HP Manganese Manual

HP CONES

WEAR MATERIALS SALES MANUAL

REVISION DATE: 4-4-2006

HP CONES LINER TERMINOLOGY............................................................................................................... 2 METALLURGY CHOICES .......................................................................................................... 4 HP CONE LINER ALLOYS AND APPLIC ATIONS ................................................................. 5 BASIC LINER SELECTION ........................................................................................................ 6 STAND ARD CAVITY COMPARISON ....................................................................................... 8 SHORT HEAD C AVITY COMPARISON................................................................................... 9 CAVITY TABLES........................................................................................................................10 HP100 LINERS...........................................................................................................................11 HP200 STANDARD AND SHORT HEAD...............................................................................12 HP300 STANDARD AND SHORT HEAD...............................................................................13 HP400 STANDARD AND SHORT HEAD...............................................................................14 HP500 STANDARD AND SHORT HEAD...............................................................................15 HP700 STANDARD AND SHORT HEAD...............................................................................16 HP800 STANDARD AND SHORT HEAD...............................................................................16 BACKI NGREQUI REMENT–STANDARD............................................................................17 BACKI NGREQUI REMENT–SHORTHEAD........................................................................19 INSTALLING HEAD WEAR RINGS.........................................................................................21 INSTALLING WEDGES.............................................................................................................22 MANTLE SEATING....................................................................................................................26 TAKING WEAR PROFILES......................................................................................................29 LINER UTILIZATION..................................................................................................................30 WEAR PROFILE AN ALYSIS FORM.......................................................................................31 CRUSHER CHAMBER PROFILING .......................................................................................32 MANGANESE BREAK IN PROCEDURES............................................................................34

SECTION 3A

1

HP CONES



LINER TERMINOLOGY Adapter Ring –t hesuppor tf ort hewedgebol t s.Dependi ngont heappl i cat i on,i tmay be necessary to change adapter rings and wedge bolts when changing to a liner of a different configuration. Bottle Neck - The dimension between the inside diameter of the bowl liner and outside diameter of the main shaft sleeve on a Standard crusher. This dimension can be a restricting area when compared to the feed opening on the open side. Bowl Liner - Secured inside of the bowl to protect it from wear. Feed Opening Closed Side - The dimension representing the maximum feed opening when the mantle is closest to the bowl liner. Feed Opening Open Side –Thedi mensi onr epr esent i ngt hemax i mum f eedopeni ng when the mantle is farthest away from the bowl liner. Head Wear Ring –Aconi calr ol l edst eelpar tt hati susual l ysuppl i edi nsegment st hati s welded to the head below the mantle when using short liners in a SHORT HEAD® crusher. The head wear ring prevents erosion to the head from the discharge of crushed material in a short crushing chamber. The head wear ring is changed once for two to three mantle changes. Locking Nut –Thel ocki ngmechani sm ont of ast ent hemant l et ot heheadSt andar d ® and SHORT HEAD crushers. The threads in the main shaft nut are left hand threads. Mantle –Cov er st heheadoft hecr ushert opr ot ecti tf r om wear . Minimum Closed Side Setting –Theoretically the tightest that a specific set of liners can be set at. Due to fines in the feed, hardness of the rock, moisture, feed distribution and feed segregation it may not be possible to achieve the minimum closed side setting. The minimum operating closed side for any set of liners is when there is no adjustment ring movement, no excessive lube oil drain line temperatures or crusher stalling. Maximum Closed Side –Aset t i ngwher et hebowli sengagedi nt o1½ t o2t hr eadsof the adjustment ring. Nip Angle - The angle that is developed between the surfaces of the bowl liner and mantle when the mantle is at its closest relationship to the bowl liner. Nip angles should not exceed 23 degrees for best material flow through a crushing chamber.

SECTION 3A

2

HP CONES


REVISION DATE: 4-4-2006 Torch Ring –Asacr i f i ci alpi ec et hati sl ocat edbet weent hemant l eandt hel ocki ngnut , which is burnt out with a torch to relieve the pressure on the mantle and allow the locking nut to be loosened. Wedge Bolt –Themeansofr et ai ni ngt hebowll i neri nt hebowli sbyasetofwedges and bolts that are inserted under the helix of the bowl liner and on top of the adapter ring. Depending on the application, it may be necessary to change adapter rings and wedge bolts when changing to a liner of a different configuration.

SECTION 3A

3

HP CONES



METALLURGY CHOICES There are different alloys that are commonly used for each model of HP cone: XT510 –Thi si san11% t o14% Hadf i el dmanganese.XT510r epl acest heMet soal l oy designation 0861-500. XT510 is used as an all-purpose liner in all secondary and fine crushing applications for the HP700 and HP800. XT610 –Thi si sa12% manganese,1. 5% chr omeand1. 25% car bonal l oymat er i al .I ti s used as an all purpose liner in all secondary and fine crushing applications with an Los Angeles abrasion index greater than 12. For applications having a Los Angeles abrasion less than 12 use the XT720 alloy. XT610 is the standard all-purpose alloy for the HP200 through HP500. XT720 –Thi si sa 22% manganese, 2.5% chrome and 1.5% carbon alloy that will typically provide longer life than the XT610 manganese. The XT720 replaces the old Metso MNS material designation. XT720 is the standard all-purpose alloy for the HP100. XT720 IS NOT USED ON HP700 AND HP800 CRUSHERS. CONTACT METSO FOR RECOMMENDATIONS. For typical applications refer to the table HP CONE LINER ALLOYS APPLIC ATIONS.

