GP Instruction Manual

NORDBERG GP CONE CRUSHERS INSTRUCTION MANUAL

MM0293378-EN REV-1.3 11/2011

GP CONE CRUSHERS

CHAPTER

0

This instruction manual applies to GP-series cone crushers, manufactured by Metso. These crushers are high-capacity cone crushers intended for secondary and tertiary crushing at crushing plants of different sizes.

Because of the continuous development of the product, the manufacturer reserves a right to alter the technical specifications written in this manual, without any advance information. In case of conflicts between different language versions, the English version of this manual is the original and prevails. Manufacturer: Metso Minerals, Inc., Tampere Works Lokomonkatu 3, P.O. Box 306 33101 Tampere Finland Phone: +358 204 84 142 Fax: +358-204-84 143

email: [email protected] www.metso.com

Copyright © 2011 Metso. Printed in Tampere, Finland.

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Nordberg GP Cone Crushers

Table of Contents GP CONE CRUSHERS PREFACE SAFETY 2.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.2 WARNING SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.2.1 Warning sign codes and texts (ANSI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.2.2 Warning sign codes and texts (ISO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

GENERAL 3.1 TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 OPERATING PRINCIPLE AND MAIN COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3 GP-SERIES CONE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.4 APPLICATION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.5 CRUSHER AUTOMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.6 SELECTION OF LINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.7 SPARE AND WEAR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.8 SETTING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

INSTALLATION 4.1 FOUNDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 INSTALLATION CLEARANCE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3 LIFTING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4 FEEDING OF THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.5 REMOVAL OF CRUSHED MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.6 MOTOR SIZE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.7 POWER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.8 LUBRICATION AND ADJUSTING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.8.1 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.8.2 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.8.3 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Nordberg GP Cone Crushers

Table of Contents 4.9 SERVICE PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.10 PRESSURIZED DUST SEALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.11 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.12 CRUSHER TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

OPERATION 5.1 BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2 GENERAL INFORMATION PRIOR TO CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.3 STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.4 OPERATING THE NEW OR RENOVATED CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.5 SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5.6 STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5.7 STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5.8 OVERLOAD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

MAINTENANCE 6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 LIFTING WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.3 SPACE REQUIREMENTS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.4 SPECIAL TOOLS FOR MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6.5 SERVICE PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6.6 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6.7 CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.8 BLEEDING AIR FROM THE ADJUSTING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.9 TIGHTENING TORQUE FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6.9.1 Cavity mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6.9.2 Other bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6.10 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 6.10.1 Countershaft system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 6.10.2 Top bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 6.11 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 6.11.1 Scheduled maintenance for new crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 6.11.2 Every eight hours of operation / every shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 6.11.3 Every 40 hours of operation / every week (one-shift operation) . . . . . . . . . . . . . . . . . 6-13 6.11.4 Every 400 hours of operation / every month (two-shift operation) / every two months (one-shift operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Nordberg GP Cone Crushers

Table of Contents 6.11.5 Every 2,000 hours of operation / every year (one-shift operation) / every six months (two-shift operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6.11.6 Seasonal maintenance (summer/winter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.11.7 Every 20,000 hours of operation / every 10 years (one-shift operation) / every 5 years (two-shift operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.12 MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 6.13 OTHER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 6.13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 6.13.2 Replacing the main shaft dust seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 6.13.3 Checking / replacing the top bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 6.13.4 Replacing the main shaft protective sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 6.13.5 Checking / replacing thrust plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 6.13.6 Replacing the top bearing seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

REPLACING WEAR PARTS 7.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.3 DISMANTLING THE UPPER FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.4 REPLACING THE BOWL LINER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 7.4.1 Fine crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 7.4.2 Secondary crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 7.5 REPLACING THE MANTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 7.5.1 Removing the old mantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 7.5.2 Installing the new mantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 7.6 INSTALLING THE UPPER FRAME ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 7.7 RE-TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 7.8 PROTECTION PLATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

TROUBLESHOOTING CHANGING THE STROKE 9.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.2 DISMANTLING THE UPPER FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.3 STROKE CHANGE AND RE-ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.4 RETIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Nordberg GP Cone Crushers

Table of Contents TECHNICAL SPECIFICATIONS 10.1 CAVITY OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2 STROKE OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.3 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 10.4 CRUSHER CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

APPENDIX A

1. 2. 3. 4. 5. 6. 7.

SAFETY, OPERATING, AND MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . .A-1 Intended purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Inspection and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

PREFACE

CHAPTER

This instruction manual is intended to assist owners and users of Metso products in the proper use of the equipment.

1

This instruction manual must be read and used by each person who works with the equipment, typically:

It includes important references to safe, proper and economical operation of the equipment. Following these instructions will help to avoid possible danger, reduce repair costs and breakdowns and to increase the reliability and life of the equipment.

–

operations, including installation, startup, operation, application engineering, materials handling, site labour, environmental engineering and safety departments.

This manual must be complemented by those instructions necessary because of existing national mandatory rules relating to accident prevention and environmental protection.

–

maintenance, including inspection and repair.

–

transport, materials handling and rigging.

A copy of this manual must be kept at the equipment's location and made available to the operators as required. In addition to this manual and accident prevention regulations mandatory in the country of use and at the equipment's place of operation, generally recognized rules for safe and professional operation must be observed.

Note that this instruction manual contains information and instructions on alternative and optional equipment. Normally the machines have only some of them. Before maintaining and servicing, find out which alternative and optional equipment your machine has. See separate instruction manuals for more detailed instructions when servicing the main components. There may be optional equipment which have separate instruction manuals. Those manuals must be read and used by each person who works with the equipment.

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2.1 GENERAL The instructions of the safety guide, these safety instructions and other manuals and safety labels for the equipment must be read, understood and used by each person who works with this equipment.

WARNING!

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.

In addition to these unit-specific safety instructions, the operators of this equipment must also read the safety guide with instructions for general operational safety.

DANGER

WARNING! Read the instruction manual for Lubrication and adjusting unit, and the instruction manual for automation system before using the GP cone crusher.

WARNING

The following symbol is used in this manual and on the machine to call attention to instructions, which will help prevent machine related injuries.

CAUTION

When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Sign

Description

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

or death. Hazards or unsafe practices that could WARNING result in severe personal injury or death Hazards or unsafe practices that could CAUTION result in minor personal injury or equipment damage Figure 2.2 Danger, warning, caution signs and their meaning Figure 2.1 Alert Symbol

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2.1.1 General safety instructions

4. Before starting the crusher make sure that no one is near the crusher. 5. It is prohibited to stay in the danger area during the crushing process. The crushing material may be thrown into a few meters distance from the crusher. Always use helmet and safety glasses.

WARNING! Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.

6. Do not look into the crushing cavity during crushing. Material may be thrown from the crusher during crushing and cause injuries. Always use a helmet and safety glasses.

LOCKOUT PROCEDURE of the diesel engine driven crushers 1. Switch off engine

7. Ensure before performing any maintenance, that the crushing cavity is empty. Material may be thrown from the crusher even when it is stopped.

2. Remove the ignition key and keep it on person during lockout 3. Place appropriate maintenance warning signs (TAG OUT)

8. Because the crusher is installed on rubber dampers, it moves during crushing. This movement causes a crushing danger. Never put your hands or feet between the moving parts and the structure of the crusher during crushing. The movement may be as much as ± 25mm (±1”).

LOCKOUT PROCEDURE of the electrical motor driven crushers 1. Switch off motor 2. Lock the main switch of the motor with a padlock or make sure in some other way that the motor cannot be started (locking must be done by every member of the work group)

9. Clearing a jammed cavity is extremely dangerous. Do not attempt to clear the cavity until the crusher has stopped completely. 10. The crusher does not stop immediately after the motor has been turned off. Make sure that the crusher has stopped completely before opening any covers, performing any maintenance, or adjusting the crusher.

