MPS Control System
Section 6 MPS Control
System
FIG. 6-2 — MPS Control Valve
Catalog
Number Description
8608-0 MPS Control Valve Assembly 8608-1 Manifold Block
8610-0 Pilot Operated Check Valve 8610-1 Relief Valve 7.5 MPa (1090 psi) 8610-2 Relief Valve 4.5 MPa (650psi)
Catalog
Number Description
8610-3 Relief Valve 3.5 MPa (500psi) 8610-4 Check Valve (Lower)
8610-5 Check Valve (Raise) 8610-6 Needle Valve 8610-7 Diagnostic Nipple
SUPERIOR MK- II
Gyratory Crushers
Section 6 —
MPS Control
System
CYLINDER ASSEMBLYIf 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
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
SUPERIOR MK- II
Gyratory Crushers
Section 6 —
MPS Control
System
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,
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
SUPERIOR MK- II
Gyratory Crushers
Section 6 —
MPS Control
System
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
WARNING
The clamp plate (2325-0) may adhere to the bottom of the piston (2205-0) and fall off the piston, causing seri- ous 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). 2205--0 2505--0 2305--0 2325--0 PISTON LOWERING ROD (3) M--041607--JRK--01 PISTON STOP PLATE
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.
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.