MP800 - Maintenance

MP CONE CRUSHERS
MAINTENANCE
TTM-5005-D
Lifting the Entire Crusher

 When lifting the entire crusher, make
certain to lift with adequately sized
cables.
 Lift from the correct lifting points on the
crusher main frame.
 Use softeners under the cables wherever
they make a turn on even a semi sharp
edge.
 Never stand under or near a suspended
load.
 Never stand in or put yourself in a
compromising position.
 SAFETY STARTS WITH YOU!
Note: If in doubt as to the correct lifting points or complete Crusher or Crusher component weights,
reference the Crusher instruction manual to a detailed explanation.
© Metso Corporation
TTM-5005-D
Main Frame Assembly
Dust Shell Clamping Ring
Adjustment Ring
Main Frame
Main Frame
Liner
“U” Seal
Main Shaft
Lower Thrust
Bearing
TTM-5005-D
Main Frame Liner & Arm Guards
► The main frame liner of the

MP800 crushers are bolted into
position.
► Main frame liners are made of
wear resistant steel.
► The arm guards of the MP800
hang on each of the main frame
arms.
Main Frame Liner Clamp Main Frame Liner
TTM-5005-D
Worn Main Frame Liner
TTM-5005-D
Worn Main Frame Liner
► Main Frame Liners should be checked at ever liner change

► Neglected Main Frame Liners will lead to very costly damage!
6
TTM-5005-D
Lower Thrust Bearing Plate
► At least once per year, the lower

Lower Thrust Bearing Hex Head Capscrew and
Spring Washer
thrust bearing should be inspected
for wear.
Shims ► The lower thrust bearing should be
replaced if it is damaged, i.e.:
scratched, gouged, galled, discolored
(from over-heating) or if it is no
longer flat.
► Fasteners should also be checked for
tightness.
► Shims will be added under this thrust
bearing plate in order to make
adjustments to backlash and root
clearance.
Main Shaft Main Frame
TTM-5005-D
Main Frame “U” Seal
Main Frame “U” Seal  The main frame “U” seal is glued
into position.
 Dry fit the seal before gluing it in to
assure proper fit up.
 If the new seal appears to be shinny
where it is to be glued, remove the
shine with sand paper.
 Never force the seal into the
groove.
 When ordering seals, order the
correct glue also.
Main Frame Center

Casting
TTM-5005-D
Main Frame Pin Arrangement
 The purpose of the main frame

Adjustment Ring Main Frame Pin Cover
pins is to prevent the adjustment
ring from turning out of position
during a force overload
(adjustment ring movement).
 The main frame pins can be
replaced in the field as required.
 Worn main frame pins can be
pressed out or cut out.
 New pins are cooled down in dry
Fulcrum Bar ice for two hours to shrink them
prior to installation.
Main Frame Pin
Main Frame Seat

Liner Main Frame
TTM-5005-D
Determining Seat Liner Wear
Measure Here
 Main frame seat liners protect the
seating surface of the main frame
from wear.
 The main frame seat liners should
be replaced when the actual
measurement taken is 5/16” (8mm)
less than the original measurement
taken.
10
TTM-5005-D
Main Frame Seat Liner Installation

 Main frame seat liners are welded to the tapered
surface of the main frame.
 On the MP800, a clearance of 3/32” (2mm) to
3/16” (5mm) must exist between the fulcrum bar
and the adjustment ring.
 Clay balls can be used to determine if fulcrum bar
clearance is correct.
 The proper electrode is a Eutectic 1855 electrode
 Do not butt vertical joints, a gap of 3/4” (18mm)
to 1” (25mm) must exist.
Main Frame Seat Liners Fulcrum Bar
Note: Seating tight on the fulcrum bar can cause failure of the adjustment ring!
11
TTM-5005-D
Clearing Jack Arrangement
Adjustment Ring
 The clearing jacks are used to clear
a plugged crusher or to raise the
adjustment ring to inspect the main
frame seat liners.
 There are four clearing jacks used
on the MP800 crusher.
Rod Seal
Clearing
Cylinder
Main Frame
12
TTM-5005-D
Tramp Release Arrangement
Adjustment Ring  The tramp release cylinders are used

to hold the adjustment ring down
tight to the main frame.
Bearing Cone  The accumulator provides an area for
& Cup the rod end oil to relocate to during a
tramp event.
 There are twelve tramp release
Rod Seal
cylinders used on the MP800 crusher
and they all point straight out from
the crusher.
 Proper oil pressure is 1500PSI
Main Frame
(103Bar) to 1900PSI (131Bar).
 Proper nitrogen pre-charge pressure is
1000 PSI ± 50 PSI (69 Bar ± 3Bar).
Tramp Release
Accumulator Cylinder
13
TTM-5005-D
Tramp Release Arrangement

