 0.25” to 1.63”, 12 piece

17-107-059-001

1

Adjustable Wrench set, 8” and 12”, 2 piece

17-107-059-002

1

Charging and Gaging Assy. 300 PSI, for balance cylinders

07-149-510-002

17X0501-01.0701

4-29

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

PARTS LIST

Instructions for Ordering Parts When ordering parts, furnish the following information to nearest Metso Minerals distributor or sales office. Serial number of machine. Catalog number of part (if part number not available). Description of part. Quantity required. Definite shipping instructions. Strict compliance with instructions will expedite delivery of your order. 8425--0 8645--0 8645--1

8075--3 8075--4 8075--9

(INCH) 1” NPT (FEMALE) MPS OIL INLET POR

8076--0 8076--1

8075--0 8525--0

8415--0 8556--3 8556--4

9901--7 8454--0 8454--1

8556--0 8556--1 A

8558--0 8028--0

8540--0 8540--1

8405--0

8530--0

8556--0 8563--0

8029--0 8029--1 8029--2 8755--8

8521--0 8555--0 8207--0 A

8558--0

8565--0 8565--4 VIEW A--A

FLOW METER STATION MOUNT NEAR CRUSHER M--012407--TAW--03

FIG. 4-21 — Balance Cylinder and MPS Piping

4-30

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

Catalog Number 8028-0 8029-0 8029-1 8029-2 8075-0 8075-3 8075-4 8075-9 8076-0 8076-1 8207-0 8405-0 8415-0 8425-0 8454-0 8454-1 8521-0

Description Pipe Clamp Bracket Assembly Bolt Nut Washer Balance Cylinder Pressure Gauge Bushing Pressure Switch Bolt Nut Pressure Transducer Manifold Assembly Balance Cylinder Support Bracket Relief Valve Discharge Cup Manifold Flange Bolt Manifold Flange Lockwasher Check Valve Welding Flange

17X0501-01.0701

Catalog Number 8525-0 8530-0 8540-0 8540-1 8555-0 8556-0 8556-1 8556-3 8556-4 8558-0 8563-0 8565-0 8565-4 8645-0 8645-1 8755-8 9901-7

Description MPS Check Valve Check Valve Gasket Check Valve Stud Check Valve Nut Pipe Assembly - Flange to Check Valve O-Ring Square Flange with O-Ring Groove Bolt Washer Pipe Assembly - Cover to Flange Square Flange with O-Ring Groove Bolt Lockwasher Relief Valve Nipple Pipe Support Clamp Bleeder Valve

4-31

4-32 2

3

18 17 PART NO. 10 11 12 13 14 15 16 17 18

PISTON ROD 5

PARTS LIST NITROGEN-OIL BALANCE CYLINDER PART NO. PART NAME QUANTITY 1 ROD END COVER 1 2 BLIND END COVER 1 3 BALANCE TUBE BODY 1 4 PISTON U-CUP TYPE 1 5 PISTON ROD 1 6 PISTON GUIDE 1 7 O-RING (BUNA) 2 8 BACKUP (TEFLON) 2 9 BACKUP (TEFLON) 2

15

AIR VALVE 14

PIPE PLUG INSPECTION HOLE 11 BUNA O-RING 12 PISTON GUIDE 6 PISTON U-CUP TYPE 4 SET SCREW 13

PART NAME QUANTITY U-CUP (BUNA) 2 PIPE PLUGS (.25” NPT) 3 O-RING (BUNA) 1 SET SCREW (0.25”-20) 2 VALVE (0.25” NPT) 1 HEX NUT JAM (1.0”-14) 1 HEX NUT (0.75”-10) 24 TIE ROD (LONG) 8 TIE ROD (SHORT) 4

8

U-CUP BUNA 10 TEFLON BACKUP 9

BUNA O-RING 7

1

SK082598-JJB-1

CATALOG DESCRIPTION NUMBER 8075-4 SEALS REPAIR KIT 8075-8 PISTON REPAIR KIT

16 TORQUE 135 TO 145 FT.-LBS. (183 TO 197 Nm)

TEFLON BACKUP 8

Section 4 — Installation

SUPERIOR MK- II Gyratory Crushers

FIG. 4-22 — Balance Cylinder

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

Catalog Number 7005-0 7005-3 7005-5 7005-8 7120-0 7150-0 7165-0 7205-0 7206-0 7207-0 7405-0 7406-0 7406-1 7505-0 7505-1 7720-0 8005-3 8005-5 8104-0 8225-0 8608-0 8609-8 8609-9 8825-0

8225--0 Description Base and Tank Assembly Lube Oil Level Transmitter Inspection Cover, Lube Tank Sight Gauge - Lube Oil Pressure Breather Sieve - Return Temperature Transmitter Lube Pumping Unit - 40 gpm [151 LPM] Lube Pumping Unit - 50 gpm [189 LPM] Pressure Transmitter Ball Valve Proximity Switch Assembly Proximity Switch Filter Filter Cartridge Check Valve MPS Oil Level Sensor MPS Oil Fill Plug MPS Pumping Unit Ball Valve Control Valve Assembly MPS Filter Indicator MPS Filter Element Immersion Heaters

8005--3

8608--0

7005--0

8104--0

8609--8 8609--9 8005--0

7005--0

7405--0 7406--0 7406--1

8825--0 7405--0 7406--0 7406--1

7205--0 7206--0

7120--0 7005--3 7207--0 7165--0

7505--0 7505--1

A

7005--3 7165--0 7207--0

7505--0 7505--1

7505--0 7505--1

7720--0 7005--0

7405--0 7406--0 7406--1

7405--0 7406--0 7406--1

7405--0 7406--0 7406--1

7005--8

7720--0

7720--0

A VIEW A--A

50 GPM (189.3 LPM) LUBE SUPPLY PUMPS

40 GPM (151.4 LPM) LUBE SUPPLY PUMPS M--012407--TAW--04

FIG. 4-23 — Lubrication System

17X0501-01.0701

4-33

SUPERIOR MK- II

Section 4 — Index

Gyratory Crushers

5650--0 5160--0 5160--1 5160--5 5160--6 5160--7 5160--9

5755--1 4050--0 5755--3 5755--2 5760--0 5760--4 5675--0 4025--4 5705--0 5706--0

5750--0 4025--3 5685--0 5685--2 5685--4 5220--0

5605--0 5240--0

4025--0 4205--0 4220--0 5150--0 5125--0 5125--1 5125--2 5125--3 5125--5

5253--0 5255--0 5313--0 5275--0 5285--0 5285--4

5635--0 5636--0 5625--0 5005--2

6395--0 6395--1 5310--0 5310--1 5310--3

5311--0 5311--1 5311--3 4175--9 4175--3 4005--0

6385--0 6385--1 6365--0 6365--1 6399--0 5340--0 5340--1 5340--3 6345--0 6345--1 6325--0 6325--1

4175--1 5005--1 1400--0 1540--0 1540--1 1540--3 1811--8 1420--0

6305--0 6305--1 4415--0 4425--0 4435--0 4435--3 6050--0

4305--0 4350--0 1010--2 (NOT SHOWN) 1010--3 (NOT SHOWN) 1010--4 (NOT SHOWN) 1010--7 1010--8 1020--1 (NOT SHOWN) 1040--0 1040--1 1040--3 1430--0 1805--0 1006--0 1005--0 1261--0 1261--4 1255--0 1250--0 1260--0 3341--6 3342--1

(NOT SHOWN) 1811--1 (NOT SHOWN) 1811--4 1811--5 4405--0 1421--0 4365--0 4365--4 (NOT SHOWN) 1405--0 (NOT SHOWN) 1405--1 (NOT SHOWN) 1405--4 (NOT SHOWN) 1408--0 1675--0 1677--0 1677--4 1676--0 1676--1 1820--0 3005--1

3835--0 1285--0 1200--0 SEE VIEW ”B”

3005--7

3005--0

1210--0 3005--2 3005--6 3030--0

3342--2

1810--0 1812--0

SEE VIEW ”A”

1910--0 1910--4 (NOT SHOWN) 1280--0 2140--0 1812--1 1812--2 1812--4 (NOT SHOWN) 1812--5 1905--0 1880--0 1855--0 1857--0 4085--0 4085--9 4135--0

2520--0

1920--0 1850--0 2020--0 2020--1 2020--3 4075--0 4035--0

3341--6 3030--0 3505--0

8560--0 2660--1 2660--2 2660--3 2660--4 2660--5

8563--0 2661--0 2661--4

8565--0 8565--4

M--012207--TAW--01

FIG. 4-24A — 60-110 SUPERIOR Crusher Sectional Elevation

4-34

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SUPERIOR MK- II Gyratory Crushers

Section 4 — Installation

5110-3

FIG. 4-24B — 60-110 SUPERIOR Crusher Sectional Elevation — Additional Views

17X0501-01.0701

4-35

SUPERIOR MK- II

Section 4 — Index

Gyratory Crushers TABLE 4-6 — Catalog Numbers and Descriptions CAT. NO. 1005--0 1006--0 1010--2 1010--3 1010--4 1010--7 1010--8 1020--1 1040--0 1040--1 1040--3 1200--0 1210--0 1250--0 1255--0 1260--0 1261--0 1261--4 1280--0 1285--0 1305--1 1305--3 1305--4 1305--6 1306--0 1306--1 1310--0 1320--0 1320--1 1320--2 1320--5 1321--1 1321--2 1350--1 1350--2 1352--0 1360--0 1365--0 1365--1 1365--2 1365--3 1400--0 1405--0 1405--1 1405--4 1408--0 1420--0 1421--0 1430--0 1505--0 1505--1 1505--2 1505--3 1540--0 1540--1 1540--3

4-36

DESCRIPTION LOWER BOTTOMSHELL UPPER BOTTOMSHELL NARROW ARM LINER NARROW ARM LINER EXTENSION HOLDING LUG PINIONSHAFT ARM LINER L.H. PINIONSHAFT ARM LINER R.H. PINIONSHAFT ARM LINER SUPPORT BLOCK BOTTOMSHELL JOINT BOLT BOTTOMSHELL JOINT BOLT NUT BOTTOMSHELL JOINT BOLT LOCKNUT BOTTOMSHELL BUSHING BOTTOMSHELL BUSHING KEY LUBRICATION PIPE PACKING SLIP--ON FLANGE FLANGE BOLT FLANGE BOLT LOCKWASHER ROLL PIN BOTTOMSHELL PIPE PLUG AIR PRESSURE PORT UPPER HUB LINER L.H. UPPER HUB LINER R.H. LOWER HUB LINER L.H. LOWER HUB LINER R.H. HUB LINER CAPSCREW BOTTOMSHELL HUB LINER WASHER BOTTOMSHELL HUB LINER PLATE BOTTOMSHELL SIDELINER PINIONSHAFT SIDELINER L.H. PINIONSHAFT SIDELINER R.H. BOTTOMSHELL SIDELINER SUPPORT BLOCK NARROW ARM SIDELINER L.H. NARROW ARM SIDELINER R.H. SIDELINER SUPPORT BLOCK SIDELINER UPPER HOLDING BLOCK SIDELINER WEDGE SIDELINER CLAMPING BLOCK LOCATING PLUG PINION SIDELINER LOCATING PLUG NARROW ARM LINER LOCATING PLUG NARROW ARM LINER LOCATING PLUG SIDELINER DUST COLLAR DUST COLLAR STUD DUST COLLAR STUD NUT DUST COLLAR STUD LOCKWASHER DUST COLLAR DOWEL UPPER COUNTERWEIGHT SPLASH RING UPPER COUNTERWEIGHT SPLASH RING BOLT DUST COLLAR GASKET PINION HOUSING STUD PINION HOUSING STUD NUT PINION HOUSING STUD LOCKWASHER PINION HOUSING STUD JAMNUT BOTTOMSHELL JOINT BOLT BOTTOMSHELL JOINT BOLT NUT BOTTOMSHELL JOINT BOLT LOCKNUT

CAT. NO. 1675--0 1676--0 1676--1 1677--0 1677--4 1805--0 1810--0 1811--1 1811--4 1811--5 1811--8 1812--0 1812--1 1812--2 1812--4 1812--5 1820--0 1850--0 1855--0 1857--0 1880--0 1905--0 1910--0 1910--4 1920--0 2005--0 2020--0 2020--1 2020--3 2050--1 2050--2 2055--0 2060--0 2060--4 2090--0 2120--0 2140--0 2205--0 2217--0 2225--0 2260--0 2280--0 2282--0 2283--0 2283--4 2305--0 2325--0 2340--0 2340--8 2345--0 2345--8 2346--0 2505--0 2506--0 2510--0 2510--2 2515--0

DESCRIPTION AIR INLET CONNECTOR SLIP--ON FLANGE PACKING FLANGE BOLT FLANGE BOLT LOCKWASHER ECCENTRIC ECCENTRIC BUSHING UPPER COUNTERWEIGHT CAPSCREW UPPER COUNTERWEIGHT LOCKWASHER UPPER COUNTERWEIGHT UPPER COUNTERWEIGHT RING LOWER COUNTERWEIGHT LOWER COUNTERWEIGHT CAPSCREW LOWER COUNTERWEIGHT WASHER LOWER COUNTERWEIGHT LOCKWASHER LOWER COUNTERWEIGHT DOWEL ECCENTRIC BUSHING KEY BEVEL GEAR BEVEL GEAR KEY GEAR KEY BOLT ECCENTRIC WEAR PLATE ECCENTRIC SUPPORT PLATE ECCENTRIC SUPPORT PLATE BOLT LOCKWASHER O--RING MPS CYLINDER MPS CYLINDER STUD MPS CYLINDER STUD NUT MPS CYLINDER STUD LOCKNUT LOWER MPS CYLINDER BUSHING UPPER MPS CYLINDER BUSHING LOWER MPS CYLINDER BUSHING BOLT UPPER MPS CYLINDER BUSHING BOLT UPPER MPS CYLINDER BUSHING LOCKWASHER MPS CYLINDER COVER ROLL PIN BOTTOMSHELL DRAIN PLUG MPS CYLINDER O--RING PISTON PLUG PISTON DOWEL PISTON WEAR PLATE STEP WASHER MAINSHAFT STEP CENTERING RING CENTERING RING BOLT LOCKWASHER OIL SEAL CLAMP PLATE MEASURING TUBE HOLDER O--RING MEASURING TUBE PLUG SEAL RING MEASURING TUBE HOLDER PLUG MPS CYLINDER COVER MPS CYLINDER COVER O--RING COVER PLATE GUARD POSITION INDICATOR CAPSCREW MPS CYLINDER COVER BOLT

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

TABLE 4-6 (continued) CAT. NO.

DESCRIPTION

CAT. NO.

2515--1

MPS CYLINDER COVER NUT

4025--4

MAINSHAFT SLEEVE LOCKWASHER

2515--3

MPS CYLINDER COVER LOCKNUT

4035--0

MAINSHAFT DOWEL

2520--0

MPS CYLINDER CAPSCREW

4050--0

EYEBOLT

2530--0

MPS CYLINDER DRAIN PLUG

4075--0

MAINSHAFT STEP

2605--1

POSITION INDICATOR

4085--0

MAINSHAFT STEP RETAINER BOLT

2606--1

CAPSCREW

4085--9

MAINSHAFT STEP RETAINER BOLT WIRE

2606--2

WASHER

4135--0

MAINSHAFT STEP RETAINER

2606--8

O--RING

4175--1

LOWER MANTLE

2630--0

MEASURING TUBE

4175--3

UPPER MANTLE

2650--0

POSITION INDICATOR ADAPTOR

4175--9

BACKING

2650--8

O--RING

4205--0

HEADNUT

2651--0

CAPSCREW

4220--0

HEADNUT DOWEL

3005--0

PINIONSHAFT HOUSING

4305--0

DUST SEAL RING

3005--1

COVER PLATE

4350--0

LOWER DUST SEAL RETAINER

3005--2

LOCKWASHER

4365--0

LOWER DUST SEAL RETAINER BOLT

3005--3

PINIONSHAFT HOUSING PLUG

4365--4

LOCKWASHER

3005--4

PINIONSHAFT HOUSING BREATHER PLUG

4405--0

SPLASH CURTAIN

3005--6

COVER PLATE BOLT

4415--0

SPLASH CURTAIN RETAINER

3005--7

PIPE PLUG

4425--0

SPLASH CURTAIN CLAMP

3006--0

PINION ADJUSTING BOLT

4435--0

RETAINER CLAMP BOLT

3006--2

NUT

4435--3

LOCKNUT

3030--0

PINIONSHAFT HOUSING GASKET

5005--1

LOWER TOPSHELL

3050--0

PINION

5005--2

UPPER TOPSHELL

3070--1

PINION END BEARING

5007--1

SHELL SEPARATOR BOLT

3070--2

DRIVE END BEARING

5007--2

SHELL SEPARATOR COLLAR

3090--1

PINION END SPACER

5110--1

L.H. SPIDER RIM LINER

3090--2

DRIVE END LOCKNUT

5110--2

CENTER SPIDER RIM LINER

3120--1

PINION END SPACER GASKET

5110--3

R.H. SPIDER RIM LINER

3120--2

LOCKNUT GASKET

5125--0

RIM LINER BOLT

3150--0

LOCKNUT LOCKWASHER

5125--1

RIM LINER BOLT

3170--1

PINION END OIL SEAL

5125--2

SPRING RETAINER WASHER

3170--2

DRIVE END OIL SEAL

5125--3

LOCKNUT

3190--1

PINION END SEAL PLATE

5125--5

RIM LINER BOLT SPRING

3190--2

DRIVE END SEAL PLATE

5150--0

SPIDER ARM SHIELD

3210--0

PINION END SEAL PLATE BOLT

5160--0

SPIDER ARM SHIELD BOLT

3210--4

LOCKWASHER

5160--1

SPIDER ARM SHIELD NUT

3220--0

DRIVE END SEAL PLATE BOLT

5160--5

SPIDER ARM SHIELD BOLT SPRING

3220--4

LOCKWASHER

5160--6

SPRING CAGE

3231--0

DRIVE END LUBE FITTING

5160--7

COTTER PIN

3240--1

PINION END SEAL PLATE GASKET

5160--9

SPRING RETAINER

3240--2

DRIVE END SEAL PLATE GASKET

5220--0

SPIDER LUBE ELBOW

3305--0

PINIONSHAFT HOUSING BREATHER

5240--0

SPIDER LUBE HOSE

3341--6

PINIONSHAFT SIGHT GAUGE PLUG

5253--0

SPIDER LOWER LUBE LINE COUPLING

3342--1

PINIONSHAFT SIGHT GAUGE TEE

5255--0

SPIDER LUBE PLUG

3342--2

PINIONSHAFT SIGHT GAUGE NIPPLE

5275--0

SPIDER LUBE HOSE BRACKET

3505--0

PINIONSHAFT

5285--0

HOSE BRACKET BOLT

3515--0

PINION KEY

5285--4

LOCKWASHER

3525--0

PINION KEY RETAINING SCREW

5310--0

SPIDER JOINT STUD

3540--0

PINIONSHAFT HOUSING JACKBOLT

5310--1

SPIDER JOINT STUD NUT

3555--0

DRIVE KEY

5310--3

SPIDER JOINT STUD LOCKNUT

3575--0

OIL INLET PLUG

5311--0

SPIDER JOINT BOLT

3585--0

OIL DRAIN PLUG

5311--1

SPIDER JOINT BOLT NUT

3835--0

EXTENDED LUBE FITTING ASM

5311--3

SPIDER JOINT BOLT LOCKNUT

4005--0

MAINSHAFT

5313--0

SPIDER LUBE LINE COUPLING

4025--0

MAINSHAFT SLEEVE

5340--0

TOPSHELL JOINT BOLT

4025--3

MAINSHAFT SLEEVE LOCKNUT

17X0501-01.0701

DESCRIPTION

4-37

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

TABLE 4-6 (continued) CAT. NO.

DESCRIPTION

CAT. NO.

DESCRIPTION

5340--1

TOPSHELL JOINT BOLT NUT

6050--0

CONCAVE SUPPORT RING

5340--3

TOPSHELL JOINT BOLT LOCKNUT

6305--0

CONCAVE--BOTTOM TIER (FIRST)

5605--0

SPIDER

6305--1

KEY CONCAVE--BOTTOM TIER (FIRST)

5625--0

SPIDER FILLER BLOCK

6325--0

CONCAVE--SECOND TIER

5635--0

SPIDER FILLER BOCK BOLT

6325--1

KEY CONCAVE--SECOND TIER

5636--0

SPIDER FILLER BOLT

6345--0

CONCAVE--THIRD TIER

5650--0

SPIDER CAP

6345--1

KEY CONCAVE--THIRD TIER

5675--0

SPIDER BUSHING

6365--0

CONCAVE--FOURTH TIER

5685--0

SPIDER BUSHING BOLT

6365--1

KEY CONCAVE--FOURTH TIER

5685--2

WASHER

6385--0

CONCAVE--FIFTH TIER

5685--4

LOCKWASHER

6385--1

KEY CONCAVE--FIFTH TIER

5705--0

SPIDER BUSHING OIL SEAL

6395--0

CONCAVE--UPPER TIER (SIXTH)

5706--0

SCRAPER

6395--1

KEY CONCAVE--UPPER TIER (SIXTH)

5750--0

BREATHER PLUG

6399--0

BACKING

5755--1

SPIDER VENT COVER

8560--0

O-RING

5755--2

VENT COVER SEAL

8563--0

BAL. CYL. TO MPS CYL. FLANGE

5755--3

VENT COVER ACCESS PLUG

8565--0

MPS PIPE TO CYL. COVER CAPSCREW

5760--0

CAPSCREW

8565--4

LOCKWASHER

5760--4

LOCKWASHER

4-38

17X0501-01.0701

SUPERIOR MK- II Gyratory Crushers

EPOXY BACKING — DIRECTIONS FOR USE General Information All crushers require some type of backing when replacing the crushing wear members. Epoxy resin backing compounds have all but eliminated the possibility of workers being accidentally burned due to molten zinc either spilling or exploding when it comes in contact with wet surfaces. Epoxy backing will flow into spaces where zinc will not, thus providing more solid support. Epoxy backing is designed for impact resistance, compressive strength, chemical resistance and economy of installation. In its cured form, epoxy backing also resists most solvents, greases, oils, acids and alkalies that are found around construction machinery. Long term exposure to water may ultimately weaken regular backing. Applications As a backing for crusher wearing parts, epoxy backing has a relatively high impact strength when tested on a “Bond Impact Tester.” The recommended backing for SUPERIOR gyratory crushers is a high performance epoxy backing with a compressive strength of 18,000psi (124 Mpa). The backing should also have good water resistance and low shrinkage properties. The 22-pound (10 Kg) kit provides 358 cubic inches (5866 cm3) of backing.

NOTICE In order to obtain these fully cured properties, the whole process of mixing, pouring, and maintaining the correct temperatures of the epoxy backing and the adjacent machinery parts must be strictly controlled. Precautions when Using Epoxy Backing

WARNING

Section 4 — Installation

THE USER NEEDS TO STRICTLY CONTROL THE COMPLETE PROCESS OF STORAGE, MIXING, POURING, AND MAINTAINING CORRECT TEMPERATURES OF THE EPOXY BACKING AND MACHINERY PARTS AS CALLED FOR IN THESE DIRECTIONS. METSO MINERALS MAKES NO WARRANTY WHETHER EXPRESSED OR IMPLIED INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY AND USER ASSUMES ALL RISK WITH RESPECT TO THE FITNESS OF THIS PRODUCT FOR HIS USE. Storing Epoxy Backing Unopened and undamaged kits of epoxy backing have a limited shelf life of one year. Do not store where temperatures exceed 90° F (32.2° C) or below 32° F (0° C) for longer than 6 months. Rotate any stock on hand to avoid exceeding storage limits. The batch number stamped on the label on each container shows the date when packaged. Do not attempt to mix partial containers of epoxy backing. Do not add foreign material to the backing. Temperature Affects Cure When curing, the hardener and resin portions react and generate heat. Epoxies are good insulators and, in large masses, the internal heat build-up will shorten the working time. When poured in thin sections, along with natural heat loss to surrounding materials, cure takes longer. The optimum temperature range for mixing and pouring epoxy backing is 70--80° F (21--26.6° C). When air temperature is below 60° F (15.6° C), warm unmixed ingredients to the 70--80° F (21--26.6° C) range. If air temperature is above 90° F (32.2° C), cool ingredients by immersion in cool water or store in air conditioned room, to optimum temperature range of 70° F -- 80° F (avoid getting water into the contents of containers).

NOTICE

Carefully follow the instructions as well as the precautions that are printed on the individual containers of epoxy before mixing and pouring. Skin contact with epoxy may cause serious delayed dermatitis. Avoid inhalation of vapor. Prevent all contact with skin. If contact occurs, wash immediately with soap and water.

The time required for a complete cure for epoxy backing used for backing crusher wear parts depends on environmental temperature. Full compressive strength may not be obtained for 7 days. Typical cure time (the time before the material is strong enough for use) as a function of temperature is shown in Fig. 4-30.

Although epoxy backing has a very low or zero volatility, it is essential to mix and pour in a well-ventilated area. Do not burn cured resin without adequate ventilation and respiration equipment. Epoxy backing should be washed immediately from skin with soap and water. Should epoxy backing get into the eyes, flush immediately with running water for at least 15 minutes. Launder soiled clothes before reuse.

Epoxy backing retains its temperature (hot or cold) for long periods of time. During cold weather, it should be maintained at 60° F (15.6° C) or above for at least 12 hours before use.

17X0501-01.0701

4-39

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

CURE TIME, HOURS

30 25 20 15 10 5 0 50 (10)

60 (16)

70 (21)

80 (27)

90 (32)

TEMPERATURE OF CONCAVES OR MANTLES, _F (_C) M--010704--TAW--01

FIG. 4-30 — Epoxy Backing Cure Time Versus Temperature

NOTICE Pouring into or against cold machinery will adversely affect curing. Parts to be filled must be warmed to 70 -80° F (21 -- 26.6° C). Effect of Moisture Epoxy backing can be poured into damp areas, although it will not adhere to damp surfaces. Small amounts (several grams) of water accidentally entrained into the material during mixing will alter the cure time and cause the backing to be slightly porous. If greater amounts of water become entrained in the material during mixing, it will lose its strength characteristics and become unusable. Preparation of Machine Parts Backing Crusher Parts 1. Prepare all parts by removing all oil, grease, scale, rust, dirt, etc. from surfaces to be bonded. Epoxy backing is normally bonded to wearing parts only and this especially applies to self tightening crusher mantles. However, in the case of SUPERIOR crusher concaves only, epoxy backing should be bonded to both wearing parts and mating surfaces for extra stability. Therefore, both surfaces must be cleaned, preferably by sandblasting.

4-40

2. Where necessary, coat surfaces not to be bonded with silicone spray or another release agent to prevent bonding. DO NOT USE GREASE OR HEAVY OILS FOR THIS PURPOSE. 3. Assemble the mating parts. 4. Seal all holes and open joints with plaster of Paris to prevent leakage of epoxy backing. 5. Protect threaded parts with clay or putty dams to direct flow away from threads. 6. To provide for proper flowing and curing of epoxy backing at temperatures lower than 60° F (15.5° C), warm parts to be bonded, and unmixed epoxy backing, to 70 - 80° F (21 - 26.6° C).

CAUTION Adequately vent working area when heating crusher parts and do not create fire hazards.

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

hardening time is extended to 30-40 minutes if pouring is started immediately after mixing. This extended hardening time occurs when epoxy backing is in thin sections or between cooler surfaces.

Mixing Epoxy Backing Epoxy backing resin must be mixed thoroughly and uniformly with hardener before using. Otherwise it will not flow and cure properly. When mixing an entire kit, 22 pounds (10Kg) of resin, with hardener supplied, follow these instructions: 1. When air temperature is lower than 60° F (15.6° C), warm unmixed epoxy backing to 70 - 80° F (21-26.6° C). 2. When air temperature is above 90° F (32.2° C) cool unmixed epoxy backing to 70° - 80° F (21° - 26.6° C) by immersion of closed and sealed container in cool water. 3. Pre-mix resin thoroughly with power drill and stirring rod, scraping bottom and sides of container. Mix for one to two minutes. Do not exceed 850 rpms. 4. Add entire contents of hardener container and continue power mixing until mixture is completely uniform in color (streaks of color in mixture or around edge indicate further mixing is required). 5. Use of less than full kits of epoxy backing for crusher wear surface backing is not recommended.

Backing Crusher Parts 1. For uniform distribution, pour mixture at several points around the cavity. 2. Additional batches of epoxy backing can be poured with positive bonding results.

NOTICE When pouring epoxy backing behind gyratory crusher concaves, flow difficulties may be avoided if poured in quantities to fill no more than one tier of concaves at a time. Quantity Requirements For estimating quantity requirements, refer to the following table.

CAUTION

NOTICE

Mix and pour epoxy backing only in quantities that allow complete usage before working life is exceeded.

If concaves are supplied with the backs paneled out, fill the panels with grout, or more epoxy backing material will be required than was supplied with your crusher. Also note that thicker sections of epoxy backing allow more shrinkage. For thick sections, a second pour may be advisable.

Pouring Epoxy Backing Pour mixed epoxy backing immediately. Hardening begins when hardener is added to resin. Mixed epoxy backing (at 70° F or 21° C) will harden into a solid mass in approximately 20 minutes if left in the container. This BACKING QUANTITY REQUIREMENTS

TABLE 4-7 — Approximate Quantities of Backing Required for Mantles and MANGANESE CONCAVES Backing Requirements — SUPERIOR Crushers Manganese Concaves SUPERIOR Crusher Model Size

Epoxy Kits

Pounds

60--110

185

18,500

Mantles

Zinc Kilograms

Epoxy Kits

8,392

Pounds

50

5,000

Zinc Kilograms 2,268

TABLE 4-8 — Approximate Number of Epoxy Backing Kits Required for ALLOY STEEL CONCAVES SUPERIOR Crusher Model Size

Lower Row Kits

60 110 60--110

53

17X0501-01.0701

Second Row Kits

Third Row Kits

Fourth Row Kits

Middle Row Kits 106

Fifth Row Kits

Upper Row Kits

Total 22 lbs. (10Kg) Each

73

232

4-41

SUPERIOR MK- II

Section 4 — Installation

MAINSHAFT LIFTING EYE DIMENSIONS The lifting eye on the mainshaft is permanently installed. If a shackle is required between the eye and the lifting hook, use the largest standard shackle fitting the 10.0 inch (254 mm) dimension. The mainshaft assembly weight for the 60--110 SUPERIOR Crusher is 229,000 lbs (103,874 Kg).

Gyratory Crushers

Ø10.00 (Ø254)

10.00 (254)

14.00 (355.6)

M--012407--TAW--05

FIG. 4-31 — Mainshaft Lifting Eye

4-42

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

PROCEDURE FOR TIGHTENING BOLTS Successful operation of a machine depends upon good maintenance. MACHINERY MUST BE INSPECTED FREQUENTLY TO INSURE 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. 1. Deburr all bolt holes before 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 4-32. 4. Use the proper size and grade of bolt required for the 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 “foot pounds” and “kilogram meters” (in parentheses).

5. Tighten bolts to the recommended torque value with a torque wrench. If a Torque Wrench is not Available 1. Install sufficient fitting-up bolts and tighten as required to bring the parts together. 2. Install bolts in the balance of the holes.Tighten the nuts by the “turn-of-nut” method. This requires that bolts be brought to a “snug-tight” condition to insure that the joint material is properly compacted before the nut is rotated through the specified turn. “Snugtight” 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.