SECTION 3A

4

AND

HP CONES



HP CONE LINER ALLOYS AND APPLICATIONS Crush ed mineral properties Very d ifficult Difficult -12

Med ium

12-17

Easy

17-22

Very easy 22-27

27-

LosAn geles Bond WI

>16

13.5-16

12-13.5

11-12

<11

>43,500

32,000-43,500

22,000-32,000

13,000-22,000

<13,000

Seco ndary crush ing

X

X

X

X

Fine crushing

X

X

X

X

XT5 10/XT610

XT7 20 (1) Seco ndary crush ing

X

X

X

Fine crushing

X

X

X

(1 ) D O NOT U SE ON HP7 00 & HP80 0 CRU SHERS. CONTACT METSO MINER ALS FOR REC OMMEN DATIONS.

SECTION 3A

5

PSI

HP CONES



BASIC LINER SELECTION Depending on if the crusher fitted with Standard liner or a SHORT HEAD® liner, the liner selection the method of selection differs between them. The procedures shown below will illustrate the differences. FEEDSI ZEI SKNOWN–STANDARDLI NER To chose a liner combination for a Standard liner configuration when the top size of the feed is known, divide the thickness of the largest feed by 0.8 to get the required feed opening on the open side. For example if the you are selecting a liner combination for a HP400 Standard crusher and the thickest piece is 7", divide 8" by 0.8 to get the required feed opening on the open side. (7" / 0.8 = 8.75"). Refer to the HP Standard cavity tables and select a liner combination that has a feed opening on the open side that is close to 8.75". In this case an N 5520 8525 Medium bowl liner and an N5530 8511 mantle would be selected. Use the shaded liner combinations where ever possible, as these are the most common. KNOWI NGTHEFEEDOPENI NG–STANDARDLI NER There are cases when the customer may want to know what the maximum size feed a given feed opening can accept. To determine the maximum size piece that will fit in a given feed opening on the open side, multiply the feed opening by 0.8. For example if the liner combination for a HP300 Standard coarse has a feed opening on the open side of 9 1/2" (9.46") the thickest piece that could be fed to it would be about 7 9/16". Multiply the feed opening o the open side by 0.8, (9.46 X 0.8 = 7.56"). FEEDSI ZEI SKNOWN–SHORTHEAD® LINER To select a liner combination for a SHORT HEAD® liner configuration when the top size of the feed is known, the liner feed opening on the closed side is used to determine the liner. For example if the you are selecting a liner combination for a HP300 SHORT HEAD® crusher and the thickest piece is 3", refer to the HP SHORT HEAD® cavity tables and select a liner combination that has a feed opening on the closed side that is close to 3". In this case an N5520 8262 Coarse bowl liner and an N5530 8261 mantle would be selected. Use the shaded liner combinations where ever possible, as these are the most common.

SECTION 3A

6

HP CONES


REVISION DATE: 4-4-2006 KNOWI NGTHEFEEDOPENI NG–STANDARDLI NER There are cases when the customer may want to know what the maximum size feed a given feed opening can accept. To determine the maximum size piece that will fit in a given feed opening refer to the HP SHORT HEAD® ca vity tables and select a liner combination that has a feed opening on the closed side that is close to the thickness of the largest piece. For example if the liner combination for a HP500 SHORT HEAD® Coarse has a feed opening on the closed side of 3 3/4" (3.75") the thickest piece that could be fed to it would be about 3 3/4".

SECTION 3A

7

HP CONES



STANDARD CAVITY COMPARISON The cavities shown below illustrate the typical differences in the chamber cross sections between the Standard fine, medium, coarse and extra coarse liners.

FINE

MEDIUM

EXTRA COARSE

COARSE

SECTION 3A

8

HP CONES



SHORT HEAD CAVITY COMPARISON The cavities shown below illustrate the typical differences in the chamber cross sections between the SHORT HEAD® extra fine, fine, medium and coarse.

EXTRA FINE

FINE

COARSE

MEDIUM

SECTION 3A

9

HP CONES



CAVITY TABLES The liners listed for the HP200 thru HP500 and the HP800 are considered our current offering and will change as new designs are issued. The HP700 liners listed are of the latest design. Availability is subject to change without notice. Contact your Metso dealer or Metso for confirmation of availability.

HP100 LINERS HP200 STANDARD AND SHORT HEAD HP300 STANDARD AND SHORT HEAD HP400 STANDARD AND SHORT HEAD HP500 STANDARD AND SHORT HEAD HP700 STANDARD AND SHORT HEAD HP800 STANDARD AND SHORT HEAD

SECTION 3A

10

HP CONES



HP100 LINERS BOWL LINER Extra-Fine Fine Medium Coarse Super Coarse Extra Coarse

FEED FEED O PENING OPENING BOWL LINER WEIGHT O PEN CLOSED MINIMUM PART NUMBER MAT'L LBS. SIDE SIDE CSS 70 5520 8000 70 5520 8001 70 5520 8001 70 5520 8002 N 5520 8005 70 5520 8003

XT720 XT720 XT720 XT720 XT720 XT720

522 565 565 542 584 538

NOTE: Adapter Rings and Backing Material are not used in the HP100 NOTE: All Bowl liners listed here use Wedge Bolts p/n 70 8846 2250 NOTE: All Mantles use Torch Ring p/n 70 1208 0200

SECTION 3A

11

2.09" 3.96" 3.83" 4.87" 6.34" 6.93"

0.59" 2.93" 2.82" 3.93" 5.55" 6.28"

0.24" 0.35" 0.35" 0.51" 0.67" 0.83"

MANTLE PART NUMBER 70 70 70 70 70 70

5530 5530 5530 5530 5530 5530

8122 8122 8121 8121 8121 8121

MAT'L

WEIGHT LBS.