MP1000 Shown
 The tramp release cylinders repressurize

automatically.
 The tramp release cylinder pressure should
be checked every day.
 The pressure gauge is attached to the
hydraulic power unit.
Tramp Release Cylinder
14
TTM-5005-D
Checking the Nitrogen Pre-charge
 A properly charges tramp release cylinder

accumulator gives the rod end oil a place to
relocate to during the passage of tramp
material.
 The tramp release cylinder nitrogen pre-charge
should be checked every month (200 hours).
 The proper accumulator nitrogen pre-charge
for the MP800 is 1000 PSI ± 50 PSI (69 Bar ±
3Bar).
 The nitrogen pre-charge checking gauge is part
of the Crusher tool kit.
 Tramp release cylinder oil pressure must be
released prior to checking the nitrogen pre-
charge.
15
TTM-5005-D
Bowl Clamping Arrangement
Clamping Ring  The bowl clamping cylinders are used

to hold the bowl tight into the
adjustment ring.
Dust Shell  There are twelve bowl clamping
cylinders used on the MP800 crusher.
 Proper oil pressure is 2400PSI (165Bar)
Clamping Cylinder
to 2800PSI (193Bar).
Adjustment Ring
16
TTM-5005-D
Clamping Ring Bolts

Tube Spacer Clamping Ring Bolts
 There are six clamping ring bolts on
the MP800.
Dust Shell
 Make certain to depressurize the
bowl clamping cylinders prior to
Clamping Ring removing the clamping ring.
Adjustment Ring
17
TTM-5005-D
Leaky Bowl Clamping Cylinder(s)
 A tell-tale sign that the bowl

clamping arrangement is
leaking is the presence of oil
weeping out from under the
crusher dust shell.
 The leaking oil could be
coming from a faulty bowl
clamping cylinder, a
damaged hydraulic hose or a
loose hydraulic fitting.
 Always depressurize the
circuit prior to tightening a
loose hydraulic fitting.
Wetness Here Indicates a Leaky Cylinder
18
TTM-5005-D
Damaged Adjustment Rings
19
TTM-5005-D
Damaged Mainshaft
20
TTM-5005-D
Countershaft Box Assembly
Countershaft Box Guard
Oil Flinger
Countershaft
Oil Flinger Housing
Pinion Box Bushings
21
COUNTERSHAFT BOX ASSEMBLY TTM-5005-D
22
TTM-5005-D
Crusher Sheave Removal

 The Crusher sheave is locked to the
countershaft with a tapered sheave
bushing.
 The sheave is removed from the
tapered bushing with jacking bolts.
 Anti-seize lubricant must be used on
the jacking bolt threads to prevent
excessive friction.
 If the sheave does not pop off easily,
warm the sheave to expand it to ease
the removal.
 Heat from the outside first, then
work your way down the spokes to
the hub.
Heating the Sheave From the Outside In
Note: The MP Series Cone Crusher sheave is made of ductile iron.
23
TTM-5005-D
Countershaft Box Removal

Main Frame Heating Torch
(rose bud)  The countershaft box is held into
position with a tight interference
fit and hex bolts.
 The main frame must be heated to
Jacking Bolt
(metric) approximately 100°F (55°C)
above ambient to relieve the tight
fit between the countershaft box
and main frame to make removal
easier.
 An anti-seize lubricant must be
used on the jacking bolts (3) to
prevent excessive friction.
 After heating the main frame, the
jacking bolts are alternately
Countershaft Box Flange tightened.
24
TTM-5005-D
Box Bushing Removal

Inner Box Bushing Hard wood block or  The countershaft box bushings are
steel rod held into position with an
interference fit and dowel pins.
 The box bushings must be
replaced if they are damaged or
worn out.
 The box bushings can be removed
by ramming or pressing them out
of the box bore.
 The box bore must be measured
after the bushings have been
removed to confirm that the box
bores are still dimensionally
correct.
Countershaft Box Outer Box Bushing  The countershaft box is made of
cast iron.
25
TTM-5005-D
Box Bushing Installation

Countershaft Box Alignment Pins
 Always measure the countershaft

box bore prior to installing new
countershaft box bushings.
 Box bushing fit is .001” tight
to .002” loose.
 Pack the bushings in dry ice to
shrink them for two to three hours
for easy installation.
 Approximately 100 lbs (50 kgs) of
dry ice is required.
Outer Box Bushing
26
TTM-5005-D
Box Bushing Oil Groove Location
 Both countershaft box bushings