Bolt

Hardened Washers

Holes Must Not Be More Than 1/16” (2 mm) Larger Than Bolt Diameter

Nut

FIG. 4-32

17X0501-01.0701

4-43

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

SUPERIOR CRUSHER BOLT TORQUES

TABLE 4-10 — Minimum and Maximum Bolt Torque Values — Foot Pounds (Kilogram Meters) A325

A490

ASTM-A354 GRADE BC

SAE GRADE 8 ASTM-A354 GRADE BD

10 (1.4) 11 (1.5) 21 (2.9) 22 (3.0)

12.5 (1.7) 13.2 (1.8) 26 (3.6) 27 (3.7)

14.3 (2.0) 15.1 (2.1) 29 (4.0) 31 (4.3)

37 (5.1) 39 (5.4)

37 (5.1) 39 (5.4)

46 (6.4) 48 (6.6)

52 (7.2) 55 (7.6)

38 (5.3) 40 (5.5)

59 (8.2) 63 (8.7)

59 (8.2) 63 (8.7)

73 (10.1) 77 (10.6)

84 (11.6) 88 (12.2)

.50

58 (8.0) 62 (8.6)

90 (12.4) 95 (13.1)

90 (12.4) 95 (13.1)

90 (12.4) 95 (13.1)

112 (15.5) 118 (16.3)

128 (17.7) 135 (18.7)

128 (17.7) 135 (18.7)

.5625

84 (11.6) 89 (12.3)

130 (18.0) 138 (19.0)

130 (18.0) 138 (19.0)

130 (18.0) 138 (19.0)

161 (22.3) 170 (23.5)

184 (25.4) 194 (26.8)

184 (25.4) 194 (26.8)

.75

116 (16.0) 123 (17.0) 207 (28.6) 218 (30.1)

180 (24.9) 190 (26.3) 319 (44.1) 337 (46.6)

180 (24.9) 190 (26.3) 319 (44.1) 337 (46.6)

180 (24.9) 190 (26.3) 319 (44.1) 337 (46.6)

222 (30.7) 235 (32.5) 394 (54.5) 416 (57.5)

254 (35.1) 268 (37.0) 451 (62.4) 476 (65.8)

254 (35.1) 268 (37.0) 451 (62.4) 476 (65.8)

.875

200 (27.6) 211 (29.1)

515 (71.2) 544 (75.2)

515 (71.2) 544 (75.2)

515 (71.2) 544 (75.2)

637 (88.1) 672 (92.9)

728 (100.7) 768 (106.2)

728 (100.7) 768 (106.2)

1.0

300 (41.5) 317 (43.8)

773 (107.0) 816 (112.8)

773 (107.0) 816 (112.8)

773 (107.0) 816 (112.8)

954 (132.0) 1007 (139.3)

1091 (150.9) 1151 (159.2)

1091 (150.9) 1151 (159.2)

1.125

425 (58.7) 448 (61.9)

953 (131.8) 1006 (139.1)

953 (131.8) 1006 (139.1)

953 (131.8) 1006 (139.1)

1352 (187.0) 1427 (192.4)

1545 (213.7) 1631 (225.6)

1545 (213.7) 1631 (225.6)

1.25

600 (83.0) 633 (87.5)

1344 (185.9) 1419 (196.2)

1344 (185.9) 1419 (196.2)

1344 (185.9) 1419 (196.2)

1908 (263.9) 2014 (278.5)

2180 (301.5) 2301 (318.2)

2180 (301.5) 2301 (318.2)

786 (108.7) 830 (114.8) 1043 (144.2) 1101 (152.3)

1763 (243.8) 1861 (257.4) 2339 (323.5) 2469 (341.5)

1763 (243.8) 1861 (257.4) 2339 (323.5) 2469 (341.5)

1763 (243.8) 1861 (257.4) 2339 (323.5) 2469 (341.5)

2501 (345.9) 2640 (365.1) 3319 (459.0) 3504 (484.6)

2859 (395.4) 3017 (417.3) 3793 (324.6) 4004 (553.8)

2859 (395.4) 3017 (417.3) 3793 (324.6) 4004 (553.8)

BOLT GRADE

SAE GRADE 2

ASTM A449

SAE GRADE 5

.3125

6.6 (.9) 6.9 (1.0) 13.5 (1.9) 14 (2.0)

10 (1.4) 11 (1.5) 21 (2.9) 22 (3.0)

.375

24 (3.3) 25 (3.5)

.4375

BOLT SIZE .25

.625

1.375 1.50

ASTM A325

ASTM A490

1.75

2743 (379.3) 2895 (400.4)

5237 (724.3) 5528 (764.5)

5985 (827.7) 6317 (873.6)

2.0

4125 (570.5) 4354 (602.2)

7875 (1089.1) 8313 (1149.7)

9000 (1244.7) 9500 (1313.9)

2.25

6033 (834.4) 6368 (880.7)

11517 (1592.8) 12157 (1681.3)

13162 (1820.3) 13894 (1921.5)

2.75

8250 (1141.0) 8708 (1204.3) 11185 (1546.9) 11806 (1632.8)

15750 (2178.2) 16625 (2299.2) 19319 (2617.8) 20393 (2820.4)

18000 (2489.4) 19000 (2627.7) 21353 (2953.1) 22539 (3117.1)

3.0

14776 (2043.5) 15597 (2157.1)

25522 (3529.7) 26940 (3725.8)

28208 (3901.2) 29775 (4117.9)

3.25

32882 (4547.6) 34709 (4800.3)

36343 (5026.2) 38362 (5305.5)

3.50

41546 (5745.8) 43854 (6065.0)

45919 (6350.6) 48470 (6703.4)

3.75

51621 (7139.2) 54488 (7535.7)

57054 (7890.0) 60224 (8329.0)

4.0

63156 (8734.5) 66665 (9219.8)

69804 (9653.9) 73682 (10190.2)

2.50

4-44

BC

17X0501-01.0701

SUPERIOR MK- II

Section 4 — Installation

Gyratory Crushers

TABLE 4-11 — Bolt Torques Torque Catalog C l Number

Description

Bolt Size

ft-lb

N-m

1306--0

Hub Liner Bolt

1.25--7 x 2.00”

1,350

1,830

1365--0

Bottomshell Side Liner Bolt

1.25--7 x 9.00”

2,721

3,689 407 430

1405--0

Dust Collar Stud

1.00--8 x 4.50”

300 317

1421--0

Splash Ring to Dust Collar

0.63--11 x 2.00”

116 123

157 167

1505--0

Bottom Shell to Pinionshaft Housing Stud

1.25--7 x 6.62”

600 633

813 850

1540--0

Bottom Shell to Top Shell Joint Bolt

4.00--4 x 32.00”

18,600

25,200 3,170 3,347

1811--1

Upper Counterweight Bolt

1.50--6 x 10.00”

2,339 2,469

1812--1

Lower Counterweight Bolt

1.50--6 x 10.00”

2,339 2,469

3,170 3,347

1857--0

Eccentric Gear Key Bolt

1.00--8 x 3.00”

300 317

407 430

1910--0

Eccentric Support Plate Bolt

1.25--7 x 3.00”

600 633

813 858

2020--0

MPS Cylinder Stud

3.00--4 x 14.75”

7,500

10,168

2055--0

Lower Bushing Bolt

0.75--10 x 1.75”

207 218

280 295

2060--0

Upper Bushing Bolt

0.75--10 x 1.75”

207 218

280 295

2283--0

Step Washer Centering Ring Bolt

0.75--10 x 5.00”

319 337

433 457

2510--2

Position Indicator Capscrew (metric)

M8--1.25 x 40

31

42

2515--0

MPS Cylinder Cover Bolt

3.00--4 x 19.00”

7,500

10,168

0.75--10 x 1.50”

207 218

280 295

2606--1

Cover Plate Bolt

2651--0

Cover Plate Closure Plug Bolt (metric)

M8--1.25 x 25

18

24 407 430

3210--0

Pinion Seal Plate Bolt

1.00--8 x 2.25”

300 317

3220--0

DRIVE End Seal Plate Bolt

1.00--8 x 2.25”

300 317

407 430

4365--0

Dust Seal Retaining Ring Bolt

1.25--7 x 3.00”

600 633

814 858

5007--1

Spider Jack Bolt

3.00--4 x 11.50”

7,500

10,168

5125--0

Spider Rim Liner Bolt

1.25--7 x 19.00”

Compress Spring to 4.80” (121.9mm)

5160--0

Spider Arm Shield Bolt

2.50--4 x 40.00”

Compress Spring 0.81” See Spider Assy Section

5285--0

Lube Hose Bracket Bolt

0.63--11 x 1.25”

116 123

157 167

5310--0

Spider to Top Shell Joint Stud

4.00--4 x 22.00”

18,600

25,200

5311--0

Spider to Top Shell Joint Bolt

4.00--4 x 36.50”

18,600

25,200

5635--0

Spider Filler Block Bolts

3.00--4 x 7.50”

14,800

20,066

5685--0

Spider Bushing Bolt

1.00--8 x 5.50”

773 816 58 62

1,048 1,106 79 84

5760--0

Spider Vent Cover Bolt

17X0501-01.0701

0.50--13 x 1.25”

4-45

Section 4 — Installation

SUPERIOR MK- II Gyratory Crushers

This page was purposely left blank.

4-46

17X0501-01.0701

Section 5 — Index

SUPERIOR MK- II Gyratory Crushers

5. Lubrication Page 5-1 5-2 5-2 5-2 5-2 5-2 5-2 5-3 5-3 5-3 5-3 5-4 5-4 5-4 5-4 5-4 5-6 Appendix 5-7 5-7 5-7 5-8 5-12 5-12 5-13 5-14 5-16 5-20 5-20 5-20 5-20 5-22 5-22 5-22 5-23 5-23 5-23 5-23 5-23 5-24 5-24 5-24 5-24 5-24 5-24 5-24 5-24 5-25 5-26

Description Index General Information Immersion Oil Heater Oil Storage Tank — Resistance Temperature Detectors (RTDs) Return Oil Sieve Lubrication Oil Pump — Pressure Transmitters Oil Filter Lubrication Oil Coolers — Air-To-Oil Coolers — Water-To-Oil Coolers Oil Flow Circuits — Flow Monitors — Pressure Transmitters — Resistance Temperature Detectors (RTDs) Sediment Separators

5

Lubrication Pumps for Crusher Circulating Oil Lubrication Systems -- 17X11113-04.0401 — Circulating Oil Lubrication Pump — Coupling Alignment — Pump Maintenance — Thrust Bearing Adjustment — Pump Safety Relief Valve — Pump Troubleshooting — Troubleshooting Guide — Pump Reducer Nelson Liquid Filters -- 17X0098-03.0401 — General Description — Pre-Operational Check — Pre-Operational Fluid Test — Operation — Maintenance — Element Replacement Basco Type 500 Heat Exchanger -- 17x10647 — Installation — Operating — Inspection — Cleaning Universal Flow Monitors — Engineering Data — Installation — Electrical Switch — Switch Specifications — Setting Switch Point — Transmitter — Calibration — Maintenance — Replacement Parts

17X0501--01.0701

5-1

Section 5 — Lubrication

SUPERIOR MK- II Gyratory Crushers

WARNING Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant suppliers instructions and safety directions when handling oils and greases. GENERAL INFORMATION The SUPERIOR gyratory crusher is equipped with an external, skid mounted, lubrication system (Fig. 5-1). Oil is pumped from a storage tank, filtered, cooled and piped to the crusher through two separate feed lines and is returned to the storage tank by gravity flow. One of the oil lines enters the crusher through the MPS cylinder (2005-0), passes through the piston (2205-0), the step bearing (2260-0, 2280-0, 4075-0), and eccentric bushing (1810-0), and lubricates these surfaces. The oil is forced outward through holes at the top of the eccentric bushing by centrifugal force and flows down between the eccentric (1805-0) and bottom shell bushing (1200-0) where it joins the second oil flow to lubricate the bushing and gears. Finally, the combined flow enters the sump below the pinionshaft housing and flows back to the storage tank by gravity. For illustration, see Section 4, Fig. 4-17.

NOTICE Never run the crusher unless the lubrication system is operating and oil is returning to the storage tank. Warm oil temperature, with the crusher operating, should be the same in winter as in summer — 100oF to 130oF (39oC to 54oC) for return oil from the crusher. (depending on the viscosity of oil used). A properly functioning cooling system will keep the oil temperature within safe operating limits. Maintain oil temperature between 100oF (39oC) and (46oC) when using an ISO Grade 68 oil (300 SSU viscosity at 100oF), and between 100oF (39oC) and 130oF (54oC) when using and ISO Grade 150 oil (750 SSU viscosity at 100oF.)

115oF

NOTICE The proper type and viscosity of oil must be used for good crusher operation. Refer to lubricant recommendations (Section 13) for oil specifications.

5-2

IMMERSION OIL HEATER Oil temperature and viscosity are important when starting up the crusher. Oil returns to the bottom of the crusher and to the storage tank by gravity, and if viscosity is too high the oil return holes in the bottom shell may not be able to pass all the oil and it will overflow the dust collar. The result will be detrimental to some crushing operations. Immersion oil heaters keep the oil warm at all times, permitting use of the same oil grade in all seasons. Heater operation is controlled by a resistance temperature detector (RTD) mounted on the side of the storage tank. OIL STORAGE TANK The oil outlet is located above the tank (7005-0) bottom to provide a reservoir for sludge. To keep sludge from building up above the outlet level, clean the tank periodically — once a month, or more frequently if sludge accumulates rapidly. To clean the tank, disconnect the pump discharge line (7250-0) at the oil filter and pump the oil into drums. Drain off the remaining oil and sludge mixture through the oil drain plug (7270-0) and dispose of properly. If the bulk of the oil pumped out of the tank is in good condition, it can be filtered and reused. Be sure to clean the tank thoroughly before replacing the oil. Resistance Termperature Detectors (RTDs) There are two RTDs located in the tank. One is installed in the oil drain sieve and the other is installed in the tank. For proper operation of the RTDs with warning signals and machinery shutdown, refer to the Mechanical Control Logic document. RETURN OIL SIEVE A return oil sieve (7150-0) is located under the inspection cover in the top of the storage tank. This wire mesh strainer will remove any large particles from oil returning to the tank. Check the sieve regularly for any unusual amount of metallic particles. LUBRICATING OIL PUMP (7205-0) Two complete oil lubrication systems, each with one primary and one backup pump are provided pre--piped with a separate valve and suction line for each pump (see Fig. 5-1). All four pump assemblies have an electric motor-driven, positive displacement gear pump for circulating oil to the crusher.

NOTICE Keep pump and motor properly aligned to assure satisfactory operation.

17X0501--01.0701

Section 5 — Lubrication

SUPERIOR MK- II Gyratory Crushers When starting the lubrication system, be sure to check the pump for correct direction of rotation. With the pump operating correctly, flow meters in the oil piping arrangement will indicate flow within five seconds after start-up. For additional information on pump operation and maintenance, refer to pump manufacturer’s instructions included in Appendix to this section. Pressure Transmitters There are six pressure transmitters located on the lube system, one on each pump discharge port and one on each outlet connection. The resulting pressure differential based on the readings is used to evaluate the cleanliness of the lube oil filters. For proper operation of the pressure transmitters with warning signals and machinery shutdown, refer to the Mechanical Control Logic document. OIL FILTER The oil filter (7505-0) supplied with the external lubrication system is the replaceable cartridge type. The filter elements will retain particles approximately 20 micron size and larger. Dual filters are provided so filter maintenance can be accomplished while the lube system and crusher are in operation. Each filter canister on the lube system contains two replaceable filter cartridges. With the valve arrangement, either of the filter canisters can be used in conjunction with either of the two lube oil pumps. The filter is supplied with an internal bypass. Pressure drop across the filters can be checked by comparing the pressure differential between the pressure transmitters. For proper operation of the pressure transmitters with warning signals and machinery shutdown, refer to the Mechanical Control Logic document. When pressure drop through the filter exceeds 25 psi (1.76 kg/cm2), the bypass relief valve (7535-0) inside the filter housing will open, allowing oil to flow through the bypass line. If this occurs when the lube oil is up to operating temperature, it indicates that the filter element is plugged with dirt and should be replaced. Some bypassing may occur if the lube system is started when the oil is cold and stiff. This may be because of the increased viscosity of the oil and does not necessarily mean that the filter elements need to be replaced. However, if bypassing continues after the oil has reached normal operating temperature, the filter elements should be replaced. When differential pressure exceeds 20 psi with the oil at normal operating temperature, the filter element should be replaced. Filter maintenance is simple. If the disposable cartridge-type element becomes clogged with dirt, remove it and replace with a new element. With the dual filter arrangement, it is not necessary to shut the lube system and crusher down, since the alter17X0501--01.0701

nate filter can be in operation when filter maintenance is being performed. To change the filter element, close the isolation valve (7405-0) on the inlet line to the filter. A check valve (7720-0) in the filter discharge line will prevent oil back-up into the filter. Drain the oil from the filter, using the drain plug at the side of the shell. Remove the filter cover and lift out the dirt filled element. Remove the bypass valve from the dirty element. Flush dirt out through the filter drain. Install a clean element, making sure that it is properly seated in the filter shell. Install the bypass valve assembly and fasten the cover securely in place. Be careful not to damage the seal. Refer to appendix, this section, Figs. 5-18, 5-19 for illustration of filter. Use the following procedure to place the filter unit in service. 1. Check and make sure that the valve (7405-0) on the inlet side of the filter is completely closed. 2. Operate either of the lube oil pumps, making sure the isolation valves on both the suction and discharge lines are fully open. 3. Loosen the vent in the filter cover to permit any entrapped air to bleed out of the filter enclosure as it is being filled with oil. 4. Partially open the valve (7405-0) on the inlet side of the filter, allowing a flow of oil to slowly and completely fill the filter.

NOTICE Be careful to prevent hydraulic hammer in the lubrication system piping whenever opening or closing valves controlling oil flow through the filters. Hammering can severely damage filter elements and main body connections. 5. Allow the vent plug to remain open long enough to permit entrapped air to escape from the vented unit. As soon as a small amount of oil is seen to flow from the loosened vent plug, close the plug securely. 6. Open the valve (7405-0) in the filter inlet line completely to allow full flow of oil through the filter. LUBRICATION OIL COOLERS SUPERIOR gyratory crusher lubrication systems can be supplied with either two air-to-oil or two water-to-oil heat exchangers to maintain the oil at the proper operating temperature. Air-To-Oil Coolers SUPERIOR gyratory crushers are generally supplied with two air-to-oil cooler units. Each unit consists of a radiator core through which oil is circulated, and an electric motor driven fan. The only maintenance required is to keep the radiator surfaces free of dust accumulations by blowing them clean with compressed air. Do not use a pressure washer because this may damage the fins of the radiator core. For piping arrangement see Section 4, Fig. 4-17. 5-3

Section 5 — Lubrication

SUPERIOR MK- II Gyratory Crushers

Install fans and radiators as close to the crusher and lubrication system as possible and in an open area where the normal air temperature can adequately cool the circulating oil. Do not restrict airflow to the fans.

NOTICE It is necessary to protect the cooler from high oil line pressure when the oil is cold. A lubrication oil bypass line is provided for this purpose, along with a 40 psi (2.8 bar) relief valve. Be sure the bypass line has been installed per the drawing furnished with it.

NOTICE Drain preservative oil from the cooler before starting the lubricating system. Air-to-oil cooler operation is controlled by an RTD in the return oil line. For proper operation of the RTD with warning signals and machinery shutdown, refer to the Mechanical Control Logic document. Water-To-Oil Coolers SUPERIOR gyratory crusher lubrication systems can be supplied with two condenser-type coolers. The coolers reduce oil temperature by passing it around water--cooled bronze tubes. The coolers have the inlet and outlet cooling water connections on one end. Under normal conditions the crusher will require from 10 to 80 gallons (38 to 300 liters) per minute of cooling water. The amount of water depends on water temperature, crusher setting and stone hardness. Maintain oil temperature between 100oF (39oC) and o 115 F (46oC) when using an ISO Grade 68 oil (300 SSU viscosity at 100oF) and between 100oF (39oC) and 130oF (54oC) when using an ISO Grade 150 oil (750 SSU viscosity at 100oF). If it levels off somewhere between these readings, the cooler is getting an adequate supply of cooling water. When cooling water is scarce, use a storage tank and re-circulate the water by pumping.

OIL FLOW CIRCUITS The 60-110 SUPERIOR gyratory has two independent lubrication oil supply circuits. Each supply line has a primary and a back-up pump, filter system, cooler, flow and pressure control components. One supply line enters the crusher through a port in the bottom shell. The other supply line enters through the MPS cylinder. Flow Monitors Oil flow monitors are installed in the two lubrication oil supply lines to the crusher. For proper operation of the flow monitors with warning signals and machinery shutdown, refer to the Mechanical Control Logic document. Pressure Transmitters There is a pressure transmitter in each lubrication oil supply line going to the crusher. One in the line that enters the MPS cylinder and one in the line that enters the bottom shell. For proper operation of the pressure transmitters with warning signals and machinery shutdown, refer to the Mechanical Control Logic document. Resistance Temperature Detectors (RTD) One RTD is located in each lubrication oil supply line to the crusher. For proper operation of the RTD with warning signals and machinery shutdown, refer to the Mechanical Control Logic document.

NOTICE Never disconnect warning devices such as RTDs and pressure transmitters. They are intended to indicate trouble which should be identified and remedied. Keep devices clean, closed and dust-tight when the crusher is operating.

NOTICE Drain water from the cooler in winter, when not operating. Water freezing in the cooler will cause serious damage. Refer to heat exchanger instructions included in Appendix to this section for further information.

5-4

17X0501--01.0701

Section 5 — Lubrication

SUPERIOR MK- II Gyratory Crushers

Catalog Number 7005-0 7005-3 7005-5 7005-8 7120-0 7150-0 7165-0 7205-0 7206-0 7207-0 7405-0 7406-0 7406-1 7505-0 7505-1 7720-0 8005-3 8005-5 8104-0 8225-0 8608-0 8609-8 8609-9 8825-0

8225--0 Description Base and Tank Assembly Lube Oil Level Transmitter Inspection Cover, Lube Tank Sight Gauge - Lube Oil Pressure Breather Sieve - Return Temperature Transmitter Lube Pumping Unit - 40 gpm [151 LPM] Lube Pumping Unit - 50 gpm [189 LPM] Pressure Transmitter Ball Valve Proximity Switch Assembly Proximity Switch Filter Filter Cartridge Check Valve MPS Oil Level Sensor MPS Oil Fill Plug MPS Pumping Unit Ball Valve Control Valve Assembly MPS Filter Indicator MPS Filter Element Immersion Heaters

8005--3

8608--0

7005--0

8104--0

8609--8 8609--9 8005--0

7005--0

7405--0 7406--0 7406--1

8825--0 7405--0 7406--0 7406--1

7205--0 7206--0

7120--0 7005--3 7207--0 7165--0

7505--0 7505--1

A

7005--3 7165--0 7207--0

7505--0 7505--1

7505--0 7505--1

7720--0 7005--0

7405--0 7406--0 7406--1

7405--0 7406--0 7406--1

7405--0 7406--0 7406--1

7005--8

7720--0

7720--0

A VIEW A--A

50 GPM (189.3 LPM) LUBE SUPPLY PUMPS

40 GPM (151.4 LPM) LUBE SUPPLY PUMPS M--012407--TAW--04

FIG. 5-1 — Lubrication System

17X0501--01.0701

5-5

Section 5 — Lubrication

SUPERIOR MK- II Gyratory Crushers

SEDIMENT SEPARATORS Two Y-pattern sediment separators are furnished along with the external lubrication package for every SUPERIOR gyratory crusher. Separators are provided as a means for collecting rust, scale, pipe sealant and other foreign particles from the lubricating oil to reduce the possibility of bearing damage from oil-borne contaminants. Mount the separator as shown in Fig. 4-17 and 5-2 to assure proper flow of the oil through the screening device, locating one in each of the two oil inlet lines, as close to the crusher as possible. Clean the separators after each eight hours of operation during break-in and the first week of full operation, and once a week thereafter. A flow meter is mounted in each of the two supply connections from the oil flow divider circuit. Plugging of the separator in either oil line will be indicated by the associated flow meter. In extreme cases, the lube oil pump motor overload relays may stop the pump and shut down the crusher. In either event, with the crusher shut down, disassemble the separators and thoroughly clean the screen with a non-toxic solvent. For disassembly, simply unscrew the bronze cap from the separator housing and slide the screen out. After cleaning, re-insert the screen and replace the cap on both separators, and resume normal operation. Toward crusher

FIG. 5-2 — Sediment Separators are Furnished for Customer Installation in Lube Lines to Crusher

5-6

17X0501--01.0701

Lubrication Pumps

MAINTENANCE AND REPAIR

for Crusher Circulating Oil Lubrication Systems CIRCULATING OIL LUBRICATION PUMP An electric motor-driven, positive displacement gear pump circulates lubricating oil to the crusher’s eccentric gearing, thrust bearing and critical bearing surfaces in the eccentric bearing assembly. The pump is mounted on the base of the circulating oil lubrication system, immediately next to the oil reservoir, and connected to the reservoir by piping. A valve in the suction line makes it possible to shut off the oil supply when working on the pump and other components of the circulating oil lubrication system. An internal safety relief valve, mounted on the head of the pump, will relieve excessive oil pressure in the pump, and serve as a protective device for other components in this system. Figure 5-3 illustrates how the pump works. As the pumping elements (gears) come out of mesh, point A, oil is drawn in to the suction port from the piping. The oil travels three-quarters of the circumference of the pump casing (270o), from the suction port to the discharge port. As the pumping elements (gears) come out of mesh, point B, oil is forced out the discharge port and into the piping. The pumping elements (gears) return to point A to repeat the cycle. In order for the pump to work properly, the oil must travel the longest circumferential distance between ports. DISCHARGE PORT

“A”

B”

PUMP CASING

DISCHARGE

LEFT HAND PUMPS SUCTION

DISCHARGE

DISCHARGE

SUCTION

RIGHT HAND PUMPS FIG. 5-4 — Determining Port Functions from Direction of Shaft Rotation

COUPLING ALIGNMENT The pump, reducer (if used) and motor were properly aligned at the time they were assembled. However, the alignment of the couplings may have been disturbed during shipping and mounting. CHECK THE ALIGNMENT BEFORE OPERATING THE PUMP.

Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any inspection, maintenance, adjustment or lubrication on the pumping unit.

IDLER PIN ON PUMP HEAD

ROTOR GEARS DIRECTION OF PUMP ROTATION OIL TRAVELS BETWEEN GEAR TEETH AND CASING AROUND THE LONGEST CIRCUMFERENTIAL DISTANCE BETWEEN PORTS

FIG. 5-3 — Cutaway View of the Lubricating Pump from the Head End

To determine which port is suction and which is discharge, always look at the direction of rotation of the pump shaft when viewing the shaft end of the pump. The oil must travel the longest circumferential distance between ports.

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SUCTION

CAUTION

SUCTION PORT

ROTOR

SUCTION

DISCHARGE

Use the following procedures to check or align couplings. 1. With the pumping unit on its operating foundation, level the unit by using shims or wedges at the foundation bolts. Additional shims or wedges may be needed for the long sides of the longer bases. 2. When the pumping unit base is level and properly shimmed, snug down all foundation bolts. 3. If the piping is already in place, check the pump parts to be sure that they are in alignment with the piping. Shim and align the pump as required. Tighten pump mounting bolts. All alignment from this point on should be done without moving the pump. 4. Remove any coupling guards or covers.

5--7

Lubrication Pumps

MAINTENANCE AND REPAIR

for Crusher Circulating Oil Lubrication Systems

B STRAIGHT EDGE ±.005 in (0.13 cm.)

A COUPLING HALF ±.008 in (0.20 cm.)

COUPLING INSERT

DO NOT ROTATE COUPLING DURING ALIGNMENT PROCESS

C

±.005 in (0.13 cm.)

PARALLEL ALIGNMENT (A)

The pumping unit jaw couplings have a built--in spacing feature. Raised dots on each side of the coupling insert give the correct premeasured gap between the coupling jaw and the insert body. Align the coupling so that a straightedge rests squarely or within .008 in (0.20 cm.) on the coupling hubs. The clearance at dimension A must not exceed the offset limit of .008 in (0.20 cm.). Repeat this procedure at 90--degree intervals. ANGULAR ALIGNMENT (B)

To check the angular alignment, measure the gap at dimension B. Next, measure the gap 180 degrees from B, at dimension C. The dimension at C should be the same as the dimension at B, or within plus or minus .005 in (0.13 cm.). Repeat this procedure at 90--degree intervals. If this procedure is done correctly, it will limit the angular misalignment to within one degree. After checking the angular alignment, recheck the parallel alignment.

FIG. 5-5 — Alignment Procedure for Pumping Unit Jaw Couplings

5. If the pump is driven through a reducer, check the alignment of the coupling between the reducer and the pump. See Figure 5-5. If any realignment is needed, move and/or shim the reducer. Tighten the reducer mounting bolts when alignment is correct. 6. Check the alignment of the coupling between the reducer and the motor. See Figure 5-5. If any realignment is needed, move and/or shim the motor. Tighten the motor mounting bolts. Recheck the coupling between the reducer and the pump to be sure that this alignment did not change.

5--8

7. If the pump is connected direct to the motor (no reducer), check the alignment of the coupling between the motor and the pump. Follow steps 1--4 and refer to Figure 5-5. If any realignment is needed, move and/or shim the motor. 8. A final alignment check should be made after any piping is connected to the pumping unit to be certain that there are no piping strains on the pump casing. 9. Replace coupling covers and guards. 10. Remove any warning tags and lockout devices before turning ON power to the circulating oil lubrication system. PUMP MAINTENANCE Performing these preventive maintenance procedures will help to extend the life of the pump. Lubrication -- Grease all lubrication fittings on the pump every 500 hours of operation or every sixty (60) days, whichever occurs first. If service is severe, grease more often. Do not over grease the bearing. Use a hand-type grease gun. Pressurized grease guns can damage bearing seals. Use an NLGI #2 grease for normal applications. Consult a grease lubricant manufacturer to determine the appropriate grease for extreme hot or cold applications. Examine Internal Parts -- Periodically remove the pump head and examine the idler, idler bushing, idler pin and the pump head. Replacing a relatively inexpensive idler bushing and idler pin after only moderate wear may eliminate the need to replace more expensive parts at a later date. See “Pump Disassembly” for instructions in removing the pump head and replacing parts. Clean the Pump -- Keep the pump exterior as clean as possible. This will result in easier inspection, adjustment, lubrication and repair work. A clean pump will also run cooler. End Clearance Adjustment -- After long term operation, it is sometimes possible to improve pump performance without major repair, through adjustment of the end clearance. See instructions on ”Thrust Bearing Adjustment” in this section. Storage -- If a pump is to be out of service or stored for more than six (6) months, drain it and protect it from rust and corrosion. Apply a light coat of lubricating and preservative oil to the internal parts and the exterior housing. Grease all lubrication fittings.

17x11113--04.0401

Lubrication Pumps

MAINTENANCE AND REPAIR

for Crusher Circulating Oil Lubrication Systems

Pump Disassembly (Fig. 5-6) Mechanical Seals (Teflon Fitted Type) Model KK4125 Superseded Model KK125 in January 1998.

ITEM

NAME OF PART

ITEM

1 2 3 4 5 6 7 8

Locknut Lockwasher End Cap, Outer Lip Seal for End Cap Bearing Spacer Collar (outer) Ball Bearing Bearing Spacer Collar (inner) Ring, Half Round

9 10 11 12 13 14 15 16

NAME OF PART End Cap (inner) Lip Seal for Seal Chamber Pressure Relief Plug Grease Fitting Bracket and Bushing Capscrew for Bracket Bracket Bushing Mechanical Seal

ITEM 17 18 19 20 21 22 23 24

NAME OF PART Bracket Gasket Casing Pipe Plug Rotor and Shaft Idler and Bushing Idler Bushing Head Gasket Idler Pin

ITEM 25 26 27 28 29 30 31

NAME OF PART Head and Idler Pin Gasket (not required) Jacketed Head Plate (not required) Capscrew for Head Relief Valve Gasket Capscrew for Valve Internal Relief Valve

FIG. 5-6 — Exploded View of Circulating Oil Lubrication Pump (KK4125) with Mechanical Seals

Pump Disassembly (Mechanical Seals) (Fig. 5-6) (Units sold after January 1998).

CAUTION Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any inspection, maintenance, adjustment or lubrication on the pumping unit. Vent any pressure from the pump casing before disassembly.. 1. Remove the pump from the pumping unit foundation and place it on a clean, sturdy working surface. 2. Mark the head and casing of the pump before disassembly to make sure the parts are reassembled properly. This is done to ensure that the idler pin, which is offset in the pump head, is positioned toward and between the port connections to allow for proper flow of liquid through the pump. 3. Loosen and remove the capscrews (28) from the pump head (25). Slowly remove the head from the pump casing (18), being careful not to damage the head gasket (23).

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CAUTION One of three conditions will occur when the pump head (25) is separated from the pump casing (18). 1. The idler (21) may be in the rotor (20) when the head (25) is removed. 2. The idler (21) may be on the idler pin (24) and be removed with the head (25). 3. The idler (21) may drop out between the head (25) and the casing (18), when the head is separated from the casing, and can cause personal injury. 4. Slowly remove the head (25) from the casing (18).Tilt the top of the head back as it is being removed from the casing to avoid dropping the idler. 5. Remove the idler and bushing assembly (21).

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Lubrication Pumps

MAINTENANCE AND REPAIR

for Crusher Circulating Oil Lubrication Systems

NOTICE The safety relief valve (31) does not have to be disassembled or removed from the pump head (25) at this time. See instructions under “Pump Safety Relief Valve” in this section. 6. Insert a piece of hardwood or brass rod in to one of the casing ports and between the teeth of the rotor to prevent the rotor and shaft assembly from turning during loosening. 7. Bend up a tang on the lockwasher (2) and with a spanner wrench remove the locknut (1) and lockwasher (2) from the rotor shaft (20). Remove the piece of hardwood or brass rod from the rotor. 8. Tap the rotor shaft assembly (20) forward approximately 1/2 in (13 mm) and check for a pair of half circle, round wire rings (8) under the inner bearing spacer collar (7).These rings must be removed before the rotor and shaft assembly can be removed from the pump. Remove the pair of rings (8). See Figure 5-7. NYLON INSERT

SET SCREWS OUTER END CAP (3)

INNER END CAP (9)

LOCKWASHER (2)

HALF ROUND RINGS (8)

LOCKNUT (1)

13. Clean all parts thoroughly and examine for wear and damage. Check lip seals, ball bearing, bushings and idler pin, and replace if necessary. Check all other parts for nicks, burrs, excessive wear or damage, and replace if necessary. The pump casing can be checked for wear or damage while still mounted on the bracket. Pump Assembly (Mechanical Seals) (Fig. 5-6) 1. Install bracket bushing (15) in bracket (13). When installing carbon graphite bushing, extreme care must be taken to prevent breaking. Carbon graphite is a brittle material and easily cracked. If cracked, the bushing will quickly disintegrate. Using a lubricant and adding a chamfer on the bushing and the mating part will help in installation. The additional precautions listed below must be followed for proper installation: a. A press must be used for installation. b. Be certain bushing is started straight. c. Do not stop pressing operation until bushing is in proper position. Starting and stopping will result in a cracked bushing. d. Check bushing for cracks after installation. 2. Install lip seal (10) in bracket (13). 3. Clean the rotor hub Fig. 5-11 and bracket seal housing bore (13), Fig. 5-6. Make sure both are free from dirt and grit. Coat outer diameter of seal seat gasket and inner diameter of seal housing bore (13) with non-detergent SAE30 weight oil.

ROTOR SHAFT (22)

INSTALLATION TOOL INNER SPACER COLLAR (7) INNER LIP SEAL (4) BALL BEARING (6)

ANTI-ROTATION PINS ALIGNED WITH SLOTS IN BUSHING

OUTER SPACER COLLAR (5) OUTER LIP SEAL (4) BRACKET (17)

FIG. 5-7 — Cutaway View of Pump Bearing Assembly on the Bracket

9. Carefully remove the rotor and shaft assembly (20) to avoid damaging the bracket bushing (15). 10. Remove rotary member of seal (16) from shaft and stationary seal seat (16) from bracket (13). 11. Loosen the four set screws in the bearing housing area of the bracket (13). Use a spanner wrench to remove both end caps (3 and 9), both lip seals(4), both bearing spacer collars (5 and 7) and the bearing (6). The inner end cap (9) can be removed through the side opening of the bracket. See Figure 5-7. 12. Examine seal chamber lip seal (10) and remove if it shows wear or damage. Lip seal must be removed if bracket bushing (15) needs to be replaced.

