HP500 Countershaft Box Assembly | Metso 1093050095 Replacement

Technical Specifications: HP500 Countershaft Box Assembly

The Countershaft Box (1093050095) is the structural guardian of the HP500 drive train.
As specialized crusher part suppliers, we manufacture this heavy-duty housing to ensure precise alignment between the pinion and the ring gear.
Unlike lightweight aftermarket copies, our Spare parts are cast from high-grade Ductile Iron to dampen the extreme vibrations generated by the 355kW main motor drive.

Core Advantages: Vibration Damping & Precision Alignment

A misaligned Countershaft Box spells disaster for your bevel gears.
Our manufacturing protocol prevents this:

• Ductile Iron Casting (ASTM A536): We strictly use nodular cast iron (Grade 80-55-06).
  Graphite nodules in the iron matrix act as natural shock absorbers, dissipating drive train vibration that would otherwise crack a standard steel housing or cause oil seal failure.
• CNC Line Boring: The seats for the Inner and Outer Countershaft Bushings are machined in a single CNC setup (“Line Boring”).
  This guarantees Concentricity ≤ 0.02mm.
  If these bores are even slightly off-axis, the countershaft will bind, leading to rapid bushing burnout and pinion shaft failure.
• Leak-Proof Flange Design: The mating flange that bolts to the Main Frame is precision ground to ensure a perfect seal.
  This prevents the notorious “drive-side oil leak” common in older HP500 crushers.

Performance Comparison: Material Integrity

Why does the Countershaft Box material matter?
See the comparison:

Field Diagnosis: Inspecting the Countershaft Box

Before installing new gears, inspect the 1093050095 box.
Look for these fatal flaws:

• Spun Bushing Bores: Measure the ID where the bronze bushings sit.
  If the bore is oversized or scored, the previous bushing “spun” inside the housing.
  You cannot install a new bushing into a loose bore; the box must be replaced or sleeved.
• Flange Cracks: Inspect the bolt holes on the mounting flange.
  Over-tightening or extreme vibration often causes hairline cracks here, which will leak oil regardless of how much sealant you use.
• Oil Flinger Rubbing: Check the interior for signs of contact.
  If the oil flinger has been rubbing against the casing, it indicates the box is distorted or the shaft bent.

Expert Tip: Installation & Gear Backlash

The “Gasket” Controls the Gears: The position of the Countershaft Box determines the Backlash and Root Clearance of the bevel gears.

Critical Procedure: When installing the 1093050095 assembly, you must adjust the thickness of the shim/gasket pack between the box flange and the mainframe.
Adding gaskets moves the pinion out (increasing backlash); removing gaskets moves it in.
Always verify the tooth contact pattern with Prussian Blue paste before running the motor.
Failure to set this gap correctly will strip your new gears in under 100 hours.

Frequently Asked Questions (FAQ)

Q1: Does the assembly include the Bronze Bushings?
A1: Our standard P/N 1093050095 refers to the Box (Housing) only.
However, as comprehensive crusher part suppliers, we highly recommend ordering the “Loaded Assembly” which includes the Inner and Outer Bushings pre-pressed and line-checked at our factory to ensure perfect fit.

Q2: Why is my Countershaft Box leaking oil at the pulley end?
A2: This is usually due to a blocked “Breather” or a worn labyrinth seal.
However, if the Box housing itself is porous (poor casting quality) or cracked at the flange, oil will seep through the metal.
Our ASTM A536 castings are non-porous and pressure tested.

Q3: Is this compatible with the HP500 Short Head?
A3: Yes.
The drive train (Countershaft Box, Shaft, Pinion) is typically identical between the Standard and Short Head versions of the HP500.
The differences lie in the liners and head angle, not the drive housing.

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