Pinion End are identical, however, their
position in the box will differ.
3:00
 The pinion end box bushing oil
groove is installed at the 3:00
position.
 The sheave end box bushing is
installed at the 12:00 position.
Sheave End
12:00
27
TTM-5005-D
Countershaft End Float
 Countershaft end float must be

established when the box is
END FLOAT
assembled.
0.8mm to 1.5mm
 Proper end float prevents the box
bushings from binding up as the
box heats up during use.
 Maximum countershaft run out
should not exceed 0.004”
(0.102mm).
28
TTM-5005-D
Establishing End Float

Step #1
Countershaft
“C” Clamp
 Lubricate the box bushings and

countershaft prior to assembly.
 Slide the countershaft and pinion
into the countershaft box.
 Clamp the pinion tight to the inner
countershaft box bushing flange.
Pinion Countershaft Box

Feeler Gauge
29
TTM-5005-D

Step #2
Heating Torch
 Heat the oil flinger to
Countershaft approximately 50°F (30°C) above
ambient.
 After heating is complete, slide
the oil flinger onto the
countershaft until the face of the
oil flinger is tight against face of
the outer box bushing.
 Allow the oil flinger to cool.
Countershaft Box Oil Flinger
30
TTM-5005-D

Step #3
 Allow the oil flinger to cool down
Seal Oil Flinger Housing
 The oil flinger housing is sealed to
the oil flinger with a cast iron
piston ring seal, place this seal in
the groove.
 The MP800 uses silastic between
the countershaft box and the
flinger housing.
 Install the oil flinger housing.
 Make certain not to disturb the
position of the oil flinger as this
Countershaft would change the countershaft box
end float
Oil Flinger
Countershaft Box
31
TTM-5005-D

Step #4
Oil Flinger Sheave Bushing  Carefully install the split

crusher sheave bushing.
 The sheave bushing is what
ultimately locks in the
established countershaft end
float.
Countershaft Sheave Bushing

Locking Bolt
32
TTM-5005-D
Crusher Sheave Arrangement

QD Tapered Sheave Bushing
 The MP Series Cone Crusher

uses a QD tapered bushing to
lock the crusher sheave to the
countershaft.
 The sheave bushing is what
ultimately locks in the
established countershaft end
float.
 NEVER lubricate the tapered
sheave bushing as the sheave
hub could crack at installation or
explode during operation.
33
TTM-5005-D
Inner Box Seal Arrangement

 The inner countershaft box outside
diameter to main frame inside diameter
is sealed with an “O” ring.
Main Frame
Frame Ring  The “O” ring seal and wear ring should
be replaced any time that the box has
been removed from the main frame.
 A large bead of silicone should be
added around the “O” Ring area during
installation.
Wear Ring
“O” Ring Seal  A new frame ring is installed by
applying Loctite 680 to the entire main
frame bore and shrinking the
replacement ring in dry ice to shrink it.
Countershaft Box  Temperature difference required to
install the frame ring is 101°F (56°C)
for the MP800.
34
TTM-5005-D
Installing the Countershaft Box

Lifting Cables
Main Frame
Main Frame Support Lug
35
TTM-5005-D
Countershaft Box Installation

20mm
#1
#4
Remove Spacer
50mm
#5
#2
Pull in Tight
Add Spacer
#6
#3
Note: The fit areas must be cleaned and lubricated and the frame warmed to approximately 100°F (55°C)
above ambient to ease installation.
36
TTM-5005-D
Eccentric Assembly
Eccentric Bushing Counterweight
Eccentric
Thrust Bearings
Counterweight Guard Gear
37
TTM-5005-D
Eccentric and Counterweight Assembly
38
TTM-5005-D
Eccentric Assembly
Eccentric
Eccentric Bushing (bronze)
“U” Seal
Counterweight
“T” Seal
Counterweight Guard
(welded)
Eccentric Gear Upper Thrust Bearing
(bronze)
39
TTM-5005-D
Eccentric Assembly
Eccentric Bushing (bronze)
Counterweight
“U” Seal
Counterweight Guard
Eccentric
40
TTM-5005-D
Eccentric Installation & Removal
 The eccentric is installed into the

crusher or removed out of the crusher by
using the eccentric lifting ring.
 The two eye bolts threaded into the
eccentric lifting ring should split the
thick and thin side of the eccentric to
assure a balanced lift.
 The socket liner and socket must be
removed in order to install or remove the
eccentric.
Eccentric Lifting Ring Eccentric
41
TTM-5005-D
Eccentric Bushing Removal