5--10

COAT WITH LIGHT OIL BEFORE ASSEMBLY BRACKET SEAL HOUSING BORE WITH SEAL SEAT INSTALLED. NOTE SPECIAL INSTALLATION TOOL USED FOR FACTORY ASSEMBLY

FIG. 5-8 — Bracket Seal Housing Bore with Seal Seat Installed

17x11113--04.0401

Lubrication Pumps

MAINTENANCE AND REPAIR

for Crusher Circulating Oil Lubrication Systems 4. Start seal seat in seal housing bore. Make sure seat anti-rotation pins (if provided) are aligned to engage slots in end of bracket bushing. Refer to Figure 5-8. 5. Using a cardboard disc to protect lapped face of seal seat, press seal seat assembly to bottom of seal housing bore using a piece of wood. An arbor press can also be used to install the seal seat. Seal seat must be started square and carefully pressed to bottom of seal housing bore. TAPERED INSTALLATION SLEEVE

MECHANICAL SEAL ROTARY MEMBER

SHAFT

FIG. 5-9

6. Place tapered installation sleeve (furnished with replacement mechanical seals) on shaft. Refer to Figure 5-9. Coat inner diameter of seal rotary member, tapered installation sleeve and the shaft with a generous quantity of non-detergent SAE30 weight oil. Place rotary member on shaft over sleeve and against hub of rotor. Refer to Figure 5-10. ROTOR HUB MECHANICAL SEAL ROTARY MEMBER

SHAFT

FIG. 5-10

Some Teflon seals are equipped with holding clips which compress the seal springs. Remove holding clips to release springs after seal is installed on shaft. Tighten all drive setscrews securely to shaft. 17x11113--04.0401

7. Coat the rotor shaft (20) with non-detergent SAE30 weight oil. Start the end of the shaft in the bracket bushing (15) and turn the rotor slowly in a counterclockwise direction while pushing it into the pump casing (18) until the end of the rotor teeth are just below the face of the casing. 8. Using a .010 in. (.25 mm) to .015 in. (.38 mm) head gasket (23), install head (25) and idler assembly (21) on pump. Pump head and casing were marked before disassembly to ensure reassembly. If the internal relief valve (31) was disassembled from the head, it can be installed now or installed after the pump is completely assembled. See instructions on “Pump Safety Relief valve” in this section. Tighten all head capscrews (28) evenly. 9. Remove tapered installation sleeve (Fig. 5-9) from the shaft. 10. Slide the inner bearing spacer collar (7) over the rotor shaft with the recessed end of the spacer collar toward the rotor. See Figure 5-7. 11. Place the pair of half circle, round wire rings (8) in the shaft groove and slide the inner bearing spacer collar over them. 12. Press the inner lip seal (4), with the lip toward the shaft end, into the inner end cap (9). Insert the inner end cap through the shaft end of the bracket (13).Turn the inner end cap clockwise (when looking from the shaft end) until it engages the threads. The spanner wrench holes in the end cap must be facing the rotor. Turn the end cap with a spanner wrench until it projects slightly into the opening on the side of the bracket. See Figure 5-7.

NOTICE The inner end cap (9) must not be turned so far that the lip of the lip seal (4) drops off the end of the spacer collar on the shaft or that the end cap disengages the bracket threads. 13. Pack the ball bearing (6) with an NLGI #2 grease. Place the bearing on the shaft and push or gently tap it into position in the bracket. 14. Install the outer lip seal (4), with the lip toward the shaft end, and the outer bearing spacer collar in the outer end cap (3). Turn the end cap into the bracket until it is tight against the bearing. 15. Insert a piece of hardwood or brass rod into one of the casing ports and between the teeth of the rotor to prevent the rotor shaft from turning during tightening. 16. Install the lockwasher (2) and locknut (1) on the shaft and tighten. Bend one tang of the lockwasher into the slot on the locknut. Remove the piece of hardwood or brass rod from the pump casing. 17. Adjust the pump end clearance. See instructions on “Thrust Bearing Adjustment” in this section.

5--11

Lubrication Pumps

MAINTENANCE AND REPAIR

18. If removed during disassembly, install the safety relief valve (31) so the valve cap is pointing toward the suction port. See instructions on ”Pump Safety Relief Valve” in this section. 19. Install the pump on the pumping unit base. Refer to the instructions on “Coupling Alignment” in this section, to insure that the pump is properly installed and aligned before operating. 20. Install all guards. Remove any warning tags or lockout devices before turning ON power to the circulating oil lubrication system. THRUST BEARING ADJUSTMENT (FIG. 5-7) The thrust bearing adjustment determines the end clearance of the rotor and the pump head. Proper end clearance will improve pump performance and efficiency. High viscosity liquids will require additional end clearances. Consult the pump manufacturer for specific recommendations when high viscosity liquids are involved.

CAUTION Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any, inspection, maintenance, adjustment or lubrication on the pumping unit. 1. Loosen the setscrews over the outer end cap (3) and the inner end cap (9). 2. Turn the inner end cap (9) clockwise (when looking from the shaft end of the pump) until it projects slightly from the bracket (17) exposing approximately three (3) threads of the inner end cap. 3. Turn the outer end cap (3) clockwise (when looking from the shaft end of the pump) until the rotor (22) is tight against the head (27) and the rotor shaft cannot be turned. 4. Make a reference mark on the end of the bracket opposite a notch on the outer end cap on K size pumps. Turn the outer end cap counterclockwise five notches from the reference mark made on the end of the bracket. Each .250 inch (6.35 mm) travel on the circumference of the outer end cap is equivalent to approximately .0015 inch (.038 mm) end clearance. 5. Tighten the inner end cap (9) with a spanner wrench. Tap the spanner wrench lightly but do not over-tighten as it will only damage the threads. 6. Tighten all the setscrews that hold the inner end cap and the outer end cap to prevent them from turning in the bracket. 7. Check the rotor to determine if it turns freely. If it is tight or does not turn freely, add more end clearnace. 8. Remove any warning tags and lockout devices before turning ON power to the circulating oil lubrication system.

5--12

for Crusher Circulating Oil Lubrication Systems PUMP SAFETY RELIEF VALVE The safety relief valve mounted on the head of the pump is of the spring-loaded poppet design. The spring holds the poppet against the seat in the valve body with a given force, determined by the spring size and how tightly the spring is compressed by the adjusting screw. During operating, the pump discharge pressure pushes against the underside of the poppet. When the force exerted by the liquid under the poppet exceeds that exerted by the spring, the poppet lifts and the liquid starts to flow throught the relief valve. As the discharge pressure builds up, more of the liquid flows through the valve until a pressure is reached when all of the liquid being pumped is going through the valve. This pressure is the relief valve setting. Pressure Adjustment The pressure setting of the safety relief valve should be 175 psi (1207 kPa). Follow the instructions below carefully to adjust, check or reset the safety relief valve. See Figures 5-11 and 5-12. 1. Remove the valve cap covering the adjusting screw. Loosen the locknut that locks the adjusting screw so the pressure setting will not change during operation of the pump. The pressure gauge, in the discharge line after the pump, must be used for actual adjustment operation. 2. Close the shutoff valve(s) in the discharge line following the oil filtering unit(s). With the discharge line closed at a point beyond the pressure gauge, the gauge will now show the maximum pressure that the safety relief valve will allow while the pump is in operation. VALVE BODY POPPET

SPRING VALVE CAP

UNDERSIDE OF POPPET WHERE OIL PRESSURE IS EXERTED

ADJUSTING SCREW OIL INLET

OIL OUTLET

FIG. 5-11 — Internal View of Pump Safety Relief Valve

3. Turning the adjusting screw clockwise will increase the pressure setting of the safety relief valve. Turning the adjusting screw counterclockwise will decrease the pressure setting of the safety relief valve. 4. When the pressure setting adjustment is completed, tighten the locknut to hold the setting. Replace the valve cap covering the adjusting screw.

17x11113--04.0401

Lubrication Pumps

MAINTENANCE AND REPAIR

for Crusher Circulating Oil Lubrication Systems

2. Remove the valve cap (1). 3. Measure and record the length of extension of the adjusting screw (2). See dimension ”A” on Fig. 5-12. 4. Loosen the locknut (3) and back out the adjusting screw (2) until the spring tension is released. 5. Remove the bonnet (5), spring guide (4), spring (7) and poppet (8) from the valve body (6). 6. Clean and inspect all parts for wear and damage. If any parts show excessive wear or are damaged, install a new safety relief valve.

LIST OF PARTS 1. Valve Cap

6. Valve Body

2. Adjusting Screw

7. Valve Spring

3. Lock Nut

8. Poppet

4. Spring Guide

9. Cap Gasket

5. Bonnet

10. Bonnet Gasket

FIG. 5-12 — Cutaway View of Pump Safety Relief Valve

Safety Relief Valve Disassembly (FIG. 5-12)

CAUTION Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any, inspection, maintenance, adjustment or lubrication on the safety relief valve.

Safety Relief Valve Assembly Assembly of the safety relief valve is the reverse of disassembly. The adjusting screw (2) should be at the same setting as it was before disassembly (see dimension ”A” on Fig. 5-12). Replace the valve in the same position as that from which it was removed. The valve cap must be pointing to the suction port. Remove any warning tags or lockout devices before turning ON power to the circulating oil lubrication system. PUMP TROUBLESHOOTING The circulating oil lubrication pump will give long and satisfactory performance when properly installed and maintained. If trouble does develop, one of the first steps toward finding the difficulty is to install a vacuum gauge at some point in the suction line and a pressure gauge at some point in the discharge line. Readings on these gauges will often give a clue as to where to start looking for the trouble. The troubleshooting guide should help to pinpoint the cause of most problems that may be encountered and suggest ways to avoid and correct the cause.

1. Mark the valve and pump head to be sure these parts will be reassembled in the same relative position.

17x11113--04.0401

5--13

Lubrication Pumps

MAINTENANCE AND REPAIR

for Crusher Circulating Oil Lubrication Systems TROUBLESHOOTING GUIDE

TROUBLE 1. High reading on vacuum gauge (suction port).

CAUSE

CORRECTION

a. Suction line blocked -- gate valve closed.

a. Unblock suction line. Open gate valve

b. Liquid too viscous to flow through piping.

b. Heat liquid or install immersion heater in tank.

c.

c.

Lift too high.

d. Suction piping too small. 2. Low reading on vacuum gauge a. Air leak in suction line. (suction port).

Modify piping to lower lift.

d. Increase piping size. a. Locate source of air leak and eliminate. Tighten pipe fittings.

b. End of suction line not in liquid.

b. Check tank level.

c.

c.

Pump is dry.

Prime pump.

3. Fluttering, jumping or erratic a. Liquid coming to pump in slugs. a. Check for air leaks and eliminate reading on vacuum gauge air leaks or insufficient liquid source. Check tank level (suction port). above end of suction pipe. b. Vibration from cavitation, b. Air leaks causing foaming in oil -misalignment or damaged parts. eliminate source. Check coupling alignment and pipe alignment. See “Pump Disassembly” for replacement of damaged parts. 4. High reading on pressure gauge a. Liquid too viscous. (discharge port).

a. Heat liquid or install immersion heater.

b. Gate valve partially closed.

b. Open gate valve all the way.

c.

c.

Clogged filter.

d. Liquid in pipes too viscous. 5. Low reading on pressure gauge a. Pump worn. (discharge port).

Check filter element and replace if clogged or dirty.

d. Heat piping. a. See “Pump Disassembly”.

6. Fluttering, jumping or erratic a. See “Cause” and “Correction” reading on pressure gauge (disunder Trouble, No. 3. charge port). 7. Pump does not deliver liquid.

a. Loss of prime caused by air leak a. Check for air leaks and eliminate. or low tank level. Check level of tank. Prime pump by hand until liquid begins to flow. b. Suction and/or discharge valves b. Check valves to be sure they are not opened. open. c.

5--14

Faulty motor or reducer.

c.

Inspect motor or reducer. Repair or replace if necessary.

d. Pump worn.

d. See “Pump Disassembly”.

e. Head position incorrect.

e. See Figure 5-3. 17x11113--04.0401

Lubrication Pumps

MAINTENANCE AND REPAIR

for Crusher Circulating Oil Lubrication Systems TROUBLE 8. Pump starts, then loses it prime prime.

9. Noisy pump.

CAUSE

CORRECTION

a. Tank empty.

a. Check tank level.

b. Air leaks in suction line or packing.

b. Locate air leaks and eliminate. Install new packing.

c.

c.

Pump worn.

a. Misalignment.

See “Pump Disassembly”.

a. Check coupling alignment -realign if necessary.

b. Bent pump shaft, or broken rotor b. Repair or replace parts if necesor idler tooth. sary. c.

Loose mounting bolts or loose c. piping.

Tighten bolts. Brace piping.

d. Foreign object in suction line or d. Inspect for and remove foreign suction port. object. e. See “Cause” and “Correction” under Trouble, No. 7. 10. Pump not up to capacity.

a. See “Cause” and “Correction” under Trouble, No. 7.

11. Pump takes too much power.

a. Pump misaligned.

a. Check alignment and realign if necessary.

b. Check parts for evidence of drag b. Increase clearance where necor contact in pump. essary. Replace parts if worn or damaged. c.

See “Cause” and “Correction” under Trouble, No. 4

12. Noisy bearings, localized heating a. Lack of lubrication. at bearings or lip seal, smoke and rapid bushing wear.

a. Grease all pump lube fittings before starting system. Consider use of auxiliary lubricating equipment.

13. Uneven wear or wear on a certain a. Misalignment. section, i.e., one side of casing or part of head.

a. Check coupling alignment and pipe alignment. See “Pump Disassembly” for replacement of damaged parts.

14. Pump stalls.

a. Pump running dry. Uneven a. Be sure sufficient liquid is in the expansion of parts caused by system and that it is being frictional heat of moving surfaces delivered to the pump. against each other.

15. Evidence of abrasion and corro- a. Dirt or contaminants entering the a. Locate source of contaminants sion of pump parts. lube system. and eliminate. Replace filter element and flush lube system completely. Disassemble pump and clean or replace parts.

17x11113--04.0401

5--15

Lubrication Pumps

MAINTENANCE AND REPAIR

for Crusher Circulating Oil Lubrication Systems

PUMP REDUCER Installation and Alignment The pumping unit components, including the pump reducer, were properly aligned during assembly. However movement during shipping and setup may have disturbed the alignment. The following instructions are provided for checking the alignment of the reducer and for setting alignment during installation of the reducer, should it ever require removal from the pumping unit. For correct alignment of the coupling, see instructions on “Coupling Alignment” in this section.

bracket to the exact center height of the pump shaft. Tighten the coupling halves on each shaft. 5. Rotate the reducer in the slots of the bracket until the high speed coupling half is at the exact center height of the motor coupling half. See Fig. 5-14. 6. Tighten the reducer to the reducer mounting bracket securely. BREATHER

ADJUSTMENT SLOTS IN BRACKET MOUNTING BOLTS

CAUTION Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any inspection, maintenance, adjustment or lubrication on the pump reducer.

INPUT SHAFT

OUTPUT SHAFT

1. Fasten the reducer bracket securely to the baseplate. See Fig. 5-13. HELICAL REDUCER HIGH SPEED COUPLING MOTOR

REDUCER MOUNTING BRACKET LOW SPEED COUPLING

REDUCER MOUNTING BRACKET PUMP

FIG. 5-14 — Installing the Reducer on the Reducer Mounting Bracket

FIG. 5-13 — Installation of Pump Reducer on Baseplate

2. Mount the reducer on the reducer bracket finger--tight. The breather cap must be located on the top side of the reducer and the drain plug on the bottom. See Fig. 5-14. 3. Place the coupling halves on the high and low speed reducer shafts. See Fig. 5-13. 4. Align the low speed shaft coupling half with the coupling half on the pump shaft. Refer to Fig. 5-5 and the instructions on “Coupling Alignment” in this section. It may be necessary to shim the reducer mounting

5--16

7. Align the high speed shaft coupling half with the coupling half of the motor shaft. Refer to Fig. 5-5 and instructions on “Coupling Alignment” in this section (it may be necessary to loosen the motor mounting bolts to properly align the coupling halves.) Tighten coupling halves on each shaft and fasten the motor securely to the baseplate. 8. Make a final alignment check of both the high speed low speed couplings after all the mounting bolts have been tightened. Realign if necessary. Reducer Lubrication The pump reducer requires approximately 8 oz (.24 l) of lubricating oil when empty. When checking the reducer oil level or when adding oil to the reducer, drain or fill the reducer to the oil level plug in the side of the reducer case. Remove the breather and add the proper amount of oil for the ambient temperature of operation. See Fig. 5-15.

17x11113--04.0401

Lubrication Pumps

MAINTENANCE AND REPAIR

for Crusher Circulating Oil Lubrication Systems Ambient Temperature

Type of Oil Required

32oF.

AGMA #3 or ISO VG 100

Above

(0oC)

Below 32oF. (0oC)

AGMA #1 or ISO VG 32

BREATHER AND FILL HOLE

OIL LEVEL PLUG

DRAIN PLUG

FIG. 5-15 — Lubrication Fittings on the Pump Reducer

After the first 100 hours of operation drain, flush and refill the reducer with the proper grade of new oil. Check the oil level every 2,000 hours of operation or every six. (6) months, whichever occurs first. Add oil as necessary. Periodically check the area under the reducer for any signs of leakage. If leakage is noticed, check the oil level more frequently. Once each year drain, flush and refill the reducer with the proper grade of new oil.

NOTICE Before operating the reducer, be sure to add the proper amount and type of oil. Do not overfill the reducer. After the first few hours of operation, inspect the reducer for leaks. If leakage between the gear case and cover cannot be stopped by tightening the nuts or capscrews, replace the gasket. Leakage around either shaft indicates a damaged lip seal which should be replaced. The operating temperature on the outside of the reducer case, after a few hours of operation, should not be more than 75oF (24oC) higher than the ambient air temperature. The oil in the reducer must never exceed 200oF (93oC). Reducer Disassembly (FIG. 5-16) Before starting disassembly, study the exploded view of the reducer in Fig. 5-16 to help determine part relationships. The reducer parts are indexed in a logical sequence of disassembly, which should prove to be a useful aid in dismantling the reducer.

17x11113--04.0401

CAUTION Shut OFF, lockout and tag all power to the circulating oil lubrication system before performing any inspection, maintenance, adjustment or lubrication on the pump reducer. 1. Remove the coupling guards. 2. Disconnect the motor and pump couplings, and remove the capscrews holding the reducer mounting bracket to the baseplate. See Figure 5-13. 3. Remove the coupling halves from the high and low speed shafts, and remove the mounting bracket from the reducer. Place the reducer on a clean, sturdy work surface. 4. Remove the breather (2) and drain plug (1). Drain all lubricant from the reducer. 5. Remove the nuts (5) and capscrews (4) holding the gear case (23) and the gear case cover (7) together. 6. Lightly tap on the gear case cover (7) to loosen it from the gear case (23). Separate the gear case cover from the gear case by carefully prying alternately at opposite ends with a screwdriver. Do not force the separation of the gear case cover and the gear case. Be careful not to damage the gasket (8) or the machined surfaces of the gear case cover and gear case. Remove the gear case cover and the gasket from the gear case. 7. Grasp the pinionshaft (20) and gear shaft (16), and pull both assemblies simultaneously from the gear case (23). 8. Use a conventional gear or bearing puller to remove the gear shaft bearings (11 and 12) from the gear shaft (16). Remove the beveled spacer (13) and press the gear (14) off the gear shaft (16). 9. Use a bearing puller and remove the pinionshaft bearings (17 and 18) from the pinionshaft (20). On reducer size 7.65 to 1 ratio, remove the spacer (13) from the pinionshaft (20). 10. Remove the lip seals (22) from the gear case cover (7) and the gear case (23) only if they show signs of deterioration or damage. The lip seals must be pressed or driven out (from the inside to the outside) on both the gear case cover and the gear case. 11. Inspect all parts for damage and excessive wear. Parts that are damaged or partially worn, such as seals and bearings, should be replaced while the unit is disassembled. Clean all parts thoroughly before assembling the reducer. Reducer Assembly (FIG. 5-16) 1. Install the pinionshaft bearings (17 and 18) on the pinionshaft (20). Be sure the bearings are seated firmly against the shoulders on the pinionshaft.

5--17

Lubrication Pumps

MAINTENANCE AND REPAIR

ITEM 1 2 3 4 5 6 7 8

NAME OF PART Drain Plug Breather Pipe Plug (Set--2) Capscrew (Set--7) Nut (Set--7) Dowel Pip Locating (Set--2) Gear Case Cover Gasket

for Crusher Circulating Oil Lubrication Systems

ITEM 11 12 13 14 15 16 17 18

NAME OF PART Ball Bearing Ball Bearing Spacer (7.65 to 1 Ratio -- 2 Req’) Gear Key Gear Shaft Ball Bearing Ball Bearing

ITEM

NAME OF PART

19 20 21 22 23

Snap Ring (for 6.27 to 1 ratio only) Pinion and Shaft Snap Ring (Set--2) Lip Seal (Set--2) Gear Case

FIG. 5-16 -- Exploded View of Pump Reducer

NOTICE Reducers with 6.27 to 1 ratio requires a snap ring (19). The snap ring (19) must be installed in the groove on the pinionshaft (20) before bearing assembly. The pinionshaft bearing (18) must be seated against the snap ring (19). Reducers with 7.65 to 1 ratio require two spacers (13), one on the pinionshaft (20) and one on the gear shaft (16). The pinionshaft spacer must be installed first, with the beveled edge toward the bearing (18). Install the bearing on the pinionshaft and seat it firmly against the spacer. 2. Install the key (15) in the keyway on the gear shaft (16). Press the gear (14) on the gear shaft, seating it firmly against the shoulder on the shaft. 3. Install the spacer (13) on the small diameter end of the gear shaft (16) with the beveled edge toward the gear (14). Install the gear shaft bearing (11) on the gear shaft and seat it firmly against the spacer. Install the 5--18

second gear shaft bearing (12) on the large diameter end of the gear shaft and seat it firmly against the shoulder on the shaft. 4. If the lip seals (22) were removed during disassembly, place the gear case cover (7) and the gear case (23), gasket side down, on a clean surface that will not mar the gasket face. Install the snap rings (21) in the gear case cover and the gear case. Apply gasket sealer on the outside diameter of each lip seal. Install the new lip seals, with the lip toward the inside of the gear case cover and the gear case, and drive the lip seals in place seating them against the snap rings. Use a wood block large enough to cover the entire lip seal and drive it evenly into position. Apply lubricant to the lip seal lips. 5. Block the gear case, open side up, to provide at least 3--1/4 in (8.3 cm) clearance between the bottom of the gear case and the assembly block. 6. Make sure the pinion and gear shaft keyways are free of burrs and sharp edges to prevent damaging the lip seal lips during shaft installation. Grasp the pinion and gear assemblies, with the gear teeth meshed, 17x11113--04.0401

Lubrication Pumps

for Crusher Circulating Oil Lubrication Systems and insert both assemblies simultaneously into the gear case. Rotate the gear shaft slightly as it is pushed through the lip seal. Tap the end of the pinionshaft and gear shaft with a hardwood block to seat the bearings (12 and 17) in the gear case counterbores. 7. Place the gasket (8) on the gear case (23). If the gasket is the least bit damaged, discard it and use a new gasket. 8. Align the gear case cover (7) with the ends of the pinionshaft and gear shaft, and carefully press the gear case cover in place. Rotate the pinionshaft during assembly as it is pushed through the lip seal. Tap the gear case cover with a hardwood block to seat the bearings (11 and 18) in the gear case cover counterbores.

17x11113--04.0401

MAINTENANCE AND REPAIR

9. Install the capscrews (4) and nuts (5), and tighten them securely, alternating around the gear case to prevent distortion, binding or cracking the gear case cover or gear case. 10. Install the drain plug (1) and breather (2). Install the reducer on the reducer mounting bracket and the baseplate. See instructions on “Installation and Alignment” in this section. Refer to Figs. 5-13 and 5-14. 11. Fill the reducer with the proper amount and type of lubricant. See instructions on “Reducer Lubrication” in this section. See Fig. 5-15. 12. Install all guards. Remove any warning tags or lockout devices before turning ON power to the circulating oil lubrication system.

5--19

Nelson Liquid Filters

OPERATION AND MAINTENANCE

Nelson Liquid Filters GENERAL DESCRIPTION This Nelson liquid filter is installed in the external lubrication system to remove solid contaminants such as dirt, rust, scale, sand and metal particles from the crusher lubricating oil. Removable access opening covers are provided to facilitate the replacement of the filter elements contained inside the main body of the unit and to permit cleaning the interior of the vessel. Single element filters are provided on 30 GPM (76 LPM) lubrication systems, and double element filters are provided on 40 GPM (151 LPM) and higher flow lubrication systems. See Fig. 5-17 and Fig. 5-18. Suitable mounting supports are provided for anchoring the unit. Inlet, outlet, vent. drain and pressure connections are provided on all units. PRE-OPERATIONAL CHECK Before submitting the unit to a fluid test: 1. Inspect the filter cover to be sure that the proper O-ring has been placed between the flange and cover.

PRE--OPERATIONAL FLUID TEST Give the filter a fluid test prior to putting it in full operation. 1. Check and make sure that the valve (7405-0) on the inlet side of the filter is completely closed. 2. Start the pump motor. 3. Loosen the vent in the filter cover to permit any entrapped air to bleed out of the filter enclosure as it is being filled with oil. 4. Partially open the valve (7405-0) on the inlet side of the filter, allowing a flow of oil to slowly and completely fill the filter.

NOTICE Be careful to prevent hydraulic hammer, in the lubrication system piping, whenever opening or closing valves controlling oil flow through the filters. Hammering can severely damage filter elements and main body connections.

2. Check all flange bolts for tightness.

5. Allow the vent plug to remain open long enough to permit entrapped air to escape from the vented unit. As soon as a small amount of oil is seen to flow from the loosened vent plug, close the plug securely.

3. Check mounting bolts and screws on all accessory items to be sure they are tightened securely.

6. Open the valve (7405-0) in the filter inlet line completely to allow the full flow of oil through the filter.

4. Check all hose lines to be sure they have not been flattened or kinked. If hose is damaged, replace it with new hose.

7. Inspect all connections for leaks. Tighten connections where necessary. If tightening connections fails to stop leaks, it indicates faulty gaskets or a damaged fitting or threads. Replace all faulty parts and re-check for leaks.

5. Check all pipe and pipe fittings to be sure they are tightened sufficiently to prevent leaks. Do not overtighten threaded connections. Stripping of threads may occur and result in leaking connections.

5--20

17x0098-03.0401

Nelson Liquid Filters

OPERATION AND MAINTENANCE

AIR VENT COVER BOLT WASHER

AIR VENT

FILTER COVER

COVER BOLT

O--RING

WASHER

BYPASS RELIEF VALVE

FILTER COVER O--RING

BYPASS RELIEF VALVE FILTER ELEMENT

FILTER ELEMENT COUPLING FILTER ELEMENT

FILTER ELEMENT

HEX NUT INLET PORT

HEX NUT

FILTER HOUSING FILTER HOUSING

INLET PORT PRESSURE GAUGE PORT iNLET SIDE

DRAIN PORT PRESSURE GAUGE PORT OUTLET SIDE OUTLET PORT

PRESSURE GAUGE PORT iNLET SIDE

DRAIN PORT PRESSURE GAUGE PORT OUTLET SIDE

17--390--206--401

FIG. 5-17 — Nelson Filter -- Single Element

17x0098-03.0401

OUTLET PORT

17--490--284--401

FIG. 5-18 — Nelson Filter -- Double Element

5--21

OPERATION AND MAINTENANCE

OPERATION After the initial installation of the filter is complete. including the fluid test for leaks, the filter is ready for operation. As the filter is used, make daily pressure differential readings. As the filter removes dirt and sediment from the product, it builds up on the filtering surfaces. Eventually, this retards the flow of the product through the elements and causes an increase in the pressure differential. MAINTENANCE There are no moving parts in the basic filter unit. Maintenance, is limited to the occasional replacement of the elements contained inside the main body of the unit. The frequency of filter element replacement is dependent on the amount of solid contaminants in the incoming product stream.

Nelson Liquid Filters

To change the filter element, shut the crusher down, stop the lube oil pump, and close the valve (7405-0) on the inlet side of the filter. A check valve (7720-0) in the filter discharge line will prevent oil back up into the filter. Drain the oil from the filter, using the drain plug at the side of the shell. Remove the filter cover and lift out the dirt filled element. Remove the bypass valve from the dirty element. Flush dirt out through the filter drain. Install a clean element, making sure that it is properly seated in the filter shell. Install the bypass valve assembly and fasten the cover securely in place. Be careful not to damage the seal. Use the following procedure to place the filter unit in service. 1. Check and make sure that the valve (7405-0) on the inlet side of the filter is completely closed.

For maximum performance efficiency, the elements must be replaced when the differential pressure across the filter reaches 20 PSI (138 KPa).

2. Start the pump motor. 3. Loosen the vent in the filter cover to permit any entrapped air to bleed out of the filter enclosure as it is being filled with oil. 4. Partially open the valve (7405-0) on the inlet side of the filter, allowing a flow of oil to slowly and completely fill the filter.

When the pressure differential readings indicate that replacement of the elements is necessary, the following procedures must be observed.

NOTICE

ELEMENT REPLACEMENT A decal, applied to the front of each filter unit, contains the Metso Minerals part number of replacement filter elements.

Be careful to prevent hydraulic hammer in the lubrication system piping whenever opening or closing valves controlling oil flow through the filters. Hammering can severely damage filter elements and main body connections.

NOTICE

NOTICE Use only Nelson filter replacement elements. Do not mix elements of different manufacture.

5--22

5. Allow the vent plug to remain open long enough to permit entrapped air to escape from the vented unit. As soon as a small amount of oil is seen to flow from the loosened vent plug, close the plug securely. 6. Open the valve (7405-0) in the filter inlet line completely to allow full flow of oil through the filter

17x0098-03.0401

Basco 500 Heat Exchanger

OPERATION AND MAINTENANCE

for External Lubrication Systems

BASCO TYPE 500 HEAT EXCHANGER INSTALLATION

INSPECTION

The heat exchanger is mounted on the external lubrication package at the factory and arranged so that the hot lubricating oil passes through the shell and around the exchanger tubes. Fittings for cooling water piping are cast into one of the bonnets at the end of the exchanger

Periodically remove bonnets at each end of the heat exchanger. Inspect zinc anodes for erosion or oxidation. Scrape to a bright surface, and replace anode if more than half corroded away. Examine tubes for scale and clean if necessary. After cleaning, examine for erosion or corrosion.

OPERATING

CLEANING

At start-up or after maintenance inspection, be sure that both the shell and tube sides are vented and full of liquid. Improper venting and fouling are the most common causes of heat exchanger malfunction. If air tends to accumulate in the system, follow a periodic venting program.

Interior tube surfaces can be flushed with a high velocity water stream, or cleaned with wire brushes or rods, if scaled.

FIG. 5-19

17x10647

5--23

Universal Flow Monitors

OPERATION AND MAINTENANCE

UNIVERSAL FLOW MONITORS

INSTALLATION

DANGER To prevent electrocution or serious bodily injury, disconnect, tag and lockout all power before working on any electrical components or controls.

FIG. 5-20

This medium-body flow monitor is designed and built to withstand the rigors of industrial service, and remain accurate. It will easily pass flows to approximately 1.5 times its rated capacity.

The materials used in constructing this flow meter were selected for use in this application and with the lube oils specified. This is an in-line device that can be mounted in any position without affecting performance. Simply thread your piping into the NPT ports, being sure that the flow goes into the port marked “IN”. Do not use Teflon tape to seal pipe threads in cast iron housings. This meter is equipped with one electric switch and one transmitter. ELECTRIC SWITCH Make connections in accordance with the wiring diagram below. The switch may be removed to facilitate wiring.

FIG. 5-22 — Wiring Diagram

SWITCH SPECIFICATIONS 3 wire SPDT switch is rated to 15A at 125, 230 and 480 VAC; 1/2A at 125 VDC or 1/4A at 250 VDC (res.). HOW IT WORKS Fluid enters at A, passes around the semi-circular vane B, exits at outlet C. The van resists the flow because of the spring D. Thje further the van is pushed the larger the passageway E becomes. This minimizes the increase infpressure drop. The van shaft turns to operate the pointer F and remote signel devices such as the switch G. FIG. 5-21

ENGINEERING DATA Standard max. temperature: 200_F Optional max. temperature: 400_F Max. operating pressure (3:1 safety factor): 300 PSI Readout accuracy, full scale: 2% Pressure drop (increases over rated flow range): 1.9 to 2.5 PSI (average 2.2) Inspect contents of shipment for shipping damage. All damage claims should be made to the shipping agent before installing.

5--24

SETTING THE SWITCH POINT The cam that actuated the switch is located on the dial assembly mounted inside the control box. The position of the cam dictates the switch point, which is the flow rate at which the cam throws the switch. Usually, the switch point is set at 80% of full flow. To set or reset the switch point, proceed as follows: Remove the cover and window from control box, then loosen the cam screw. Insert a screwdriver into the pointer screw, and direct the pointer along the scale to the flow rate you wish to signal. Then rotate the cam until the switch actuates (clicks), and tighten the cam screw. To adjust the setting under flow conditions, simply adjust the flow to the flow rate you wish to signal. Then loosen the cam screw and rotate the cam until the switch actuates (clicks). Tighten the cam screw and the switch is set for that flow rate. For ease and accuracy in determining contact closure an ohmmeter can be connected across terminals. To check the setting, direct the pointer again to the switch point, noting when the switch actuates and make fine adjustments as necessary.

17x0501--01.0701

Universal Flow Monitors

OPERATION AND MAINTENANCE

FIG. 5-23 — Lubrication System

TRANSMITTER The flow monitor box contains a transmitter (and driving potentiometer) that provide a two wire 4--20 mA DC linear output signal proportional to flow. The transmitter comes factory calibrated for use in this application and with the lube oils specified. For proper operation of the transmitter with warning signals and machinery shutdown, refer to the Mechanical Control Logic document. For proper wiring of the transmitter see the Index for Field Connections drawing provided in the crusher drawing transmittal. CALIBRATION All flow meters are individually calibrated (for a specific fluid) before leaving the factory. Scales are therefore not interchangeable. Be sure any scale removed is put back on the same meter. MAINTENANCE Observe the flow monitor when the lube system is shut down and under full flow conditions. The meter should reflect accurately the flow under these two conditions. If not, there may be an obstruction around the flow-sensing element. In order to ensure proper calibration and operation, it is the recommendation of Metso Minerals Industries Inc. that all service done on the flow monitors is performed by the factory.

17x0501--01.0701

CAUTION Shut off flow to the meter and bleed off pressure prior to disassembly. The meter may also have to be purged if it is metering hazardous materials. Mark position of bowl on both the body and bowl to ensure reassembly in the proper position. Open the flow chamber as shown in the diagram. Check for obstructions and remove any. If the vane is in good condition (not pitted or corroded), and the spring is intact, it is likely that the original calibration is still good. Reassemble the meter, matching the marks previously made on the bowl and meter body, and continue the operation. Actual verification of flow accuracy requires a calibration flow test stand. If there is no sign of corrosion or blockage and the flow element is still frozen in place, it is likely that the O-rings have been chemically attacked. If the attack is not likely to be repeated, then replacement O-rings can be ordered as a seal kit. If the chemical attack is due to a permanent change in fluid conditions, then the meter must be rebuilt using new O-rings of a different material. Please consult the factory when making this selection. It is also possible that gaskets, switches, control box mechanical moving parts and O-rings may become damaged and need replacement. Consult the factory when ordering these parts kits based on the flow meter model number.