3. Keep the keys on person during lockout 4. Place appropriate maintenance warning signs (TAG OUT).

11. The 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. Metso highly recommends that dust protective devices such as an appropriate respirator be worn by anyone exposed to airborne dust to prevent its inhalation. 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!

1. Ignoring the safety instructions or the warning signs increases the risk of severe injury or death. 2. GP cone crushers have been designed for safe operation when used by professional staff in the operating situations included in this instruction manual. All other service and repair procedures must be performed by specially trained personnel or authorized Metso service staff. 3. Never operate the crusher without proper covers and safety devices. If the covers or safety devices have not been purchased from Metso, a customer has to ensure that the covers and safety devices are according to law and regulations.

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12. The noise level is dangerously high near the crusher. All personnel working near the crusher must wear hearing protection. The noise level is typically about 100-115 dB(A) next to the crusher during crushing.

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13. Make sure that the main shaft is in down position before performing any maintenance. The adjusting circuit may contain high pressure even when the crusher is stopped.

DANGER! There are components made of manganese steel in the crusher, such as liners and in some models protection plates of the upper frame arms. Welding or flame cutting these components generates gas that is extremely hazardous to health and causes manganese poisoning. This kind of work must be done outdoors or in well-ventilated premises equipped with local exhaust ventilation.

14. Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out. 15. The surfaces of the crusher may become hot during crushing. Hot surfaces can cause severe burn injuries. Make sure that the surfaces have cooled before performing any maintenance work. 16. The lubricating oil and grease may be hot. Make sure that hot oil and grease do not come into contact with skin. 17. Before handling oil or grease refer to Operational Safety Bulletin delivered by the oil manufacturer. 18. Before changing any wear parts of the crusher, read chapter “Replacing wear parts” carefully. 19. Before lifting any wear parts, check the weight of the component and ensure that lifting equipment being used is adequate to lift the weight. 20. Read the instructions regarding lifting and replacing wear parts carefully before replacing any wear parts. Make sure that the parts are adequately supported before lifting. Never go under the suspended load. 21. Follow the occupational safety rules during all maintenance and lifting procedures! 22. If the crusher is equipped with a pressure accumulator, it may be charged only by a professional. If the pressure accumulator is charged incorrectly, it may explode. Do not charge the accumulator yourself. 23. Release the pressure from the hydraulic system according to instructions before any maintenance to the system. 24. The cooler blower of the lubricating device starts automatically during crushing. Do not go near the blower or remove the covers during crushing.

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2.2 WARNING SIGNS The warning signs attached to the equipment must always be kept readable and clean. Damaged or loose signs must be replaced at once before starting the crusher. Make sure that the warning signs are

not covered during installation. If a part of the crusher with an attached a warning sign is replaced, always make sure that the required warning signs are included with the new part.

Figure 2.3 The locations of the warning signs

The number and exact locations of the warning signs may vary according to options (for example, guards).

IMPORTANT! There are two different sets of warning signs depending on the delivery country. You can check which set of warning signs is used on your machine from the side of the machine or the spare part manual.

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1 2

3

5

4

6

7

Figure 2.4 Warning signs (ANSI)

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2.2.1 Warning sign codes and texts (ANSI) 1. MM0229994 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. DANGER Lung disease hazard. Dust protection required. WARNING Risk of eye injury. Use of eye protection required.

6. MM0230002 WARNING Servicing while pressurized can cause severe injury. Lock out source and relieve pressure before servicing. 7. MM0230498 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. High voltage. High pressure oil.

CAUTION Risk of head injury. Use of a helmet required.

Failure to follow lockout procedure before servicing may result in death or serious injury.

CAUTION Hazardous noise level. Use of ear protection required. 2. MM0229995 DANGER Moving parts can crush and cut. Do not insert tools in the crusher cavity when the motor is running. WARNING Material can fall out. do not stand in the vicinity of the crusher when the motor is running. 3. MM0229997 WARNING Exposed moving parts can cause severe injury. Do not open drive guard before machine is completely stopped. 4. MM0229996 WARNING Exposed moving parts can cause severe injury. Do NOT operate this machine without proper guards. 5. MM0231186 WARNING Moving parts can crush and cut. Do not open the hatch before machine is completely stopped.

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3 4

2

5

6

7

Figure 2.5 Warning signs (ISO)

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2.2.2 Warning sign codes and texts (ISO) 1. MM0250258 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. DANGER Lung disease hazard. Dust protection required. WARNING Risk of eye injury. Use of eye protection required.

6. MM0250241 WARNING Servicing while pressurized can cause severe injury. Lock out source and relieve pressure before servicing. 7. MM0265819 WARNING Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury. High voltage. High pressure oil.

CAUTION Risk of head injury. Use of a helmet required.

Failure to follow lockout procedure before servicing may result in death or serious injury.

CAUTION Hazardous noise level. Use of ear protection required. 2. MM0250251 DANGER Moving parts can crush and cut. Do not insert tools in the crusher cavity when the motor is running. WARNING Material can fall out. do not stand in the vicinity of the crusher when the motor is running. 3. MM0250244 WARNING Exposed moving parts can cause severe injury. Do not open drive guard before machine is completely stopped. 4. MM0250244 WARNING Exposed moving parts can cause severe injury. Do NOT operate this machine without proper guards. 5. MM0252118 WARNING Moving parts can crush and cut. Do not open the hatch before machine is completely stopped.

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GENERAL

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3.1 TERMINOLOGY Feed = The raw material to be crushed. Product size = The size of the material after it has been crushed. Capacity = The output of the crusher computed in tons per hour (mtph or STPH). Feed opening (closed side) = The shortest distance between the top of the mantle and bowl liner as measured when the mantle and bowl liner are at their closest position during mantle gyrating circle Feed opening (open side) = The longest distance between the top of the mantle and bowl liner as measured when the mantle and bowl liner are at their farthest position during mantle gyrating circle. As a general rule, the maximum size of feed should be 60-80 % of the open side feed opening depending on the crusher type and the raw material to be crushed. Liners= The members which perform the crushing are commonly referred to as liners. The liners consist of mantle and bowl liner. Mantle= Inner part of the liners, moves eccenterically in the crushing chamber

3

Open circuit operation = The type of operation where precise uniformity of product size is not considered to be of prime importance and the feed is run through the crusher only once. Closed circuit operation = The type of operation where part of the crusher product is returned back to the crusher. The crusher output is fed to a screen, from which the oversize is returned back to the crusher. The closed circuit is used when the next stage of process needs a precise product size or when crushing process needs to be balanced. Choke feed = The crusher is fed so that the crushing chamber is full all the time. It is recommended to maintain the choke feed, as it ensures good crushing quality and improves the efficiency of the crusher. The recommended choke feed level for secondary GP-cone is at the level of mantle fixing nut. The recommended choke feed level for fine GP-cone crusher is max 1 meter above top bearing arrangement. Circulation material = Oversize material, which is fed back into the crusher.

Bowl liner= Outer part of the liners, stationary Crushing cavity = The internal contour formed by the two crushing members. Discharge setting = The distance between the bottom of the mantle and bowl liner as measured at the point where the liners are at their closest position during mantle gyrating circle (a.k.a. closed side setting, CSS). The discharge setting regulates product size. Minimum discharge setting = The shortest permissible distance between the bottom of bowl liner and mantle as measured at the point where the liners are at their closest position during mantle gyrating circle. Discharge opening = The distance between the bottom of the bowl liner and mantle as measured at the point where the liners are at their farthest position during mantle gyrating circle. This wide opening permits rapid discharge of the crushed material. Stroke = The difference of the maximum and minimum distance between the bottom of bowl liner and mantle during one revolution of the eccentric shaft.