 The eccentric bushings must be
replaced if it is damaged or worn
out.
 The eccentric bushing is held into
position with epoxy locking
compound.
 The epoxy locking compound
must be drilled out and completely
removed
 The eccentric bushing can be
removed by ramming it out of the
eccentric bore.
 When ordering a new bush, order
the locking compound also.
Bushing Lock Eccentric Bushing
Compound
42
TTM-5005-D
Eccentric Bushing Removal

Timber Centering Plate
 The eccentric can be

Eccentric
blocked up and the bushing
forced out by ramming or
by pressing.
 An alternative method is by
using a cut-off disc on a
grinder.
 The eccentric bore must be
measured after the bushing
has been removed to
confirm that the bore is still
dimensionally correct.
Eccentric Bushing
Counterweight
Blocking
43
TTM-5005-D
Eccentric Bushing Failure

 It takes a tremendous amount of heat to
turn a bronze bushing black.
 Whenever a bushing overheats to this
extent, there is a definite possibility that
the excessive temperature has damaged
the bore of the eccentric.
 For this reason, the bore must be
checked for dimensional accuracy and
for cracks before a new bronze bushing
is installed.
44
TTM-5005-D
Eccentric Bore Measurements

 Any time that an eccentric bushing has burnt
itself black in color, there is a good possibility
that the eccentric bore has become pulled in,
egg shaped or distorted.
 If a new bronze bushing is installed into a
damaged eccentric bore, the softer bronze
bushing will take the same shape as the
damaged bore.
 This will lead to a reoccurring bushing failure.
 Make certain to measure the eccentric bore with
micrometers prior to installing a new eccentric
bushing.
 If the dimensions taken show that there is
distortion in the bore, call Metso Minerals for
advice.
45
TTM-5005-D
Eccentric Bushing Installation

FLUSH HERE
 The eccentric bushing is installed by

shrinking the bushing in dry ice for a
approximately four hours.
 Approximately 400 lbs (180 kgs) of dry
ice is required.
 The eccentric and bushing should be at
room temperature 60°F (16°C) to 90°F
(32°C) prior to pouring the epoxy locking
compound.
 The eccentric bushing must be flush with
the top of the eccentric and the oil holes in
the bushing must line up with the oil holes
of the eccentric.
Lifting Eyes With Eccentric
Flat Washers
46
TTM-5005-D
Upper Thrust Bearing Arrangement
Eccentric  Anytime that the eccentric is out of

the crusher, the upper thrust bearing
should be inspected for damage or
wear.
 A worn upper thrust bearing allows
the eccentric assembly to lower,
causing the gear teeth to mesh father
into the mating teeth of the pinion.
 Excessive wear can also cause
inadequate lubrication and the thrust
bearings would run hot.
 The thrust bearing capscrews are
Eccentric
Bushing tightened to 275 ft. lbs. (373 Nm).
Upper Thrust Bearing (bronze)
47
TTM-5005-D
Upper Thrust Bearing
Max. Worn Ramp Length 2.09” (53mm)  The upper thrust bearing
must be replaced when the
oil groove width reaches the
maximum worn ramp length
dimension.
Oil Groove New Ramp Length 2.40” (61mm)
Flat
48
TTM-5005-D
Counterweight Cover & Guard

Counterweight “U” Seal
 The MP800 uses a bolted on
counterweight guard.
 The condition of the counterweight
guard & cover should be checked
regularly.
Counterweight
Counterweight
Guard & Cover
Counterweight “T” Seal

49
TTM-5005-D
Stationary Counterweight Guard

MP1000 Shown
Socket Liner Counterweight
 Most MP Series Crushers are

fitted with a stationary
counterweight guard.
 The purpose of the guard is to
prevent crushed material from
contacting the rotating
counterweight assembly.
 The condition of the stationary
counterweight guard should be
checked regularly.
 The stationary counterweight
guard is made of mild steel or
Bisalloy.
Stationary Counterweight Guard Eccentric

50
TTM-5005-D
“T” & “U” Seal Arrangement
“U” Seal
 The counterweight has a non-metallic
molded seals glued into position.
 The seals and grooves must be cleaned
with a non-oil base solvent prior to
gluing in the seal.
 The seal contacting surfaces should be
roughed up with a coarse sandpaper to
remove the shine prior to gluing in
Counterweight position.
“T” Seal  The glue to be used is Loctite Depend or
equivalent.
 Currently, the lower seals are red in
color and the upper seals are blue in
color.
Counterweight
51
TTM-5005-D
Backlash & Root Clearance

Adjusting Backlash & Root Clearance
Shims Lower Thrust  Shims are placed under the lower