5--25

OPERATION AND MAINTENANCE

Universal Flow Monitors

REPLACEMENT PARTS Every Universal flow meter has a nameplate stamped with a model number that describes the unit in detail, including materials of construction and all working parts, and all options. For an explanation of the model number breakdown, visit the factory website at www.universalflow.com or contact the factory with the complete model number. It is recommended that all parts be ordered from Universal Flow Monitors, Inc.

Remove bowl and look for obstruction on “S” or “M” housing types. *See: “Caution” above. FIG. 5-24 — Vane Style

5--26

17x0501--01.0701

Section 6 — Index

SUPERIOR MK- II Gyratory Crushers

6. MPS Control System Page 6-1 6-2 6-3 6-3 6-4 6-4 6-4 6-4 6-4 6-4 6-6 6-6 6-6 6-6 6-6 6-7 6-7 6-7 6-7 6-8 6-8 6-9 6-9 6-9 6-10 6-13 6-13

Description Index General Information TC 1000-M Mainshaft Position Indicator System Under Crusher Bin Level Sensor Oil Supply System — Maintenance Oil Supply System Relief Valve Settings — Adjusting 500 psi (3.5 MPa) Relief Valve — Adjusting 650 psi (4.5 MPa) Relief Valve — Adjusting 1090 psi (7.5 MPa) Relief Valve Cylinder Assembly — Removal and Inspection — Bushing Removal — Bushing Assembly — Replacing the MPS Oil Seal — MPS Cylinder Cover Assembly — Piston and Clamp Plate Assembly — Replacing the Assembly — Alternate Method — Replacement of MPS Oil Seal — Probe Assembly Balance Cylinder — Seals Repair Kit — Piston Repair Kit Relief Valves Pressure Transducer Oil Filter Bleeding Air From the System

17X0501--01.0701

6

6-1

Section 6 — MPS Control System GENERAL INFORMATION Principal parts of the Mainshaft Position System (MPS) control system include a cylinder assembly, balance cylinder assembly and the oil supply system. The cylinder assembly for MPS control includes those parts connected to the crusher itself such as the — step support piston (2205-0), oil seal (2305-0), clamp plate (2325-0), and cylinder (2005-0). For illustration, see Fig. 6-1. The balance cylinder assembly (8075-0) for primary crushers prevents the mainshaft assembly from dropping suddenly when forced upward by crushing pressures. It is installed with a check valve (8525-0), which regulates the flow of oil to the balance cylinder. A more complete description is given under the “Balance Cylinder” subsection later in this section. Catalog Number 2005--0 2050--1 2050--2 2055--0 2060--0 2060--4 2090--0 2120--0 2140--0 2205--0 2217--0 2225--0 2260--0 2280--0 2282--0 2283--0 2283--4 2305--0 2325--0 2340--0 2340--8 2345--0

6-2

Description MPS Cylinder Lower MPS Cylinder Bushing Upper MPS Cylinder Bushing Lower MPS Cylinder Bushing Bolt Upper MPS Cylinder Bushing Bolt Upper MPS Cylinder Bushing Lockwasher MPS Cylinder Dowel Bottom Shell Drain Plug MPS Cylinder O--ring Piston Plug Piston Dowel Piston Wearing Plate Step Washer Mainshaft Step Centering Ring Centering Ring Bolt Lockwasher Oil Seal Clamp Plate Measuring Tube Holder Gasket Measuring Tub Plug

SUPERIOR MK- II Gyratory Crushers

NOTICE The piston wearing plate (2260-0, Fig. 6-1) is supplied with a wear indicator as standard equipment. This wear indicator consists of a cavity, that is machined into the non-wearing (back) side of the piston wearing plate, which is filled with silver powder and sealed with a threaded plug. When wear reaches the depth at the bottom of the oil grooves on the piston wearing plate, the cavity opens and silver powder is released into the lubrication oil. An oil analysis will show the presence of the powder. A particle count of 50 ppm or higher indicates that a step component has reached its wear limit and must be replaced. Catalog Number 2345--8 2346--0 2505--0 2506--0 2510--2 2515--0 2515--1 2515--3 2520--0 2530--0 2605--1 2606--0 2606--1 2606--2 2606--7 2606--8 2630--0 2650--0 2650--8 2651--0 Note 1: Note 2:

Description Seal Ring Measuring Tube Holder Plug MPS Cylinder Cover MPS Cylinder Cover O--ring Position Indicator Capscrew MPS Cylinder Cover Bolt MPS Cylinder Cover Nut MPS Cylinder Cover Locknut MPS Cylinder Capscrew MPS Cylinder Drain Plug Position Indicator Cover Plate Guard Capscrew Spring Washer Bushing O--ring Measuring Tube Position Indicator Adaptor O-ring Capscrew Threads to be locked with Loctite #242. See Table 4-11 for torque values.

17X0501--01.0701

Section 6 — MPS Control System

SUPERIOR MK- II Gyratory Crushers

2280--0 2283--0 2283--4 2005--0

2060--0 2060--4

2345--0

SEE VIEW ”E”

2260--0

2217--0

2225--0

2345--8

2340--0 2140--0

2282--0

2630--0 VIEW ”E” 2050--2 2205--0 2050--1

2325--0

2120--0

2515--0 SEE NOTE 2 2515--1 2515--3 2090--0 (NOT SHOWN)

2340--8 2340--0

2630--0

2217--0

2340--0 2520--0 2346--0

VIEW ”D”

2305--0 2055--0 2505--0 2530--0

SEE VIEW ”D”

2325--0 2606--1 2606--2

2650--8

2506--0

2606--7

SEE VIEW ”C”

2650--0 2510--2 SEE NOTE 1 SEE NOTE 2

2606--0 MPS CYLINDER DETAIL

2651--0 SEE NOTE 1 SEE NOTE 2 2606--8 2605--1 VIEW ”C”

M--012407--TAW--06

FIG. 6-1 — MPS Cylinder Assembly

TC 1000-M MAINSHAFT POSITION INDICATOR SYSTEM For control of the MPS refer to the TC 1000-M Installation, Operation and Maintenance Instruction manual.

17X0501--01.0701

UNDER CRUSHER BIN LEVEL SENSOR An Under Crusher Bin Level Sensor is provided to monitor the level of the material in the discharge chute. For proper operation of the level sensor with warning signals and machinery shutdown, refer to the Mechanical Control Logic document. Refer to Fig. 4-6 to view illustration showing the Under Crusher Bin Level Sensor.

6-3

Section 6 — MPS Control System

SUPERIOR MK- II Gyratory Crushers

OIL SUPPLY SYSTEM The system includes a MPS storage tank (7005-0), a motor driven gear pump assembly (8104-0) and a MPS control valve assembly (8608-0). See parts manual for complete breakdown. All components are mounted on the external lubrication system base. Fig. 5-1, Section 5 shows the system arrangement. The MPS control valve asembly consists of a mainfold block with cartridge valves. See Fig. 6-2. With this control valve assembly, the MPS pump motor must operate in both directions. Maintenance

WARNING Any maintenance on any of the devices in the hydraulic system must be preceded by properly depressurizing the circuit. This is of vital importance to personal safety of the mechanic working on the machine. The circuit will remain pressurized even with the hydraulic system turned off. Before working on the circuit, shut off the hydraulic pump motor and lock out the power source so that the circuit is not accidentally pressurized while working on the circuit. Before depressurizing the circuit, record the crusher setting on the TC 1000-M display as the mainshaft assembly will lower to its lowest postion. Recording the crusher setting will allow the mainshaft to be raised to its previous position after the maintenance work is completed. Ensure that no personnel are under the crusher discharge area. To depressurize the circuit, loosen the locknut on the needle valve (8610-6) and open the valve by turning the stem counter-clockwise. OIL SUPPLY SYSTEM RELIEF VALVE SETTINGS The following procedures are for adjusting the pressure settings of the various relief valves in the MPS system whenever the replacement of the relief valve is required or if they go out of adjustment. All relief valves are factory preset. Refer to Fig. 6-2 and 6-3.

NOTICE All adjustments must be made when the Crusher is not operating. All adjustments must be checked with the Maintenance/Local Remote selector switch in the Local position.

6-4

Adjusting 500 psi (3.5 MPa) Relief Valve 1. Remove protective cap from port “F” and connect a pressure gauge to the test fitting. 2. The 500 psi (3.5 MPa) relief valve (8610-3) adjusting screw must be turned in or out as required to obtain 500 psi (3.5 MPa). 3. After an adjustment has been made pull up on the Push Off-Pull On pushbutton and push the Lower pushbutton on the TC 1000-M enclosure. While holding the Lower pushbutton down read the pressure on the pressure gauge connected to port “F”. 4. Push down on the Push Off-Pull On pushbutton on the TC 1000-M enclosure. 5. Remove the pressure gauge from port “F”. Adjusting 650 psi (4.5 MPa) Relief Valve 1. Disconnect the hose at port “C” (oil supply line to crusher) and install a pressure gauge into port “C”. Do not allow hose end to get dirt into it. 2. The 650 psi (4.5 MPa) relief valve (8610-2) has a tamper proof cap. Remove cap and adjust the relief valve by turning in or out as required to obtain 650 psi +/-- 50 psi (4.5 MPa +/-- 0.3 MPa). 3. After an adjustment has been made pull up on the Push Off/Pull On pushbutton and push the Raise pushbutton On the TC 1000-M enclosure. While holding the Raise pushbutton in, read the pressure on the pressure gauge connected to port “C”. 4. Push down on the Push Off-Pull On pushbutton on the TC 1000-M enclosure. 5. Remove the pressure gauge from port “C” and reconnect the hose. 6. Reinstall the tamper proof cap. Adjusting 1090 psi (7.5 MPa) Relief Valve 1. Disconnect the hose at port “C” (oil supply line to crusher) and install an auxiliary hydraulic power unit and pressure gauge. Do not allow hose end to get dirt into it. 2. The 1090 psi (7.5 MPa) relief valve (8610-1) has a tamper proof cap. Remove cap and adjust the relief valve by turning in or out as required to obtain 1090 psi +/-- 50 psi (7.5 MPa +/-- 0.3 MPa). After an adjustment has been made operate the power unit and observe the pressure on the power unit gauge. Slowly close the needle valve and read the pressure on the power unit gauge. 3. Remove the auxiliary hydraulic power unit.

17X0501--01.0701

Section 6 — MPS Control System

SUPERIOR MK- II Gyratory Crushers

FIG. 6-2 — MPS Control Valve Catalog Number 8608-0 8608-1 8610-0 8610-1 8610-2

Description MPS Control Valve Assembly Manifold Block Pilot Operated Check Valve Relief Valve 7.5 MPa (1090 psi) Relief Valve 4.5 MPa (650psi)

Catalog Number 8610-3 8610-4 8610-5 8610-6 8610-7

Description Relief Valve 3.5 MPa (500psi) Check Valve (Lower) Check Valve (Raise) Needle Valve Diagnostic Nipple

FIG. 6-3 — MPS Control Valve and Replacement Parts

17X0501--01.0701

6-5

Section 6 — MPS Control System

SUPERIOR MK- II Gyratory Crushers

CYLINDER ASSEMBLY If maintenance is required on the cylinder assembly for MPS control, remove the entire assembly from the crusher. Removal And Inspection

DANGER Lockout power source during installation, cleaning, or servicing the equipment or when making repairs. Failure to do so could result in severe bodily injury or death. Block up the mainshaft at the bottom shell arms, lowering the mainshaft to that point. This will avoid having full mainshaft weight on the cylinder lowering mechanism during removal. Then disconnect the lubrication and hydraulic lines, and drain the oil from the crusher by removing the bottom shell drain plug (2120-0) from the bottom of the MPS cylinder flange. Also remove the under crusher bin level sensor and disconnect the wires. In removing the cylinder assembly, it is customary to leave the eccentric in place unless some work is necessary on it. The eccentric support plate (1905-0), held up by cap screws (1910-0), will retain the eccentric in position while the cylinder assembly is not in place. Locate the eccentric cart or skid under the MPS cylinder. Raise the eccentric cart using cables from the overhead crane until it is in contact with the cylinder. Insert the guide rods (8955-0) into the bottom shell and remove the nuts (2020-1, 2020-3) from the studs (2020-0) that hold the MPS cylinder assembly to the bottom shell. If necessary raise the eccentric cart in order to take weight off the nuts (2020-1, 2020-3). Slowly lower the eccentric cart with the MPS cylinder assembly using the overhead crane, and remove it from under the crusher.

WARNING The guide 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. When the cylinder assembly is free of the crusher, remove the step washer (2280-0) and the piston wearing plate (2260-0) from on top of the piston (2205-0). Screw an eyebolt into the tapped hole in the center of the piston. The piston can now be hoisted out of the hydraulic cylinder.

6-6

WARNING The clamp plate (2325-0) may adhere to the bottom of the piston (2205-0) 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 (2325-0) remains in the hydraulic cylinder. A slight jar can be used to separate the clamp plate (2325-0) from the bottom of the piston (2205-0). Screw eyebolts into the clamp plate (2325-0) and hoist it out of the hydraulic cylinder. Bushing Removal Remove the upper bushing bolts (2060-0) from the flange of the hydraulic cylinder upper bushing (2050-2). Then jack the bushing from the cylinder, using the tapped holes provided for that purpose in the flange of the bushing. The lower bushing must be removed from the bottom of the hydraulic cylinder. Remove the lower bushing bolts (2055-0) from the flange of the hydraulic cylinder lower bushing (2050-1). Then jack the bushing from the cylinder using the tapped holes in the bushing flange. Inspect the wearing surfaces of the lower bushing, piston, and clamp plate carefully. 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. Any chip out of the seal means leakage and consequent inability of the crusher to maintain its setting. This seal should be inspected closely and handled carefully at all times. Bushing Assembly The upper and lower MPS cylinder bushings (2050-1 and -2) are a close clearance fit. Chill with dry ice before attempting to install them in the MPS cylinder. They may also be slightly out of round until installed in the thicker, more stable containment of the cylinder. Before actually installing them in the cylinder, install two long guide bolts, 180o apart, in holes in the cylinder and in the bushing flange so that the joint bolt holes will match when the bushing is seated in the cylinder. Start the bushings into the cylinder squarely, and push into place. Replacing the MPS Oil Seal The MPS oil seal (2305-0) can be replaced from the top or bottom of the MPS cylinder (2005-0). When assembling from the bottom, place the clamp plate (2325-0) on the cover plate (2505-0). Carefully lubricate the oil seal (2305-0) and place it on the clamp plate (2325-0). Place O-ring (2506-0) into the groove in the cover plate (2505-0). Carefully lower the MPS cylinder (2005-0) over the oil seal and clamp plate assembly. Complete the assembly with the MPS cylinder cover bolts (2515-0 and 2520-0). Torque bolts to 7500 ft-lbs. (10,168 N-m). 17X0501--01.0701

Section 6 — MPS Control System

SUPERIOR MK- II Gyratory Crushers When assembling the oil seal (2305-0) from the top, assemble cover plate (2505-0) with O-ring (2506-0) to the MPS cylinder (2005-0) with bolts (2515-0 and 2520-0). Torque bolts to 7500 ft-lbs. (10,168 N-m). Lower clamp plate (2325-0) with eyebolts into the MPS cylinder, onto the cover plate (2505-0). Lubricate each part of the oil seal (2305-0) and carefully assemble it, piece by piece, to the clamp plate (2325-0). Lubricate the piston (2205-0) and lower it into the cylinder, on top of the oil seal. The weight of the piston holds it in place on the clamp plate. Replace the piston wearing plate (2260-0), being sure the dowel (2205-0) enters the hole in the bottom of the wearing plate so the plate is flat on top of the piston. Check that capscrews (2283-1) for the mainshaft step centering ring (2282-0) are tight before locating the step washer (2280-0) on the wearing plate.

NOTICE Place the step washer on top of the piston wearing plate with the concave side up. Make certain that all parts are coated with oil before assembling. MPS Cylinder Cover Assembly The MPS cylinder cover (2505-0) fastens to the bottom of the cylinder (2005-0) with bolts (2515-0) and nuts (2515-1 and 2515-3). An O-ring (2506-0) is used to seal between the cover (2505-0) and the lower bushing (2050-1). 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, either raise the cover up to the cylinder with the three piston lowering rods (see Fig. 6-5) or lower the cylinder onto the cover plate. Be sure the roll pin seats into the corresponding cylinder roll pin hole. Install bolts (2515-0) with nuts (2515-1 and 2515-3). Torque per Table 4-11. Piston and Clamp Plate Assembly Lightly coat the upper and lower cylinder bushings with oil. Place two correct size eyebolts in the top of the clamp plate assembly (2325-0) and lower it into the cylinder (2005-0) 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 (2205-0) into the cylinder (2005-0) until it rests on top of the clamp plate (2325-0). 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 (2205-0). 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 (2205-0).

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NOTICE Coat all parts with oil before assembling. Replacing The Assembly Place the MPS cylinder assembly on the eccentric cart or skid. Install the O-ring (2140-0) into the groove on the upper face of the cylinder (2005-0). Locate the eccentric cart with the MPS cylinder assembly under the crusher and place the 3.0” diameter guide rods into position in the bottom shell (See Fig. 6-4).

WARNING The guide 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. Raise the eccentric cart with the MPS cylinder assembly into place using cables from the overhead crane. After the assembly is in place, tighten the nuts (2020-1) evenly per table 4-11 to ensure there are no leaks and replace the lubrication and hydraulic piping.

2020--0 2020--1 2020--3

GUIDE ROD M--041007--JRK--01

FIG. 6-4 — MPS Cylinder Removal and Installation

Alternate Method — Replacement of MPS Oil Seal The piston, clamp plate with oil seal (2305-0) and cover plate can be removed from the hydraulic cylinder (2005-0) without removing the hydraulic cylinder assembly from the crusher. Insert the three 2.00” (50.8 mm) lowering rods, which are provided with the tools, through the cover plate into the threaded holes in the bottom flange of the MPS cylinder and secure the lowering rods with a nut on the topside of the bottom flange of the MPS cylinder. This will prevent the lowering rod from turning out when the cover 6-7

Section 6 — MPS Control System

SUPERIOR MK- II Gyratory Crushers

plate is lowered. The end of the lowering rod with the .69” (17.5 mm) diameter hole should be below the cover plate. The 4.00” (101.6 mm) long sections of 2.00” (50.8 mm) pipe are used as spacers to gain clearance past the cover plate nuts on the bottom of the cover plate. Thread a nut and washer onto the lowering rods up to the sections of pipe. Tighten these nuts against the pipes in order to clamp the cover plate to the bottom flange of the MPS cylinder. After this is done the cover plate bolts and nuts (2515-0, 2515-1 and 2515-3) can be removed. Lower the piston, clamp plate with oil seal and cover plate by turning down the nuts on the lowering rods. Rotate turning the lowering nuts only a few turns at a time so the weight of the cover plate, clamp plate and piston remains distributed on the three lowering rods.

WARNING The threaded lowering rods must be securely locked into the threaded holes of the bottom flange of the MPS cylinder with a hex nut on top of the bottom flange (see Fig. 6-5). This is to prevent the lowering rods from turning out of the MPS cylinder when the hex nuts holding the cover plate are lowered. Failure to properly secure and maintain the tight fit of the lowering rods in the MPS cylinder could result in the component or assembly being lowered to shift and fall causing serious injury and possible death. Note that the piston and clamp plate are not fastened together. The piston simply sets on the clamp plate and the parts are held together by the weight of the piston. For disassembly of the MPS oil seal from the cover plate see “Replacing the MPS Oil Seal” in this section. The MPS oil seal may be removed from the crusher without removing the piston. This procedure is the same as removing the piston except that a piston stop plate, which is furnished with the tools, is inserted in a groove about 1 inch (25.4 mm) above the bottom of the piston after the piston has been lowered far enough so that the groove is below the bottom flange of the MPS cylinder. Then this piston stop plate is bolted to the MPS cylinder holding the piston in the cylinder while the clamp plate with oil seal and cover plate are lowered using the lowering rods as described above. See Fig. 6-5.

WARNING The clamp plate (2325-0) may adhere to the bottom of the piston (2205-0) and fall off the piston, causing serious injury and possible death. A slight jar can be used to separate the clamp plate (2325-0) from the bottom of the piston (2205-0).

PISTON STOP PLATE 2325--0 2305--0

2505--0

2205--0

PISTON LOWERING ROD (3)

M--041607--JRK--01

FIG. 6-5 — Removal of MPS Oil Seal with MPS Cylinder Assembled to Crusher

Probe Assembly SUPERIOR M-II crushers are furnished with a mainshaft position indicator system for electronic monitoring of the position of the mainshaft in the crusher. The probe assembly, as part of the system, is directly attached to the bottom of the MPS cylinder assembly. See Fig. 6-1 for assembly, bolt torques and Loctite sealant placement. Also, refer to the separate instruction manual for the Mainshaft Position Indicator System. BALANCE CYLINDER Large chunks of feed in the chamber of primary crushers sometimes force the mainshaft upward in a quick “jumping” action. Balance cylinders are furnished with primary crushers to make the piston follow the mainshaft up when it is raised by jumping and ease the shaft down to its original position.

6-8

17X0501--01.0701

SUPERIOR MK- II Gyratory Crushers

Section 6 — MPS Control System

This is accomplished by the balance cylinders (8075-0) and check valve (8525-0). See Fig. 6-6, 6-7, and 6-8. Under normal operating conditions, the balance cylinders contain a fixed quantity of oil and nitrogen. After the system has been bled of air and with the shaft raised hydraulically to its operating position, the balance cylinders must be charged with 115 PSIG (739 KPa) of nitrogen. NOTE: Pre-charge pressure must be measured after the MPS system is filled with oil and the mainshaft assembly is supported on a column of oil underneath the MPS piston. The pre-charge pressure is less than the hydraulic pressure produced by the weight of the mainshaft assembly (even when the mantle is in a totally worn condition) and more than that produced by the weight of the crusher piston. For example, when the 60-110 mainshaft assembly rises, the hydraulic pressure will drop below 115 psi (793 KPa). The nitrogen in the balance cylinders will force oil into the MPS system and make the piston rise with the shaft. When the mainshaft is released and starts to drop, the pressure in the hydraulic system builds up to more than 115 psi (793 KPa), forcing the oil back into the balance cylinders. To prevent the mainshaft from returning to its original position too rapidly, the check valve meters the oil returning to the balance cylinders. See Fig. 6-9. Seals Repair Kit A seals repair kit (8075-5), consisting of items 7, 8, 9, 10 and 12 shown in Fig. 6-8, is available. The repair kit contains the correct quantity of each item for one balance cylinder. Piston Repair Kit A piston repair kit (8075-8), consisting of items 4, 5, 6 and 15 shown in Fig. 6-8, is available. The repair kit contains the correct quantity of each item for one balance cylinder. RELIEF VALVES Two relief valves (8645-0) are located in the MPS control pipe line. They are set at 750 psi (5171 KPa). Their purpose is to relieve the pressure in the hydraulic system if it becomes excessive. See Fig. 6-7. The relief valve normally requires little maintenance. If it is believed to be inoperative, it may be checked by attaching it to a high pressure device, such as a hydraulic jack, high pressure grease gun or gauge line of a hydraulic press, with a gauge, and noting the pressure at which the valve operates. This should be within 10% of that stamped on the valve. Be sure that the pressure side, male port, is attached to the high pressure pipe, and that the relief side, female port, is away from the pressure and open to atmospheric pressure. DO NOT PLUG RELIEF END AT ANY TIME.

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6-9

Section 6 — MPS Control System

SUPERIOR MK- II Gyratory Crushers

PRESSURE TRANSDUCER A pressure transducer is located in the MPS control pipe line. It allows monitoring of the oil pressure. For the proper operation of the pressure transducer with warning signals and machinery shutdown, refer to the Mechanical Control Logic document. Nitrogen Under Pressure

Balance Cylinder(s)

Oil Pressure

Check Valve Normal Crushing

Charging Valve Upward Jumping of Mainshaft Caused by an Occasional Rock Position or Tramp Iron in Crushing Chamber.

Piston

Loose Step Bearing Components. When the Mainshaft Jumps, the Balance Cylinder Forces Oil Under Piston to Keep the Piston Clamp Plate, Piston, Piston Wear Plate, Step Washer, Step, and Shaft Tight Together, Preventing Separation and Damage.

Free Flow of Oil Thru Check Valve. Restricted in Opposite Direction.

Clamp Plate

Floating Piston

Oil Pressure is Less Than Nitrogen Pressure When Mainshaft Jumps.

Check Valve

FIG. 6-6 — How the Balance Cylinder Operates

6-10

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Section 6 — MPS Control System

SUPERIOR MK- II Gyratory Crushers

8425--0 8645--0 8645--1

8075--3 8075--4 8075--9

(INCH) 1” NPT (FEMALE) MPS OIL INLET POR

8076--0 8076--1

8075--0 8525--0

8415--0 8556--3 8556--4

9901--7 8454--0 8454--1

8556--0 8556--1 A

8558--0

8540--0 8540--1

8028--0

8405--0

8530--0

8556--0 8563--0

8521--0 8555--0

8029--0 8029--1 8029--2 8755--8

8207--0 A

8558--0

8565--0 8565--4 VIEW A--A

FLOW METER STATION MOUNT NEAR CRUSHER M--012407--TAW--03

FIG 6-7 — Balance Cylinder and MPS Piping Catalog Number

Description

Catalog Number

Description

8028--0 8029--0 8029--1 8029--2 8075--0 8075--3 8075--4 8075--9 8076--0 8076--1 8207--0 8405--0 8415--0 8425--0 8454--0 8454--1 8521--0

Pipe Clamp Bracket Assembly Bolt Nut Washer Balance Cylinder Pressure Gauge Bushing Pressure Switch Bolt Nut Pressure Transducer Manifold Assembly Balance Cylinder Support Bracket Relief Valve Discharge Cup Manifold Flange Bolt Manifold Flange Lockwasher Check Valve Welding Flange

8525--0 8530--0 8540--0 8540--1 8555--0 8556--0 8556--1 8556--3 8556--4 8558--0 8563--0 8565--0 8565--4 8645--0 8645--1 8755--8 9901--7

MPS Check Valve Check Valve Gasket Check Valve Stud Check Valve Nut Pipe Assembly -- Flange to Check Valve O-Ring Square Flange with O--Ring Groove Bolt Washer Pipe Assembly -- Cover to Flange Square Flange with O-Ring Groove Bolt Lockwasher Relief Valve Nipple Pipe Support Clamp Bleeder Valve

17X0501--01.0701

6-11

6-12 2

3

18 17 PART NO. 10 11 12 13 14 15 16 17 18

PISTON ROD 5

PARTS LIST NITROGEN--OIL BALANCE CYLINDER PART NO. PART NAME QUANTITY 1 ROD END COVER 1 2 BLIND END COVER 1 3 BALANCE TUBE BODY 1 4 PISTON U--CUP TYPE 1 5 PISTON ROD 1 6 PISTON GUIDE 1 7 O--RING (BUNA) 2 8 BACKUP (TEFLON) 2 9 BACKUP (TEFLON) 2

15

AIR VALVE 14

PIPE PLUG INSPECTION HOLE 11 BUNA O--RING 12 PISTON GUIDE 6 PISTON U-CUP TYPE 4 SET SCREW 13

PART NAME QUANTITY U--CUP (BUNA) 2 PIPE PLUGS (.25” NPT) 3 O--RING (BUNA) 1 SET SCREW (0.25”--20) 2 VALVE (0.25” NPT) 1 HEX NUT JAM (1.0”--14) 1 HEX NUT (0.75”--10) 24 TIE ROD (LONG) 8 TIE ROD (SHORT) 4

8

U-CUP BUNA 10 TEFLON BACKUP 9

BUNA O--RING 7

1

SK082598--JJB--1

CATALOG DESCRIPTION NUMBER 8075--4 SEALS REPAIR KIT 8075--8 PISTON REPAIR KIT

16 TORQUE 135 TO 145 FT.--LBS. (183 TO 197 Nm)

TEFLON BACKUP 8

Section 6 — MPS Control System

SUPERIOR MK- II Gyratory Crushers

Fig. 6-8 — Balance Cylinder

17X0501--01.0701

Section 6 — MPS Control System

SUPERIOR MK- II Gyratory Crushers OIL FILTER The oil filter (8609-1) is mounted between the control valve and the MPS tank (see Fig. 5-1 in Section 5). The oil filter is the full flow type which requires all of the oil to pass through it. The filter element (8609-9) is the throw-away type. When a filter change is carried out -- which should be each time the MPS oil is changed or every six months -relieve the pressure in the system by lowering the mainshaft to its bottom position. Unscrew the filter element and replace with a new one. BLEEDING AIR FROM THE SYSTEM The system requires air to be removed during the original start-up of the system or when a break in the line occurs. Start the pump by depressing the “raise” push button so that oil is pumped to the crusher. Open the upper bleeder plugs (9901-7) until bubble free oil comes out. The upper air bleeder plugs (9901-7) are located at the lower end of the balance cylinder(s) (8075-0). See Fig. 6-7. Close the bleeder plugs (9901-7) and stop the MPS pump when the shaft has been raised 0.125 to 0.25 inches (3.2 to 6.4 mm). Remove bleeder plug (2530-0). (Fig. 6-1) at bottom of MPS cylinder cover (2505-0) to bleed air from the cylinder.

FIG. 6-9 — Check Valve for MPS System — with Balance Cylinder Catalog Number 8525-0 8525-1 8525-2 8525-3 8525-4 8525-5

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Description Check valve assembly Check valve housing Check valve seat Check valve spring Check valve piston O-ring

6-13

Section 6 — MPS Control System

SUPERIOR MK- II Gyratory Crushers

This page was purposely left blank.

6-14

17X0501--01.0701

Section 7 — Index

SUPERIOR MK- II Gyratory Crushers

7. Bottom Shell Assembly

Page 7-1 7-2 7-2 7-2 7-2 7-2 7-2 7-2

Description Index General Information Bottom Shell Assembly Dust Collar Upper Counterweight Splash Ring Bottom Shell Bushing — Removal — Assembly

7

17X0501-01.0701

7-1

Section 7 — Bottom Shell Assembly GENERAL INFORMATION The bottom shell assembly (Fig. 7-1) consists of the lower and upper bottom shells (1005-0 and 1006-0) with hub, arm and side liners (Section 4, Figs. 4-2a, 4-2b and 4-2c), bottom shell bushing (1200-0) with key (1210-0), dust collar (1400-0) with gasket (1430-0) and upper counterweight splash ring (1420-0).

DANGER Lockout power source during installation, cleaning, or servicing the equipment or when making repairs. Failure to do so could result in severe bodily injury or death. BOTTOM SHELL ASSEMBLY (FIG. 7-1) Inspect the taper fits on both the upper and lower bottom shell sections. Remove any burrs, bruises, or interfering accumulations of rust or dirt. Coat the horizontal surfaces of the upper bottom shell with light oil. Do not use white lead as it will harden making subsequent removal of the upper bottom shell difficult. Make a level hitch on the upper bottom shell (1006-0) and lower it into the matching taper fits on the lower bottom shell (1005-0). Position it as level as possible so that the bolting flanges are as close to parallel as possible. Check the gap between flanges at 90_ increments. On the 60-110 this gap should be between 0.115 to 0.170 inches (2.92 to 4.32 mm) when checking the dry assembly of the taper fits. Tighten down two bolts, 180_ apart, making sure that the gap between the upper and lower shells is equal. Then install two bolts 90_ from the first two, again making sure the gap is equal. Install the balance of the bolts at approximately the same tightness as the first four. Continue to tighten bolts in the same sequence, approximately the same number of turns, until a 0.004 inch (0.1 mm) feeler gauge cannot be inserted between the bolting flanges at any point on the circumference. If there is any clearance between upper and lower bottom shells after tightening, it is an indication that the joint has not been pulled up tightly enough or that something in the joint is holding it open. KEEP THIS JOINT TIGHT TO PREVENT JOINT BOLT BREAKAGE. After the crusher has been operated a few hours the nuts holding the upper and lower bottom shells together sometimes loosen a slight amount. After a little operation these nuts should be checked again and drawn down as tightly as possible. DUST COLLAR The dust collar has an interference fit with the turn of the bottom shell hub. The collar is secured to the bottom shell with studs and nuts on the outside rim of the collar (1405-0, 1405-1 and 1405-4). The mainshaft must be removed to 7-2

SUPERIOR MK- II Gyratory Crushers provide access to the studs. Use the split pin (1408-0) to position the dust collar on the bottom shell hub correctly. Take care when removing the collar to prevent damage to the gasket (1430-0) between the collar and bottom shell. The collar can be removed from the short interference fit with the bottom shell by using jack bolts in the threaded holes provided. When reassembling the dust collar, be careful with the gasket installation. Large holes in the gasket must line up with the oil return holes in the bottom shell and in the dust collar. UPPER COUNTERWEIGHT SPLASH RING The upper counterweight splash ring (1420-0) bolts to the dust collar (1400-0) lifting eyebolt holes (3) with fasteners (1421-0). Coat fasteners (1421-0) with Loctite No. 242 and refer to torque chart Table 4-11 for proper torque value. BOTTOM SHELL BUSHING The bronze bottom shell bushing is keyed with a straight type key (1210-0). Assembly and removal is from the top, after removal of the spider, mainshaft assembly, dust collar and eccentric. Removal Bottom shell bushing removal after a bearing failure is easily accomplished, using the eyebolts provided and lifting the bushing out with a crane. Overheating shrinks the bushing in the normal slight clearance fit with the bottom shell, and very little resistance occurs. The hoisting hitch should have a spreader bar at the eyebolts between the two hoisting slings to prevent collapsing of the bushing top from the strain on the cables. The eyebolt holes are relatively small, so a small amount of pressure should be applied for pulling. If a good, reusable bottom shell bushing has to be removed for any reason, the fit may be snug. Bushings sometimes go out of round from removal of the clamping device on the machine tool after manufacture. If the bushing does not show evidence of coming out with a taut hitch in the eyebolt holes, it may be necessary to use one of the following methods to remove it: 1. Block the bushing bottom with plywood and shrink the bushing by soaking in pulverized dry ice. 2. Fit a steel plate or bar on the bushing bottom and jack it out from cribbing underneath the crusher. This normally can be done with a ten or twenty ton jack. Assembly Before installing a new bottom shell bushing, inspect the surface of the bottom shell bore. The bore should be relatively smooth, round and not tapered. Remove any burrs or protrusions. Make certain that the end of the bushing, marked “top,” is upward. If the bushing is inserted upside down, the oil holes in the bushing will not match the annular oil

17X0501-01.0701

SUPERIOR MK- II Gyratory Crushers feed groove in the bottom shell and lubricating oil will not flow into the eccentric and bushing. Chill the bottom shell bushing with the key in place in a refrigerator, or by using dry ice chipped extremely fine in the bore. If dry ice is used, cover the bushing with an insulating blanket or tarpaulin. Two hours of chilling is usually sufficient to allow easy installation into the bottom shell bore. The reason for chilling the bottom bushing, although a slight clearance fit in the bottom shell bore, is that they frequently go out of round after removal from the machine tool in manufacturing. Chilling allows easy installation with less chance of metal pick up and bushing distortion. If chilling is not sufficient to do the job, it may be necessary to use a jack to replace the bushing. Place a

17X0501-01.0701

Section 7 — Bottom Shell Assembly heavy bar or I-beam across the top of the bottom shell and hold it in place by bolting. Use a small jack between this bar and a plate laid over the bottom shell bushing. The jack will force the bushing into the bore.