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1 2 3 4

↔

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Figure 3.1 Terminology used in the instruction manual

Callout 1 2 3 4 5

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INSTRUCTION MANUAL

Description Feed opening Mantle Bowl liner(s) Discharge setting Stroke

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3.2 OPERATING PRINCIPLE AND MAIN COMPONENTS The crushing takes place between the eccentrically moving mantle (1) and the stationary bowl liner (2). The motor rotates the countershaft (3) via V-belts, and the countershaft rotates the eccentric shaft (4) via pinion and a gear (5). The eccentric shaft causes

the crusher strokes by eccentrically moving the main shaft (6), which has bearings at the bottom (7) and top end (8). The material to be crushed is fed into the crusher through the top, and the crushed material exits through the bottom.

Figure 3.2 Operating principle of the crusher

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Callout 1 2 3 4 5 6 7 8

Description Feed hopper (option) Cone crusher Drive motor (option) Belt guard (option) Lubrication and adjusting unit Discharge chute (option) Subframe (option) Overpressure device

Figure 3.3 GP-crusher with some optional devices

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10 11 12 13

2

14 3 15

4

16 5

17 18

6

7 8

20 21

9 Callout 1 2 3 4 5 6 7 8 9 10 11 12

23

Description Upper frame protection Intermediate frame Bowl liners Mantle Lower frame arm protection Lower frame Setting sensor Thrust bearing set Cylinder cover Main shaft protecting sleeve Top bearing Upper frame

Callout 13 14 15 16 17 18 19 20 21 22 23

19

22

Description Main shaft Head Thrust bearing Gear Pinion Countershaft Countershaft housing Frame bushing Eccentric shaft Eccentric bushing Piston

Figure 3.4 Main components of the secondary GP-cone crusher

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9 10 11 12

2 3

13 14

4

15 16

5

17

6 19 21 20

7 8 Callout 1 2 3 4 5 6 7 8 9 10 11

18

22

Description Upper frame protection Bowl liners Mantle Lower frame arm protection Lower frame Setting sensor Thrust bearing set Cylinder cover Main shaft protecting sleeve Top bearing Upper frame

Callout 12 13 14 15 16 17 18 19 20 21 22

Description Main shaft Head Thrust bearing Gear Pinion Countershaft Countershaft housing Frame bushing Eccentric shaft Eccentric bushing Piston

Figure 3.5 Main components of the fine GP-cone crusher

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3.3 GP-SERIES CONE CRUSHER

3.6 SELECTION OF LINERS

The Nordberg GP-series cone crusher is intended for secondary and tertiary crushing at crushing plants of different sizes.

The appropriate liner type depends on the feed material used and the product size required.

GP200S, GP300S and GP500S are defined as secondary crushers. Secondary crushers have separate intermediate frame and the feed opening is bigger than in fine crushers. Also the cavity is longer. Secondary crushers are mainly used as a second crusher after the jaw or impactor. GP200, GP300 and GP550 are designed for fine crushing purposes. Feed opening is not as big and cavity is not as long as in secondary crushers. Fine crushers are used for tertiary and quarternary crushing. There are different cavity options for the crusher. See the different options in the TECHNICAL SPECIFICATIONS chapter. There are different stroke options for the crusher. See the options in the TECHNICAL SPECIFICATIONS chapter. If necessary, the stroke may be changed by turning or replacing the eccentric bushing and by replacing the top bearing (refer to chapter 9).

If the liners are unsuitable for the crushing application, the liners may wear quicker, the product quality may be worse or the yield of the wanted end product may decrease. In this kind of situation, the change of liner type to another typically improves the situation. Feed material that is unsuitable for the liners causes the mantle and bowl liner wear unevenly, which may lead to a machine breakdown. When determining the suitable liner type, contact your local construction expert at Metso. The following information is required to determine the suitability of various liner types: 1. Feed material size (distribution curve) 2. Feed material type (rock material type) 3. End product size 4. End product capacity 5. Crusher type and size

3.4 APPLICATION OPTIONS The crusher operates in fixed crushing plant, in a Lokotrack crushing plant or in a Nordwheeler mobile crushing plant.

3.5 CRUSHER AUTOMATION The crusher is automatically controlled by the automation system. See the separate Instruction manual.

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3.7 SPARE AND WEAR PARTS

3.8 SETTING RANGE

Metso endeavors to carry an ample supply of parts in stock to provide prompt and efficient service on all orders for repairs and replacements.

The minimum setting to be used depends on, e.g., the following: the stroke used, crushing ratio, feeding level, variation of feeding speed, stone type (gravel or rock), feed material distribution, and cavity wear.

To avoid delay and the possibility of incorrect parts being furnished, the following information should be given: 1. Crusher size. 2. The serial number of the crusher which is stamped on the crusher nameplate. The serial number is also on the cover of the spare parts books. 3. Complete name and part code number as shown in the Spare Parts Book. 4. Exact quantity of each part ordered.

The allowable setting range depends on the stroke used. The minimum setting is limited by either the power requirement or setting pressure, both of which increase when the setting is decreased. Thus, selection of motor size is largely dependent on the stroke used. In coarse crushing in particular, variation in the process can be a factor that prevents the use of the minimum setting. Accordingly, it is recommended that the minimum allowable setting be used continuously only if the operating conditions are well known and sufficiently stable.

5. Complete shipping instructions. If your crusher Spare Parts Books have been lost, destroyed or misplaced, an additional set can be ordered. IMPORTANT! For proper operation, only genuine factory parts should be installed. These are guaranteed as to accuracy, workmanship and material. Using pirate parts may put your safety and that of your crusher at risk. Make sure you completely understand your crusher's Warranty conditions at all times.

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INSTALLATION

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4.1 FOUNDATION The crusher is to be installed on a sufficiently steady steel or concrete foundation by using the rubber dampers (4 pcs.). During normal operation, the crusher oscillates horizontally about ±2 mm (±0,08”) on the dampers. During starting and stopping, the oscillation is about ±10 mm (±0,39”). Due to this, the clearance around the crusher must be at least 20 mm (0,79”). The installation dimension drawing delivered in the installation documents indicates the static and dynamic forces from the crusher to the foundation. When installing

4

the crusher on the foundation, ensure that all four rubber dampers are equally affected by the weight of the crusher. This requires that all four support surfaces be level with each other. If necessary, shims may be used to level the support surfaces. If the crusher has been delivered mounted on a steel frame (element or mobile wagon), the frame must be installed so that the rubber dampers of the crusher are level with each other. The steel frame (element or wagon) must be supported well on the ground, and the vertical alignment of the crusher must be checked.

Figure 4.1 Examples of the GP crusher installations

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4.2 INSTALLATION CLEARANCE DIMENSIONS A well planned installation is absolutely necessary for the success of the crusher. One of the major considerations are crusher clearances. In order to accurately determine crusher clearances refer to the Installation Drawings.

4.3 LIFTING THE CRUSHER The weight of the crusher and its parts, as well as the space required for lifting them, must be taken into account in selection of the crusher foundation and lifting equipment. Lifting equipment must be used when erecting, disassembling, and servicing the crusher and replacing liners. The lifting equipment, wires, hooks and other components must be dimensioned to withstand the weight of the basic crusher without options (Figure 4.2). The maximum weight of that basic assembly for each crusher type is shown in the Table 4-1.

Crusher GP200 GP200S GP300 GP300S GP550 GP500S

Maximum weight 9500 kg 10900 kg 13700 kg 16500 kg 26000 kg 33500 kg

Table 4-1 Maximum weights of the crusher

Figure 4.2 Lifting the crusher

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4.4 FEEDING OF THE CRUSHER The material to be crushed may be fed into the crusher using a belt conveyor, screen, or various feeders, either directly or by using guiding troughs. The feeding equipment should be easy to move, to enable quick and easy maintenance of the crusher.