XT720 XT720 XT720 XT720 XT720 XT720

489 489 485 485 485 485

HP CONES



HP200 STANDARD AND SHORT HEAD

BOWL LINER Standard Fine Standard Fine Standard Medium Standard Medium Standard Coarse Standard Coarse

Short Head Extra Fine (1) Short Head Fine Short Head Fine Short Head Medium Short Head Medium Short Head Coarse Short Head Coarse

BOWL LINER PART NUMBER N 5520 8140 N 5520 8142 N 5520 8137 N 5520 8139 N 5520 8134 N 5520 8136

FEED FEED OPENING OPENING MANTLE WEIGHT OPEN CLOSED MINIMUM PART MAT'L LBS. SIDE SIDE CSS NUMBER XT610 5013 0813 1185 5.04" 3.74" 0.54" XT720 70 5530 8001 XT610 5013 0813 1160 6.15" 4.92" 0.69" XT720 70 5530 8001 XT610 5013 0813 1210 8.20" 7.28" 0.75" XT720 70 5530 8001

70 5520 8121 N 5520 8149 N 5520 8151 N 5520 8146 N 5520 8148 N 5520 8143 N 5520 8145

70 5530 8006 Lower 70 5530 8002 Upper 5013 0815 70 5530 8003 5013 0815 70 5530 8003 5013 0815 70 5530 8003

XT720 XT610 XT720 XT610 XT720 XT610 XT720

740

2.32"

0.38"

0.24"

1113

2.60"

0.91"

0.24"

1125

3.56"

2.11"

0.24"

1060

4.49"

2.99"

0.41"

(1) Only Available in XT720 NOTE: All Bowl liner s listed here use Adapter Ring p/n 6391 7032 and Wedge Bolts p/n 70 8846 3250 NOTE: All Mantles listed here use Torch Ring p/n 6391 4005

SECTION 3A

12

MAT'L XT610 XT720 XT610 XT720 XT610 XT720

XT720 XT720 XT610 XT720 XT610 XT720 XT610 XT720

WEIGHT LBS. 1062 1062 1062

760 99 945 945 945

HP CONES



HP300 STANDARD AND SHORT HEAD BOWL LINER Standard Fine Standard Fine Standard Me diu m Standard Me diu m Standa rd Coarse Standa rd Coarse Stand ard Extra Coarse Stand ard Extra Coarse

Short Head Extra Fine

FEED FEED OPENING BOWL LI NER WEIGHT OPENING CLOSED MINIMUM MANTLE PART PART NUMBER MAT'L LBS. OPEN SIDE SIDE CSS NUMBER N 5520 8 269 XT610 N 553 0 8261 1 622 5.84" 4 .21" 0.54" N 5520 8 273 XT720 N 553 0 8262 N 5520 8 268 XT610 N 553 0 8261 1 624 7.51" 5 .91" 0.66" N 5520 8 272 XT720 N 553 0 8262 N 5520 8 267 XT610 N 553 0 8261 1 886 9.45" 8 .33" 0.79" N 5520 8 271 XT720 N 553 0 8262 N 5520 8 270 XT610 N 553 0 8263 1 725 10.50" 9 .19" 0.99" N 5520 8 266 XT720 70 5530 8 252

N 5520 8 265

XT610 1 280

Short Head Extra Fine Short He ad Fin e Short He ad Fin e Short Hea d Med ium Short Hea d Med ium Short Head Coarse Short Head Coarse

70 552 0 8277

XT720

N N N N N N

XT610 XT720 XT610 XT720 XT610 XT720

5520 8 264 5520 8 276 5520 8 263 5520 8 275 5520 8 262 5520 8 274

2.36"

0 .17"

0.20"

1 688

2.84"

0 .89"

0.20"

1 666

3.91"

2 .09"

0.23"

1 776

4.86"

3 .04"

0.39"

NOTE: All Bowl liners l iste d here use Adapter Ring p/n 639 1 7418 and We dge Bolts p/n 1957 8 065 NOTE: All Ma ntles li sted here use Torch Ring p/n 6391 4652

SECTION 3A

13

N 553 0 8260 Lower 50 13 212 3 Upp er N 553 0 8264 Lower 70 5530 8 254 Upp er N 553 0 8261 N 553 0 8262 N 553 0 8261 N 553 0 8262 N 553 0 8261 N 553 0 8262

MAT'L XT6 10 XT7 20 XT6 10 XT7 20 XT6 10 XT7 20 XT6 10 XT7 20

WEIGHT LBS. 1 720 1 720 1 720 1 689

XT6 10

1 307

XT6 10

90

XT7 20

1 307

XT7 20

90

XT6 10 XT7 20 XT6 10 XT7 20 XT6 10 XT7 20

1 720 1 720 1 720

HP CONES



HP400 STANDARD AND SHORT HEAD BOWL LINER

FEED FEED OPENING OPENING BOWL LINER WEIGHT OPEN CLOSED MINIMUM ADAPTER PART NUMBER MAT 'L L BS. SIDE SIDE CSS RING

Standard Fine Standard Fine Standard Medium Standard Medium Standard Coarse Standard Coarse Standard Coarse (1) Standard Coarse (1) Standard Extra Coarse Standard Extra Coarse Standard Extra Coarse (1) Standard Extra Coarse (1)

70 5520 8382 70 5520 8383 N 5520 8525 N 5520 8527 N 5520 8398 N 5520 8400 6666 4404 6666 4405 N 5520 8522 N 5520 8524 6666 4406 6666 4409

XT 610 XT 720 XT 610 XT 720 XT 610 XT 720 XT 610 XT 720 XT 610 XT 720 XT 610 XT 720

Short Head Extra Fine Short Head Extra Fine Short Head Fine Short Head Fine Short Head Medium Short Head Medium Short Head Coarse Short Head Coarse