Bearing
thrust bearing plate to make
adjustments to the gear and pinion
mesh.
 Shims are added in order to
increase backlash and root
clearance dimensions or removed
in order to decrease backlash and
root clearance dimensions.
 Shims must be made of steel.
Main Shaft Main Frame
52
TTM-5005-D

Prior to Checking Backlash & Root Clearance
Main Shaft
Eccentric Always push the thick

side of the eccentric
tight to the main shaft
Eccentric Gear
Always push or pull the

pinion over tight to the
inner box bushing
Main Frame Pinion

53
TTM-5005-D

MP Crusher with Straight Teeth
 The proper method of setting up a
set of gears on a Crusher with
Gear Backlash straight teeth is to achieve proper
backlash without going below the
minimum root clearance.
 With straight teeth, backlash and
root clearance is checked with a
feeler gauge right at the pinion and
gear teeth.
 Shims are added or subtracted from
under the lower thrust bearing to
Root Clearance attain proper mesh.
Pinion
Crusher Backlash (mm) Min. Root (mm)
MP800 .043 (1.09) to .060 (1.52) .194 (4.93)
54
TTM-5005-D

MP Crusher with Spiral Teeth
 The proper method of setting up a
set of gears on a Crusher with spiral
Gear Backlash teeth is to achieve proper backlash
without going below the minimum
root clearance.
 With spiral teeth, backlash is
checked with a dial indicator at the
pinion pitch diameter (or other
diameters) at the crusher sheave or
coupling.
 Shims are added or subtracted from
Root Clearance under the lower thrust bearing to
Pinion
attain proper mesh.
Crusher Backlash (mm) Min. Root (mm) Pinion Pitch Diameter Circumferential Range at PPD
MP800 .070 (1.78) to .081 (2.06) .040 (1.0) 19.916 (505.9) .095 (2.41) to .110 (2.79)
55
TTM-5005-D

Circumferential Movement at Other Diameters

Equation:
Circumferential Motion at Pitch Diameter x Other Diameter
÷ Pinion Pitch Diameter
Example:
MP800 / 2.41 x 800 ÷ 573.2 = 3.36mm minimum
MP800 / 2.79 x 800 ÷ 573.2 = 3.89mm maximum
Crusher Backlash (mm) Min. Root (mm) Pinion Pitch Diameter Circumferential Range at PPD
MP800 .070 (1.78) to .081 (2.06) .040 (1.0) 19.916 (505.9) .095 (2.41) to .110 (2.79)
56
TTM-5005-D

 With spiral teeth, backlash is checked with a dial indicator at the

pinion pitch diameter (or other diameters) at the crusher sheave or
coupling.
 Shims are added or subtracted from under the lower thrust bearing to
attain proper mesh.
Shim thickness Backlash change Circumferential

motion change at
PPD
0.40 mm (0.016”) 0.27 mm (0.011”) 0.39 mm (0.015”)
0.75 mm (0.030”) 0.52 mm (0.020”) 0.72 mm (0.029”)
1.70 mm (0.067”) 1.17 mm (0.046”) 1.64 mm (0.065”)
3.00 mm (0.118”) 2.06 mm (0.081”) 2.90 mm (0.114”)
57
TTM-5005-D
Socket Assembly
Socket Liner
Socket
58
TTM-5005-D
Socket Assembly
Socket Liner Capscrews

 The socket is held rigidly to the
main shaft by an interference fit
and a series of capscrews.
 The socket liner is tight to the
socket with an interference fit
and dowels.
Socket
Dowels
Main Shaft
59
TTM-5005-D
Socket Liner Inspection
 The socket liner is a bearing

surface and its oil groove depth
should be measured at every liner
change or once per year
whichever comes first.
 The socket liner is considered
worn out when the oil groove
depth measures .197” (5mm).
60
TTM-5005-D
Excessive Socket Liner Wear
TTM-5005-D
Socket Liner Removal

Socket Liner Jacking Bolts
 The socket liner is removed from the
socket by using jacking bolts (4).
 Lubricate the jacking bolt threads
with an anti-seize compound.
 Alternately tighten the jacking bolts
in small amounts.
 In stubborn cases, the upper portion
of the socket can be heated to assist
removal.
HEAT
HERE
Socket
62
TTM-5005-D
Socket Removal
Socket Jacking Bolts
 The socket fit area must be heated
quickly to relieve the interference fit.
 Two rosebuds should be used for this
procedure.
 The MP800 socket fit area must be
heated to 154°F (86°C) above
ambient.
 Jacking bolts must be coated with
anti-seize compound.
HEAT  Jacking bolts are alternately tightened
HERE until the socket is forced free from the
main shaft.
Main Shaft
63
TTM-5005-D
Socket Installation
Socket  Install two eye bolts into the socket and hang
the socket over the main shaft making sure that
it is level with the main shaft top.
 Alignment studs are threaded into the top of the
main shaft and are used as guides to assure
proper socket alignment.
 The MP800 socket fit area must be heated to
154°F (86°C) above ambient.
 Once heated, the socket is lowered into position
HEAT
as quickly as possible.
HERE
 Tighten the socket fasteners to their proper
torque level and recheck after the socket has
completely cooled.
Main Shaft Alignment Studs
64
TTM-5005-D
Socket Installation
65
TTM-5005-D
Checking Socket Contact