NOTICE Never use a hammer or sledge to drive the bushing into place. Hammering will distort the bronze, reducing bearing clearance and possibly causing bearing failure during crushing operations.

7-3

SUPERIOR MK- II

Section 7 — Bottom Shell Assembly 1010--7 1010--8

Gyratory Crushers

1405--0 1405--1 1405--4 1405--0

1421--0 1400--0

1420--0

1430--0

1006--0

1040--0 1040--1 1040--3

1005--0 1260--0 1250--0 1675--0

1261--0 1261--4 1255--0

1910--0 1910--4 1280--0 (NOT SHOWN)

1505--0 1505--1 1505--2 1505--3

1200--0 1210--0

3030--0

2020--0 2020--1 2020--3

M--012907--TAW--01 FIG. 7-1 — Bottom Shell Assembly Catalog Number

Description

Catalog Number

Description

1005--0 1006--0 1010--7 1010--8 1040--0 1040--1 1040--3 1200--0 1210--0 1250--0 1255--0 1260--0 1261--0 1261--4 1280--0 1400--0 1405--0

Bottom Shell Lower Bottom Shell Upper Pinion Shaft Arm Liner (L.H.) Pinion Shaft Arm Liner (R.H.) Joint Bolt Assembly Nut Hex Jam Nut Bottom Shell Bushing Bottom Shell Bushing Key Bottom Shell Lube Pipe Braided Packing Packing Flange Flange Bolt Flange Bolt Washer Split Pin (not shown) Dust Collar Stud

1405--1 1405--4 1408--0 1420--0 1421--0 1430--0 1505--0 1505--1 1505--2 1505--3 1675--0 1910--0 1910--4 2020--0 2020--1 2020--3 3030--0

Nut Lock Washer Split Pin (not shown) Splash Ring Capscrew Dust Collar Gasket Stud Nut Lockwasher Hex Jam Nut Air Inlet Connector Capscrew Lockwasher Stud Nut Hex Jam Nut Pinionshaft Housing Gasket

7-4

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Section 8 — Index

SUPERIOR MK- II Gyratory Crushers

8. Eccentric Assembly

Page 8-1 8-2 8-2 8-4 8-5 8-5 8-5 8-5 8-6 8-6 8-6 8-6 8-7 8-7 8-8

Description Index General Information Eccentric Assembly Removal Eccentric Assembly Replacement Eccentric Bushing Eccentric Gear — Removal — Inspection — Reassembly Lower Counterweight — Removal — Assembly Upper Counterweight Assembly — Removal — Assembly

8

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8-1

Section 8 — Eccentric Assembly

SUPERIOR MK- II Gyratory Crushers

GENERAL INFORMATION The eccentric assembly consists of the eccentric (1805-0), the eccentric bushing (1810-0), the eccentric gear (1850-0), the lower counterweight (1812-0), the upper counterweight assembly (1811-0), and keys (1820-0 and 1855-0). The eccentric rests on the eccentric wearing plate (1880-0) and is held in place by the eccentric support plate (1905-0). See Fig. 8-1 for arrangement. ECCENTRIC ASSEMBLY REMOVAL

DANGER Lockout power source during installation, cleaning, or servicing the equipment or when making repairs. Failure to do so could result in severe bodily injury or death. The eccentric can be removed after removing the MPS cylinder assembly. However, if an optional large upper counterweight is used then the dust collar splash ring and large upper counterweight must first be removed from above (see Figure 8-10).

NOTICE On the 60-110 gyratory the eccentric assembly cannot be installed or removed from the Crusher with the (optional) large upper counterweight bolted to the top. Leave the eccentric support plate screws (1910-0) in place, so the support plate holds the eccentric in the crusher while the cylinder is removed. Then lower the eccentric assembly using the guide rods and eccentric cart or skid suspended with cables from the overhead crane. Refer to “Cylinder Assembly -- Removal and Inspection” in section 6. Use the guide rods and the eccentric cart to lower the eccentric assembly in the same manner as the MPS cylinder assembly is lowered.

8-2

WARNING The guide 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. Occasionally, due to a problem, an eccentric will seize while operating. If the seizure is between the mainshaft and the eccentric bushing (1810-0), the crushing mantle will rotate at eccentric speed and will not raise or lower the full amount with the MPS control when the crushing chamber is empty. The crusher will stall when material is fed into the crushing chamber. If the eccentric bushing is badly seized, it will stay on the mainshaft when the eccentric is removed. It will probably be necessary to cut the bushing to remove it from the mainshaft. (Be careful not to damage the mainshaft, should cutting be necessary.) If the seizure is between the eccentric and the bottom shell bushing (1200-0), the pinionshaft cannot be turned. To remove the eccentric under these conditions is often difficult. If the eccentric cannot be removed as usual, remove the top shell, mainshaft assembly, dust collar (1400-0), and the MPS cylinder assembly. Lower the eccentric support plate one inch (2.54 cm). Place a hydraulic jack on top of the eccentric and under a cross beam bolted to the bottom shell. Warming and chilling the eccentric several times may help to crack the eccentric loose. Do not attempt to push the eccentric up. Inspect the eccentric to determine if wearing surfaces are scored or show evidence of excessive wear or heating. Also inspect the inside of the eccentric bushing for wear, scoring and dark spots which indicate that it has been subjected to excessive heating. Mike the eccentric to check for out-of-roundness or taper.

17X0501--01.0701

Section 8 — Eccentric Assembly

SUPERIOR MK- II Gyratory Crushers

1811--0

1810--0 1820--0

1850--0

1812--0

1920--0

8955--0

1855--0

1910--0 1910--4

1880--0 1905--0

1805--0 M--013107--TAW--01

FIG. 8-1 — Eccentric Assembly, Showing Location in Bottom Shell, with Support and Wearing Plates Catalog Number 1805-0 1810-0 1811-0 1812-0 1820-0 1850-0 1855-0

Description Eccentric Eccentric Bushing Upper Counterweight Assembly Lower Counterweight Assembly Eccentric Bushing Key Eccentric Gear Eccentric Gear Key

17X0501--01.0701

Catalog Number 1880-0 1905-0 1910-0 1910-4 1920-0 8955-0

Description Eccentric Wearing Ring Assembly Eccentric Support Plate Bolt-Eccentric Support Plate Lock Washer Eccentric Support Plate O-Ring Guide Rod Assembly

8-3

Section 8 — Eccentric Assembly

SUPERIOR MK- II Gyratory Crushers

ECCENTRIC ASSEMBLY REPLACEMENT 1. Replace the eccentric in reverse order to that of removal. Center the eccentric support plate on the eccentric cart or skid. Position the support plate so that the oil drain hole lines up with the hole in the MPS cylinder flange. Inspect the eccentric support plate Oring (1920-0). Replace if damaged. Use a light grease to hold the O-ring in the support plate groove. 2. Place the eccentric wearing ring on top of the eccentric support plate and center the eccentric assembly on top of the eccentric wearing ring. 3. Locate the eccentric assembly with the eccentric cart under the crusher. Install the three guide rods (8955-0), provided with the tools, into the bottom shell. Make sure the guide rods are fully threaded into the bottom shell. The guide rods are used to help guide the eccentric assembly into place.

WARNING The guide 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. 4. Raise the eccentric assembly by lifting the eccentric cart with cables from the overhead crane. As the assembly is being raised, guide the eccentric so that the mainshaft enters the eccentric bushing bore. Guide the eccentric as it enters the bottom shell bushing. Watch for any binding of the top of the eccentric with the bushing -- there will be a significant increase in the amount of force required to continue raising the eccentric. If this occurs, lower the eccentric slightly and rock it back and forth on the eccentric cart to properly engage the bushing as it moves upward. 5. After the eccentric enters the bottom shell bushing, it should move easily to its top position. As the drive gear engages the pinion, rotate the pinion slightly, back and forth, to mesh the teeth. 6. When the eccentric assembly is in position, attach the eccentric support plate to the bottom shell with screws (1910-0) and lock washers (1910-4). The eccentric support plate will hold the eccentric assembly in place in the bottom shell until the MPS cylinder can be mounted. 7. Check the gear and pinion backlash and tooth contact. See “Bevel Gear Installation and Maintenance”, in section 9.

FIG. 8-2 — Eccentric Assembly Shows Oil Groove in Eccentric

Building joist Hydraulic jack Block Bevel gear Plate Eccentric

Eccentric bushing

Steel blocks

07--010--275

FIG. 8-3 — Removing Eccentric Bushing

8-4

17X0501--01.0701

SUPERIOR MK- II Gyratory Crushers

Section 8 — Eccentric Assembly

FIG. 8-4 — Miking Eccentric Bore Opposite Keyway Before Assembly

ECCENTRIC BUSHING The removal of the eccentric bushing is normally an easy operation after the upper counterweight assembly (1811-0) is removed. (See “Removal -- Upper Counterweight” in this section.). In a few cases it is possible to tap or drive the bushing out the top with a piece of wood and hammer with the eccentric on its side. If this operation is difficult, force the bushing out of the eccentric bore, as shown in Fig. 8-3. When replacing the bushing, it should go into the eccentric bore with a push fit. It is keyed to the eccentric and should be assembled by placing the key in the eccentric bushing and pushing the bushing with key into the bore. Chilling the bushing, with key in place, with finely chipped dry ice is recommended. Cover with an insulating blanket until frost appears on the outside diameter — usually a minimum of two hours. See Fig. 8-5. The bushing must be pressed in, not pounded, as this will distort the top of the sleeve, decreasing the inside diameter. If no other means are available, press it in by placing a jack between a stone bin or strong joist and the eccentric and pressing the bushing down into the eccentric.

NOTICE Never use a hammer or sledge to drive the bushing into place. Hammering will distort the bronze, reducing bearing clearance and possibly causing bearing failure during crushing operations.

17X0501--01.0701

FIG. 8-5 — Installing Chilled Bushing in Eccentric

ECCENTRIC GEAR Removal The eccentric gear has a slight interference fit on the eccentric. The recommended method for removal is to press it off, using a hydraulic jack. The gear seats against a shoulder on the eccentric, and is usually removed with the eccentric upside down. See Fig. 8-6 for an illustration of gear removal. Inspection Inspection of the eccentric gear primarily involves looking for broken teeth or excessive wear.

NOTICE It is common to get some early pitting in the gear teeth. However, once the gear set has aligned itself, the pinion teeth should polish the gear teeth over their full length and pitting should decrease. Excessive wear may be caused by improper backlash between the gear and pinion, by operating the crusher at a setting closer than that for which it was designed, by unclean oil, or pinion improperly set. When replacing worn gears, use proper thickness of gasket to align the pitch lines of the gear and pinion.

8-5

Section 8 — Eccentric Assembly

SUPERIOR MK- II Gyratory Crushers

BUILDING JOIST JACK PLATE OVER ECCENTRIC ONLY ECCENTRIC GEAR

07--010--631

FIG. 8-6 — Eccentric Gear Removal for all Crushers. Gear is installed below a small flange on eccentric.

Reassembly The assembly of the gear on the eccentric involves the following steps. 1. Install the key in the eccentric to the proper depth of engagement with the gear. The square key is held in place by a 1.00” hex socket head screw (1857-0). The key cannot be assembled to the eccentric with the gear in place. 2. Check both portions of the fit and stop shoulders for burrs or bruises. Remove excess material until flush with the adjacent surfaces. 3. The gear, with or without the lower counterweight, must be shrunk on the eccentric. Heat the gear in oil brought up to approximately 300o F (150o C). When the oil starts smoking, it is near the flash point, which is above 300o F (150o C) for most oils.

NOTICE If heating torches (Fig. 8-7) are used to expand the gear, the lower counterweight (1812-0) should be removed as it is lead filled and local heating could melt the lead. See “Lower Counterweight: Removal” in this section.

CAUTION Be extremely careful when handling heated oil and heated machine components. 4. Place the heated gear on edge supports with at least 1” (25 mm) clearance underneath (teeth upwards.) 8-6

5. Install the three (3) correct size Heavy Duty Hoist Rings (see Tool List in Section 4) in top of the eccentric. Lift and lower it into the bore of the gear until the shoulder on the eccentric is in contact with the face of the gear.

FIG. 8-7 — Heating Eccentric Gear Before Assembly on Eccentric

LOWER COUNTERWEIGHT (1812-0) The lower counterweight is held in place by three hex socket head capscrews (1812-1) and is retained from horizontal movement by dowels (1812-5). Removal (See Fig. 8-8) 1. Lower the eccentric assembly onto blocks, a minimum of 12” (300 mm) high, using 3 correct size Heavy Duty Hoist Rings (see Tool List in Section 4) in the top of the upper counterweight (1811-0) or in the top of the eccentric if the upper counterweight has been removed. The blocks should be positioned under the lower counterweight (1812-0), between screws (1812-1). 2. Remove the hex socket head capscrews (1812-1) fastening the counterweight to the gear. 3. Lift the eccentric assembly off the lower counterweight. If counterweight lifts with the eccentric assembly, use a pry bar between the counterweight and the gear to break it loose. Assembly (See Fig. 8-8) 1. Block up the counterweight (1812-0) between bolt holes, a minimum of 12” (300 mm) off the floor. 2. Install three (3) correct size Heavy Duty Hoist Rings (see Tool List in Section 4) in the top of the upper counterweight (1811-0) or in the top of the eccentric if the upper counterweight has been removed. Lift and lower the eccentric assembly onto the lower counterweight (1812-0). Be sure the two dowel pins in the lower counterweight seat into the dowel holes in the gear (1850-0). 3. Fasten the lower counterweight to the gear with three (3) hex socket head screws (1812-1) and hardened washers (1812-2). See Table 4-11 in Section 4 for the proper torque value on the bolts. 17X0501--01.0701

Section 8 — Eccentric Assembly

SUPERIOR MK- II Gyratory Crushers UPPER COUNTERWEIGHT ASSEMBLY (1811-0) The upper counterweight assembly is made up of the upper counterweight (1811-5) and retaining ring (1811-8). The retaining ring is shrunk fit into the bore of the counterweight and prevents the eccentric bushing (1810-0) from moving up in the eccentric. In the event where the eccentric bushing is seized on the mainshaft, the retaining ring will be pressed out of the counterweight as the mainshaft is lifted out.

1. Remove screws (1811-1). 2. Install three (3) correct size Heavy Duty Hoist Rings (see Tool List in Section 4) into the lifting holes in the top of the counterweight assembly and lift it off the eccentric. 3. Press out the retaining ring (1811-8) through the top of the counterweight. Normally the retaining ring should not be removed from the counterweight unless it is severely damaged or bent.

Removal (See Fig. 8-9) The upper counterweight assembly is fastened to the top of the eccentric with four hex socket head capscrews (1811-1).

1811--0

1800--0

1812--5

1850--0

1812--0

1812--1 1812--2

BLOCKS M--013107--TAW--02 FIG. 8-8 — Lower Counterweight Removal and Assembly Catalog Number 1800-0 1811-0 1812-0 1812-1

Description Eccentric Assembly Upper Counterweight Assembly Lower Counterweight Assembly Bolt-Lower Counterweight

17X0501--01.0701

Catalog Number 1812-2 1812-5 1850-0

Description Washer Dowel Pins Eccentric Gear

8-7

Section 8 — Eccentric Assembly

SUPERIOR MK- II Gyratory Crushers

1811--1 1811--4 1810--0

1811--8

1811--5

1805--0

M--020907--JRK--01 FIG. 8-9 — Upper Counterweight Assembly Catalog Number 1805-0 1810-0 1811-1 1811-4 1811-5 1811-8

Description Eccentric Eccentric Bushing Capscrew Lockwasher Upper Counterweight Upper Counterweight Retainer Ring

Assembly (See Fig. 8-9) 1. Remove any burrs or upset metal in the bore of the counterweight and on the outside diameter of the retaining ring. 2. Pack the retaining ring in chipped dry ice for two hours or heat the counterweight to 250_ F. (121_ C.). 3. Press the retaining ring into the counterweight through the top until it seats on the shoulder in the bore of the counterweight. The narrow face of the retaining ring must be assembled such that it is in contact with the shoulder in the bore of the counterweight. 4. If an optional large upper counterweight is used, the eccentric assembly must be installed into the crusher before installing the upper counterweight. This applies only when an optional large upper counterweight is used.

8-8

5. Place the counterweight assembly on top of the eccentric and fasten it to the eccentric with capscrews (1811-1) and lockwashers (1811-4). See torque chart in Section 4 for proper torque.

NOTICE The eccentric assembly cannot be installed into the crusher with the optional large upper counterweight bolted to the top.

17X0501--01.0701

Section 8 — Eccentric Assembly

SUPERIOR MK- II Gyratory Crushers

1805--0 1811--1 1811--4

1811--8

1820--0

1810--0

1811--5

1400--0

M--020907--JRK--02 FIG. 8-10 — Large Upper Counterweight Assembly (Optional)

17X0501--01.0701

Catalog Number

Description

1400--0 1805--0 1810--0 1811--1 1811--4 1811--5 1811--8 1820--0

Dust Collar (Large Upper Counterweight) Eccentric Eccentric Bushing Capscrew Lockwasher Large Upper Counterweight Large Upper Counterweight Retainer Ring Eccentric Bushing Key

8-9

Section 8 — Eccentric Assembly

SUPERIOR MK- II Gyratory Crushers

This page was purposely left blank.

8-10

17X0501--01.0701

Section 9 — Index

SUPERIOR MK- II Gyratory Crushers

9. Pinionshaft Assembly

Page 9-1 9-2 9-4 9-6 9-6 9-6 9-7 9-9 9-9 9-10 9-10 9-10 9-11 9-11

Description Index General Information Pinionshaft Oil Level Sight Gauge Assembly Pinionshaft Assembly Removal from Bottom Shell Disassembly Reassembly Replacement in Crusher Gear and Pinion Backlash Adjustment Curved Tooth Spiral Bevel Gear Installation and Maintenance Assembling and Installing Spiral Bevel Gears Measuring Backlash To Set Backlash Tooth Contact Pattern of Curved Tooth Spiral Bevel Gears

9

17X0501--01.0701

9-1

Section 9 — Pinionshaft Assembly GENERAL INFORMATION SUPERIOR gyratory crushers are equipped with a cartridge type, anti-friction bearing, pinionshaft assembly. Bearings are pool lubricated with a filler hole on the upper front surface of the housing for adding lubricant. An oil level assembly with a level transmitter and a sight gauge is provided to monitor the oil at the proper level. For the proper operation of the level transmitter with warning signals and machinery shutdown, refer to the Mechanical Control Logic document. There are two resistance temperature detectors (RTD) located in the pinionshaft housing to monitor the

9-2

SUPERIOR MK- II Gyratory Crushers pinionshaft bearing temperatures, an inner bearing RTD and an outer bearing RTD. There are two vibration sensors located in the pinionshaft housing to monitor the pinionshaft bearing condition, an inner bearing sensor and an outer bearing sensor. For the proper operation of the RTDs and vibration sensors with warning signals and machinery shutdown, refer to the Mechanical Control Logic document. The entire pinionshaft assembly can be removed from the bottom shell when maintenance is required. See Fig. 9-1, 9-2, and 9-3 for illustrations.

17X0501--01.0701

Section 9 — Pinionshaft Assembly

SUPERIOR MK- II Gyratory Crushers

3341--6 3240--1

3835--0

3342--1

3240--2 3575--0

3005--4 3305--0

3190--1 3050--0

3070--1

3220--0 3220--4 3090--2

3070--2

3090--1

3555--0 3515--0

3120--2 3150--0

3525--0

3190--2

3120--1

3170--2

3170--1

3585--0

3210--0 3210--4

3005--0

3505--0 3005--3

3342--1

3341--6 M--013107--TAW--03

FIG. 9-1 — Pinionshaft and Housing Assembly Catalog Number

Description

3005--0 3005--3 3005--4 3050--0 3070--1 3070--2 3090--1 3090--2 3120--1 3120--2 3150--0 3170--1 3170--2 3190--1 3190--2 3210--0

Pinionshaft Housing Pinionshaft Housing Plug Pinionshaft Housing Breather Plug Pinion Pinion end Bearing Drive end Bearing Pinion end Spacer Drive end Locknut Pinion end Spacer Gasket Locknut Gasket Locknut Lockwasher Pinion end Oil Seal Drive end Oil Seal Pinion end Seal Plate Drive end Seal Plate Pinion end Seal Plate Bolt

17X0501--01.0701

Catalog Number

Description

3210--4 3220--0 3220--4 3240--1 3240--2 3305--0 3341--6 3342--1 3505--0 3515--0 3525--0 3555--0 3575--0 3585--0 3835--0

Lockwasher Drive end Seal Plate Bolt Lockwasher Pinion end Seal Plate Gasket Drive end Seal Plate Gasket Pinionshaft Housing Breather Plug Tee Pinionshaft Pinion Key Pinion Key Retaining Screw Drive end Key Oil Inlet Plug Oil Drain Plug Extended Lube Fitting Assembly

9-3

Section 9 — Pinionshaft Assembly

SUPERIOR MK- II Gyratory Crushers

3341--7 3344--5 3346--6

3341--2

3345--0 3346--4 3343--8 3344--3

3346--3 3346--5 RED LINE ON SIGHT GAUGE 3341--1 3346--1 3346--5 3346--2

157.2 [6.19]

OIL LEVEL 3344--4 3343--8 3346--7 3346--9

PINIONSHAFT CENTERLINE

3346--8 3344--2 3344--6 3341--7

M--021907--JRK--01

FIG. 9-2 — Pinionshaft Oil Level Sight Gauge Assembly

PINIONSHAFT OIL LEVEL SIGHT GAUGE ASSEMBLY NOTES: 1. SIGHT GAUGE/TRANSMITTER ASSEMBLY MAY BE INSTALLED ON EITHER SIDE TO SUIT INSTALLATION. 2. SIGHT GAUGE/TRANSMITTER ASSEMBLY TO BE LOCATED AS CLOSE AS POSSIBLE TO THE PINIONSHAFT ASSEMBLY. CUT HOSES (3341--2 & 3344--2) TO LENGTH AND INSTALL REUSABLE HOSE ENDS (3344--3 & 3344--4). 3. MINIMUM WELD PER AWS CLASS E--60XX, UNLESS OTHERWISE SPECIFIED. Catalog Number

Description

3341--1 3341--2 3341--7 3343--8 3344--2 3344--3 3344--4 3344--5 3344--6 3345--0

Sight Gauge Upper Hose Assembly Pipe Bushing Hose Adapter Sight Gauge Assembly Lower Hose Assembly Upper Reusable Swivel Hose End Lower Reusable Swivel Hose End Upper Hose Adapter Lower Hose Adapter Oil Level Transmitter Assembly

9-4

Catalog Number

Description

3346--1 3346--2 3346--3 3346--4 3346--5 3346--6 3346--7 3346--8 3346--9

Pipe Assembly Pipe Cap Pipe Coupling Pipe Bushing U--Bolt Assembly Mounting Bracket Pipe Nipple -- Drain Pipe Tee -- Drain Pipe Plug -- Drain

17X0501--01.0701

Section 9 — Pinionshaft Assembly

SUPERIOR MK- II Gyratory Crushers

3075--9

3003--0 3003--2

3003--1 A SECTION C--C

3075--3

3075--6 3075--4

3075--0

3075--8

3075--0

B A

3075--0 3075--7 C C

D 3072--9

3072--4 3071--5

D 3072--5

3072--7 3071--3

A 3071--7 3072--0 3073--1 3072--8

SECTION D--D

3004--4

3004--2 3004--0

3071--0 3073--2 B 3071--8

3072--6

3071--6 SECTION A--A SECTION B--B INNER BEARING SENSORS OUTER BEARING SENSORS

3071--5 3071--7

M--021907--JRK--01

FIG. 9-3 — Pinionshaft RTDs and Vibration Sensor Assembly Catalog Number

Description

Catalog Number

Description

3003--0 3003--1 3003--2 3004--0 3004--2 3004--4 3071--0 3071--3 3071--5 3071--6 3071--7 3071--8 3072--0 3072--4

Conduit Clamp Screw Conduit Screw Clamp Temperature Transmitter Thermoconductive Silicone Temperature Sensor Cable Assembly Cord Grip Transmitter Cover Temperature Transmitter Thermoconductive Silicone

3072--5 3072--6 3072--7 3072--8 3072--9 3073--1 3073--2 3075--0 3075--3 3075--4 3075--6 3075--7 3075--8 3075--9

Temperature Sensor Cable Assembly Cord Grip Transmitter Cover Cord Grip Transmitter Clamp Transmitter Clamp Shock Pulse Transducer PVC Cable Assembly Drive End PVC Cable Assembly Pinion End Cable End Sealing Cover Cord Grip Display Module

17X0501--01.0701

9-5

Section 9 — Pinionshaft Assembly PINIONSHAFT ASSEMBLY REMOVAL FROM BOTTOM SHELL

DANGER Lockout power source during installation, cleaning, or servicing the equipment or when making repairs. Failure to do so could result in severe bodily injury or death. To remove the pinionshaft assembly from the crusher, take the following steps (refer to Fig. 9-1, 9-2, and 9-3 for parts relationship): 1. Remove the floating drive shaft assembly between the crusher and motor. 2. Remove the coupling half from the pinionshaft. 3. Drain the oil by removing drain pipe plug (3341-6).

WARNING Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant suppliers instructions and safety directions when handling oil and greases. 4. Disconnect the hose assemblies to the oil sight gauge at the pinionshaft housing. 5. Remove the nuts from the attaching studs or bolts from the flange on the pinionshaft housing that holds the assembly in the bottom shell. 6. Use the two square head withdrawal bolts provided in the flange of the pinionshaft housing to remove the assembly from the fit in the bottom shell opening. 7. Install (2) Heavy Duty Hoist Rings in mounting flange of pinionshaft housing, attach sling and apply slight crane or ratchet hoist pressure to the assembly. 8. Place a pipe as a counterbalance over the exposed end of the pinionshaft where the coupling was removed. Apply hand pressure to the pipe to balance the pinionshaft assembly and slowly begin to remove the pinionshaft housing from the crusher. 9. After the pinionshaft housing has been drawn out of the crusher approximately two-thirds of the way, a third threaded hole for another Heavy Duty Hoist Ring will become visible at the top of the pinionshaft housing. Install a Heavy Duty Hoist Ring and attach a sling. Remove the pipe being used as a counterbalance. The pinionshaft housing can now be lifted out of the crusher with a three-point lift.

9-6

SUPERIOR MK- II Gyratory Crushers DISASSEMBLY After the pinionshaft assembly has been removed from the crusher, placed on blocks and the oil drained, it can be dismantled. 1. Opposite the pinion end, remove the seal plate (3190-2) with oil seal (3170-2). 2. With a hammer and screwdriver, drive the lockwasher (3150-0) tab out of the locknut spacer (3090-2) groove. Unscrew the locknut and remove it and the lockwasher (NOTE: Left-handed threads). 3. Back out the seal plate bolts (3210-0) and washers (3210-4) on the pinion end as far as possible. 4. Press the pinionshaft (3505-0) with the pinion end bearing (3070-1), pinion end spacer (3090-1) and pinion (3050-0) partially out of the housing, toward the pinion end (see Fig. 9-4). This will provide sufficient clearance to back the seal plate bolts (3210-0) completely out of the tapped holes in the housing. The shaft can now be pushed completely out of the housing. 5. Remove the drive end bearing (3070-2) from the housing (3005-0). It is a loose fit in the housing bore 0.00 -- 0.11 mm (0.000 -- 0.0043 inch). 6. Press off the pinion (3050-0) from the shaft (3505-0). The pinion is shrunk fit to the shaft with 0.10 -- 0.15 mm (0.004 -- 0.006 inch) interference. See Fig. 9-5 for method of removal. 7. Remove pinion end seal plate (3190-1) with oil seal (3170-1) and seal plate gasket (3240-1). 8. Remove pinion end spacer (3090-1) and spacer gasket (3120-1). 9. Press off pinion end bearing (3070-1). The pinion end bearing is shrunk fit to the shaft with 0.05 -- 0.10 mm (0.0020 -- 0.0044 inch) interference. The pinion shaft is machined to facilitate hydraulic removal of this bearing. To remove the pinion end bearing, replace the pipe plug in the pinion end of the shaft with a high-pressure fitting and attach a 10,000 psi (68,900 kPa) grease gun. Pump the gun to build up hydraulic pressure between the inner race of the bearing and the shaft while pulling the bearing from the shaft. 10. Clean all parts and replace those that have been damaged or have failed.

17X0501--01.0701

Section 9 — Pinionshaft Assembly

SUPERIOR MK- II Gyratory Crushers

HYDRAULIC JACK SUPPORT

PLATE

BLOCKS

5. Assemble the drive end bearing (3070-2) onto the pinionshaft (3505-0). This bearing has a fit of 0.02 mm (0.0010 inch) loose to 0.03 mm (0.0012 inch) tight between the inner race and the pinionshaft. Make sure the bearing is tight against the shaft shoulder. 6. After the bearing has cooled, install in sequence, one locknut spacer gasket (3120-2), lockwasher (3150-0) and the other locknut spacer gasket (3120-2) onto the drive end of the pinionshaft. 7. Install the locknut spacer (3090-2) and tighten. Bend down the tab on lockwasher (3150-0) into the recess on the locknut spacer (3090-2). 8. Insert the pinionshaft (3505-0) into the housing (3005-0) until the drive end bearing (3070-2) shoulder comes to rest against the seat in the housing bore. The drive end bearing (3070-2) is a loose fit in the housing bore 0.00 -- 0.11 mm (0.000 -- 0.0043 inch). 9. Install the drive end seal plate (3190-2) snugly to the housing, without gasket (3240-2) installed. Measure the gap between the seal plate and the housing. Add gaskets (3240-2) 0.20 mm (0.008 inch) thicker than the gap and fasten the seal plate (3190-2) with oil seal (3170-2) into place.

SK030592JJB-15

FIG. 9-4 — Method of Removing Pinionshaft from Housing

REASSEMBLY

NOTICE Heat bearings and pinion in oil not exceeding 149_C (300_F) when needed for shrink fit assembly.

CAUTION Be extremely careful when handling heated oil and machine components. 1. Heat bearings (3070-1 & 3070-2) and pinion (3050-0) in oil not exceeding 149_C (300_F) when needed for shrink fit assembly. 2. Assemble the pinion end bearing (3070-1) onto the pinionshaft (3505-0). This bearing has a shrink fit of 0.05 -- 0.10 mm (0.0020 -- 0.0044 inch) between the inner race and the shaft. Make sure the bearing is tight against the shaft shoulder. 3. Cement the spacer gasket (3120-1) to the pinion end spacer (3090-1) and assemble them to the pinionshaft (3505-0). 4. With the pinionshaft housing (3005-0) supported horizontally, insert the drive end of the pinionshaft (3505-0) into the pinion end of the housing until the drive end bearing shoulder of the pinionshaft extends beyond the pinionshaft housing. 17X0501--01.0701

NOTICE Assemble drive end oil seal (3170-2) with lip pointing toward the drive end bearing (3070-2). 10. Secure the pinion end seal plate (3190-1) with oil seal (3170-1) and gasket (3240-1) into place. Pinion end oil seal (3170-1) should be assembled in the seal plate (3190-1) as follows. a. Locate the oil seal contamination discharge port of the pinion end Protech labyrinth seal (3170-1) and mark its position on the face of the seal with paint or a grease pencil. b. Install the Protech seal (3170-1) into seal plate by hand pressure, making sure to line up the contaminant discharge port with one of the half circle cutouts, on the seal plate flange outer diameter. c. Assemble the seal plate (3190-1) with the contaminant port on the Protech labyrinth seal so that it is pointing down when the pinionshaft assembly is installed in the crusher. 11. Assemble the pinionkey (3515-0) to the shaft and fasten it with capscrews (3525-0). 12. The pinion has a shrink fit of 0.10 -- 0.15 mm (0.004 -- 0.006 inch) between the inside diameter of the pinion and the pinionshaft. Heat the pinion in oil to approximately 149_C (300_F) and assemble it to the shaft. The pinion must be pushed tightly against the pinion spacing collar to be sure that the spacing collar turns with the shaft. 13. Use the grease fitting (3835-0) at the drive end seal plate (3190-2) to inject enough grease to fill the gap 9-7

Section 9 — Pinionshaft Assembly seal around the locknut to exclude dirt. Do this while rotating the shaft to ensure the grease is distributed evenly. Use a grease of NGLI NO.2 or NO.3 consistency such as MOBILUX EP2 or equivalent. 14. Refer to Section 4, Table 11 for torque values on bolts. 15. Fill the pinionshaft housing with preservative oil to prevent corrosion of the pinionshaft and bearings during periods of non-use. Fill to the proper oil level (see Section 3, General Specifications sheet for approximate oil quantity for the pinionshaft housing). Lubricant recommendations are discussed in Section 13. 16. If the pinionshaft assembly is to be stored or shipped, the Pinionshaft assembly must be shipped and stored in a flat horizontal position so that oil does not leak past the pinion end seal.