The maximum crushing capacity and optimal wear to the liners can be achieved only if the feeder is directly above the crushing cavity and the material is distributed evenly on both sides of the supporting arms of the upper frame. If necessary, the upper frame assy may be turned in steps of one bolt pitch.

50% 50%

Figure 4.3 Feeding the crusher

The following must be taken into account in arranging the feed: –

–

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All fine material and material smaller than the crusher setting must be separated from the feed material. These could cause packing and damage the machine. In addition, any metal pieces must be removed from the feed material using, e.g., a magnetic separator. The manufacturer is not responsible for damage resulting from the above causes. The feed must be directed such that there is an equal load around the entire bottom edge of the crusher gap. This ensures more even loading and better lubrication for the crusher bearings, as well as more uniform wear to the liners. To achieve this, the feed can be directed by changing the position of the conveyors and feeding troughs and by using barriers.

–

The speed of the feed material upon entering the crusher must not exceed 5 m/s, which corresponds to a free fall height of 1.3 m. If necessary, the speed must be limited by stone ledges.

–

To ensure even wear to the liners, the crushing cavity must be evenly filled to the top.

–

Overfilling of the feed hopper must be prevented by using, e.g., level controls.

–

Feeding of the crusher when it is not running must be prevented. This can be achieved electrically by allowing starting of the feeding device only when the crusher drive motor is running.

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4.5 REMOVAL OF CRUSHED MATERIAL The crushed material may be removed using a belt conveyor or different hoppers or silos, either directly or by using guiding troughs. The removal equipment should be easy to move, to enable quick and easy maintenance of the crusher. The discharge opening of the crusher must be covered, or safety distances in accordance with applicable national standards must be observed.

IMPORTANT! The crushed material must be allowed to exit freely at all times. The removal equipment must be built to prevent the accumulation of crushed material. If the level of crushed material reaches the bottom of the mantle, the seal under the main shaft becomes damaged and dust enters the lubricating oil, possibly causing further damage.

The following must be taken into account in removing the crushed material:

4-4

Figure 4.4 Removal of crushed material

–

If the crushed material is removed from under the crusher with a conveyor or feeder, the device feeding the crusher must not start before the removal device begins running.

–

If there is a silo below the crusher, it must be equipped with a level control that stops the feeding device if the level of crushed material in the silo is too high.

–

The lubrication and adjusting oil hoses for the crusher must be protected from the crushed material exiting the crusher.

–

Use the inspection hatches on the crusher’s lower frame to remove any trees, stumps, plastic covers of explosives, and other debris from the protection plates of the lower frame to prevent the accumulation of material. These objects prevent the crushed material from exiting freely, which might damage the crusher.

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4.6 MOTOR SIZE SELECTION Table below will give max. recommended motor power for the different GP Cones. Table is valid for dry, medium-hard granite NOTE: If you choose a nominal power for the motor bigger than the recommended Maximum power, then the crusher automation system limits the power.

Max. motor power IEC/NEMA standards (kW)

(hp)

GP200

160

215

GP200S

160

215

GP300

250

340

GP300S

250

340

GP550

350

475

GP500S

315

430

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4.7 POWER TRANSMISSION

Each belt is measured separately, and the average force needed to produce the deflection is then calculated. A single belt must not deviate from the average value by more than 20%, since this causes the service life of the belt to be halved.

IMPORTANT! In the subframe delivered by the Metso, location of the drive motor and the alignment of the V-belts is guaranteed to be correct. The crusher is driven by the drive motor, from which power is transmitted through V-belts to the crusher countershaft. The V-belt is recommended for this purpose since it prevents the transmission of impact loads from the crusher to the drive motor. The V-belt pulley on the drive motor shaft must be aligned precisely with the V-belt pulley on the crusher countershaft. The drive motor shaft and crusher countershaft must be parallel. In replacing V-belts, all belts must be replaced at the same time. Never mix new and used belts. The belts must also belong to the same length category (this information is stamped on the belts) to ensure equal power distribution on all belts. If the crusher drive motor is installed on a fixed platform and the crusher oscillates in relation to the motor, the motor must be located directly above or below the crusher countershaft or at a maximum angle of 15° from this position (Figure 4.5). This is to prevent additional strain caused by crusher oscillation. If the drive motor and crusher are installed on the same foundation (i.e., oscillate together), the location of the drive motor may be selected freely.

To avoid damage caused by falling stones and to prevent accidents, the drive motor and V-belts must be protected. The size and location of the openings must meet occupational safety requirements.

Figure 4.5 Installation of the drive motor

The V-belts must be tightened to the correct tension. This can be checked by pulling or pressing the V-belt halfway between the shafts with a force indicated in the Table 4-2. The belt deflection should be 16 mm per meter of the belt span (center distance) (Figure 4.6).

Belt Section SPB SPC 8V

Min.Tension N (lbf) 50 (11) 60 (13) 80 (18)

Max.Tension N (lbf) 65 (15) 100 (22) 120 (27)

Table 4-2 Required forces for proper V-belt tensioning Figure 4.6 V-belt tension

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4.8 LUBRICATION AND ADJUSTING UNIT

4.8.2 Hoses

4.8.1 Installation The location of lubricating and adjusting equipment should be selected to be as dustless as possible within the length of hoses.

The hoses between the lubricating and adjusting equipment and the crusher should be properly fastened in every point, where they can be affected by rubbing. Points affected by rubbing should be covered with rubber plates etc. when necessary.

NOTE: It is highly recommended that original hose lengths are used when installing the lubrication and adjusting unit

The minimum bending radius of hoses (R) are:

Lubricating and adjusting equipment should be separated from the shaking frame construction and lay down on a stand on ground. By doing this, the life time of the components of lubricating and adjusting equipment can be significantly increased.

•

When choosing a location for lubricating and adjusting equipment, pay attention also to the following:

•

–

Adjusting oil hose –

•

Lubricating oil hose –

–

An adequate space should be reserved around the equipment for the oil change.

–

The air flow caused by the cooling fans through the coolers above the lubricating device should not be prevented by any obstacles on either side of the coolers. The air flow is approximately 100 m3/min (3530 ft3/min) and the speed of the air through cells is about 5 m/s (16 ft/s). The direction of the air flow should be arranged according to the figure 4.8.

1 1/4” => R = 420 mm (R =16 ½")

Return oil hose –

The water should never, in any conditions (spring flood etc.), enter the equipment, because the electrical components of the devices might be damaged.

1” => R = 310 mm (R =12")

4” => R = 450 mm (R = 18")

The return oil hose of circular lubrication should descend all the way from the crusher to the lubricating equipment. The depression should be at least 50 mm by every meter (2" by every yard) of length of the hose. NOTE: To prevent the splashing of the oil in the tank the depression of the hose should not be more than 50 mm (2”) in the last meter before the tank. The sag of the hose should not exceed 50 mm (2"), to allow the crusher to breathe via lubricating equipment after having been stopped (Figure 4.8). High sag acts like a water seal in return hose compelling the crusher to breathe via the dust seal area and to suck the silicious dust into the crusher.

NOTE: If the lubrication and adjusting unit is installed in a closed space make sure that the air flow is sufficient. A safe and capable route should be arranged to the lubricating and adjusting equipment, to allow the daily (shiftly) inspection of proper functioning of the devices.