Socket Feeler Gauge
 After the socket has been installed, a

feeler gauge is used to verify that the
socket is seated flat on the main shaft
(no clearance).
 No clearance should exist between
the bottom of the socket and the top
of the main shaft.
Main Shaft
66
TTM-5005-D
Install the Backstop Clutch

 Install the spindle shaft to the socket, torque
the capscrews to 123 ft. lbs. (167 Nm).
 Install the backstop clutch on the spindle shaft
(backstop clutch has “TOP” marked on it).
 Attach the driveshaft assembly to the backstop
clutch (four lower u-joint capscrews must be
removed to give access in order to bolt the
driveshaft to the clutch).
 Install the stand up bolt down through the
driveshaft and thread it into the spindle (this
stand up bolt will temporarily hold the drive
shaft vertically so the head can be lowered
safely).
Stand Up Bolt
Socket Spindle Clutch Driveshaft
67
TTM-5005-D
Socket Liner Installation

 The socket liner must be cooled to
54°F (30°C) below ambient
temperature.
 After cooling, line up the clearance
holes in the bottom of the socket liner
with the socket dowels and lower into
position.
 If the socket liner fit becomes slightly
loose, it does not matter because the
dowels will prevent the socket liner
from turning.
Socket Liner
68
TTM-5005-D
Head Assembly
Feed Plate
Mantle
Upper Head
Locking Nut Bushing
Head
Lower Head
Bushing
Head Ball
69
TTM-5005-D
Head and Bowl Liner Change
70
TTM-5005-D
Head Removal & Installation
 A head lifting plate which is part of

the Crusher tool kit must be used to
install or remove the head assembly
from the Crusher.
 When removing the head assembly,
the offset eye bolt fastened to the
head lifting plate must be lined up
with the high side of the head.
 When installing the head assembly,
the offset eye bolt fastened to the
head lifting plate must be lined up
with the thick side of the eccentric.
Head Lifting Plate Eye Bolt

71
TTM-5005-D
Head Installation
 Carefully lower the head over the
driveshaft.
 After the head ball has seated properly
to the socket liner, lift the head 1/4”
(6mm) to 3/8” (10mm) and run the lube
pump for 10 to 15 minutes to flush out
any dust, after which set the head back
down.
 Remove the head lifting plate.
 Remove the stand up bolt.
72
TTM-5005-D
Head Installation
 Bolt the torque limiter to the cover plate.
 Secure the cover plate w/gasket to the head.
 Install the socket head pipe plug to the cover
plate with teflon tape.
 Install the feed plate.
Cover Plate Torque Limiter Feed Plate Pipe Plug

73
TTM-5005-D
Removing a Worn Mantle

 Cut through the torch ring (be
Feed Plate
careful not to damage the head
Locking Nut
threads)
Torch Ring  Attach the locknut wrench to the
locking nut (line up wrench pins
Mantle with holes in the nut).
 Pound the wrench counterclockwise
to remove the locking nut.
 Weld two lifting lugs to the worn
mantle and lift it off the head.
 Thoroughly clean the head.
 Check the mantle seating surface on
the head and grind smooth if
necessary.
74
TTM-5005-D
Installing a New Mantle

 Examine the head threads and locking nut threads,
Mantle Locking Nut remove any nicks or burs, and lubricate the threads.
 Apply a light coating of oil to the head to prevent the
epoxy from sticking to it.
 Lower the new mantle on to the head.
 Set the torch ring in place.
 Thread the locking nut down making sure that the
space is equal all around.
 Lightly ram the locking nut tight.
Torch Ring  Check to be sure that the mantle bears tight to the head
with a feeler gauge.
 Ram the locking nut tight with a ram suspended from a
cable and ram until the locking nuts rotates less then
1/16” (1mm) with each blow.
 Check gap between the lower portion of the mantle and
the head, maximum clearance is 0.25mm (0.010”).
 Plug any gap that may exist with silicone.
 Pour the epoxy backing to the level of the pouring
Head Locking Nut Wrench
holes cast into the mantle.
75
TTM-5005-D
Turning the Head Over