SUPERIOR MK- II Gyratory Crushers

BUILDING JOIST

HYDRAULIC JACK BAR PINION PLATE

BLOCKING PINION SHAFT

BLOCK

FIG. 9-5 — Method of Removing Pinion

9-8

17X0501--01.0701

Section 9 — Pinionshaft Assembly

SUPERIOR MK- II Gyratory Crushers REPLACEMENT IN CRUSHER 1. To reinstall the pinionshaft assembly: a. Position the counterbalancing pipe on the bare drive end of the shaft. Place the gaskets (3030-0) on the bolting flange of the pinionshaft housing. CAUTION: ALWAYS USE THE ORIGINAL THICKNESS OF GASKETS WITH THE SAME PINION AND GEAR. ANY CHANGE FROM THE ORIGINAL WILL CHANGE THE TOOTH CONTACT PATTERN ON THE PINION AND GEAR. b. Install heavy duty hoist rings in the threaded holes on top of the pinionshaft housing and the pinionshaft housing mounting flange. c. Position the pinionshaft assembly in the bottom shell opening (see Fig. 4-8, in Section 4). The close clearance fit in the bottom shell may require some movement of the assembly with the pipe counterbalance to engage the leads of the fit. As the pinion reaches the gear it may be necessary to turn the pinionshaft to engage the teeth of the pinion and gear to complete the entrance. d. Draw up the attaching bolts evenly and securely. e. Set the proper backlash between gear and pinion. See “Gear and Pinion Backlash Adjustment” in this section. f. Re-connect the hose assemblies (3341-2) (Fig. 9-2) from the oil sight gauge to the pinionshaft housing. g. Remove oil fill plug (3575-0) and fill to the correct oil level with the proper oil. See Fig. 9-2 for correct level. See Section 13 “Lubrication” for type of oil.

“A”

2. If a new pinion, gear or eccentric has been installed, check backlash and tooth contact, per “Bevel Gear Installation and Maintenance,” later in this section. 3. Install the pinionshaft coupling half and floating drive shaft assembly. Realign the drive shaft if backlash was readjusted. 4. Replace drive guard. GEAR AND PINION BACKLASH ADJUSTMENT Fig. 9-6 shows a front elevation of the pinionshaft assembly mounted in the bottom shell. Slotted holes (“A”) are provided in the pinionshaft housing flange for bottom shell to pinionshaft housing studs (1505-0), so that the housing can be rotated about its center line. The pinionshaft center line is offset from the housing center line in the horizontal plane. Rotating the housing in a clockwise direction will cause the pinion gear to move downwards, toward the eccentric drive gear. Counterclockwise rotation will cause the pinion gear to move away from the eccentric gear. Rotational adjustment in either direction to the correct backlash setting for the gear and pinion is accomplished by means of jack bolts (3006-0) mounted on the bottom shell housing and bearing on a flanged portion of the pinionshaft housing (“B”). Hex nuts (3006-2) are provided to lock the jack bolts in the desired location after adjusting gear and pinion backlash. See Table 9-1 which lists the correct range for the “pitch line” backlash.

1505-0 1505-1 1505-2 1505-3

Catalog Number

3006-0

1505-1 1505-2 1505-3 3006-0 3006-2

3006-2

1505-0

Description Stud — bottomshell to pinionshaft housing Nut Washer Locknut Bolt — pinion adjusting Nut

“B”

SK022792JJB-10

FIG. 9-6 — Backlash adjustment between eccentric and pinion gears is accomplished by pinionshaft housing rotation. Front elevation shows parts arrangement, with pinionshaft housing mounted in bottom shell. 17X0501--01.0701

9-9

Section 9 — Pinionshaft Assembly CURVED TOOTH SPIRAL BEVEL GEAR INSTALLATION AND MAINTENANCE Bevel gears of the curved tooth spiral type are used in SUPERIOR crushers.The following information is to assist you in installing and maintaining these gears. Since the tooth “contact patterns” (area of contact) of spiral bevel gears vary with each gear installation, the following information pertains to the ideal installation. Some slight apparent misalignment will occur with all installations because the gears are not rigidly mounted. However, tooth “contact patterns” which show obvious serious misalignment should be corrected. When reinstalling gears, note and check the tooth “contact patterns” under heavy loads and accept these as normal. Then, using the charts provided on spiral bevel gear misalignment, make the necessary adjustments to maintain the proper tooth “contact patterns” for the gears. ASSEMBLING AND INSTALLING SPIRAL BEVEL GEARS 1. Check to make certain the gear and pinion are properly located on the eccentric and pinionshaft. 2. Check the tooth contact patterns. 3. Check for correct amount of backlash. 4. Tighten all lock nuts, bolts, etc., on the mountings. 5. Lubricate gears properly before operating under power. MEASURING BACKLASH Spiral bevel gears are machined to have a definite amount of backlash (clearance) as determined by the pitch of the gears and the operating conditions. The correct amount of backlash is necessary for safe and proper operation of gears. See Fig. 9-7. Insufficient backlash results in noisy gears, excessive wear, scored tooth surfaces, and breakage. When checking the backlash of the gears, move the eccentric assembly toward the pinion to remove all clearance between the eccentric and the bottom shell bushing. If the crusher is assembled, put a block of wood in the crushing chamber on the side opposite the pinion. Raise the mainshaft assembly, using the MPS control. Applying 50 psi pressure above the level caused by the static load of the mainshaft assembly should be sufficient to push the combined mainshaft and eccentric assemblies toward the pinion to remove all clearance between the eccentric and bottom shell bushing.

9-10

SUPERIOR MK- II Gyratory Crushers Be sure to use accurate instruments to measure backlash. A dial indicator is recommended if available.

CONTACT

BACKLASH

FIG. 9-7 — Backlash in the Plane of Rotation

Table 9-1 lists the “Normal Backlash” which is the backlash measured perpendicular to the tooth surface at the outer end of the tooth. Due to the design of the Superior gyratory, it is not possible to physically measure the “Normal Backlash” of the gear and pinion as assembled in the crusher. However, it is possible to measure the “Backlash in the Plane of Rotation” which is directly proportional to the “Normal Backlash.” To obtain “Backlash in the Plane of Rotation,” the “Normal Backlash” must be divided by the cosine of the spiral angle and the cosine of the pressure angle. Table 9-1 also lists the “Backlash in the Plane of Rotation” which has been calculated and can be used in the formula below to determine an equivalent rotation at the pinionshaft coupling OD. The following formula is suggested for checking the backlash: CMC (Circumferential Movement at Coupling) = Backlash in Plane of Rotation x COD PDP (Pitch Diameter of Pinion) Where COD = Coupling Outside Diameter Example: Model 60-100 SUPERIOR crusher may have a 21.60--inch COD. What should the circumferential movement measurement be on the coupling outside diameter? See Table 9-1 for correct “backlash in the plane of rotation” and solve as below. CMC =

CMC =

.108 x 21.6 21.6 .131 x 21.6 21.6

= .108 inches (2.74 mm) minimum

= .131inches (3.33 mm) maximum

17X0501--01.0701

Section 9 — Pinionshaft Assembly

SUPERIOR MK- II Gyratory Crushers

Crusher Size 60-110

Pitch Diameter of Pinion In. mm 21.6

548

“Normal Backlash” at pitch line In. mm .083--.100

“Backlash in plane of rotation” In. mm

2.11--2.54

.108--.131

2.74--3.33

Table 9-1 Pinion pitch diameter, “normal backlash” and “backlash in plane of rotation.”

TO SET BACKLASH 1. Use “Blueing” to check tooth contact patterns. 2. Adjust to get the proper tooth contact by adding or removing a gasket between the bottom shell and pinionshaft housing. See Fig. 9-8 and the photos on following page for illustrations. 3. Check backlash as previously outlined. 4. If backlash is incorrect, adjust it by rotating the pinionshaft assembly. The pinionshaft housing flange has slotted holes for this purpose. Loosen the bolts (1505-0) which hold the assembly to the bottom shell. The pinionshaft center line is offset from the housing center line in the horizontal plane. Rotating the assembly raises or lowers the pinion to change the backlash. Jack bolts are mounted in the bottom shell adjacent to the pinionshaft to facilitate rotating the assembly. See “Gear and Pinion Backlash Adjustment” earlier in this section.

teeth. The ideal tooth contact pattern is slightly high on the pinion and low on the gear, as shown in Fig. 9-8. Under light load its length is usually one-half the total length to allow for adjustment for smooth operation. Usually the tooth contact pattern will shift toward the heel under heavy load — for this reason gears are cut so they will bear nearer the toe. See Fig. 9-9 for gear tooth nomenclature.

TOE CENTER

HEEL

ADDENDUM PROFILE DEDENDUM

PINION

GEAR LARGE END

FIG. 9-8 — Ideal Tooth Contact Patterns for Spiral Bevel Gears FIG. 9-9 — Gear Tooth Nomenclature

TOOTH CONTACT PATTERN OF CURVED TOOTH SPIRAL BEVEL GEARS Spiral bevel gears are produced to run with a localized tooth bearing. Since the area of contact does not cover the whole gear tooth, a slight tolerance in positioning the gears in assembly and some displacement under operating loads is possible without any resultant strain on the ends of the

17X0501--01.0701

The pictures in Fig 9-10 represent the possible tooth contact patterns on a gear member of a pair of correctly machined bevel gears . . . their causes and corrections. Remember, however, that these are deviations from the ideal situation and the gears will NOT have ideal areas of contact. If serious misalignment occurs and cannot be corrected, contact the nearest Metso Minerals sales office.

9-11

Section 9 — Pinionshaft Assembly

SUPERIOR MK- II Gyratory Crushers

A. NORMAL GEAR PATTERN

Note centralized contact pattern on both pressure and non-pressure side of teeth.

C. PINION IN 0.020” (0.5 mm) Results in heavy heel contact on pressure side of tooth. Corrective action — move pinion away from center line of crusher until normal gear pattern results.

B. PINION OUT 0.020” (0.5 mm)

Results in heavy toe contact on pressure side of tooth. Corrective action — move pinion towards center line of crusher until normal gear pattern results.

D. BEVEL GEAR DOWN, PINION UP 0.020” (0.5 mm) Results in abnormal backlash. Corrective action — loosen bolts (1505-0) and rotate pinionshaft housing assembly clockwise to lower pinion until normal gear pattern results and correct backlash is obtained.

FIG. 9-10 — Tooth contact pattern — curved tooth spiral bevel gears. 9-12

17X0501--01.0701

Section 10 — Index

SUPERIOR MK- II Gyratory Crushers

10. Mainshaft Assembly

Page 10-1 10-2 10-3 10-3 10-3 10-4 10-4 10-4 10-4 10-6 10-6 10-7 10-7 10-7 10-8 10-8 10-8 10-9 10-9 10-9 10-9 10-9 10-10 10-10 10-10 10-10

Description Index General Information Mainshaft Assembly Removal Head Nut — Head Nut Removal — Head Nut Installation Mantle — Removal — Assembly On Mainshaft — Zinc Backing — General — Epoxy Backing Dust Seal — Removal -- One Piece Dust Seal Ring — Removal -- Two Piece Dust Seal Ring — Inspection — Assembly -- One Piece Dust Seal Ring — Assembly -- Two Piece Dust Seal Ring Splash Curtain Mainshaft Sleeve — Mainshaft Sleeve Removal — Mainshaft Sleeve Assembly Mainshaft Step — Removal — Inspection — Assembly

17X0501--01.0701

10

10-1

Section 10 — Mainshaft Assembly

SUPERIOR MK- II Gyratory Crushers

GENERAL INFORMATION The principal components of the mainshaft assembly (Fig. 10-1) are the mainshaft (4005-0), lower mantle (4175-1), upper mantle (4175-2), head nut (4205-0), mainshaft sleeve (4025-0), mainshaft step (4075-0), dust seal (4305-0), and splash curtain (4405-0). 4050--0 4025--3 4025--4 4025--0 4005--0 4205--0 4220--0 4175--2 4175--9 4175--1 CONCRETE SUPPLIED BY CUSTOMER 4405--0 4425--0 4435--0 4435--1 4365--0 4365--4 4350--0 4305--0

Catalog Number

Description

4005--0 4025--0 4025--3 4025--4 4035--0 4050--0 4075--0 4085--0 4085--9 4135--0 4175--1 4175--2 4175--9 4205--0 4220--0 4305--0 4350--0 4365--0 4365--4 4405--0 4425--0 4435--0 4435--1

Mainshaft Mainshaft Sleeve Mainshaft Locknut Mainshaft Lockwasher Dowel Pin Eyebolt Mainshaft Step Capscrew Annealed Wire Step Retainer Plug Lower Mantle Upper Mantle Backing Headnut Dowel Dust Seal Ring Lower Dust Seal Retainer Lower Dust Seal Retainer Bolt Lockwasher Splash Curtain Splash Curtain Clamp Capscrew Nut

4035--0 4075--0 4135--0

4085--0 4050--9

M--022207--JRK--01

FIG. 10-1 — Mainshaft Assembly

10-2

17X0501--01.0701

SUPERIOR MK- II Gyratory Crushers

NOTICE The mainshaft step (4075-0) is supplied with a wear indicator as a standard feature. This wear indicator consists of a cavity that has been machined into the back (non-wearing) side of the mainshaft step. The cavity is filled with a silver powder and sealed with a threaded plug. When wear reaches the depth at the bottom of the oil grooves in the mainshaft step, the cavity is opened and the silver powder is released into the lubrication oil. An oil analysis will show the presence of the silver powder. A silver particle count of 50 PPM or higher indicates that a step component has reached its wear limit and must be replaced.

Section 10 — Mainshaft Assembly HEAD NUT Self-tightening head nuts (4205-0) are used, assuring a tight assembly between the mantle and mainshaft taper. Crushing action turns the nut and mantle downward for a secure fit. The standard design is a one piece head nut which threads onto the threaded portion of the mainshaft sleeve.

MAINSHAFT ASSEMBLY REMOVAL

DANGER Lockout power source during installation, cleaning, or servicing the equipment or when making repairs. Failure to do so could result in severe bodily injury or death. The spider must be removed before attempting to remove the mainshaft assembly. Except for small settings, the mainshaft assembly can be removed without removing the top shell or concaves. For lifting use the factory installed eyebolt on top of the mainshaft assembly. See Section 4 “Mainshaft Lifting Eye Dimensions”, for eyebolt dimensions. If a shackle is used, use a standard shackle adequate to lift the mainshaft assembly. On crushers with smaller eccentric throws, the mainshaft will easily withdraw from the eccentric bushing with the hoisting hook directly over the eyebolt. If the eccentric throw is more than 1-1/2” (36 mm), let the hook hang about one to two inches (25-50 mm) toward the thick side of the eccentric since the mainshaft has a slope toward that side. Do not force withdrawal unless there has been a bearing seizure as it may damage the eccentric bushing. Handle the mainshaft carefully when putting it into a repair well or when laying it down. Do not damage journal surfaces. If the mainshaft has to be laid down horizontally, place a piece of plywood or belting under the end of the shaft or step bearing before tilting (Fig. 10-2). Be careful to avoid damaging the mainshaft step at the base of the mainshaft.

17X0501--01.0701

FIG. 10-2 — Lifting a Mainshaft Assembly During Installation Note protective belting under mainshaft step.

Head Nut Removal To remove the head nut from the mainshaft, the dowel pins (4220-0) must be drilled out (see Fig. 10-1). They lock the self-tightening head nut (4205-0) to the mantle so that when the mantle turns the head nut turns also, maintaining a tight assembly. The mainshaft sleeve and head nut have right hand threads; be careful not to damage them when working on the assembly. A bar or set hammer may be placed against the lugs on the head nut and struck with a sledgehammer. If the head nut is firmly set and will not loosen with a sledge and set, it can be heated with a torch and then removed by sledging. If the head nut or mantle are peened at the joint where they bear against each other it will be necessary to chip or burn the joint open.

10-3

Section 10 — Mainshaft Assembly Head Nut Installation

NOTICE Prior to installing the mantle, the head nut should be run all the way down on the sleeve threads to be sure it turns freely. After the mantle has been assembled on the mainshaft and backed with zinc or epoxy backing, examine the threads on which the head nut is to be assembled. Remove the zinc splatter and any other foreign material that might prevent assembly of the head nut. Assemble the head nut on the sleeve and drive it down for a tight fit on the mantle. Place dowel pins in slots that line up (two locations) and weld them to the head nut (only) per AWS class E70XX.

NOTICE Be extremely careful when handling heated components. MANTLE Removal Mantles are usually removed only when beyond further use. However, it is possible to salvage a mantle by cutting of the head nut. The value and availability of the used mantle must be weighed against that of a new head nut before cutting the head nut. There is a small hole in the head nut for starting the cut.

WARNING Provide adequate ventilation when it is necessary to use a cutting torch near parts backed by epoxy like the mantle. Avoid inhaling fumes. Personnel should wear air-line respirators to prevent inhalation of fumes (when torch cutting) or dust (when grinding or chipping).

WARNING Precautions in general 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 OSHA or MSHA standards as appropriate. Assuming that the mantle is to be scrapped, make a torch cut around it approximately one-fourth to one-half inch (6-12 mm) below the head nut and mantle joint. Use 10-4

SUPERIOR MK- II Gyratory Crushers one of the vacant half-round dowel holes in the mantle for starting the cut. Remove the top piece that was cut around. This usually relieves the pressure against the head nut so that it can be salvaged for reuse. The mantle can be removed from the mainshaft with a crane, after welding lifting lugs on the upper portion. Stand clear when removing, as pieces of the backing may fall and cause injury. Assembly On Mainshaft (See Figs. 10-1 and 10-4) 1. Trial fit the head nut onto the mainshaft sleeve’s threads to ensure free running of threads. 2. Remove any burrs from the mainshaft taper that may come in contact with the backing and act as a key, preventing the mantle from moving downward when the manganese stretches. Fill any depressions with Babbittrite to match the surrounding taper. 3. Coat the mainshaft taper lightly with oil for zinc or with beeswax or a silicone mold release for epoxy backing. Heavy grease can prevent proper curing of epoxy backing. 4. Place the mainshaft in the repair bay. 5. Position and center the lower mantle section on the mainshaft and block up under the lower mantle section. The gap between the mantle and the mainshaft taper, at the lower end (Gap ”B”, Fig. 10-3) should be 0.13 inch (3.31 mm). 6. Lower the upper mantle section over the taper on the mainshaft. Match up the helical wave pattern between the mating edges of the upper and lower mantle sections. Using six hardwood shims, set a 0.375 inch (9.5 mm) gap between upper and lower mantle sections at the three closest positions (where the gaps are parallel) around the circumference. See Figs. 10-3 and 10-4 for mantle location (dimension A). 7. Locate the head nut over the threads on the mainshaft sleeve and turn the nut down to contact the lip of the upper mantle. There should be 80% contact, all around, between the mantle and head nut. When the head nut is in place, there will be approximately 1/4 inch (6.4 mm) of threads on the head nut above the threads on the mainshaft sleeve. 8. Wedge up the bottom of the lower mantle until the top of the upper mantle is tight completely around the bottom of the head nut. 9. Remove the head nut carefully and measure the gap between the mantle and mainshaft (B dimension) at four evenly spaced points. 10. Center the bottom of the lower mantle lip on the taper of the mainshaft with four small hardwood wedges, 1 inch (25.4 mm) wide x 1/8 inch (3.2 mm) thick at the small end by 1/2 inch (12.7 mm) thick at the large end by approximately 3 inches (76 mm) long. 11. Again check the contact of the upper mantle to the head nut. 12. Carefully remove the head nut and the upper mantle section making sure not to disturb the lower mantle. 17X0501--01.0701

SUPERIOR MK- II Gyratory Crushers

13. 14.

15.

16.

17.

18.

19. 20.

21.

Check the gap between the top of the lower mantle and the mainshaft at four evenly spaced points around the circumference. Refer to Figures 10-3 and 10-4. Block the opening at the bottom of the lower mantle section. Evenly heat the lower mantle to approximately 200_F (92_C) when zinc is ready to pour at 1000_F (540_C). If epoxy backing is used, preheating of the mantle is not necessary, but will speed up the cure time. Pour a small amount of backing and check for leaks at the bottom of the lower mantle. Reseal as necessary. Use Babbittrite to dam the top joint of the lower mantle so that the backing material will have the same profile as the mantle. If using epoxy allow the initial pour to set for 1 hour before proceeding. Finish pouring the backing to fill the cavity between the lower mantle and the mainshaft and allow the backing to cure. See “Epoxy Backing” in Section 4 for a cure time versus temperature graph. After the backing has cured, apply a layer of Babbittrite in the top corner between the mainshaft and backing. Make sure that the Babbittrite extends out just beyond the edge of the backing so that a barrier will be formed between each section of backing. The backing of each mantle section must be kept independent of each other to allow sections to rotate independently and allow the head nut to self-tighten. Position the upper mantle section on the mainshaft, matching the helical pattern of the mating edges of the upper and lower mantle sections. Set a gap of approximately 3/8 inch (9.5 mm) between mantle sections using hardwood shims at the three closest positions (where the gaps are parallel) around the circumference. Plug the space between upper and lower sections. Each section must be zinced or epoxy backed independently of the other. Center and locate upper mantle section in position using hardwood shims and wedges. Align top surface of upper mantle with head nut; the lip of the upper mantle must bear on almost the full circumference of the head nut. Remove the head nut; carefully shim between the upper mantle and mainshaft. Again check contact between the upper mantle and the head nut.

Section 10 — Mainshaft Assembly 22. Evenly heat the upper mantle to approximately 200_F (92_C) when zinc is ready to pour at 1000_F (540_C). If epoxy backing is used, preheating of the mantle is not necessary, but will speed up the cure time. 23. Pour zinc or epoxy backing to approximately 1 inch (25.4 mm) below the top of the tapered turn of the mainshaft. Do not fill the cavity under the head nut with backing. Exceeding this level will prevent tightening of the head nut. 24. After pouring is complete allow the backing to cure. Refer to “Epoxy Backing” in section 4 for a cure time versus temperature graph. 25. Apply a coat of anti-seize compound to the head nut threads and assemble it to the mainshaft. Drive head nut for a tight fit on mantle and line up the half rounds with the half rounds on the mantle. Assemble dowel pins in slots that line up. Weld pins to the head nut (only) per AWS class E70XX. 26. Remove the lifting lugs from the upper and lower mantles. Do not exceed 800_F (427_C) when burning to remove lugs.

NOTICE The head nut may be spaced away from the mantle and three or more parallels (or spacers) placed between the mantle and head nut with the head nut tightened against the parallels to insure that no movement occurs. If a pouring spout is designed properly, the backing can be poured into the space between the parallels into the cavity between the mantle and mainshaft.

17X0501--01.0701

10-5

Section 10 — Mainshaft Assembly

SUPERIOR MK- II Gyratory Crushers Zinc Backing 4050--0

General a. Preheat mantle sections to approximately 200_F (93_C) before pouring so that zinc will not chill. b. Use only prime western zinc. c. Thoroughly clean the inside of the mantle and mainshaft taper, and make sure they are dry.

4025--3 4025--4 4025--0 4005--0

”A”

4205--0

WARNING

4220--0

Molten zinc coming in contact with moisture can cause explosions and endanger personnel. Molten zinc is poured at 1000_ to 1100_F (540_ to 590_C)

4175--2 4175--9

ZINC OR EPOXY LEVEL

d. Seal the bottom gap (lower mantle to mainshaft) and the gaps between mantle sections with Babbittrite, or equivalent oil-based putty, before pouring.

9.5 mm (0.38”) 4175--1 ”C”

WARNING

”B”

Do not use water-based putty where zinc is used. Molten zinc coming in contact with moisture can cause explosions and endanger personnel.

HARDWOOD WEDGE

M--022607--JRK--01 FIG. 10-3 — Mantle location in Preparation for Pouring Backing Catalog Number

Description

4005--0 4025--0 4025--3 4025--4 4050--0 4175--1 4175--2 4175--9 4205--0 4220--0

Mainshaft Mainshaft Sleeve Mainshaft Locknut Mainshaft Lockwasher Eyebolt Lower Mantle Upper Mantle Backing Headnut Dowel MANTLE LOCATION FOR BACKING Dimensions For Mantle Location A

B

C

Crusher Size

In.

mm

In.

mm

In.

mm

Backing Quantity Requirements

60-110

59.93

1522

0.13

3.31

0.59

15

See Section 4

FIG. 10-4 — Dimensions for Mantle Location, reference Fig. 10-3

10-6

17X0501--01.0701

Section 10 — Mainshaft Assembly

SUPERIOR MK- II Gyratory Crushers Epoxy Backing Unless specifically requested by the purchaser, all SUPERIOR gyratory crusher mantles are backed with a high performance epoxy backing. 1. Follow the “Assembly” directions previously given. Do not heat the mantle for normal use of epoxy backing at 60_F (15.5_C) or higher. 2. Thoroughly mix epoxy backing resin and hardener as instructed in Section 4 “Epoxy Backing—Directions For Use.”

WARNING Carefully follow the instructions as well as the precautions that are printed on the individual cans of epoxy before mixing and pouring. Skin contact with epoxy may cause serious delayed dermatitis. Avoid inhalation of vapor. Use ventilation, particularly if heated. Prevent all contact with skin. If contact occurs, wash immediately with soap and water.

DUST SEAL The dust seal ring is free to move between the retaining rings beneath the mantle (Fig. 10-5). It is an easy sliding fit on the dust collar and is the only barrier between the crushing chamber and the oil system inside the crusher. The enclosed ring-type dust seal consists of two major parts; the urethane dust seal ring (4305-0); and the lower dust seal retainer (4350-0). As delivered the crusher is equipped with a one piece dust seal ring (4305-0) which requires removal of the mainshaft to replace the ring. A two piece dust seal ring (4305-0) is also available (Fig. 10-6), which does not require removal of the mainshaft in order to replace the ring. Splash curtain

Dust seal ring Dust collar Retainer

3. If temperature is below 60_F (15.5_C), special provisions are needed so backing will flow and cure. Heat parts to be bonded, as well as unmixed resin and hardener, to 70-80_F (21-27_C).

NOTICE For low temperature applications, consult factory. 4. Seal the bottom gap (lower mantle to mainshaft) and the gaps between mantle sections (if applicable) with plaster of paris or a water-based putty. DO NOT use oil-based putty. 5. Pour mixed epoxy backing into the cavity between the mantle and the mainshaft. Initially pour a small quantity, 1 or 2 kits of backing, and check for leaks. Reseal as necessary and wait for the initial pour of backing to start to cure and harden, approximately one hour, before continuing to pour the remainder of the backing.

NOTICE Keep the epoxy backing level below the top of the tapered turn on the mainshaft. Exceeding this level will prevent tightening the head nut. 6. To determine the height of epoxy backing in the pour, use either a flexible electrical wire or an annealed soft iron wire in the hole 180o opposite the pouring hole being used. Grasp the wire, with the fingers, at the desired pour height. Pour the epoxy slowly, and completely withdraw the wire to observe for epoxy. 7. Allow the epoxy backing to cure following assembly instructions previously given. 17X0501--01.0701

FIG. 10-5 — Dust collar and seal arrangement. Splash curtain bolted to mainshaft.

Removal — One Piece Dust Seal Ring 1. Lift the mainshaft from the crusher. 2. Remove retaining ring bolts (4365-0). Use four of these bolts in the tapped holes of the retaining ring to jack the lower retaining ring (4350-0) from the mainshaft (4005-0).

NOTICE Support the lower retaining ring (4350-0) so it cannot fall and damage the mainshaft journal. 3. Slide the retaining ring and dust seal ring over the end of the shaft. A second method of removing the dust seal ring is to remove the lower retaining ring (4350-0) and dust seal ring (4305-0) prior to removing the mainshaft from the crusher. This procedure is as follows: 1. Block up or use jacks between the bottom shell arms and the lower dust seal retainer (4350-0).

10-7

Section 10 — Mainshaft Assembly

SUPERIOR MK- II Gyratory Crushers

2. Follow Step 2, above. Next, lower the lower dust seal retainer (4350-0) and dust seal ring onto the bottom shell arms. 3. Remove the mainshaft from the crusher. Removal — Two Piece Dust Seal Ring With the two piece dust seal ring (4305-0) it is not necessary to remove the mainshaft assembly from the crusher. To remove the dust seal ring, block or crib up from the bottom shell arms to the under side of the lower retaining ring (4305-0). Remove the retaining ring bolts (4365-0) and use four of the bolts in the tapped holes of the retaining ring to jack the lower retaining ring from the mainshaft (4005-0). Lower the retaining ring to rest on the bottom shell arms. The dust seal ring can then be removed by cutting it in two pieces. Inspection Inspect the polished surfaces of the mainshaft and lower retaining ring and smooth all rust or score marks which might scratch the plastic dust seal ring. Check the fit between the mainshaft (4005-0) and lower (4350-0) retaining ring. This fit must be tight, 0.004” to 0.009” (.10 to .23 mm) tight, as any motion between these parts will wear the fit and eventually break bolts (4365-0).

Assembly — One Piece Dust Seal Ring With the mainshaft out of the crusher, proceed as follows: 1. Place the dust seal ring (4305-0) on top of the lower dust seal retainer (4350-0) and raise the retainer and seal to the underside of the mainshaft (4005-0). 2. Bolt the lower retaining ring (4350-0) to the mainshaft (4005-0) with bolts (4365-0). 3. Check the clearance between the lower retaining ring and the dust seal ring. This clearance should be 0.03 to 0.09 inches (0.76 to 2.29 mm) with new parts. Wear allowance is 0.125 inches (3.2 mm). Use shims if necessary between the retaining rings to give at least the minimum clearance. 4. After installation, make sure that the ring is free to move in the retainer. 5. Use caution when lowering the mainshaft into the crusher since the seal has to be fed onto the dust collar fit from underneath. The material is relatively fragile compared to the weight of the mainshaft and could be broken. An alternate method is to place the lower retaining ring (4350-0) and dust seal ring (4305-0) over the dust collar, onto the bottom shell arms. Lower the mainshaft into the crusher and then follow steps 1, 2 and 3 above. USE BONDING CEMENT SUPPLIED WITH SEAL BETWEEN JOINTS 5.0” (127mm) 0.1” (2.5mm) MAX.

SECTION A-A

SK022692JJB-12

O-RING BONDED TO SEAL WITH LOCTITE 910 ADHESIVE

.1” (2.5mm) MAX.

SECTION B-B

FIG. 10-6 — Two Piece Dust Seal Ring

10-8

17X0501--01.0701

Section 10 — Mainshaft Assembly

SUPERIOR MK- II Gyratory Crushers Assembly — Two Piece Dust Seal Ring With the mainshaft in the crusher, proceed as follows: 1. Place each half of the dust seal ring around the dust collar (1405-0). Apply bonding cement to each joint and bolt each joint together (See Fig. 10-6). 2. Slide the dust seal ring up into the mainshaft and bolt the lower retaining ring (4350-0) to the mainshaft (4005-0) with bolts (4365-0). 3. Check the clearance between the lower retaining ring and the dust seal ring. This clearance should be 0.03 to 0.09 inches (0.76 to 2.29 mm) with new parts. Wear allowance is 0.125 inches (3.2 mm). Use shims if necessary between the retaining rings to give at least the minimum clearance. SPLASH CURTAIN A splash curtain (4405-0) is provided to prevent lube oil from splashing up over the dust collar and leaking out onto the crushed product. The curtain is bolted to the mainshaft with the splash curtain retainer (4415-0), which is welded to the mainshaft, and the splash curtain retainer clamp (4425-0).

CAUTION

CAUTION Be extremely careful when handling heated oil and heated machine components. Mainshaft Sleeve Assembly 1. Coat the outside of the shaft with molydisulphide paste on the area designated “B” on Fig. 10-7. 2. Heat the sleeve in an oil bath to 300_F (150_C). 3. Slip the sleeve over the shaft until the lip in the bore at the top contacts the shoulder on the shaft. 4. Install the lockwasher (4025-4) making sure the two locking tabs seat in the slots on top of the mainshaft sleeve (4025-0). 5. Install locknut (4025-3) tight against lockwasher (4025-4). Use a bar and sledgehammer into slots provided in the locknut for tightening. 6. Place four 0.25-inch (6.4 mm) welds, 6.0 inches (152.4 mm) long, 90_ apart, between the locknut (4025-3) and lockwasher (4025-4) to prevent loosening. 4 WELDS 90_ APART 152mm 6mm (.25”) (6”)

330.2 [13.00]

”B”

571.5 [22.50]

Splash curtain bolts must be installed with heads facing outwards to prevent interference with the dust collar. MAINSHAFT SLEEVE A sleeve (4025-0) is shrunk over the upper portion of the mainshaft, so that the bearing journal may be easily renewed if it becomes worn or scored. The standard mainshaft sleeve for the 60-110 SUPERIOR crusher is threaded on the outer diameter of the lower portion for mounting the head nut (Fig. 10-7). A locknut (4025-3) with lockwasher (4025-4), threaded onto the top of the mainshaft bear down on the upper rim of the mainshaft sleeve to prevent upward movement due to pressure from the manganese mantle during crusher operation. Mainshaft Sleeve Removal 1. Grind off the welds between the locknut (4025-3) and the lockwasher (4025-4) and remove the locknut and washer. 2. Cut on one side with an air arc or acetylene cutting torch to within one-sixteenth to one-eighth of an inch (1.6 to 3.2 mm) of the basic mainshaft journal. It is important to not cut into the mainshaft as this may act as a stress riser and promote mainshaft breakage. 3. Use a hand chisel to complete the cut. 4. Drive wedges into the joint to provide clearance and remove the sleeve. Inspect the turned surfaces of the mainshaft and the sleeve. Smooth any irregularities or rust that may have developed and clean both parts thoroughly. 17X0501--01.0701

4025--3 4025--3

4025--0 4005--0 4025--4 M--022707--JRK--01

FIG. 10-7 — Mainshaft and Threaded Sleeve Assembly Catalog Number

Description

4005--0 4025--0 4025--3 4025--4 4050--0

Mainshaft Mainshaft Sleeve Mainshaft Locknut Mainshaft Lockwasher Eyebolt

10-9

Section 10 — Mainshaft Assembly

SUPERIOR MK- II Gyratory Crushers

MAINSHAFT STEP Removal The mainshaft step assembly is supported on a three-piece step bearing, including the bronze step (4075-0), which is secured to the bottom of the mainshaft by means of the step retainer plug (4135-0). To remove the step, thread the lowering rod (8955-1) provided with the tools, into the tapped hole in the bottom of the mainshaft. The end of the threaded bar that does not have a hole drilled in it should be the end that is threaded into the bottom of the mainshaft. Draw the lowering bar up snugly against the bottom of the step with the lowering rod nut. Remove the mainshaft step retainer plug bolts (4085-0) and lower the step to a skid. While lowering the mainshaft step using the lowering nut on the lowering rod, insert a bar into the hole at the end of the lowering rod and maintain positive pressure to keep the lowering rod turned all the way into the bottom of the mainshaft.