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4.8.3 Functions Automation system controls the functions of the crusher and the lubrication unit according to the temperature limits shown in the table below. Operation (with ISO VG150) Fan starts Fan stops Feed stops Crusher stops Restart of the crusher or feed Stop the crusher (safety) Heaters on Heaters off Permission to start the pump Permission to start the crusher

Temperature limit

Sensor

Control point

+50°C (122°F) +45°C (113°F) +63°C (145°F) +65°C (149°F)

Temperature sensor 1 Temperature sensor 1 Temperature sensor 1 Temperature sensor 1

Return oil Return oil Return oil Return oil

+55°C (131°F)

Temperature sensor 1

Return oil

+68°C (154°F) +20°C (68°F) +30°C (86°F)

Temperature switch Temperature sensor 2 Temperature sensor 2

Return oil Tank Tank

+15°C (59°F)

Temperature sensor 2

Tank

+10°C (50°F)

Temperature sensor 1

Return oil

Figure 4.7 (1) Temperature sensor 1, (2) Temperature sensor 2, (3) Temperature switch

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Figure 4.8 (A) Air flow to the cooler, (B) Minimum decline of the return oil hose 50 mm/m, (C) Maximum decline 50 mm in the last meter before the tank

.

Figure 4.9 Installation of oil hoses: (A) Adjusting oil hose, (B) Lubricating oil hose, (C) Return oil hose, (D) Pressurized dust sealing

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4.9 SERVICE PLATFORM

internal parts of enclosed assemblies, such as engines, compressors, pumps, gear sets, and hydraulic assemblies. The rust preventives function by displacing water from metal surfaces, by forming strong water-resistant films on the surfaces, and by absorbing water in the system into a water-in-oil emulsion. These products provide as much as 30 to 40 times the protection against rust compared to high quality lubricating oils that have not been especially formulated to prevent rust.

To make maintenance and operation easy and safe, the crusher should be equipped with a service platform. If the service platform has not been ordered and supplied with the crusher, it must be built by the operator. The crusher’s service platform must meet the requirements of ISO 2867 or a corresponding standard. The appropriate height for the platform is the level of the support brackets. The platform and steps must be equipped with handrails to prevent personnel from falling down.

In most applications, the residual rust preventive film left by these products need not be flushed away or otherwise removed when the crusher is to be filled with lubricating oil and put into normal service. The viscosity of the oil should be in the 32 to 66 cSt at 38°C (100°F) range.

All international and national regulations on service platforms for crushing equipment must be observed.

4.10 PRESSURIZED DUST SEALING The crusher is equipped with pressurized dust sealing system. It should be noticed that the blower unit must be installed as close to the crusher as possible but not further than 10 m (30 ft) from the crusher.

•

Fill countershaft housing with lubricating oil. When crusher is put into normal service remove the oil that exceeds the normal limit.

•

Then reinstall the main shaft assembly, upper frame assembly, and top cover into the crusher and cover the entire crusher with a sheet of 2 mm polyethylene to prevent water from seeping into the crusher. Black is recommended as transparent sheeting will deteriorate four times faster than black. The countershaft assembly should also be covered. Steel strapping or banding is an ideal method of holding the polyethylene sheeting in place.

•

Where it is necessary that the crusher is being shipped or stored dismantled, all the machined surfaces of the various sub-assemblies must be painted with rust preventive oil and covered with black polyethylene sheeting.

•

When crusher is put into normal service check the condition of the painting. If it is poor, re-paint.

Mounting height is correct when the pressure port of the blower is higher than frame connection flange of the lower frame.

4.11 STORAGE To protect your crusher from rust corrosion during seasonal shutdown, shipment or storage over 3 months, the following protective measures have to be taken. If you have further questions related to the storage or safety at work, contact Metso. •

•

Remove the top cover, upper frame assembly and main shaft assembly. Disconnect the oil drain line at the bottom of the lower frame. Make sure that all piping is sealed with pipe plugs. Clean the crusher. Use a paint brush to paint rust preventive lubricating oil to the flange connection of the frames. Using the paint brush, coat the protection bushing and all the visible outer surfaces of the main shaft and the head. Then coat all the visible surfaces of the slip ring. Use lubricating oil which has a rust preventive blend that is designed for the protection of

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4.12 CRUSHER TRANSPORTATION During transportation the crusher main shaft must be supported with wooden wedges (3 pcs) which are placed equally to the crusher cavity (Figure 4.10). After the transportation remove the wedges.

Figure 4.10 Wooden wedges

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OPERATION

CHAPTER

5.1 BEFORE STARTING Remove all transport latches. Remove wooden blocks (3 pcs) from the crusher cavity (see figure 5.1). Check the condition of the machine. Ensure that the crusher is operated only in a safe manner and is in good condition. Use the crusher only when all necessary protective and safety devices – e.g., guards, emergency stop devices, silencers, aspirators – are in place and in operating condition. Starting the crusher is possible when the lubrication oil is warm enough. Connect the control voltage to warm up the oil. NOTE: Read the Instruction Manual before starting the crusher.

5

5.2 GENERAL INFORMATION PRIOR TO CRUSHING Crushing is most efficient when the crusher is full of stones.

Do not climb on the crusher, when it is in operation and do not touch any moving parts.

Do not try to clear the blocked crushing cavity, when the crusher is running. Be always very careful when clearing the cavity.

WARNING! Before starting the crusher, ensure that there are no persons in the area whose safety may be endangered! Walk around the crusher and ensure that there is nobody on, by or below the crusher. Warn everybody in the vicinity before starting.

Do not try to clear the blocked crushing cavity alone.

IMPORTANT! Ensure that the crusher cavity is empty.

IMPORTANT! At least once per shift, visually check the machine for defects and deficiencies. Report any changes (including changes in the operation of the machine) to the unit/person in charge immediately. If necessary, the crusher must be stopped without delay and the necessary safety precautions taken.

Immediately stop the crusher and take the necessary safety precautions in the event of a malfunction! Repair any faults or have them repaired immediately!

Figure 5.1 Remove the wooden blocks

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NOTE: IF THE CRUSHER STOPS UNEXPECTEDLY, TAKE THE FOLLOWING STEPS:

the main shaft down (be careful not to make the shaft drop quickly). –

If the crusher stops when loaded, it may pose a hazard to life and safety.

Remove all personnel from the vicinity of the machine, and report the situation to the person in charge of the plant. Switch the crusher power off to prevent unexpected starting. NOTE: Never inspect a stopped crusher from above; use the inspection hatches on the hopper or crusher instead. The pressure could cause a piece of material to fly out from the gap, causing an accident.

If the blockage is so bad that the above procedures do not help, remove the upper frame to release the pressure from the main shaft.

When the main shaft is fully down, the foreign metal object should fall out of the cavity, and it can then be removed using the conveyor as usual. Then ensure that there are no more foreign objects in the cavity. The crusher may be started again when the reason for the foreign object in the crusher cavity has been determined and possible damages have been repaired. WARNING! The foreign metal object in the crusher might be very hot. Do not touch it!

Determine why the crusher stopped. If a careful inspection indicates that the crusher did not stop due to an electrical or hydraulic fault, it may have stopped because of a foreign, metal object in the cavity. In this case, the crusher may pose a threat to life. If the crusher stops when loaded, release the pressure from the adjusting system by opening the manual valve on the lubricating device until the adjusting system pressure gauge indicates zero. Now there should be no pressure on any foreign object, apart from the weight of the stones on top of it. After releasing of the pressure, the crushing cavity may be inspected and the foreign object removed safely. If the main shaft must be lowered to empty the crusher, one of the following methods may be used:

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–

Lower the main shaft by using the manual valve (no electricity needed). Open the manual valve on the lubrication unit until the adjusting system pressure gauge indicates zero. Shut down the valve immediately after that.

–

Fill the crushing cavity with stones, or cover it with a suitable, approved cover to make it safe. Place a jack between the upper frame arm and shaft nut, and press

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5.3 STARTING •

Start the discharge conveyor (1), if equipped, for crushed material.