Lifting Cables
Head Lifting Plate
Locking Nut
Blocking Shackle Wood Blocks
76
TTM-5005-D
Head Ball Removal

Sledge Hammer
 Ram, press, or sledge the worn or

Steel Rods
damaged head ball out of the head fit
area.
Head Ball  If the head ball is difficult to remove,
Heat Here
heat the area of the head just outside
the head ball to a maximum of 300°F
(149°C) to relieve the fit.
 After the worn head ball has been
removed, flip the head over in
preparation to install the new head
ball.
 Plug the head ball knock-out holes
using pipe plugs.
Blocking
77
TTM-5005-D
Head Ball Installation
Head Ball  Prepare the head ball in dry ice for 12

to 16 hours making sure that there is at
least a 85°F (47°C) temperature
difference.
 Approximately 100 lbs (46 kgs) of dry
ice is required.
 After cooling, quickly lower the head
ball into position over the head dowels
making sure that it if fully and squarely
seated against the bottom of the head
counterbore.
 Reinstall the two head ball capscrews
and tack weld the bolt heads to the head
but do not use loctite.
Blocking Head
78
TTM-5005-D
Head Bushing Installation

Lower Head Bushing Lifting Eye
 Prepare the head bushing in dry ice

for approximately four hours making
sure that there is at least a 32°F
Head (18°C) temperature difference.
 Approximately 200 lbs (90 kgs) of
dry ice is required.
 After cooling the bushing
sufficiently, lower it into position
using eye bolts.
 The flange of the head bushing must
be tight to the head.
Blocking
79
TTM-5005-D
Head Bushing Retention
Capscrew  After the bushing has come back to room

temperature, install the special washers
and retaining capscrews.
 Use Loctite 271 on the retaining
capscrews.
 Tighten in a criss-cross pattern to the
proper torque level shown in the table to
the bottom left.
Crusher Bolt & Torque

MP800 M16 x 40 134 ft lbs (182 NM)
Head
Head Bushing
80
TTM-5005-D
Upper Head Bushing Installation

Upper Head Bushing Lifting Eye
 Prepare the head bushing in dry ice for
approximately four hours making sure
that there is at least a 35°F (20°C)
Head temperature difference.
 Approximately 75 lbs (34 kgs) of dry ice
is required.
 After cooling the bushing sufficiently,
lower it into position against the shoulder
using eye bolts.
 Place the four L-shaped keys into
position and bolt in place (threads should
be coated with loctite 271).
Upper Head Bushing Key
 After final tightening, the retaining bolts
should be wire-tied together.
81
TTM-5005-D
Head “T” Seal
 The new head “T” seal is glued

into position.
 Dry fit the seal before gluing it in
to assure proper fit up.
 Never force the seal into the
groove.
 The correct adhesive used is
Loctite Depend 330.
Head
“T” Seal Seal Grove
82
TTM-5005-D
Bowl Assembly
Wedge Bolt Assemblies
Hopper
Adjustment Cap
Bowl Liner
Bowl
83
TTM-5005-D
Bowl Removal
 Prior to turning the bowl out of
the crusher, depressurize the
bowl clamping cylinders by
opening up the bowl clamping
cylinder needle valve.
 This is a very important step.
Bowl Clamping Cylinder

Needle Valve
84
TTM-5005-D
Lifting the Bowl Assembly

 Once the bowl is turned out of the
adjustment ring threads and
clamping ring threads, the bowl
assembly is lifted by use of the
lifting lugs mounted to the top of
the adjustment cap.
 Use adequately sized lifting cables.
 Never lift the entire crusher with

these lugs!
85
TTM-5005-D
Bowl Assembly
Hopper Wedge Bolt Assemblies
 Bowl clamping pressure should
be dumped prior to removing
the bowl from the crusher.
 The bowl assembly is lifted by
use of the lifting lugs mounted
to the top of the adjustment cap.
 The bowl should be placed on

level ground with the blocking
placed under the bowl liner.
Bowl Liner Blocking Bowl
86
TTM-5005-D
Bowl Liner Wedge Assemblies

Wedge Bolt  Lubricate the bowl surface with crusher oil
prior to mounting a new bowl liner to assure
Spherical Nut & Retainer
that the backing material will not stick to it.
 Wedge bolt assemblies hold the replaceable
bowl liner in position.
 Make sure that the incline point of the wedges
are smooth.
Wedge
 Add or subtract shims from under the wedge
to obtain proper midpoint contact on the
incline surface of the wedges..
 Place shims above the wedges to a height that
Bowl Liner
is even with the top of the bowl, then bolt the
wedge retainers in place.
 Using a sledging wrench, alternately tighten
each spherical nut in a criss-cross pattern until
they are all tight.
Blocking Bowl
87
TTM-5005-D
Bowl Liner Retention