70 5520 8387 70 5520 8396 70 5520 8385 70 5520 8386 4830 0032 70 5520 8394 4830 0031 70 5520 8393

XT 610 XT 720 XT 610 XT 720 XT 610 XT 720 XT 610 XT 720

3150

6.44"

4.37"

0.55"

6343 7879 1957 9056

3015

9.65"

7.79"

0.79"

6343 7879 1957 9056

3185

11.50"

9.93"

0.98"

6343 7879 1957 9056

3185

11.38"

9.80"

1.00"

6343 7879 1957 9056

3060

13.11"

11.79"

1.18"

6343 7880 1957 9055

3062

13.41"

11.90"

1.18"

6343 7880 1957 9055

2232

4.09"

2.06"

0.24"

6343 7878 1957 9057

2540

4.08"

2.02"

0.24"

6343 7878 1957 9057

2535

4.20"

2.06"

0.31"

6343 7879 1957 9056

2590

5.64"

3.61"

0.39"

6343 7879 1957 9056

(1) Special Application - No steps in the lo wer portion o f th e b owl liner NOTE: All Mantles listed here use To rch Ring p/n 6391 5676

SECTION 3A

WEDGE BOLT

14

MANT LE PART NUMBER

MAT 'L

70 70 70 70 70 70 70 70 70 70 70 70

5530 5530 5530 5530 5530 5530 5530 5530 5530 5530 5530 5530

8381 8384 8381 8384 8381 8384 8381 8384 8381 8384 8381 8384

XT 610 XT 720 XT 610 XT 720 XT 610 XT 720 XT 610 XT 720 XT 610 XT 720 XT 610 XT 720

70 70 70 70 70 70 70 70

5530 5530 5530 5530 5530 5530 5530 5530

8383 8386 8282 8385 8282 8385 8282 8385

XT 610 XT 720 XT 610 XT 720 XT 610 XT 720 XT 610 XT 720

WEIGHT LBS. 2796 2796 2796 2796 2796 2796

2193 2705 2705 2705

HP CONES



HP500 STANDARD AND SHORT HEAD BOWL L INER Standar d F ine Standar d F ine Standard Medium Standard Medium Standard Coarse Standard Coarse Standard Coar se (1) Standard Coar se (1) Standard Coar se (2) Standard Coar se (2) Standard Extra Coarse Standard Extra Coarse Standard Extra Coarse (1) Standard Extra Coarse (1) Standard Extra Coarse (2) Standard Extra Coarse (2) Shor t Head Extra Fine Shor t Head Extra Fine Shor t Head Fine Shor t Head Fine Short Head Medium Short Head Medium Short Head Coarse Short Head Coarse

FEED FEED OPENING OPENING BOWL LINER WEIGHT OPEN CLOSED MINIMUM PART NUMBER MAT'L LBS. SIDE SIDE CSS 70 5520 8502 XT610 4570 7.15" 5.23" 0.63" 70 5520 8504 XT720 4831 4227 XT610 4602 9.67" 8.05" 0.79" 70 5520 8512 XT720 4831 4236 XT610 5053 12.69" 11.27" 0.98" 70 5520 8514 XT720 6666 4501 XT610 5218 11.02" 9.28" 1.00" 6666 4502 XT720 6666 4505 XT610 5774 12.08" 10.46" 1.00" 6666 4507 XT720 4831 4240 XT610 4227 14.65" 13.19" 1.18" 70 5520 8513 XT720 6666 4503 XT610 4464 12.46" 10.68" 1.18" 6666 4504 XT720 6666 4508 XT610 4982 12.62" 10.86" 1.18" 6666 4509 XT720 70 5520 8508 70 5520 8509 70 5520 8510 70 5520 8511 4831 4219 70 5520 8518 4831 4222 70 5520 8517


ADAPT ER RING

6343 7875 1957 8985 6343 7875 1957 8985 6343 7877 1957 8940 6343 7877 1957 8940 6343 7877 1957 8940 6343 7877 1957 8940 6343 7877 1957 8940 6343 7877 1957 8940

3480

4.21"

2.08"

0.23"

6343 7875 1957 8985

4073

4.14"

2.04"

0.32"

6343 7875 1957 8985

3765

4.57"

2.25"

0.39"

6343 7875 1957 8985

3890

5.98"

3.75"

0.51"

6343 7875 1957 8985

(1) Special Application - No steps in the lower portio n of th e Bo wl Liner (2) Special Application - No steps in the lower portio n of th e Bo wl Liner - For Use With T all Bo wl p/n N2350 8202 NOTE: All Man tles listed h ere use Torch Ring p/n 6391 5668

SECTION 3A

WEDGE BOLT

15

MANTLE PART NUMBER 70 5530 8501 70 5530 8503 70 5530 8501 70 5530 8503 N 5530 8514 N 5530 8516 N 5530 8514 N 5530 8516 6666 3502 6666 3503 N 5530 8514 N 5530 8516 N 5530 8514 N 5530 8516 6666 3502 6666 3503 70 70 70 70 70 70 70 70

5530 5530 5530 5530 5530 5530 5530 5530

8506 8507 8502 8504 8502 8504 8502 8504

MAT 'L XT610 XT720 XT610 XT720 XT610 XT720 XT610 XT720 XT610 XT720 XT610 XT720 XT610 XT720 XT610 XT720 XT610 XT720 XT610 XT720 XT610 XT720 XT610 XT720