•

Start the process by pressing the “start” button at the control cabinet (refer to the automation system manual). Lubrication unit (2) starts.

•

Crusher (3) starts. NOTE! Bleed air from the setting adjustment system before starting the crusher for the first time. Refer to chapter 6.8.

•

.

After process has given permission, start the feeding device (4).

START

Figure 5.2 Starting steps (example arrangement with the IC50 automation system)

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5.4 OPERATING THE NEW OR RENOVATED CRUSHER •

Operate new or renovated crusher for 1 hour without load before feeding material in. If the renovating is done at the customers facilities, the operating time for an unloaded crusher is 4 hours.

•

After the unloaded operating time, the crusher is operated for 2 hours with a 50% load.

•

Operate the crusher for 5 hours with a maximum 75% load.

•

After this running-in period, the crusher can be operated with the maximum load.

•

Ensure that the pipes and hoses do not leak.

•

Ensure that the upper and lower frame do not move in relation to each other.

•

Ensure that the cooling of lubricating oil works as shown in the operating manual. Check that the oil temperature and the settings of thermostats are according the oil viscosity used.

•

Observe pressure and temperature of the lubricating oil.

•

Check and clean regularly the magnetic plugs and strainer located in the oil reservoir. It is possible that there are some steel and bronze particles in them during running-in period.

•

Ensure that the feed distributes evenly in the cavity.

•

Observe the cleanliness indicator of the pressure filter in the lubricating device.

•

Stop feeding sometimes and listen to the crusher for any abnormal noise. Knocking sound may come from loose liner.

•

Ensure that the top bearing does not leak grease.

•

Check oil level in the reservoir.

•

Check that the setting keeps constant.

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5.5 SETTING Setting is the closest relation between the bowl liner and mantle during the work cycle. It must be measured at the lowest point of the mantle. The setting determines the maximum size of the discharging material, crusher capacity and load. The setting may be measured by lowering a piece of lead with a wire through the crushing cavity when the crusher is idling, then measuring the thickness of the compressed lead (Figure 5.3). A piece of lead is delivered with the crusher in the tool box.

IMPORTANT! The crusher is equipped with cone crusher automation system. Therefore the setting can not be adjusted if the automation system is disconnected. Normally the setting adjustment is performed from the automation system display (i.e. manual or setting mode). However the setting can also be adjusted with the LCP (Local Control Panel) in local mode with separate panel. NOTE: For safety reasons the crusher must be running before the automation system allows the setting decrease.

WARNING! When measuring the setting the wire must not be wrapped around the hand. Since the liners could wear unevenly, measure the setting at three or four different points and then calculate the average of these measurement to obtain the crusher setting. Use of too small a setting increases the crusher load considerably. More accurate way to measure the setting is to perform contact calibration. For more detailed instructions refer to automation system manual.

IMPORTANT! Figure 5.3 Measuring the crusher setting

Contact calibration is possible ONLY for fine crushers. Automation keeps the crusher setting at the preset value. Overload situation opens the setting. System returns the setting to preset value when the overload situation is over.

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5.7 STOPPING •

Stop the process by pressing the “stop” button at the control cabinet (refer to the automation system manual).

•

Stop the feeding device (1).

•

Crusher (2) stops.

•

Stop the discharge conveyor (3).

•

Lubrication unit (4) stops.

.

STOP

Figure 5.4 Stopping order (example arrangement with the IC50 automation system)

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5.8 OVERLOAD PROTECTION The crusher is equipped with a shock valve which acts as an additional overload protection in extreme overload situations (fig 5.5). The shock valve has been adjusted at the pressure level indicated in the Table 5-1. When the pressure in the adjusting system reaches that pressure due to overload, the valve opens, oil flows to the lubrication unit return line and the setting increases. When the overload situation is over, automation system will adjust the setting back to the preset value. . Crusher GP200 GP200S GP300 GP300S GP550 GP500S

Pressure level bar (PSI) 30 (435) 20 (290) 35 (510) 26 (375) 35 (510) 35 (510)

Figure 5.5 Shock valve acts as an overload protection

Table 5-1

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MAINTENANCE

CHAPTER

6

6.1 GENERAL

WARNING! Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.

When the equipment is switched off during maintenance and repair, the motor controls must be locked out/off. Secure the lock keys and attach a hazard notice at the main disconnect switch. All service/repair, except those told in this manual, are allowed only for the servicemen qualified by Metso, to keep the warranty valid.

LOCKOUT PROCEDURE of the diesel engine driven crushers 1. Switch off engine 2. Remove the ignition key and keep it on person during lockout 3. Place appropriate maintenance warning signs (TAG OUT) LOCKOUT PROCEDURE of the electrical motor driven crushers 1. Switch off motor 2. Lock the main switch of the motor with a padlock or make sure in some other way that the motor cannot be started (locking must be done by every member of the work group) 3. Keep the keys on person during lockout 4. Place appropriate maintenance warning signs (TAG OUT).

The crusher repair and maintenance is allowed only for reliable and qualified craftsmen.

In any work related to the operation, modification, conversion or adjustment of the equipment and its safety devices including inspection, maintenance and repair, observe all starting, stopping and maintenance procedures as outlined in the instruction manual.

IMPORTANT! Ensure as extensively as possible that the immediate area is safe and secure.

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6.2 LIFTING WEIGHTS

GP200 GP200S GP300 GP300S GP550 GP500S

1 Countershaft Assy kg (lbs)

2 Main Shaft Assy kg (lbs)

3 Upper Frame Assy kg (lbs)

170 (375) 170 (375) 260 (573) 260 (573) 350 (772) 350 (772)

1700 (3750) 1950 (4300) 2540 (5600) 2970 (6550) 5280 (11600) 6600 (14600)

1600 (3530) 2650 (5840) 2150 (4740) 3850 (8200) 4600 (10100) 8380 (18500)

4 Lower Frame Assy (w/o countershaft) kg (lbs) 4300 (9480) 4300 (9480) 6820 (15000) 6830 (15100) 11630 (25600) 11550 (25500)

Figure 6.1 Lifting weights of assemblies (fine crushers)

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Figure 6.2 Lifting weights of assemblies (secondary crushers)

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6.3 SPACE REQUIREMENTS FOR MAINTENANCE When designing crusher installation remember that there must be enough space around the crusher for lifting and maintenance (figures 6.3 and 6.4). Required measures are indicated in the table below.

A B C D E F G H I J K L M N O

6-4

GP200 1013 1853 2620 2581 1881 1428 453 717 132 1103 1540 830 830 1165 1710

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GP200S 925 2166 2933 3205 2196 1742 454 717 132 1413 1540 830 830 1165 1710

GP300 1199 1873 2603 2590 1901 1411 490 680 132 1130 1820 939 1029 1400 2018

.

GP300S 1160 2231 2961 3291 2265 1766 499 680 132 1477 1820 943 922 1297 1915

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GP500S 1518 2840 3697 4209 2891 2236 655 807 132 1925 2280 1150 1134 1587 2334

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Figure 6.3 Space requirements for maintenance (fine crushers)

Figure 6.4 Space requirements for maintenance (secondary crushers)

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6.4 SPECIAL TOOLS FOR MAINTENANCE The delivery of the crusher includes a tool box containing tools and accessories necessary to maintain the crusher.

6.5 SERVICE PLATFORM To make maintenance and operation easy and safe, the crusher should be equipped with a service platform. If the service platform has not been ordered and supplied with the crusher, it must be built by the operator. The crusher’s service platform must meet the requirements of ISO 2867 or a corresponding standard. The appropriate height for the platform is the level of the support brackets. The platform and steps must be equipped with handrails to prevent personnel from falling down. All international and national regulations on service platforms for crushing equipment must be observed.