Wedge Bolt
Wedge Retainer
Shims
Wedge
Shims
Bowl Ring
(MP1000 only)
Spherical Nut & Retainer
Bowl Liner Bowl
88
TTM-5005-D
Bowl Thread Wear
 The bowl, adjustment ring, and

clamping ring threads can be inspected
for wear by use of a checking template.
 Hold the template flats tight to the
thread flats and push in as far as it will
go.
 Then measure and record the gap (if
any) that exists between the tapered
portion of the template to the tapered
portion of the threads.
89
TTM-5005-D
Greasing the Bowl Threads

 Bowl threads should be
lubricated every week (40
hours).
 The proper grease is a NLGI #1
with at least 3% molybdenum
disulfide mixed with it.
 There are four grease fittings on
the adjustment ring.
 The bowl threads should be
greased in both the clamped
position and unclamped position.
 The ramifications of not properly
greasing your bowl threads is a
stuck bowl!
Grease Fitting
90
TTM-5005-D
Proper Break-in Procedure

After the installation of any new bushing, the following break-in
procedure must be followed:
 The lube oil drain line temperature must be 60ºF (16ºC) before starting the crusher.
 Start the crusher and operate for 2 hours WITHOUT material. Be sure the lube oil drain
line temperature reaches at least 80ºF (27ºC).
 Next, run the crusher for 2 hours with sufficient material in the crushing cavity to attain
50% of rated power of the drive motor (65% amps).
 Next, run the crusher for 4 hours with sufficient material in the crushing cavity to attain
75% of rated power of the drive motor (80% amps).
 After completing the 4 steps above, crusher can be run at full load, 100% of rated power
of the drive motor (100% amps).
Note: This is considered the initial start-up and break-in procedure, not the daily start up procedure.
91
TTM-5005-D
Crusher Tool Kit
Lifting Ring Head Lifting Plate

Washers Hex Bit Socket
Ring Bolt
Accumulator
Jackscrews Charging Assembly
Head Turning Plate
Mainshaft Support Safety Block Valve Extension

Bowl Lifting Pin
Locknut Wrench
92
TTM-5005-D
93

MP800 - Maintenance

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MP800 - Maintenance

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MP CONE CRUSHERS

Lifting the Entire Crusher

Main Frame Assembly

Dust Shell Clamping Ring

Main Frame Liner & Arm Guards

► The main frame liner of the

Main Frame Liner Clamp Main Frame Liner

Worn Main Frame Liner

Worn Main Frame Liner

► Main Frame Liners should be checked at ever liner change

Lower Thrust Bearing Plate

► At least once per year, the lower

Main Frame “U” Seal

Main Frame Center

Main Frame Pin Arrangement

 The purpose of the main frame

Main Frame Seat

Determining Seat Liner Wear

Main Frame Seat Liner Installation

Main Frame Seat Liners Fulcrum Bar

Clearing Jack Arrangement

Tramp Release Arrangement

Adjustment Ring  The tramp release cylinders are used

Tramp Release Arrangement

 The tramp release cylinders repressurize

Tramp Release Cylinder

Checking the Nitrogen Pre-charge

 A properly charges tramp release cylinder

Bowl Clamping Arrangement

Clamping Ring  The bowl clamping cylinders are used

Clamping Ring Bolts

Leaky Bowl Clamping Cylinder(s)

 A tell-tale sign that the bowl

Damaged Adjustment Rings

Countershaft Box Assembly

Countershaft Box Guard

Oil Flinger Housing

Pinion Box Bushings

Crusher Sheave Removal

Note: The MP Series Cone Crusher sheave is made of ductile iron.

Countershaft Box Removal

Box Bushing Removal

Box Bushing Installation

 Always measure the countershaft

Outer Box Bushing

Box Bushing Oil Groove Location

 Both countershaft box bushings

Countershaft End Float

 Countershaft end float must be

Establishing End Float

 Lubricate the box bushings and

Pinion Countershaft Box

Establishing End Float

Countershaft Box Oil Flinger

Establishing End Float

Establishing End Float

Oil Flinger Sheave Bushing  Carefully install the split

Countershaft Sheave Bushing

Crusher Sheave Arrangement

 The MP Series Cone Crusher

Inner Box Seal Arrangement

Installing the Countershaft Box

Main Frame Support Lug