WEIGHT LBS. 4256 4256 4163 4163 4572 4163 4163 4572

3700 3960 3960 3960

HP CONES



HP700 STANDARD AND SHORT HEAD BOWL L INER Standar d Extr a- Fine Standar d F ine Standar d F ine Standar d F ine Standard Medium Standard Medium Standard Coarse Standard Coarse Standard Extra-Coarse Shor t Head Fine Shor t Head Fine Shor t Head Fine Shor t Head Fine Short Head Medium Short Head Medium Short Head Coarse Short Head Coarse

FEED FEED OPENING OPENING BOWL LINER WEIGHT OPEN CLOSED MINIMUM T HRU PART NUMBER MAT 'L L BS. SIDE SIDE CSS BOLT 7383 8.06" 6.23" 0.79" 4831 4369 (3) XT510 4831 4346 (1) XT510 6442 10.39" 8.61" 0.63" 4831 4347 (3) XT510 6698 10.51" 8.74" 0.75" 4831 4318 (4) XT510 4871 10.31" 8.27" 0.75" 233 0876 4831 4345 (1) XT510 6592 12.11" 10.51" 1.00" 4831 4319 (2) XT510 6410 11.97" 10.39" 0.98" 233 0916 4831 4356 (1) XT510 6446 13.52" 11.85" 1.25" 7009 15.43" 14.33" 1.25" 233 0916 4831 4320 (2) XT510 4831 4344 (1) XT510 6878 14.78" 13.91" 1.25" 4831 4831 4831 4831 4831 4831 4831 4831

4350 4312 4370 4367 4349 4310 4348 4315

(3) (4) (3) (4) (3) (4) (3) (4)


4729 4421 5657 4819 4828 4869 4782 4690

3.86" 3.86" 5.23" 5.23" 5.94" 5.91" 8.37" 8.35"

1.28" 1.34" 3.27" 3.27" 3.62" 3.58" 6.15" 6.10"

0.20" 0.20" 0.25" 0.25" 0.39" 0.39" 0.50" 0.50"

233 0896 233 0896 233 0876 233 0876

WEDGE BOLT 1958 4411 1958 4411 1958 4410 1958 4411 1958 4411 1958 4408

MANTLE PART NUMBER 5014 3849 5014 3849 5014 3849 5014 3849 5014 3849 5014 3849 5014 3849 5014 3849 5014 3849

MAT 'L XT510 XT510 XT510 XT510 XT510 XT510 XT510 XT510 XT510

WEIGHT LBS. 6779 6779 6779 6779 6779 6779 6779 6779 6779

1958 4410 1958 4410 1958 4410 1958 4410 -

5014 3811 5014 3811 5014 3860 5014 3860 5014 3810 5014 3810 5014 3810 5014 3810


6105 6105 6713 6713 5924 5924 5924 5924

(1) Fo r Use With Stan dard Bo wl p/n 2005 5031 (2) Fo r Use With Stan dard Bo wl p/n 2005 5030 (3) Fo r Use With Sho rt Head Bowl p/n 2005 7056 (4) Fo r Use With Sho rt Head Bowl p/n 2005 7055 NOTE: All Man tles listed h ere use Torch Ring p/n 6391 5673

HP800 STANDARD AND SHORT HEAD BOWL LINER Standard Extra-Fin e Standard Extra-Fin e Standard Fine Standard Fine Standard Fine Standard Fine Standard Mediu m Standard Mediu m Standard Coarse Standard Extra-Coarse Short Head Fine Short Head Fine Short Head Fine Short Head Medium Short Head Medium Short Head Coarse Short Head Coarse

FEED FEED OPENING OPENING MANTLE BOWL LINER WEIGHT OPEN CLOSED MINIMUM WEDGE PART WEIGHT PART NUMBER MAT'L LBS. SIDE SIDE CSS BOLT NUM BER MAT'L LBS. 9" 7.36" 0.62 " 1958 4408 5014 3851 XT510 9974 4831 4360 (2) XT510 10379 48 31 4369 (3)(4) XT510 7383 8.06" 6.23" 0.79 " 1958 4408 5014 3849 XT510 6779 4831 4346 (1) XT510 6442 10.39" 8.61" 0.63 " 1958 4408 5014 3849 XT510 6779 4831 4347 (3) XT510 6698 10.51" 8.74" 0.75 " 1958 4409 5014 3849 XT510 6779 4831 4361 (2) XT510 10379 10.19" 8.61" 0.63 " 1958 4408 5014 3851 XT510 9974 4831 4359 (4) XT510 9277 10.32" 8.62" 0.75 " 1958 4408 5014 3851 XT510 9974 6592 12.11" 10.51" 0.98 " 1958 4408 5014 3849 XT510 6779 4831 4345 (1) XT510 4831 4362 (2) XT510 10357 11.41" 9.83" 1.00 " 1958 4408 5014 3851 XT510 9974 48 31 4356 (1)(2) XT510 6446 13.41" 11.68" 1.25 " 1958 4408 5014 3849 XT510 6779 48 31 4344 (1)(2) XT510 6878 14.78" 13.91" 1.25 " 1958 4408 5014 3849 XT510 6779 4831 4350 (3) 4831 4363 (4) 48 31 4370 (3)(4) 4831 4349 (3) 4831 4364 (4) 4831 4348 (3) 4831 4365 (4)

XT510 XT510 XT510 XT510 XT510 XT510 XT510

4729 9118 5657 4828 9118 4782 9663

(1) For Use With Standard Bowl p/n 2005 503 3 (2) For Use With Standard Bowl p/n 2005 503 4 (3) For Use With Short Head Bowl p/n 200 5 7058 (4) For Use With Short Head Bowl p/n 200 5 7059 NOTE: All Mantles listed here use Torch Ring p/ n 6391 56 73