WARNING The lowering rod is to be properly threaded into the bottom of the mainshaft until the thread bottoms out inside the mainshaft. Turning the nut on the lowering rod to lower the mainshaft step can loosen the lowering rod from the bottom of the mainshaft. Failure to properly secure and maintain the tight fit of the lowering rod in the bottom of the mainshaft could result in the mainshaft step falling, causing serious injury and possible death. Inspection Inspect the bottom surface of the step for excessive wear, scoring or any signs of failure. The step is of high lead bronze, which provides maximum lubrication properties without deformation. Normally, the surface will polish highly. The bronze may become blackened, but if it is smooth and has few score marks it will work itself into the desired polished condition. Assembly To assemble the step, using the lowering rod, raise the step into position over the projection on the bottom of the mainshaft. Make sure that the hole in the top of the step engages the dowel (4035-0) in the bottom of the mainshaft. Insert the two retainer plug bolts (4085-0) and wire the heads together to prevent loosening.

10-10

17X0501--01.0701

Section 11 — Index

SUPERIOR MK- II Gyratory Crushers

11. Top Shell Assembly

Page 11-1 11-2 11-2 11-2 11-2 11-4 11-6 11-6

Description Index General Information Top Shell Removal Inspection Assembly Steps In Concave Removal Concave Placement Inspection of Manganese Concaves

11

17X0501--01.0701

11-1

Section 11 — Top Shell Assembly GENERAL INFORMATION The principle components of the top shell assembly are the upper (5005-2), lower (5005-1) sections of the top shell and the concaves. See Fig. 11-1 for parts arrangement. It acts as a support for the spider assembly and a retention base for the concave crushing surfaces. Top Shell Removal

DANGER Lockout power source during installation, cleaning, or servicing the equipment or when making repairs. Failure to do so could result in severe bodily injury or death. Removing the top shell from the bottom shell requires the application of pressure to separate the interference taper fit between the two as well as between the upper and lower sections of the top shell. Below is the recommended procedure. 1. Remove all attaching bolts (5340-0) between the upper and lower top shell sections. 2. Place hardened steel wedges (9975-0) with a slope of 5_ or 0.087 inch (2.21 mm) per inch (25.4 mm) of length in the eight wedge slots provided in the upper top shell flange. 3. Evenly apply a twelve or sixteen pound (5.4 or 7.0 Kg) sledgehammer to the eight wedges, after hitching the upper top shell section to an overhead crane or hoist. Use steady overhead pressure to assist in removal. Watch for sudden movement of the upper top shell section when it breaks loose from the fit. 4. To remove the lower top shell section, remove nuts from bottom shell joint bolts (1540-0). Break the lower top shell--bottom shell joint with wedges and a crane lift in the manner described in step 3. After removal, lubricate machined surfaces of both the bottom and top shell fits to prevent rusting. Place the up-

11-2

SUPERIOR MK- II Gyratory Crushers

per and lower top shell sections on timbers to protect the machined surfaces. Inspection Inspect the taper on machined surfaces of the top and bottom shells to see that surfaces are not rusting or that there is no working between surfaces. Assembly Coat the horizontal surface of the lower top shell with light oil and place the lower top shell (5005-1) on the upper bottom shell (1006-0). Check the gap between flanges at 90_ increments. On the 60-110 crusher, the gap should be 0.115 to 0.170 inches (2.92 to 4.32 mm) when checking the dry assembly of the taper fits. These same gap values as well as the noted assembly procedure are valid for the tapered joint between the upper top shell and the lower top shell. Tighten the fasteners in a diagonal sequence to draw the lower top shell down evenly all around. A 0.004 inch (0.1 mm) feeler gauge may be used to determine whether the lower top shell has been drawn down tight. If there is any clearance between the lower top shell and upper bottom shell it is an indication that the tapers of the two pieces are not engaged. Find the cause and remedy. There should be nothing to prevent these two surfaces from being drawn together. Assemble the upper top shell section to the lower top shell section in the same manner. Make sure that the upper section is drawn down evenly and tightly. After the crusher has been operated a few hours the nuts holding the top shell and bottom shell together sometimes loosen a slight amount. After a few hours of operation, these nuts should be checked again and drawn down as tightly as possible. See Table 4-11 for proper bolt torque value.

17X0501--01.0701

Section 11 — Top Shell Assembly

SUPERIOR MK- II Gyratory Crushers

SPIDER ASSEMB LY 6395--0 6385--0 5005--2 6365--0 5340--0 5340--1 5340--3 6345--0

6325--0 5005--1 1540--0 1540--1 1540--3 6305--0 6050--0 M--030207--JRK--01

FIG. 11-1 — Top Shell Assembly Catalog Number

Description

1540--0 1540--1 1540--3 5005--1 5005--2 5340--0 5340--1 5340--3

Stud w/nut Heavy hex nut Heavy hex jamnut Lower top shell Upper top shell Stud w/nut Heavy hex nut Heavy hex jamnut

17X0501--01.0701

Catalog Number

Description

6050--0 6305--0 6325--0 6345--0 6365--0 6385--0 6395--0

Concave support ring Concave--first tier Concave--second tier Concave--third tier Concave--fourth tier Concave--fifth tier Concave--sixth tier

11-3

Section 11 — Top Shell Assembly Steps In Concave Removal 1. Remove all residual stone from around the spider rim liners in the truck dump pit. Also remove any covering over the joint between the rim liners and the concrete flooring. 2. Remove the spider assembly. 3. Locate the key concave in the top row. It is usually found under a protective arm of the spider assembly. It can be recognized by the parallel sides on the outer section (in plan view). The balance of the regular concaves in the top row will have sides profiled as if generating from a radius. 4. Create a safe working platform before proceeding onto the following steps.

WARNING Precautions in general 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 OSHA or MSHA standards as appropriate. 5. When removing manganese concaves it is recommended to weld on a lifting lug to provide a safe handling method. The lifting lug (see Fig. 11-3) should be welded on near the top of the concave following the procedures below.

FIG. 11-2 — Wedge Inserted in Slot Between Top and Bottom Shells

11-4

SUPERIOR MK- II Gyratory Crushers

WARNING Failure to use the proper welding procedure for securing the lifting lug to the concave can result in the concave falling during the removal process which can result in serious bodily injury. Be sure to follow the welding procedure as outlined below and make sure that there is no one below the concaves while they are being lifted out of the crusher. For Manganese Concaves: When lifting a worn manganese concave using a welded on lifting lug, be certain the lug is strong enough to carry the load and that a welding rod suitable for welding on manganese steel is used. Construct the lifting lugs to the dimensions shown in Figure 11-3 using ASTM A36 material as a minimum. Use the following welding procedure for welding the lifting lugs to the concaves. • Use Nicro Mang (Efe Mn-A) welding electrodes. • Do not preheat -- manganese concaves are to be kept as cool as possible. • Thoroughly clean the concave area where the lifting lug is to be welded. (Minimum of wire brushing required.) • Some minor trimming of the lug edge contacting the concave may be required to accommodate the curvature of lower tier concaves. • To reduce the possibility of sudden rotation of the concave during a lift, the lifting lug must be placed in the center of the concave near the top in order to be sure of being above the center of gravity of the concave as positioned in the gyratory. • A 6mm (1/4 inch) fillet weld on both sides of the lifting lug is recommended. • Fill any craters in the weld with additional weld. • Check for cracks with magnetic particles or dye penetrant before using the lug to lift. • The lift is to be performed using a shackle rated in excess of the concave weight. • If a nylon sling engages the shackle, let the concave cool sufficiently to avoid damaging the nylon during hitching and lifting. Failure to properly secure the lifting lug to the concave can result in the concave falling during the removal process which can result in serious bodily injury.

17X0501--01.0701

Section 11 — Top Shell Assembly

SUPERIOR MK- II Gyratory Crushers 6. Using an air arc, remove zinc or epoxy in the two vertical side joints of the key concave. 7. Prior to loosening any concaves, attach a suitable lifting device to its lifting lug. Follow safe working and lifting procedures. 8. Remove the key concave, using a chisel pointed bit in the wedge slots cast into the back of the concaves. See Fig. 11-4. A large paving breaker or air operated pile driver, suspended from an overhead crane, is suggested as a chisel power source. 9. Remove the balance of the regular concaves in the top row in the same manner. 10. Each succeeding row has a key concave and is removed in the manner outlined in steps 4 through 8, above. In some instances the operator may desire to change the lower set of concaves only. There are various methods for removing the lower set of concaves without removing the upper sets. One method is to line up all the key concaves when the concaves are first installed so they can all be removed without disturbing any of the other concaves. Then the lower set can be removed in the usual manner, set out or replaced, and re-zinced. Thus, only the key concaves of the upper tiers need be removed and replaced. Another method used is to burn through one of the lower concaves on three sides, starting at the bottom to give the slag room to run out of the cut. If the concave is burned properly, it will sometimes fall out when struck on the face with a 12 or 14 pound (5.4-6.4 kg) sledge. If it is not loose, drive a long tapered wedge or chisel bar behind concave to remove it. Then the remainder of the lower set can be removed and reset.

17X0501--01.0701

M--031307--JRK--01

FIG. 11-3 — Lifting Lug Callout

Description

1 2 3 4 5 6 7 8

150 mm (5.91 inches) 50 mm (1.97 inches) 8.3 mm (0.33 inches) 25 mm (0.98 inches) 18 mm (0.71 inches) 12 mm (0.47 inches) Diameter hole 12 mm (0.47 inches) x 45 deg Chamfer 12 mm (0.47 inches)

11-5

Section 11 — Top Shell Assembly

SUPERIOR MK- II Gyratory Crushers

Concave Placement Refer to “Installing Concaves” in Section 4, for details on concave installation. If the concave support ring (6050-0) is worn off, a new plate ring, made in sections, may be put in the space in the joint between the top and bottom shell and allowed to project far enough to serve as a support. Refer to “Backing Quantity Requirements” in Section 4 for approximate quantities of backing material needed for proper installation of concaves. Inspection of Manganese Concaves Special precautions must be taken when using manganese concaves on crushers that crush hard but less abrasive material. A hard material which is not abrasive will peen the manganese faster than it will wear out the concaves. See Fig. 4-13.

CAUTION The gaps between the concaves can disappear completely and this can lead to cracks in the top shell.

FIG. 11-4 — Removing Key Concave in Top Tier

The gaps between concaves should be checked daily. When the gaps decrease below 6 mm, the corners of the concaves must be burnt off. Refer to “Installing Concaves” in Section 4 and Fig. 4-13.

11-6

17X0501--01.0701

Section 12 — Index

SUPERIOR MK- II Gyratory Crushers

12. Spider Assembly

Page 12-1 12-2 12-3 12-3 12-6 12-6 12-6 12-6 12-7 12-7 12-7 12-7 12-7 12-7 12-9 12-9 12-9

Description Index General Information — Removal — Inspection — Assembly To Top Shell Spider Vent Assembly — Removal — Assembly Spider Bushing — Removal — Inspection — Assembly — Spider Bearing Oil Seal Spider Lubrication System — Level Sensor — Spider Oil Level Spider Arm and Rim Liners

12

17X0501--01.0701

12-1

Section 12 — Spider Assembly

SUPERIOR MK- II Gyratory Crushers

GENERAL INFORMATION The spider assembly has a taper fit with the top shell. Main components include the spider (5605-0), spider bushing (5675-0), spider bearing oil seal (5705-0), spider cap

5685--0 5685--2 5685--4

5650--0 5750--0

5160--0 5160--1 5160--5 5160--6 5160--7 5160--9

(5650-0), arm shields (5150-0) and rim liners. See Fig. 12-1 and 12-2 for detail, and Fig. 12-3 for illustration of typical spider. 5755--1 5755--3

5755--2 5760--0 5760--4

5675--0

5150--0

5150--0

5220--0

5112--0

5605--0 5125--0 5240--0

5110--0

5255--0

5125--1 5125--2 5125--3 5125--5 5635--0 5636--0

5275--0 5285--0 5285--4

5625--0

5310--0 5310--1 5310--3

5705--0

5311--0 5311--1 5311--3

5706--0

M--030207--JRK--02

FIG. 12-1 — Spider Assembly Catalog Number

Description

Catalog Number

Description

5110--0 5112--0 5125--0 5125--1 5125--2 5125--3 5125--5 5150--0 5160--0 5160--1 5160--5 5160--6 5160--7 5160--9 5220--0 5240--0 5255--0 5275--0 5285--0 5285--4 5310--0 5310--1

Spider Rim Liner Spider Liner Locating Pins Rim Liner Bolt Rim Liner Nut Sprin Retainer Washer Locknut Rim Liner Bolt Spring Spider Arm Shield Spider Arm Shield Bolt Spider Arm Shield Nut Spider Arm Shield Bolt Spring Spring Case Cotter Pin Spring Retainer Spider Lube Elbow Spider Lube Hose Spider Lube Plug Spider Lube Hose Bracket Hose Bracket Bolts Lockwasher Spider Joint Stud Spider Joint Stud Nut

5310--3 5311--0 5311--1 5311--3 5311--8 5605--0 5625--0 5635--0 5636--0 5650--0 5675--0 5685--0 5685--2 5685--4 5705--0 5706--0 5750--0 5755--1 5755--2 5755--3 5760--0 5760--4

Spider Joint Stud Locknut Spider Joint Bolt Spider Joint Bolt Nut Spider Joint Bolt Locknut Spider Joint Bolt Retainer Spider Spider Filler Block Spider Filler Block Bolts Spider Filler Bolts Spider Cap Spider Bushing Spider Bushing Bolt Washer Lockwasher Spider Bushing Oil Seal Scraper Spider Cap Breather Spider Vent Cover Vent Cover Seal Vent Cover Access Plug Capscrew Lockwasher

12-2

17X0501--01.0701

Section 12 — Spider Assembly

SUPERIOR MK- II Gyratory Crushers

SPIDER BUSHING 5675-0

DUAL OIL SEALS 5705-0 LIP UPWARDS

SK021892JJB7A

FIG. 12-2 — Spider Bearing Oil Seal Arrangement

Removal

DANGER Lockout power source during installation, cleaning, or servicing the equipment or when making repairs. Failure to do so could result in severe bodily injury or death. Removing the spider assembly from the top shell requires application of pressure to separate the interference taper fit between the spider rim and top shell. To apply this pressure there are several options: For all options first remove all attaching fasteners (5310-0 and 5311-0). 1. Standard Jackscrew Separator — Eight 3.0--4UNC jackscrews (5007-1) are threaded into collars (5007-2) which are seated in counterbored holes in the top shell flange (Fig. 12-4). With these jackscrews, apply pressure to break the fit. The jackscrews should be turned a measured amount in sequence to prevent the spider from getting cocked in the top shell. The sequence should be as follows: Turn the first screw. Next turn the second screw which is 180o apart. Next, turn the third screw which is 90o from the second. Then, turn the fourth screw which is 180o from the third. Repeat the sequence. In addition, strain applied with an over-head crane will assist. 2. Hydraulic Shell Separator — The hydraulic shell separator is an optional item that must be ordered with the crusher. It consists of hydraulic cylinders (5008-1) which are threaded into collars (5008-2) which are seated in counterbored holes evenly spaced in the top shell flange. See Fig. 12-5. With the use of a hydraulic hand pump (5008-4), the jacks push up the spider and break the joint fit. 17X0501--01.0701

As an additional assist, the shaft can be raised to apply pressure as follows: Lower the mainshaft. Place heavy steel blocks between the head nut and spider arms, and apply the vertical force of the Mainshaft Position System (MPS) control as you would a powerful jack. Put the MPS control in the “raise” position. Again, steel wedges and an overhead crane can be useful as an assist in spider removal. After removing spider, lubricate the tapered machined surface of both the spider and the top shell to prevent rust. Rust destroys the fit between the top shell and spider. Place the spider on timbers to protect the machine surfaces. Inspection Inspect the taper on machined surfaces of the top shell and spider to see that surfaces are not rusting or that there is no working between surfaces. Movement would be indicated by smooth bright spots below which there may be an accumulation of iron dust. Taper fit wear between the spider and top shell can only be measured by gauges available exclusively from Metso Minerals. Consult your local Metso Minerals representative or the Field Service Department.

12-3

Section 12 — Spider Assembly

SUPERIOR MK- II Gyratory Crushers

FIG. 12-3 — Spider Hub, Arms and Rim

FIG 12-4 — Spider -- Top Shell Jackscrew Separator Catalog Description Number 5005-2 5007-1 5007-2

12-4

Upper Top Shell Jackscrew Collar

17X0501--01.0701

Section 12 — Spider Assembly

SUPERIOR MK- II Gyratory Crushers

5011-4

5011-5 “B” “B”

5011-6

5011-3

5005-2

5011-7 5011-2

“A”

5008-4

5008-8 5011-8

5011-1

“A”

5008-2 5009-1

SECTION “B” -- “B”

5009-2 5010-0 5010-2 5008-1 5010-3 5010-4 5009-0 5010-1

SECTION “A” -- “ A” SK091799-JJB-1

FIG. 12-5 — Optional Spider -- Top Shell Hydraulic Separator Catalog Number 5005-2 5008-1 5008-2 5008-4 5008-8 5009-0 5009-1 5009-2 5010-0 5010-1 5010-2 5010-3

Description Upper Top Shell Hydraulic Cylinder Hydraulic Cylinder Collar Hydraulic Hand Pump Hydraulic Hose 20 Ft. (6.1 m) Long Hydraulic Manifold Hydraulic Tee Hydraulic Hex Nipple Capscrew Hydraulic Manifold Bracket Washer Hex Nut

17X0501--01.0701

Catalog Number 5010-4 5011-1 5011-2 5011-3 5011-4 5011-5 5011-6 5011-7 5011-8

Description Lockwasher Hydraulic Hose 6 Ft. (1.8 m) Long Hydraulic Hose 10 Ft. (3 m) Long Hydraulic Hose 20 Ft. (6.1 m) Long Hydraulic Hose 25 Ft. (7.6 m) Long Hydraulic Hose 25 Ft. (7.6 m) Long Hydraulic Hose 20 Ft. (6.1 m) Long Hydraulic Hose 10 Ft. (3 m) Long Hydraulic Hose 6 Ft. (1.8 m) Long

12-5

Section 12 — Spider Assembly

SUPERIOR MK- II Gyratory Crushers

Assembly To Top Shell

CAUTION

NOTICE It is recommended that the spider bushing (5675-0) be installed after the spider is in place on the top shell to prevent the possibility of damaging the seals (5705-0) when lowering over the mainshaft. 1. Inspect the taper fits of both the spider and top shell. Remove all burrs, bruises and any interfering accumulation of rust or dirt. Coat the horizontal surfaces of the spider fit with light oil. Do not use white lead as it will harden, making subsequent removal of the spider assembly difficult. 2. Inspect the jackscrew collars (5007-2) and insure the jack screws are retracted. In the case of the hydraulic shell separator, ensure the pistons are retracted.

NOTICE Collars (5007-2 or 5008-2) must be in place before spider assembly. 3. Make a level hitch on the spider assembly and lower over the mainshaft into the matching taper fits of the spider and top shell. Position as level as possible so that the bolting flanges are as close to parallel as possible. Check the gap between flanges at 90o increments. The gap should be within the ranges listed in Table 12-1 when checking the dry assembly of the taper fits. If the spider bushing seal is in place, carefully feed it around the mainshaft so that no pinching or damage to the seal occurs. Crusher Size

In.

mm

60-110

.115 - .170

2.92 - 4.32

Table 12-1 — Spider to Top Shell -- Gap (Unlubricated)

4. Tighten down two bolts, 180o apart, making sure that the gap between the spider and top shell is equal. Then install two bolts opposite each other and 90o from the first two, also ending up with an equal gap between the two shells. Install the balance of the bolts at approximately the same tightness as the first four. Continue to tighten the bolts in sequence approximately the same number of turns until a .004” (.1 mm) feeler gauge cannot be inserted between the bolting flanges at any point in the circumference.

12-6

Torque the jackscrew separator jackscrews (5007-1) shown in Fig. 12-4, against the spider flange (5605-0) to 150 ft. lbs. (203 Nm) or remove them entirely to prevent the jackscrews (5007-1) from dropping out due to vibration during crusher operation. 5. Assemble shaft scraper (5606-0) into the spider hub. 6. Install spider bushing (5675-0) with oil seals in spider hub. 7. After the crusher has been operated a few hours, the nuts holding the top shell and spider together sometimes loosen a slight amount. After a little operation, these nuts should be checked again and drawn down as tightly as possible. Use a .004” (.1 mm) feeler gauge while the crusher is crushing to determine if there is any movement between the top shell and spider. If there is, it will be possible to push the feeler in between the spider and top shell. The movement can also be noticed by placing the finger on the joints. Movement indicates the tapers are not engaged properly. SPIDER VENT ASSEMBLY The spider vent assembly vents the spider bearing oil reservoir and keeps contaminants out. It consists of a breather (5750-0), a cover (5755-1), cover sealant (5755-2), and fastener hardware (5760-0, 5760-4). It must be removed to access the spider bushing (5675-0). See Fig. 12-1. Removal 1. Clean the cover top to prevent contamination into the spider bearing. 2. Remove capscrews (5760-0). 3. Lift off cover (5755-1). After removing cover, remove sealant from cover bottom and from spider hub and clean breather (5750-0). Assembly 1. Place a bead of sealant (5755-2) as provided around the spider hub. Use Permatex No. 2C if factory supplied sealant is not available. 2. Attach cover (5755-1) with capscrews (5760-0) and lockwashers (5760-4). 3. Install breather (5750-0).

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Section 12 — Spider Assembly

SUPERIOR MK- II Gyratory Crushers SPIDER BUSHING Removal The spider bushing can be removed from the top shell while the crusher is still assembled. There is a tapered fit between the spider bushing and the spider hub. First, remove spider bushing bolts (5685-0) and washers (5685-4). The bushing may now be jacked out of the spider hub by screwing jack bolts into the tapped holes provided for this purpose in the spider bushing flange. On the 60-110 crusher there are 12 tapped holes provided for this purpose. If the reason for removing this bushing is to replace it, it may be more expeditious to chip a groove down the bushing bore to loosen it. This will destroy the bushing. The spider must be removed from the top shell to do this. Inspection Check the clearance between the spider bushing and the mainshaft sleeve at the fulcrum point before removing the bushing from the crusher. The fulcrum point is the point of the smallest diameter in the hourglass-shaped spider bushing. If the clearance between the mainshaft sleeve and spider bushing at the fulcrum point is equal to or greater than the value shown in Table 12-2, one or both items must be replaced. Inspect bushing surface as well as dimensions. If it is worn or badly scored discard it. Inspect mainshaft sleeve and replace if necessary. If a new bushing is installed, check its outside surface and the inside surface of the bore of the spider before assembly. If evidence of turning of the old bushing in the spider is noted, be sure to check the bore of the spider and turn of the new bushing to be sure it has a light press fit. Otherwise, the new bushing may turn in the spider and enlarge the bore. If the bore of the spider is larger than the turn of the bushing, do not install the bushing and operate crusher as this will also enlarge the bore. This condition can be corrected by ordering an oversized bushing from the factory to fit the spider or by building up the bore of the spider and remachining. The latter is recommended in preference to the oversized bushing as standard bushings could be used on future replacements.

17X0501--01.0701

Crusher Size

60-110

As Manufactured Inches

mm

.034 - .058 1.14 - 1.65

Maximum Inches

mm

0.184

4.67

Table 12-2 — Spider Bushing/Mainshaft Sleeve Clearances

Assembly When the bushing is placed in the spider hub, there will be a gap of approximately .060” to .100” (1.5 to 2.5mm) between the bottom of the bushing flange and the top face of the spider. The flange must be pulled down tightly on the spider with the spider bushing bolts. Tighten bolts evenly to prevent the bushing from becoming cocked in the spider hub.

NOTICE Shaft scraper (5706-0) must be assembled into the spider hub before assembling the bushing. Spider Bearing Oil Seal Spider bearing oil seals (5705-0) are designed to take the eccentric motion in the seal in crusher operation. See Fig. 12-2 for detail. For SUPERIOR crushers, dual oil seals are pressed into a counterbore in the bottom of the bushing. The bushing must be removed in order to replace these seals. The seals can then be tapped out the bottom. Install new seals by pressing them into position in the spider bushing counterbore. Install so that the lips of the seals will be pointing toward the flanged end of the bushing (upward). SPIDER LUBRICATION SYSTEM The crusher is supplied with an automatic spider lubrication system as a standard feature. The system consists of a spider lube barrel pump unit, spider lube power unit, spider lube local/remote switch, level sensor and delivery hose assembly. The barrel pump fits a standard 400 lb. (181 kg) refinery oil drum. See Fig. 12-6.

12-7

Section 12 — Spider Assembly

SUPERIOR MK- II Gyratory Crushers

M-010604-TAW-01

FIG. 12-6 — Spider Lubrication System Outline Catalog Number 5239-0 5240-0 5286-0 5286-2 5286-3 5286-4 5287-0 5288-0 5293-0 5298-0

12-8

Description Spider Lube Supply Hose ASM -- Pump to Spider Arm Spider Lube Supply Hose ASM -- Internal to Spider Arm Hydraulic Power Unit Assembly Pump -- Hydraulic Power Unit Motor -- Hydraulic Power Unit Filter Element -- Hydraulic Power Unit (not shown) Supply Hose ASM -- Hyd Power Unit to Barrel Pump Return Hose ASM -- Barrel Pump to Hydraulic Pump Unit Spider Lube Barrel Low Level Indicator Spider Lube Barrel Pump Assembly

17X0501--01.0701

SUPERIOR MK- II Gyratory Crushers Level Sensor Mount sensor bracket (5245-2) to top of bushing using one of the threaded jackbolt holes making sure not to locate sensor near one of the two .38” (9.5 mm) diameter pressure relief holes (spaced 180_ apart) in upper flange of spider bushing. See Fig. 12-7. For the proper operation of the level sensor with warning signals and machinery shutdown, refer to the Mechanical Control Logic document.

NOTICE Adjust level sensor (5245-1) so that there is 2.0” (50.8 mm) from the bottom end of the sensor and the top of the spider bushing flange.

Section 12 — Spider Assembly SPIDER ARM AND RIM LINERS Arm and rim liners are easily removed by lifting them off after removing the fasteners. Observe liners regularly for excessive wear. They protect the spider from possible damage. A wear concentration on one arm liner may indicate an uneven feed arrangement, which can result in shock loading on the bearings. Arm and rim liners should be fitted so that no rocking occurs on any contact point. After locating liners, insert plugs through holes provided in them until they contact the spider arm or rim, then weld plugs to the liner. See “Spider Assembly” in Section 4 (Installation), for arm and rim liner installation.

See the Spider Lubrication System Outline, Spider Lube Local/Remote Switch Schematic drawings and the separately supplied instruction manual. Spider Oil Level Recommendations for operation: 1. Install system so that the hydraulic power unit has power only when the crusher motor is running. 2. Initial oil fill should be done with the shaft at its lowest position.

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12-9

Section 12 — Spider Assembly

SUPERIOR MK- II Gyratory Crushers

5245--3 5245--1

5245--2

5685--0 5685--2 5685--4

5245--4

5246--0 5246--4 5675--0

5675--0

50.8 [2.00]

5601--0 5245--3

5245--5

5245--3

VIEW A--A

SCALE 1:4

5245--5 A

5245--3

A

5705--0 5706--0 4205--0 SCALE 1:4

4001--0

5245--9

5005--0

M--030507--JRK--01

FIG. 12-7 — Spider Bushing with Oil Level Sensor Catalog Number

Description

Catalog Number

Description

4001--0 4205--0 5005--0 5245--1 5245--2 5245--3 5245--4 5245--5 5245--9

Mainshaft Assembly Headnut Topshell Assembly Sensor Bracket Cable Assembly Compression Fitting Clip Cable End

5246--0 5246--4 5601--0 5675--0 5685--0 5685--2 5685--4 5705--0 5706--0

Capscrew Lockwasher Spider Assembly Spider Bushing Spider Bushing Bolt Washer Lockwasher Seal Scraper

12-10

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Section 13 — Index

SUPERIOR MK- II Gyratory Crushers

13. Lubricant Recommendations

Page 13-1 13-2 13-2 13-2 13-2 13-2 13-3 13-3

Description Index General Information Circulating Oil System Circulating Oil Specification MPS Control Pinionshaft Assembly Spider Bearing Typical Recommendations

13

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13-1

Section 13 — Lubricant Recommendations GENERAL INFORMATION

DANGER Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant suppliers instructions and safety directions when handling oils and greases. Four major areas of the SUPERIOR gyratory crusher requiring lubricants are the circulating lubrication system, MPS control, pinionshaft assembly and spider bearing. Use only high quality lubricants in the crusher, to help insure proper lubrication. Consult a local oil company representative for recommendations on specific products which will meet these general specifications. CIRCULATING OIL SYSTEM Oil in the circulating lubrication system must cool and lubricate the step bearings, eccentric wearing plate, eccentric bushing, bottom shell bushing, bevel gear and pinion. Since this is a circulating system, the oil used must be light enough so that it can be easily pumped, filtered, cooled and returned to the holding tank by gravity, yet heavy enough to properly lubricate the various components. Fill the lube oil tank (7005-0) to a level approximately 1” (25 mm) below the sieve. See “General Specifications,” near the end of Section 3 for lube tank capacity. The circulating oil lubrication system is designed to provide the proper quantity of lube oil to the SUPERIOR crusher, see “General Specifications” in Section 3. CIRCULATING OIL SPECIFICATION 1. Mild extreme pressure gear oil. 2. High stability against oxidation with mild extremepressure characteristics. 3. Foaming tendency at a minimum. 4. Timken film strength of 60 minimum. 5. Viscosity index of 90 minimum. This must be a natural property of the oil, and not obtained through use of viscosity index improvers which reduce oil stability. 6. Oil viscosity will depend on oil temperature during operation. If return oil temperature can be maintained between 100oF. (38oC.) and 115oF. (46oC.), use an oil with the following viscosity specification year around: ISO VG 68 (AGMA grade 2EP) 68 cSt at 40oC (350 SUS at 100oF) 8.5 cSt at 100oC (55 SUS at 210oF) Note the viscosity values listed are in cSt (Centistokes) and SUS (Saybolt, Universal Seconds).

SUPERIOR MK- II Gyratory Crushers If operating conditions are such that the return oil temperature cannot be maintained below 115o F. (46o C.), use a slightly heavier oil with the following viscosity specification: ISO VG 150 (AGMA grade 4EP) 150 cSt at 40oC (750 SUS at 100oF) 14.5 cSt at 100oC (78 SUS at 210oF)

NOTICE It is essential that the proper type and viscosity of oil, as outlined above, is used. This will help assure proper lube system and crusher operation. MPS CONTROL In the MPS control, oil is used to raise or lower the piston, and adjust the crusher setting. A light oil is recommended in the MPS control system. Use oil in the MPS control of the same general type (mild extreme-pressure gear oil) as is used in the circulating oil system. However, use the light grade ISO VG 68 viscosity oil at all times, regardless of temperature. See “General Specifications,” in Appendix to Section 3 for the required quantity of MPS oil for the SUPERIOR crusher.

NOTICE Never use an oil heavier than ISO VG 68 grade viscosity in the MPS control system. DO NOT use a regular hydraulic oil. PINIONSHAFT ASSEMBLY (SEE FIG. 9-2) Pinionshaft assembly lubrication is a separate system; oil from the external system never enters the pinionshaft housing. However, the same grade of oil is used in both systems. Be sure to use new or very clean oil, when changing or adding to the pinionshaft lubricant. The oil supply in the housing should be ample for a long period of time, unless the oil seals are damaged and leaking. Inspect oil regularly and change if dirty. Oil is poured into the housing through a pipe plug (3575-0) opening on top of the housing. Maintain oil level at the red line on the sight gauge (3341-1) adjacent to the housing. For true oil level readings, inspect level only when the crusher is not operating. Approximate oil quantities are listed in “General Specifications” in Section 3.

NOTICE Do not overfill the pinionshaft. Too much oil will cause overheated bearings.

13-2

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Section 13 — Lubricant Recommendations

SUPERIOR MK- II Gyratory Crushers SPIDER BEARING The crusher mainshaft has both rotary and gyratory motion at slow speed and exerts fairly high pressures on the bearing surfaces. An oil pool is used to lubricate this bearing. Since ferrous metals are used in both the mainshaft sleeve and the spider bushing, the oil should contain an “extreme-pressure” additive. Oil is retained in the bearing cavity by two spring-loaded oil seals (5705-0) which are pressed into the bottom of the spider bushing (5675-0) with the lip facing upward. (See Fig. 12-2). Oil is added to the cavity through the spider lube hose (5240-0). The cavity is vented from a mushroom type vent (5750-0) at the top. The oil level should be maintained at approximately 1.4 inch (36 mm) above the spider bushing flange. The crusher is supplied with an automatic spider lubrication system as a standard feature. The dual oil seal spider bearing is designed to use a heavy oil as its lubricant. The oil used should have the same general specifications used in the circulating oil system. However, in general, an oil with a viscosity of about 2,400 SUS at 100oF (460 cSt at 40oC) (ISO VG 460) is most suitable. Depending on the ambient temperature and crusher operating conditions, it may be desirable to use a slightly lighter or heavier oil in the spider bearing. The approximate quantity of oil in the spider oil reservoir is listed in “General Specifications” in Section 3. The quantity is accurate with the shaft at its lowest position.

17X0501--01.0701

TYPICAL RECOMMENDATIONS Here is a partial list of lubricant producers and their products. Regard these as typical recommendations. Lubricants with equivalent specifications from other producers may be used.

Texaco Gulf Mobil Exxon

(ISO VG 68) 350 SUS Oil Meropa 68 EP Lub HD68 Mobilgear 626 Spartan EP 68

(ISO VG 150) 750 SUS Oil Meropa 150 EP Lub HD150 Mobilgear 629 Spartan EP 150

(ISO VG 460) 2400 SUS Oil Meropa 460 EP Lub HD460 Mobilgear 634 Spartan EP 460

The preceding information covers the four major areas requiring lubrication. Other areas such as the lubrication pump and reducer (see Lubrication Pump — Maintenance and Repair in the appendix of Section 5) are covered in detail in their respective sections regarding quantity and frequency of recommended lubrication. The suggested lubricants are summarized below: Equipment

Lubrication

Lube Pump

Grease — Lithium Base NLGI No. 2

Lube Pump Reducer

Oil — ISO VG 100 above 32oF (0oC) Oil — ISO VG 32 below 32oF (0oC)

Hydraulic Power Unit

Oil — ISO VG 68

Hyd Power Unit Motor

Grease — Lithium Base NLGI No. 2

Pinionshaft Drive End Seal

Grease — Lithium Base NLGI No. 2

Drive Shaft Couplings

Grease — Falk LTG (Long Term Grease) Lithium Base NLGI No. 2

Spider Lube Hydraulic Power Unit

Hydraulic Oil — ISO VG 32 AW (antiwear)

13-3

Section 13 — Lubricant Recommendations

SUPERIOR MK- II Gyratory Crushers

This page was purposely left blank.