6.6 WELDING

Figure 6.5 Welding arrangement

When electric arc welding must be used to install or disassemble wear parts etc., the ground cable must be fastened directly to the part to be welded and as close to the welding point as possible (Figure 6.5).

IMPORTANT! Welding current must never pass through any connection or bearing.

IMPORTANT!

DANGER! There are components made of manganese steel in the crusher, such as liners and in some models protection plates of the upper frame arms. Welding or flame cutting these components generates gas that is extremely hazardous to health and causes manganese poisoning. This kind of work must be done outdoors or in well-ventilated premises equipped with local exhaust ventilation.

Before welding the crusher switch off the control voltage.

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6.7 CORROSION PROTECTION Corrosion occurs on iron and steel surfaces that are exposed to water and oxygen. Metal surfaces are exposed to oxygen and humidity practically all the time. On account of this, corrosion occurs constantly unless the equipment is sufficiently protected. The corrosion rate is influenced by the following: –

humidity

–

impurities in the air

–

physical conditions (temperature, rain, wind)

Corrosion can be expensive and dangerous.

6.8 BLEEDING AIR FROM THE ADJUSTING CYLINDER Air must be bled from the adjusting cylinder when the adjusting oil hose has been connected. Bleeding is done via bleed screw which is located on the lower frame. NOTE: Before bleeding the system, the oil must be at least +20°C (68°F) •

Fix the hose to the bleeding screw. Suitable hose is about 6 mm and it must be long enough to reach to the collector tray. Open the bleeding screw and close the manual valve in the lubrication unit.

•

Start the lubrication pump and the crusher manually (refer to automation system manual). Notice that there is 2 minutes delay before the crusher starts. Run the crusher until only oil is coming through the hose to the collector tray. Do not run the crusher more than 30 seconds. Stop the crusher.

•

After the crusher has stopped, tighten the bleeding screw and remove the hose.

Corrosion can –

cause unnecessary downtime

–

increase maintenance costs

–

decrease the service life of equipment

–

cause dangerous situations

To ensure economical and safe crushing, regular corrosion-protection procedures must be used for the equipment. Use only well-tried methods and substances. Before long-term storage, the machine must be protected against corrosion, and a suitable storage location must be selected.

IMPORTANT! Use a collector tray so that the oil does not spill to the ground.

After long-term storage, the machine must be inspected for corrosion. Corrosion may occur, e.g., between the bronze bearings and the steel eccentric shaft and main shaft due to the materials differing. In this case, rust must be removed by grinding the parts.

Figure 6.6 The air bleeding screw.

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6.9 TIGHTENING TORQUE FOR BOLTS 6.9.1 Cavity mounting bolts The bowl liner bolts are to be tightened in accordance with the table below. The tightening torque indicated is for a clean, unlubricated bolt. The threads are not surface-treated. The bolts must be tightened according to class 5.6.

Crusher

Bolt

GP200 GP200S GP300 GP300S GP550 GP500S

M30 M30 M30 M30 M36 M36

Torque Nm 579 579 579 579 1,010 1,010

ft lbs 426 426 426 426 744 744

6.9.2 Other bolts Other bolts must be tightened in accordance with the table below. The tightening torque indicated is for a clean, unlubricated bolt. The threads are not surface-treated. The bolts’ strength class is 8.8.

Torque

Bolt M10 M12

Nm

ft lbs

47

35

81

60

Width across the flats mm in 17

43/

64

19

3/

4 64

M16

196

145

24

61/

M20

382

282

30

1 3/16

M24

662

488

36

1 27/64

M30

1324

976

46

1 13/16

M36

2314

1705

55

2 11/64

M42

3707

2732

65

2 9/16

M48

5590

4120

75

2 61/64

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6.10 LUBRICATION For the main lubrication see Instruction Manual for GP Lubrication System.

6.10.1 Countershaft system The amount of oil in the countershaft system is shown in the table below. Oil is filled via the breather hole on the countershaft housing, so the breather must be unscrewed before filling (A). For draining the oil, there is a drain plug on the bottom of the housing (B). The oil level should reach up to the level plug hole (C).(Figure 6.7) Use the same lubricating oil as in the lubrication and adjusting system; refer to separate instructions.

Crusher GP200 GP200S GP300 GP300S GP550 GP500S

Oil amount liters (US gallons) 2,0 (0,5) 2,0 (0,5) 2,0 (0,5) 2,0 (0,5) 5,0 (1,3) 5,0 (1,3)

Table 6-1 The filling amount of oil in the countershaft system

Figure 6.7 Draining and adding oil to the countershaft

6.10.2 Top bearing The top bearing grease capacity is shown in the table 6-2. The usual filling has to be accomplished at the liner change, when the crusher is dismantled. If the top bearing seal leaks, change the sealing and fill top bearing housing with grease. The housing of the bearing should be filled with grease, when the main shaft is fully lowered (figure 6.8). Suitable grease quality is a semisolid EP (pressure-proof) grease.

Crusher GP200 GP200S GP300 GP300S GP550 GP500S

Grease capasity kg (lbs) 7 (15,4) 7 (15,4) 8 (17,6) 8 (17,6) 10 (22) 10 (22)

Table 6-2

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Recommended brands are e.g.:

Brand BP MOBIL PETRO CANADA SHELL NESTE CALTEX

Type Energrease LS-EPO Mobilith SCH 007 Precision XL EP000 Alvania GC 00 Centergrease 00 EP Multifak EP 0

Table 6-3

NOTE: Oil brands listed above are suitable for temperature range -25 - +40°C (-13 - +104 F). If the temperature is outside this range, contact your local construction expert at Metso.

Figure 6.8 Fill top bearing housing with grease

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6.11 SCHEDULED MAINTENANCE 6.11.1 Scheduled maintenance for new crusher A new or renovated crusher has to be inspected and the following maintenance should be accomplished during the first 100 hours of operation. After first 10 hours of operation LINERS Check the bowl liner bolt tightening torques (Figure 6.9 and 6.10). NOTE: This check must also be performed after changing the wear parts

Figure 6.9 Check the bowl liner bolts (fine crusher)

HOSES AND PIPES Check all hose and pipe connections. Repair all leakages immediately. V-BELTS Check the tension of V-belts and tighten as necessary.

Figure 6.10 Check the bowl liner bolts (secondary crusher)

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6.11.2.3 Top bearing seal

6.11.2 Every eight hours of operation / every shift

Check the condition of the top bearing seal. The seal prevents grease from leaking out from the top bearing housing. A leak is indicated by grease on the main shaft, above the tightening nut (Figure 6.12). A damaged seal must be replaced immediately. For more detailed instructions, refer to subsection 6.13.6.

6.11.2.1 Lubricating and adjusting equipment NOTE: For more maintenance information, refer to the Lubrication unit manual Check the oil amount in the lubrication tank. The oil level should be above the middle of the scale. When the crusher is running, the oil level should not descend below the minimum point in the scale (A, Figure 6.11). Add oil as necessary. Check the return oil filter basket (B, behind the cover).

Figure 6.12 If there is grease on the main shaft, the top bearing seal must be replaced

A

B

Figure 6.11 Check the oil level (A) and the return oil filter basket (B)

6.11.2.2 Hoses Check the hoses and fittings, and repair any leaks immediately.

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6.11.3 Every 40 hours of operation / every week (one-shift operation)

6.11.3.1 Entire crusher Check visually the overall condition of the crusher (bolt tightness, leaks, wear, any cracks, etc.). Repair any faults immediately.

6.11.3.2 Liners Observe the possible uneven wear of the liners. Uneven wear of the liners may be caused by incorrect feeding of the crusher. In this case, the feed must be adjusted. For instructions, refer to subsection 4.4.