SECTION 3A

16

3.86" 3.52" 5.23" 5.92" 5.92" 8.32" 8.12"

1.28" 1.28" 3.27" 3.61" 3.62" 6.11" 6.12"

0.20 " 0.20 " 0.25 " 0.39 " 0.39 " 0.50 " 0.50 "

1958 4412 1958 4409 1958 4409 1958 4409 1958 4409 1958 4409 1958 4409

5014 3811 5014 3852 5014 3860 5014 3810 5014 3852 5014 3810 5014 3852

XT510 XT510 XT510 XT510 XT510 XT510 XT510

6105 10016 6713 5924 10016 5924 10016

SECTION 3A

EXTRA COARSE LINER

FINE

MEDIUM LINER

COARSE LINER

EXTRA COARSE LINER

HP400

HP400

HP400

HP400

MEDIUM LINER

HP300

HP300

FINE

HP300

17 NO

NO

NO

NO

NO

NO

NO

NO

44

110

88

132

44

44

44

66

22

2

5

4

6

2

2

2

3

176

388

355

476

124

170

170

276

57

93

1 1

121

2

ZINC LBS

EPOXY LBS KITS ZINC LBS

3 3 55

3 55

55

3

3

66

55

3

3

220

210

210

210

152

132

132

132

77

2

3

77

77

ZINC LBS

2

2

66

66

66

44

44

44

EPOXY LBS KITS

BACKING REQUIRED FOR MANTLE

02SEP02

COARSE LINER

COARSE LINER

HP200

22

44

EPOXY LBS KITS

WITH FILLER PIECES

BACKING REQUIRED FOR BOWL LINER WITHOUT FILLER PIECES

DJN

HP300

NO

MEDIUM LINER

HP200 NO

NO

FINE

LINER CONDITION

HP200

CRUSHER SIZE

FILLER PIECES AVAILABLE

HP CONES WEAR MATERIALS SALES MANUAL


BACKI NG REQUI REMENT– STANDARD CRUSHERCAVITY TABLES HP STANDARD CRUSHER BACKING MATERIAL REQUIREMENTS PAGE 1 OF 1

Metso Minerals Engineerig Department

SECTION 3A NO

NO NO NO NO NO

NO

COARSE LINER

EXTRA COARSE LINER

FINE LINER IN FINE BOWL

FINE LINER IN COARSE BOWL

MEDIUM LINER IN COARSE BOWL

COARSE LINER IN COARSE BOWL

X-COARSE LINER IN COARSE BOWL


HP500

HP500

HP700

HP700

HP700

HP700

HP700

HP800

18 NO

NO

COARSE LINER IN COARSE BOWL

HP800


NO


HP800

176

176

396

484

8

8

18

22

8

8

8

18

22

640

640

1605

1995

640

640

640

1605

1995

640

205

KITS

EPOXY LBS

ZINC LBS

176

176

176

176

176

176

176

176

176

176

88

88

88

88

8

8

8

8

8

8

8

8

8

8

4

4

4

4

EPOXY LBS KITS

640

640

640

640

640

640

640

640

640

640

337

337

337

337

ZINC LBS

CRUSHER CAVITY TABLES HP STANDARD CRUSHER BACKING MATERIALREQUIREMENTS

HP800

NO

FINE LINER IN COARSE BOWL

176

176

176

396

484

8

3

66

190

386

489

ZINC LBS


02SEP02

176

3

5

6

66

110

132

EPOXY LBS KITS

WITH FILLER PIECES


DJN

HP800

NO

NO

MEDIUM LINER

HP500

NO

FINE

LINER CONDITION

HP500

CRUSHER SIZE




PAGE 2 OF 2


SECTION 3A NO

NO NO

NO NO

FINE LINER

MEDIUM LINER

COARSE LINER

EXTRA FINE

FINE LINER

MEDIUM LINER

COARSE LINER

EXTRA FINE

FINE LINER

MEDIUM LINER

COARSE LINER

HP200

HP200

HP200

HP300

HP300

19

HP300

HP300

HP400

HP400

HP400

HP400

132

154

198

198

66

88

6

7

19

19

3

4

4

3

505

645

745

745

275

370

370

66

66

150 150

3

150

150

150

150

150

150

75

75

75

75

ZINC LBS

3

3

3

66 66

3

3

3

3

2

2

2

2

66

66

66

66

275

44

44

44

EPOXY LBS KITS

44

ZINC LBS

130

165

170

80

EPOXY LBS KITS

CRUSHERCAVITY TABLES HP SHORT HEAD CRUSHER BACKING MATERIAL REQUIREMENTS

NO

NO

NO

NO

88

66

2

2

2

1

ZINC LBS


22SEP02

44

44

44

22

EPOXY LBS KITS

WITH FILLER PIECES


DJN

NO

NO

NO

EXTRA FINE


HP200

CRUSHER SIZE

LINER CONDITION



BACKI NG REQUI REMENT– SHORT HEAD

PAGE 1 OF 1


SECTION 3A NO

NO

NO NO NO

NO NO NO

FINE LINER

MEDIUM LINER

COARSE LINER







HP500

HP500

HP500

HP700

HP700

HP700

HP800

HP800

HP800

NO

NO

EXTRA FINE


HP500

CRUSHER SIZE

LINER CONDITION

20 88

264

330

88

264

330

4

12

15

4

12

15

640

1605

1315

640

1605

1315

640

1605

1315

205

EPOXY LBS KITS ZINC LBS

154

154

154

154

154

154

7

7

7

7

7

7

4

88

610

610

590

610

610

590

335

335

4

88

335 335

4

ZINC LBS

4

88

88

EPOXY LBS KITS

22SEP02

4

12

15

3

ZINC LBS


DJN

88

264

330

66

EPOXY LBS KITS

WITH FILLER PIECES




CRUSHERCAVITY TABLES HP SHORT HEAD CRUSHER BACKING MATERIAL REQUIREMENTS PAGE 2 OF2


HP CONES



INSTALLING HEAD WEAR RINGS The head wear ring prevents erosion to the head from the discharge of crushed material in a short crushing chamber. The head wear ring is changed once for two to three mantle changes. In order for the head wear ring to perform correctly and remain on the head through out its life, it must be installed correctly. Follow the installation as shown in the illustration; Installing Head Wear Ring.