13-4

17X0501--01.0701

Section 14 — Index

SUPERIOR MK- II Gyratory Crushers

14. Operation

Page 14-1 14-2 14-2 14-2 14-2 14-3 14-3 14-4 14-4 14-4 14-5 14-6 14-6 14-7 14-7 14-8 14-8 14-8 14-8 14-8 14-8 14-8 14-9 14-9 14-9 14-9

Description Index Preparation For Start-up Starting Lubrication System MPS Control Check-out — Oil Supply System with a Reversible Gear Pump Drive Inspection Starting The Crusher — Setting Crusher For Product Sizing Break-in Period Operating Limits Trouble Shooting Chart Preventive Maintenance Daily Maintenance Check Weekly Maintenance Check Major Maintenance Checks — Spider Assembly — Top Shell Assembly — Bottom Shell Assembly — Bottom Shell Bushing — Eccentric Bushing — Eccentric and Gear — MPS Cylinder Assembly — Pinionshaft Assembly — Eccentric Wear Plate — Eccentric Support Plate — Mainshaft Assembly

14

17X0501--01.0701

14-1

Section 14 — Operation

PREPARATION FOR START-UP

WARNING A hard hat, eye protection, and hearing protection are required at most crushing and screening installations. Hard hats and safety goggles can prevent injury. Wear hearing protection when noise levels exceed 85 dBA and breathing protection when dust levels exceed acceptable limits. 1. Thoroughly clean the lubrication oil tank (7005-0) and fill with the recommended oil (see Section 13, “Lubricant Recommendations”). For required quantities of both lubricating and MPS control oil see “General Specifications,” in Section 3.

NOTICE Thoroughly flush all lube oil lines before pumping oil into the crusher. Disconnect both lube inlet lines at the crusher and flush the system a minimum of four hours. Failure to properly flush the lube lines may result in contaminants entering the crusher bearings. After flushing has been completed, replace the lube oil filter elements with the spare elements provided. 2. Thoroughly clean the oil tank for the MPS control system and fill it with the recommended oil. 3. Drain the preservative oil from the pinionshaft assembly and refill with the correct amount of the recommended oil (see Section 13, “Pinionshaft Assembly”). The preservative oil used by Metso Minerals is generally compatible with the recommended lubricating oil, and flushing should not be required. 4. Fill the spider bearing cavity with the recommended lubricant (see Section 13, “Spider Bearing”), and the approximate quantity listed in “General Specifications” in Section 3. The spider lube pump can be used to fill the spider bearing cavity. 5. Pipe water to the lube oil coolers (7705-1, 7705-2). If an air-to-oil cooler is being used, check piping connections and fan rotation, and drain preservative oil. 6. Check wiring of all lubrication and MPS control system components. 7. Check drive alignment.

CAUTION Do not operate the crusher without having a suitable drive guard, conforming with statutory requirements, in place.

14-2

SUPERIOR MK- II Gyratory Crushers STARTING LUBRICATION SYSTEM 1. Open the hand valve (7405-0) on the pump suction line and filter inlet line. 2. Make sure oil in the tank is at proper operating temperature (see the Mechanical Control Logic document). If an immersion heater has been installed and put in operation, oil should be at approximately 90oF (32oC).

NOTICE If lubricating oil is too cold, lube system operation will cause high pressures and possibly damage system components. 3. Start the lube oil pumps (7205-0, 7206-0) and inspect system piping for leaks. Tighten any loose joints or fittings.

NOTICE See cautionary note under item 1 in “Preparation For Start-up.” DO NOT operate lube system without first flushing it thoroughly. 4. Check operation of oil feed line flow meters (see “Flow Meters” in Section 5). 5. Check pressure drop across the oil filter (7505-0). With a clean filter cartridge, and oil at operating temperature, pressure drop should be .5 to 3 psi (3 to 20 KPa), with no oil flowing through the bypass line. Bleed air from the filter through the plug in the cover. MPS CONTROL CHECK OUT Oil Supply System with a Reversible Gear Pump 1. The valve (8225-0) on the pump suction line between the tank and the control valve (8608-0) must be open. 2. Port “C” of the control valve must be connected to the MPS cylinder. 3. The check valve (8525-0), see Fig. 6-7, must be installed with the free flow arrow pointing toward the crusher. (Section 6, Fig. 6-9) 4. Any high points in the MPS line between the control valve and the crusher should have a high pressure (1500 psi (10.3 MPa) minimum) bleeder plug to remove air from the MPS line. Air entrapment in the high points of a line would allow a spongy mainshaft, producing an erratically sized product under crushing loads. See Section 6, “Bleeding Air From System” and Fig. 6-7 for bleeder plug location. 5. Fill the MPS tank with lubricating oil. See Section 13 for recommendation. 6. The system has a reversible gear pump and the pump motor is connected to run in both directions. Pushing the “raise” button starts the pump in the forward direction pressurizing the control valve assembly and allows oil to pass freely to the crusher, raising the mainshaft. Releasing the “raise” button stops the pump and 17X0501--01.0701

SUPERIOR MK- II Gyratory Crushers

7.

8. 9.

10.

11. 12.

a check valve in the control valve assembly keeps oil from returning back to the tank. To lower the mainshaft, push the “lower” button which starts the pump in the reverse direction, pressurizing the control valve assembly and allows oil to pass freely back to the tank, lowering the mainshaft. See Section 6 for MPS control valve details. Releasing the “lower” button stops the pump and the check valve in the control valve assembly stops oil from returning to the tank. With the plug removed from the bottom of the crusher, put the MPS control in the “Raise” mode and hold until clear oil runs out of the plug hole. A cloudy or milky color indicates air entrainment in the oil which must be removed. When clear oil runs out, install the plug and tighten securely. See Section 6, “Bleeding Air From System”. Again put the MPS control in the “Raise” mode and bleed the air or air entrained oil at any high points in the MPS line. Check the MPS line thoroughly for any oil seepage or leaks at all connections, after raising the mainshaft assembly to operating position. Check the line again after operating under load. Crushing pressures frequently expose leaks that are not visible from the static weight of the mainshaft assembly. Raise and lower the mainshaft assembly several times, several hours apart, and repeat the bleeding operation to insure that air entrained in the oil escapes to the MPS system high points for bleeding out. The bottom of the crusher will require only the initial bleeding. For precharging the Balance Cylinder with nitrogen refer to Section 6, “Balance Cylinder.” If the balance cylinder is losing pre-charge pressure, check the filler valve for leakage. Other causes for pressure loss may be a leaky piston or scored cylinder wall — both will require disassembly, inspection and repair of the balance cylinder.

DRIVE INSPECTION 1. Check the drive for proper alignment. Make sure that the drive couplings are lubricated per the manufacturer’s recommendations. STARTING THE CRUSHER

CAUTION Before starting or operating equipment, walk around the work area and the equipment to check that no personnel, animals, tools, parts, or other foreign objects are in, on, under, or around the equipment. Make sure that all guards and safety devices are properly installed and in good working condition.

17X0501--01.0701

Section 14 — Operation

CAUTION Use appropriate devices such as sirens or flashing lights to warn personnel and visitors that equipment is starting. 1. The oil level in the lubrication tank should be 1” (25 mm) below the oil screen before starting the pump. Check the two flow meters to verify that the proper quantity of oil is being supplied to each of the two lube supply lines. 2. Before starting up the crusher, check the backlash of the pinion and gear. See “Bevel Gear Installation and Maintenance,” in Section 9. The backlash should not be less than listed backlash values in Section 9. Recheck the backlash after operating temperatures have leveled off.

NOTICE Prior to starting the crusher verify that the Metso Minerals recommended control logic settings, interlocks, and requirements as defined in the Mechanical Control Logic document are in place and operational. 3. After the lube pump is started and the oil return is entering the tank, phase in the crusher for correct rotation. This requires a momentary energizing of the crusher drive motor. Correct pinionshaft rotation is clockwise, as viewed in front of the pinionshaft looking towards the crusher. If incorrect, reverse two electrical leads to obtain clockwise rotation. 4. The crusher may be run idle for several hours break-in if clockwise mainshaft spin is not over 12 rpm. If over 12 rpm spin occurs, introduce a light feed of enough material into the crusher to prevent excessive spin. A rubber tire or two suspended from ropes, or similar object, can be put into the crushing chamber if no feed is available. The idle break-in period should continue until the oil return temperature levels off. During the break-in period, small, fine pieces of bronze may accumulate on the oil return screen in the tank, due to lapping of step bearing components into full contact. This may approach one or two teaspoons in quantity, but will diminish. 5. Audible noise is normally heard during break-in as follows: a. An uneven gear noise that coincides with each gyration of the mainshaft assembly is due to the unloaded eccentric and gear moving around in the bearing clearances. The dynamic mainshaft force may also cause pinion gear overrun. This noise will lessen when the crusher is under load. b. A slight slapping sound underneath the crusher mainshaft assembly is from the dust seal slapping the dust collar, and is normal. 14-3

Section 14 — Operation

c.

During the warm-up period, the lubrication pump may make noises due to cold oil and a degree of cavitation from air entrainment. The air leaves cold oil much more slowly than from warm oil due to the viscosity change. 6. Problem areas during start-up and their identification: — High oil return temperature, in excess of 115oF (46oC) with ISO VG 68 viscosity oil or 130oF (54oC) with ISO VG 150 viscosity oil may be due to insufficient cooling water, or incorrect fan rotation, if air to oil cooling is used. — Lack of oil flow in the lubrication line may be due to ia blocked or broken line. Setting The Crusher For Product Sizing

DANGER Lockout power source during installation, cleaning, or servicing the equipment or when making repairs. Failure to do so could result in severe bodily injury or death. The crusher setting should be checked with the crusher not running and the power source locked out. Drop a round wooden ball (or other lightweight material) approximately the size of the desired setting through the crusher chamber. Ball may be attached to a manila rope and dropped through the chamber to the crushing point at the widest opening. The ball should just pass through to determine the open side setting. Actuate the MPS mechanism to raise or lower the mainshaft to obtain the proper setting. Check again with the ball. The crusher open side setting should normally be that for which the crusher was originally intended as sold. Crushing action should start at the optimum (as designed) point on the mantle, well up in the crushing chamber, to reduce development of injurious ski slides on the mantle or hooks on the concaves. BREAK-IN PERIOD When operating a new crusher, or when new bearings have been installed, operate initially with a light load. This will allow the new bearings to “wear in” before they are subjected to heavy loads. 1. Run the crusher at one-half capacity for a minimum of two hours and a maximum of one day. 2. Make the initial feed adjustments so that material is evenly distributed around the chamber, with no segregation of coarse and fine materials. 3. Check return oil temperature frequently to be sure it remains within safe limits. Check oil cooler operation.

14-4

SUPERIOR MK- II Gyratory Crushers

NOTICE If the suggested control interlocks have been properly implemented and the return oil temperature rises above the safe operating limit, the “high oil temperature” warning and alarm signals will be actuated and the crusher drive motor will be shut down. 4. Inspect all lubrication and MPS control piping fittings for leaks. Check pinionshaft and spider bearing seals for leaks. 5. Check oil tank sieve for metallic chips. A small amount of bronze and steel flakes is normal during initial break-in. 6. Recheck all bolts for tightness. 7. Gradually increase crusher load until full load operation is reached. 8. Make final feed adjustments.

NOTICE Feed must be evenly distributed around the entire crushing chamber, with coarse and fine material well mixed. OPERATING LIMITS Always operate the SUPERIOR crusher within the following limits: 1. Keep power draw within the maximum specified for the crusher. 2. Keep return oil temperature within safe limits, less than 115oF (46oC) when an ISO VG 68 oil is used and less than 130oF (54oC) when an ISO VG 150 oil is used. Pressure in the MPS control, power draw and return oil temperature are affected by the crusher setting, crusher capacity, and hardness of the material being crushed. If high steady power draw beyond specified limits occurs, relieve the load by temporarily increasing the crusher setting when operating with a worn chamber, change liners if appropriate, or reduce the amount of feed to the crusher if an apron feeder is providing feed to the crusher. If power draw is erratic, the cause may be unevenly distributed feed, feed segregation, packing in the crushing chamber, or air in the MPS control system.

17X0501--01.0701

SUPERIOR MK- II Gyratory Crushers

Section 14 — Operation

TROUBLE SHOOTING CHART Correction Crusher stoppage Packing in crusher chamber. Clean out chamber by lowering head. Reset crusher and restart. Check crusher setting to be sure it is not smaller than recommended. Check feed regulation Tramp iron. Remove obstruction by lowering head. Reset and restart crusher. If head cannot be lowered because obstruction is wedged too tightly, loosen the top shell. A long acetylene lance may be used to cut out the obstruction, if other methods fail. Blocked oil line (causes lubrica- Clean oil lines. Clean lubrication oil storage tank screen. tion pump to overload). Cold oil (increased oil viscosity Heat oil before starting crusher. causes lubrication pump to overload). Crusher fails to maintain Oil leakage. Check all piping for leakage. Oil leakage would be appresetting ciable since leakage of a drop periodically would not change the setting even over eight hours. Check valve in control valve as- Inspect check valve for damaged parts and replace. sembly is leaking, allowing oil to return to tank. Air in system. Close side setting opens during crushing. When crusher is empty, head will return to the setting erratically. Bleed oil lines. MPS oil seal. If none of the above remedies correct the trouble, either the oil seal is worn or cracked or the MPS cylinder is worn. Install new seal or repair cylinder. Loose or breaking mantles Weaving of mantle on the head Check mantle for tightness occasionally by shutting off caused by elongation of the the feed so the crushing chamber may be observed. As mantle through work hardening the last part of the feed is being crushed, study the joint in localized areas. between the head nut and the mantle. If the mantle is loose, movement will occur at the joint. Consider alternative chamber. Improperly poured backing. Backing poured too high and preventing self-tightening of mantle. Unusual crusher noises Incorrect gear backlash causes Reset gear backlash to the proper value. See Section 9 a high frequency rattle by the ”Gear and Pinion Backlash Adjustment”. pinion bottoming on the gear. Excessive load causes a growl- Excessive load may cause extreme pressures to develop ing noise near the bottom of the between gear teeth and on the step bearing surface. Incrusher or the step bearing is spect screen in the oil tank for excessive amounts of failing. bronze or lead flakes. Movement between the top and Replace broken bolts. Tighten the nuts. If taper joint is bottom shells (breakage of worn or rusted and the fit is destroyed, build up taper by bolts). welding and machining. Note: Crusher may be operated TEMPORARILY by shimming the taper joint. Air-oil cooler plugged with dirt, Remove dust and other debris from radiator fins. Oil too hot dust or other debris. No cooling water or water too Check water supply and temperature. warm. Packing in chamber. Clean out chamber by lowering head. Check crusher setting to be sure it is not smaller than recommended. Check feed regulation. Bearing trouble beginning. Check screen of oil tank for excessive flakes of bronze or lead. Check bearings. Trouble

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Cause

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Section 14 — Operation

SUPERIOR MK- II Gyratory Crushers

PREVENTIVE MAINTENANCE

DANGER Lockout power source during installation, cleaning, or servicing the equipment or when making repairs. Failure to do so could result in severe bodily injury or death. Operating conditions vary so widely that it is impossible to recommend one schedule of preventive maintenance for all crushers. Follow some sort of regular inspection and keep records of the periodic inspections and maintenance of your crusher. This recognition of maintenance procedure will keep your crusher in good working condition and prevent costly breakdowns. One of the best rules in crusher maintenance is to keep a record of actual operating hours. Then, after a predetermined period of operation, give the crusher a thorough

major inspection. The length of this operating period will vary with the type of product and the number of hours of operation, and can best be determined from experience. New equipment, however, should be examined after a relatively short period of operation. The next major inspection period can be lengthened somewhat. Follow this system until a maximum period of operation is reached, and adhere to it as the operating schedule between inspections. Systematic inspections of your crusher will result in less maintenance — less down-time — fewer repair bills. Maintenance checks will help in determining wear — detecting failures before they cause serious damage. Crushers operating many hours each day will require more frequent checks. Note that the Metso Minerals automation package along with the various sensors provides for continuous monitoring of oil levels if the sensors are working properly.

DAILY MAINTENANCE CHECK Lubrication system

Check amount of oil in storage tank. Oil level should be about 1” (25.4 mm) below sieve before starting. Check oil filter pressure drop. Change filter element when pressure drop reaches 25 psi (172 KPa). Check oil pump and grease if necessary.

Hydraulic system

Check oil storage (it should be full when mainshaft assembly is in lowest position). Do not fill tank after setting the head as it will overflow if the head is lowered considerably. After starting crusher and starting feed, check oil lines for leaks. Leaks will cause the crusher to lose its setting.

Pinionshaft housing

Check oil level on pinionshaft housing when crusher is not running.

General

Check for loose bolts and parts — tighten where necessary. Check oil screen for metal chips. A small amount of chips will occasionally appear on the screen; however, a sudden increase indicates excessive pressures on the bearing surfaces — and possible failure. Check for excessive noise when crusher is operating. Check return oil temperature every hour until it levels off. Check oil temperature when changing shifts and at shutdown. Inspect concaves for tightness. When the concaves are manganese steel, the gaps between concaves should be checked daily.

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Section 14 — Operation

SUPERIOR MK- II Gyratory Crushers WEEKLY MAINTENANCE CHECK Lubrication system

Check all of the items on the Daily Maintenance Chart. Check for dirt and sludge. If dirty, check the filter and change cartridge if necessary. Change oil when there is dirt suspended in it or when a large amount of sludge has formed in the bottom of the storage tank. Drain the tank, clean and refill with new oil when necessary. Check sediment separators in oil inlet lines to crusher, and clean if necessary. Check all oil lines and crusher joints for leaks. Lubricate the oil pump motor, if necessary. Check oil pump for noise and indication of wear.

Pinionshaft

Check oil level. Oil level should not change unless oil seals are damaged or leaking. Replace if necessary.

Spider bearing

Check lubricant in the spider bearing. Lubricant level should be about 1.4” (36 mm) above spider bearing.

General

Check space between head nut and bottom of spider to determine amount of wear. Check dust seal for wear and dust seal retainer for tightness to prevent breaking of bolts. Check mantle and concaves for wear and cracks. Inspect concaves for manganese growth in joints. Toward end of allowable mainshaft adjustment, inspect bottom two rows frequently for wear. Manganese growth from work hardening and stretching across the original concave spacing may cause elongation of joint bolts between top and bottom shells, and separation in the taper fit. If this occurs, initiate a program for regularly air arcing out the peened space between concaves, vertically and horizontally.

MAJOR MAINTENANCE CHECKS

DANGER Lockout power source during installation, cleaning, or servicing the equipment or when making repairs. Failure to do so could result in severe bodily injury or death.

CAUTION Permit only trained and competent personnel to work on electrical components, in the plant or on any equipment.

WARNING Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant suppliers instructions and safety directions when handling oils and greases. Disassemble the crusher. Inspect the major parts and subassemblies as follows. Refurbish and repair, or replace, as required. For specific information on disassembly and reassembly of major components, refer to the applicable section of this manual.

WARNING Do not disconnect any cylinders, hoses or fittings on a pressurized system until all pressure in the system is relieved.

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Section 14 — Operation

Spider Assembly 1. Check the clearance between the spider bushing and mainshaft sleeve before removing the spider or spider bushing from the crusher. The fulcrum point is the point of smallest diameter in the hour-glass-shaped bushing. If the clearance between the mainshaft sleeve and spider bushing at the fulcrum point is equal to or greater than the maximum allowable clearance listed in Table 12-2, one or both components must be replaced. 2. Inspect spider bushing seals (5705-0) for nicks, cracks and wear. Replace worn or damaged seals. 3. Check spider arm and rim liners for wear, and for loose fits. They protect the spider from wear and possible damage. Excessive wear on one arm liner may indicate an uneven feed arrangement. Correct the feed to even up the wear pattern and relieve shock loading on bearings. 4. Check taper fit with the top shell. Wear in this fit can only be measured by gauges which are available only from Metso Minerals. Remove burrs, bruises, or accumulated rust and dirt. Coat the taper fit and horizontal surface of the spider with oil before reassembly. Do not use white lead, which can harden and make subsequent removal of the spider assembly difficult. Top Shell Assembly 1. Check the interference taper fits of the top shell to the bottom shell and to the spider assembly for fretting or wear. Clean up as required. Wear in fits can be measured by gauges which are available only from Metso Minerals. 2. Check general condition of concaves for unusual wear patterns, excessive manganese growth or other trouble symptoms. Bottom Shell Assembly Check for wear on components, including: 1. All liners, arms, hub and other surfaces subject to abrasion. 2. Taper joint with top shell (see item 1 under “Top Shell Assembly”). 3. Bore of hub and keyway (see “Bottom Shell Bushing,” below). 4. Dust collar (1400-0). Check for wear on the O.D., or sealing area. Excessive wear can cause oil contamination leading to accelerated step bearing wear, gear wear, etc. Check the dust collar gasket — a faulty gasket may lead to excessive oil loss. If drain holes have not been properly cut in the gasket, oil may overflow the dust collar and contaminate the product. Bottom Shell Bushing 1. Check for wear, scoring or burning and heat checks in the bore. Remove any burrs or protrusions. 2. Check bushing for cracks, particularly around the keyway, before reusing.

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SUPERIOR MK- II Gyratory Crushers Eccentric Bushing 1. Check for wear, scoring, or burning and heat checks in the bore. 2. Before approving reuse of the bushing, check for cracks, particularly around the keyway. Eccentric And Gear 1. Check for wear, scoring or burning and heat checks on the eccentric turn. 2. Inspect closely for cracks if the eccentric has been burned badly. 3. Inspect and polish the bottom of the gear where it rotates on the eccentric wear plate. 4. Remove all burrs and sharp edges from gear teeth. Inspect teeth for cracks. MPS Cylinder Assembly 1. Inspect step washer for wear and roughness. Hone surfaces if rough. Inspect bottom for flatness. Replace, if necessary. Wear limits are 3/8” (9.5 mm) on all crushers. 2. Inspect piston wear plate for wear, burns, roughness and flatness. If burned, but in relatively small areas, it may be reused. Hone off any roughness. If seriously burned, replace it. If worn or not flat, replace it. If it is not flat, inspect the piston top surface for flatness. Extreme wear plate wear may be a symptom of either oil contamination or extreme MPS pressure during operations. Wire edges on outside surfaces is an indication of high operating pressure. Wear limits at edges are 3/8” (9.5 mm) on all crushers. 3. Inspect the MPS piston for flatness on top and for gall and score marks on the diameter. If the piston is not flat on top, re-machine or replace it. If gall or score marks are not too great, hand hone them and reuse the piston. Avoid using if marks could score the cylinder wall. 4. Inspect the lower MPS cylinder bushing for score marks, particularly vertical grooving in the seal area. If there are gall or vertical marks, replace the bushing, unless they can be removed by hand honing. Under extreme operating pressures, small depth grooves (visible to the eye) can pass large quantities of oil. 5. The upper MPS cylinder bushing is not so critical, with respect to gall or score marks. It may be reused if honed smooth and not out of round. If worn excessively, replace it. 6. Replace the MPS oil seal if worn or nicked due to oil contamination. 7. Inspect the clamp plate for vertical score marks in the packing recess. Inspect the top, where the piston rests on the clamp plate, for smoothness. Dress it with a flat file, if necessary. 8. Replace the cylinder cover O-ring each time the bottom plate cover is removed. 9. Inspect the MPS cylinder lower bushing face in the O-ring seal area for burrs or scratches. 17X0501--01.0701

SUPERIOR MK- II Gyratory Crushers 10. Check the cylinder for flatness on the top of the upper flange. Remove any burrs or bruises. Check the bottom flange in the same manner. 11. Replace the MPS cylinder O-ring each time the cylinder is removed. Pinionshaft Assembly 1. Remove burrs and sharp edges from pinion teeth before reassembly in the bottom shell. 2. If the two oil seals have been leaking, replace them. Oil loss from the sheave end oil seal may be either from a damaged seal or a grooved spacer. 3. Check both pinion and drive end spacers. Replace if rough or grooved. 4. Inspect bearings for evidence of fatigue, grooving, spalling of race or rolling elements wear or cage deterioration. Replace, if necessary. Eccentric Wear Plate If worn, but smooth, with oil slots in good condition, reuse it. If rough and worn, replace it. Eccentric Support Plate 1. Remove burrs and bruises. Check for flatness on bottom side. If not flat, also check to top of the MPS cylinder flange. Excessive pressures can be the cause of a bent plate and flange. 2. Replace the support plate O-ring each time the support plate is removed.

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Section 14 — Operation

Mainshaft Assembly 1. Change the mantle, if badly worn. Normally, manganese will crack or break when approximately 1” (25.4 mm) thickness remains. 2. Inspect mainshaft sleeve for wear. If grooved by wear, or if vertical score marks are evident, replace the sleeve. 3. Inspect the head nut and mainshaft sleeve threads for burrs. Remove all burrs. 4. Inspect the lower bearing journal for grooves, wear, bruises and heat checks. If not too deep, remove them by hand polishing. If deep, remove them by re-machining. 5. Inspect the mainshaft taper. If indented from wear, or for other reasons, stone down the area to match surrounding surfaces. Fill indentations to contour with Babbittrite, Devcon or a similar heat-resistant material so that the mantle and its backing will not be keyed to the shaft. Otherwise, the self-tightening head nut cannot perform its function. 6. Inspect the mainshaft step bearing for wear, burns or roughness. If badly worn, or burned, replace it. If roughened slightly, hand polish and check with bluing for contact with the step washer. If 50% contact can be obtained, it may be reused. 7. Inspect the dust seal for wear on both the thickness and bore. If worn 1/8” (3.175 mm) or more in inside diameter, replace it. Check for cracks that can be caused by product build-up under the head. Check the dust seal retainer to make sure the lower edge has not worn down to knife edge sharpness. Check attaching bolts for tightness.

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SUPERIOR MK- II Gyratory Crushers

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Section 15 — Index

SUPERIOR MK- II Gyratory Crushers

15. Low Temperature Operation

Page 15-1 15-2 15-2 15-2 15-2 15-3 15-3 15-3

Description Index Making Starting and Running Easier in Cold Weather — Additional Oil Heaters — Heating Cables on Oil Lines — Synthetic Oils — Blanking Off the Oil Cooler Radiator — Insulated Oil Tank — Continuous Running of the Lubrication Oil Pump

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Section 15 — Low Temperature Operation MAKING STARTING AND RUNNING EASIER IN COLD WEATHER All of the suggestions listed are based on making the oil flow more easily and thus improve the movement of oil through the crusher. The suggestions described below are not given in any special priority. The order in which the suggested measures are applied must be judged in each individual case. It may be best to use a combination of several suggested measures. 1. Additional oil heaters 2. Heating cables on oil lines 3. Synthetic oils 4. Blanking off the oil cooler radiator 5. Insulated oil tank 6. Continuous running of the lubrication oil pump 1. Additional Oil Heaters Under very cold weather conditions it may be necessary to install extra heaters in the lube tank in order to keep the oil warm. The standard lube tank is furnished with six -2 KW heaters, and has mountings available for adding as many as six additional 2 KW heaters. To add additional heaters all that is required is to remove the 2-1/2” pipe plug from the mounting coupling, thread in the heater and wire the heater. Heater — 2 KW, Cat. No. 8825-0 2. Heating Cables on Oil Lines At low temperatures, the oil in the lines between the tank unit and the crusher can solidify and form a “plug” which stops oil flowing to the crusher during starting. This problem can be minimized by insulating the oil lines and installing heating cables. Before heating cables are installed, the slope of the return oil line should be increased, if this is possible. The heating cable should have a rating of 8 -- 10 W/m and 1.5 in. (40 mm) thick insulation should be used. Install the heating cable on the underside of the oil line and use electrical tape to keep the cable in place. In the case of oil lines larger than 2 in. (50 mm) in diameter and/or when it is desired to heat the oil to a temperature 90o F (50o C) above the ambient temperature, the heating cable can be led backwards and forwards on the same line. Heating cables are in many countries considered as high voltage equipment and must therefore be installed by an authorized electrician, in compliance with the relevant regulations. Heating cable is normally supplied for 120 or 240 V. It is often most convenient to purchase the heating cable from a local supplier who can also install it. If required, Metso Minerals can supply suitable heating cable but it is probably still most convenient to turn to a local electrician for installation. 15-2

SUPERIOR MK- II Gyratory Crushers The heating cable which Metso Minerals recommends is of a self-regulating type, which needs no thermostat since over-heating cannot occur. 3. Synthetic Oils During recent years, synthetic oils have appeared on the market. These oils are in all respects superior to mineralbased oils. Unfortunately they are expensive. However, the higher price can be outweighed by the advantages provided by the oil. According to suppliers, the characteristics of synthetic oils can in general be described as: Advantages — Longer life due to high stability which gives longer intervals between oil changes. — Easier starting at low temperatures. — Lower energy consumption due to lower friction. — Wider temperature range. — Elimination of the risk of dangerous oxidation and “coking”. Characteristics — Maximum lubricating effect. — Lower friction than corresponding mineral oils. — Very good protection against corrosion and foaming. — Very high oxidation stability. — Completely free from aggressive aromatics. In the case of a SUPERIOR crusher, it could be said that a synthetic oil provides the same starting conditions as an equivalent mineral oil, but at a temperature about 18o F (10o C) lower. The following ISO-150 synthetic oils can be recommended for SUPERIOR crushers. Other brands can also be used but the selection of a suitable type must be discussed with the supplier. Supplier

Type

Min. Pour point (o)

Viscosity (cSt) at 40oC

Mobil

Mobilgear SHC150

--50o F (--46o C)

150

Texaco

Pinnacle EP150

--60o F (--51o C)

150

The oils mentioned here can be mixed with mineralbased lubricating oils but the crusher and oil tank should be carefully emptied so that the synthetic oil is diluted as little as possible. If a change is made to a synthetic lubricating oil it is also advisable to change over to a synthetic MPS oil. This is in order to reduce the dilution which can occur in the lubricating oil if there is any leakage past the MPS packing. In addition, a synthetic oil will give smoother operating than a mineral oil in valves and pipes. The oil normally used in the MPS system is a grade with viscosity 68 cSt at 40o C but when synthetic oil is used, a grade with viscosity 32 cSt at 40o C can be selected. 17X0501--01.0701

Section 15 — Low Temperature Operation

SUPERIOR MK- II Gyratory Crushers The following synthetic oils can be used in the MPS system. Note these oils do not contain extreme pressure additives but are compatible should there be some unintentional mixing of the lubricating and MPS oils. Type

Supplier

Min. Pour point (o)

Viscosity (cSt) at 40oC

Mobil

SHC 626

--65o F (--54o C)

66

Mobil

SHC 624

--65o F (--54o C)

32

Texaco

Pinnacle 68

--62o F (--52o C)

65

Other brands can also be used but the selection of a suitable type must be discussed with the suppliers. Whatever the type selected, it must be possible to mix the lubricating and MPS oils used in the crusher. In order to maximize the life of the expensive synthetic oil, we recommend that special care is taken with cleanliness and the maintenance of dust seals and filters. 4. Blanking Off the Oil Cooler Radiator During operation it can occasionally happen that the crusher suddenly stops for no apparent reason. One explanation for a sudden stop like this can be that the oil temperature has reached the level at which the cooling fan cuts in. If the air is cold, the oil can be cooled so efficiently in the cooler that the viscosity increases and oil “solidifies” in the relatively small passages of the radiator. This increases pressure drop, which either reduces the oil flow and the crusher stops because insufficient oil passes the flow monitors; or oil by-passes the cooler with little cooling and the crusher stops because too hot of oil passes the high temperature shut-down switch in the return line.

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The easiest way to avoid stoppages of this kind is to blank off the radiator so that a smaller mass of air is passed through the radiator core. The degree of blanking must be determined by trial-and-error in each individual case. 5. Insulated Oil Tank During the winter, one way of making the most of the heat put into the oil tank (with the heating elements, from friction in the crusher, etc.) is to insulate the tank. This means that the oil in the tank does not cool down as rapidly and after a cold night it will be easier to start the crusher since the oil temperature is higher than it would be if the tank were not insulated. When the ambient temperature rises (i.e. with seasonal changes from winter to spring) it may be necessary to remove the insulation if the cooling capacity of the system is insufficient. Metso Minerals does not have standard off-the-shelf insulation kits. Insulation can easily be installed by the plant personnel. Suitable material is Rockwool 1330-00, 2 inches (50 mm) thick. The insulation material must be protected from moisture as it will otherwise lose its insulating properties. 6. Continuous Running of the Lubrication Oil Pump During cold weather it may be difficult to start the crusher since oil has solidified in the oil lines and in the crusher itself. This can be avoided or minimized if the oil pump is allowed to run continuously during the time when the crusher is standing still., The heaters in the oil tank must be switched on and the crusher’s feed opening must be covered over to avoid excessive cooling by cold air passing freely through the crushing chamber. If this is allowed to happen, the heating power installed in the tank will probably be insufficient.

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Section 15 — Low Temperature Operation

SUPERIOR MK- II Gyratory Crushers

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Metso Minerals North and Central America 20965 Crossroads Circle Waukesha, WI 53186 USA Phone: +1-262-717-2500 Fax: +1-262-717-2505 Metso Minerals South America Caixa Postal 272 18035-240 Sorocaba Brazil Phone: +55-15-2102-1300 Fax: +55-15-2102-1695 Metso Minerals Asia-Pacific Level 2, 1110 Hay Street West Perth, WA 6005 Australia Phone: +61-8-9420 5555 Fax: +61-8-9320 2500 Metso Minerals Europe, Middle East and Africa P.O. Box 4004 20311 Malmö Sweden Phone: +46-40-24 58 00 Fax: +46-40-24 58 78 Metso Minerals P.O. Box 307 33101 Tampere Finland Phone: +358 20 484 140 Fax: +358 20 484 141 Metso Minerals (Mâcon) SA 41, rue de la République 71009 MACON France Phone: +33(0) 3 85396200 Fax: +33(0) 3 85396328 www.metsominerals.com E-mail: [email protected]

Instruction Manual No. 17x0501.01-0701-N-English

©2007 Metso Minerals

Printed in U.S.A.