MANTLE

HEAD

WELD HEAD WEAR RING TO HEAD USING AN E7018 ELECTRODE.

GAP

.5

1-7

HEAD WEAR RING ALIGN HERE

SECTION 3A

21

HP CONES



INSTALLING WEDGES After the bowl has been installed on the bowl liner and it is centered, seated properly on the seat and the bowl has been prepared for the backing, the wedges need to be installed to keep the bowl liner tight in the bowl. The high points of the helix should have been marked on the bowl liner at this point. Refer to the illustration "Locating High Point of Helix."

LOCATING HIGH POINT OF HELIX

CHAMFER

SPHERICAL SURFACE

SPHERICAL NUT

SQUARE HEAD BOLT

Proceed to install the wedge bolts as follows: 1. Pre-assemble each of the square head bolts, spherical nuts as shown in illustration "Assembling Bolt and Spherical Nut." Make sure that the spherical surface of the nut is against the wedge. 2. Place each wedge and bolt assembly on top of the bowl adapter ring with the head of the bolt into a cored pocket around the inside of the bowl. Refer to the illustration "Installing Wedge and Wedge Bolt." The chamfered corners of the square head bolt should be vertical in the pockets. The wedge assembly should also fit between stop blocks welded to the top of the adapter ring. These stop blocks prevent the wedges SECTION 3A

22

HP CONES


REVISION DATE: 4-4-2006 from moving sideways as the liner self tightens. Such movement of the wedges could cause the bowl liner to become loose.

WEDGE

BOWL LINER

LOCK PLATE

STOP BLOCKS

COTTER PIN

BOWL AD APTER RING

BOLT STOP

SQUARE HEAD BOLT

INSTALLING W EDGE AND W EDGE BOLT

3. Using an open wrench, turn the spherical nut behind each wedge until the wedge engages in the helix on the bowl liner. 4. Alternately tighten each nut, in a criss-cross pattern, until all the wedges tight against the helix portion of the bowl liner. The wedges must be securely tightened and properly seated in the bowl. Check that the bowl liner bears tight against the bowl by using a feeler gauge all around the liner seat. Clearance should be no more than

SECTION 3A

23

HP CONES


REVISION DATE: 4-4-2006 0.025 mm (0.010"). Should any openings exist due to wear on this area of the bowl, packing these openings with clay, caulking or glazing compound where the bowl liner contacts the bowl to keep the backing from leaking out during pouring. Refer to the illustration Checking Bowl Seating Surface.

CHECKING BOWL SEATING SURFACE 5. IN THE EVENT THE "NOSE" PORTION OF THE WEDGE CONTACTS THE SIDE OF THE BOWL LINER DUE TO C ASTING VARIATIONS IN THE LINER, A SHIM MUST BE PLACED UNDER THE WEDGE SO TH AT CONTACT IS MADE ON THE SLANTED PORTION OF THE WEDGE AS SHOWN IN CHECKING GAP. IF SHIMS ARE USED, TACK WELD THEM TO THE BOWL.

CHECKING GAP 6. Recheck all the wedges and spherical nuts for tightness after the backing has hardened.

SECTION 3A

24

HP CONES


REVISION DATE: 4-4-2006 7. Install the lock plates over the spherical nuts and fasten the lock plates to the wedge using a long cotter pin as shown in the illustration "Installing Wedge and Wedge Bolt." The lock plates will keep the spherical nuts from vibrating loose and causing the bowl liner to become loose in the bowl. 8. Weld a 12mm X 12mm (1/2" X 1/2") steel bolt stop to the bowl liner, just above the head of the square head bolt as shown in the illustration Bolt Stop. The stop will keep the bolt from "slipping" upwards during crushing, which could cause the bowl liner to become loose. Pack the area between the wedges with fiberglass insulation to keep out dirt and facilitate change outs; refer to the illustration "Fiberglass Packing."

WELD WITH E7018 ROD

BOLT STOP

BOLT STOP

BOWL

FIBER GLASS

BOWL LIN ER

FIBERGLASS PACKING

SECTION 3A

25

HP CONES



MANTLE SEATING It is important that the mantle is seated properly, both for pouring of the epoxy and the self-tightening feature. A loose or cocked mantle can result in damage to the mantle seat on the head. Install mantle as follows: 1. Lower the mantle onto the head. 2. Place the torch ring on top of the mantle. 3. Thread the lock bolt down CLOSE to the top of the torch ring. By comparing the distance between the top of the torch ring and the bottom of the lock nut, the mantle can be positioned squarely so that the distance is equal all the way around. During installation, a new mantle must be correctly positioned and aligned on the head before the lock bolt is tightened. 4. Do not rely on the lock bolt alone to force a cocked mantle into correct alignment. The parts and the distance to be compared are shown in Illustration below. If the distance is uneven the mantle must be shifted by bumping the top of the mantle sideways, or by bumping or prying upward on the low side of the mantle at the bottom. Before tightening the lock nut, the distance should be equal all around within 1 mm (0.040") or less.

SECTION 3A

26

HP CONES



LOCK BOLT EQUAL DISTANCE

EQUAL DISTANCE

TORCH RING

MANTLE

HEAD

5. Sledge the locking bolt down tight to center and position the mantle on the head. 6. Check that the mantle bears tightly against the head by using a feeler gauge all around the mantle seat as shown in illustration below. Clearance should be no more

LOCK BOLT

0.20MM (0.10") MAXIMUM CLEARANCE ALLOWED

FEELER GAUGE

SECTION 3A

HEAD

27

APPLY SEAL AT JOINT OF HEAD AND MANTLE

HP CONES


REVISION DATE: 4-4-2006 than 0.25 mm (0.010"). Should any openings exist due to wear on this area of the head, pack these openings with clay, caulking or glazing compound to keep the backing from leaking out during pouring. DO NOT apply seal to seating surface of the head. 7. Paint a vertical line on the lock bolt and the spacer ring. Then heat the lower portion of the mantle (head seat area) with a torch. Heat the mantle to approximately 55° C (130°F). You should be able to touch the mantle but not hold your hand on it! Let mantle cool down before pouring the backing material. 8. Turn the bolt with the wrench until fully tightened. Check the mark. The lock bolt should have turned approximately 25 mm (1 inch). 9. After tightening the lock bolt on the head, weld the mantle and the torch ring and between the torch ring and the lock bolt as shown in the illustration below. WARNING: The weld must not prevent the plate from bearing on the lock bolt. Use a stainless steel welding rod.

10.After the mantle has cooled, fill the entire cavity behind the mantle with backing material up to the bottom of the pouring holes in the mantle.

SECTION 3A

28

HP CONES



TAKING WEAR PROFILES In order to properly answer any inquiry, it is important that the following information be included. Use the Wear Profile Analysis Form to record your information. Feed gradation. Type of feed (i.e. granite). Product gradation. Circuit diagram complete with screen cloth openings and all crusher settings. Part numbers of current mantle and bowl liner. Crusher power draw. Crusher capacity. To operate continuously with liners having a crushing cavity unsuited to the operation, results in uneconomical wear of the liners, poor crushing efficiency and, in some instances, abuse to the Crusher. To obtain a wear profile of the bowl liner and mantle proceed as follows: Torch Cut Through Mantle or Bowl Liner Trace Worn Contour on Cardboard or Heavy Paper Inserted in Cut Original Contour Refer to the illustration, "Obtaining Wear Contour." 2

3

1

OBTAINING WEAR CONTOUR

SECTION 3A

29

HP CONES



LINER UTILIZATION The target amount of liner utilization on a HP cone is 50% to 55%. Wearing liners more than that can cause damage to the seats on the bowl and head as a result of the liners flexing because of thin cross sections. To determine the amount of utilization, proceed as follows: Weigh the bowl liner and mantle prior to installation, record the weight. After removal of the set of liners remove backing material and weigh each piece. Subtract the worn weight from the new weight and divide the difference by the new weight to get the worn percentage. EXAMPLE: HP500 SHORT HEAD - COARSE New Weights Bowl Liner 10 4831 4222 Mantle 70 5530 8502 Total Weight

3,845 Lbs. 3,955 Lbs. 7,800 Lbs.

Worn Weights Bowl Liner 10 4831 4222 Mantle 70 5530 8502 Total Weight

1,920 Lbs. 1,775 Lbs. 3,695 Lbs.

Liner Utilization Bowl Liner ( 3, 845–1, 920)/3, 845=50. 0% Mantle ( 3, 955–1, 775)/3, 955=55. 0% Total ( 7, 800–3, 695)/7, 800 = 52.6% Records should be kept and averaged over three or more sets of liners.

SECTION 3A

30

HP CONES



WEAR PROFILE ANALYSIS FORM

SECTION 3A

31

HP CONES



CRUSHER CHAMBER PROFILING Now it is possible to model the shape of the chamber without dismantling the crusher. By using NORDBERG-FOAM KIT it's easy to see how the mantle and bowl wear during the life of the liners. This process can be used on Standard and SHORT HEAD crushers up to HP500. It also helps to solve the problem cases. The spare part number of the Nordberg-Foam Kit is 803582. Instructions: 1.)

Set the plastic sheath into the chamber.

2.)

Mo ve the sheath to the closed side position in the chamber.

3.)

Mi x 0.35 kg A-component and 0.5 kg B-component (half tin A&B).

4.)

Pour out mixed A+B components into the sheath.

5.) After expansion of the foam has hardened, raise the adjustment ring and remove the sheath. 6.) Draw worn contour by using the expanded foam sheath or send the filled sheath (or drawing) to Metso

NORDBERG-FOAM KIT contains: - A-component 0.7 kg/tin - B-component 1.0 kg/tin - plastic sheath 2.0 m

SECTION 3A

32

HP CONES



SECTION 3A

33

HP CONES



MANGANESE BREAK IN PROCEDURES It has been found that there is a proper way to break in a set of manganese liners that will increase the work hardening of the manganese and increase the overall life of the liners. It is as follows: 1. Start the crushing process after the new liners are installed at a larger CSS then normal to allow the crusher to operate at approximately 50% of full load power with a full cavity. 2. Operate at 50% power for 6 hours. 3. At the 6 hour mark, reduce the CSS to a point that the crusher will operate at approximately 75% of full load power with a full cavity. 4. Operate at 75% of power for 2 hours and then go to full power operation. There are certain items that have to be in place: 1. The crusher normally operates near full power. 2. Increasing the CSS does not affect the remaining parts of the circuit. When customers have implemented this procedure, we have seen as high as 30% increases in total life of the liners.

SECTION 3A

34

Added 1-28- 04

HP Manganese Manual

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