6.11.3.3 Lower frame arms Open the inspection hatches (3 pcs.) on the lower frame, and clean the arms and slip ring, removing crushed rock and other accumulated material. Cleaning must be performed more frequently if there are tree roots, wires, iron bars, etc. among the rock material. If there is oil on the slip ring under the head, the cause must be determined and rectified.

6.11.3.4 V-belts Check the tension and wear of the V-belts. Tension as necessary, or replace the entire set of V-belts at the same time. For tensioning instructions, refer to subsection 4.7.

6.11.3.5 Electrical equipment Check visually the condition of electrical cables and components, ensuring that there are no cracks or signs of abrasion. Immediately repair any faults, and follow the regulations on electrical safety and inspections.

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6.11.4 Every 400 hours of operation / every month (two-shift operation) / every two months (one-shift operation)

6.11.5 Every 2,000 hours of operation / every year (one-shift operation) / every six months (two-shift operation)

6.11.4.1 Main shaft dust seal

6.11.5.1 Thrust plates

Check the clearance between the slip ring and the main shaft dust seal every 400 hours or always during the mantle change. For more information refer to section 6.13.2.

Check the condition of the main shaft’s thrust plates. If the oil grooves in the bronze plates are less than 2 mm deep, the plates must be replaced. The inspection is to be made during mantle replacement. For more detailed instructions, refer to subsection 6.13.5.

6.11.4.2 Lubricating oil of the countershaft system Change the lubricating oil of the countershaft system. Drain the oil through the plug. Fill new oil through the breather hole (Figure 6.7). For the amount of oil, refer to Table 6-1. For the oil type, refer to the lubricating and adjusting device manual

6.11.5.2 Checking the gear backlash Check the countershaft and eccentric shaft gear backlash.

6.11.4.3 Feed and discharge hoppers and crusher protecting guards Check the condition of the hoppers, guards, and protective cap. If necessary, replace the wear part. Check the protection plates. Refer to 7.8.

6.11.4.4 Dust removal Remove dust from the V-belt guards, v-belt pulleys and the lubrication unit.

6.11.4.5 Pressurized sealing system Check the operation of the overpressure device and the condition of the hose.

Figure 6.13 Checking the gear backlash

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Crusher

GP200 GP200S GP300 GP300S GP550 GP500S

Pulley [mm] 450 530 560 530 450 475 530 560 560 560

Lower limit [mm] 1,4 1,7 1,8 1,7 1,2 1,3 1,5 1,5 1,3 1,3

Upper limit [mm] 1,8 2,1 2,2 2,1 1,6 1,7 1,9 1,9 1,7 1,7

Table 6-4 Free movement on the outer diameter of the V-belt pulley

NOTE: If the backlash is outside the limits above, contact your local construction expert at Metso.

6.11.5.3 Breathers Replace the breather air filters and check the function of the breather. Refer to figure below.

Figure 6.14 Breathers

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6.11.6 Seasonal maintenance (summer/winter) Change the lubricating oil. For oil recommendations, refer to the lubricating and adjusting device manual. If necessary, also change the filter and clean the lubricating oil tank. Change top bearing grease every six months if not done during mantle change Replace the the air filter of the pressurized dust sealing.

6.11.7 Every 20,000 hours of operation / every 10 years (one-shift operation) / every 5 years (two-shift operation) Entire crusher is inspected. Special attention is paid to following points: •

All bearings (clearances)

•

Clearances between the frame joints

•

Wear of the frames

•

Condition of the Lubrication unit and the hoses

•

Condition of the safety devices (e.g shock valve)

NOTE: This procedure is performed by the Metso specialist.

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6.12 MAINTENANCE CHART

ELECTRICAL EQUIPMENT Check the condition of cables and components. THRUST BEARINGS Check the condition of the thrust bearings. COUNTERSHAFT SYSTEM Change the lubricating oil of the countershaft system. Check the clearance. TOP BEARING SEAL Check the condition of the seal. MAIN SHAFT DUST SEAL Check the condition of the seal. PRESSURIZED SEALING Check the operation of the overpressure device. Replace the air cleaner. CRUSHER Check the tightness of the hydraulic hoses and connections. Check the tension and wear of the V-belts. Observe the possible uneven wear of the liners. Check the condition of the hoppers, guards, and protective cap. Clean the lower frame arms, removing debris. Check the overall condition. Overhaul the crusher. Remove dust from the crusher LUBRICATING AND ADJUSTING UNIT Check the oil amount in the lubrication tank Check the return oil filter basket

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20,000 h

summer/ winter

2,000 h

400 h

40 h

8h

More detailed instructions for each maintenance procedure are provided above.

X X X

X X

X X X X

X X X X X X X X X X

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6.13 OTHER MAINTENANCE

6.13.2 Replacing the main shaft dust seal

6.13.1 General

The condition of the main shaft must be checked every time the mantles are replaced. The seal must be replaced if it is damaged, if the clearance between the seal and slip ring exceeds 1.5 mm (Figure 6.15), or if the top or bottom surface of the seal is heavily worn.

The machine must be serviced and repaired by reliable professionals who are adequately acquainted with it. The startup and shutdown instructions in the instruction manual, and all applicable servicing instructions, must be followed in all proceedings concerning the operation of the machine and its safety devices, as well as inspection, servicing, and repairing of the machine. Reserve a large safety zone around the machine for maintenance. When the crusher has been shut down for servicing or repairs, make sure that it cannot be restarted unintentionally. Open the main switch, and remove the ignition key. Attach a warning sign to the main switch, and lock the switch. Maintenance procedures not described in this manual must be performed by Metso authorized technicians only; otherwise, the machine’s warranty becomes void.

IMPORTANT! Following maintenance operations may be done during the liner change

Figure 6.15 The maximum clearance between the slip ring (A) and dust seal (B) is 1.5 mm

Lift the main shaft off. Screw an eye bolt (supplied with the tools and accessories) into the hole at the upper end of the shaft, and carefully lift the main shaft up. For the main shaft weight, refer to subsection 6.2. NOTE: Intermediate thrust plate may shift when you lift up the shaft. Check and relocate (if necessary) intermediate thrust plate before installing main shaft back.

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GP200 GP200S GP300 GP300S GP550 GP500S

Figure 6.16 Lower the main shaft onto the ground

Slide ring kg (lbs) 25 (55) 26 (57) 64 (141) 64 (141) 171 (377) 130 (287)

Seal kg (lbs) 3 (7) 3 (7) 5 (11) 5 (11) 12 (27) 10 (22)

Place the main shaft on its side, taking care not to damage the bearing surfaces at its lower and upper end (Figure 6.16). Do not lower the thrust bearing at the lower end of the shaft onto the ground; use a rubber plate as protection. Remove the slide ring mounting bolts. Remove the slide ring by screwing four jacking bolts into the threaded holes and forcing the slide ring out. Protect the bearing surface on the shaft with, e.g., a board or rubber plate to prevent the slide ring from damaging the bearing surface when it comes loose. Lift the slide ring away, and remove the old seal. Clean the new seal and the seal housing, and install the new seal. The seal does not require greasing. Lift the slide ring onto the seal. Fasten the slide ring in place with the mounting bolts. Do not forget the washers. Ensure that the seal moves freely in the housing (Figure 6.17). If necessary, shims may be used between the slide ring and head.

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Figure 6.17 Ensure that the seal moves freely in the housing

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6.13.3 Checking / replacing the top bearing The top bearing must be replaced if it is damaged or exceeds wear limits. The top bearing may be replaced only when the upper frame has been lifted off – e.g., during replacement of the liners.

mount using bolts; refer to subsection 6.9 for the tightening torque. Test run the crusher without load, ensuring that it is operating properly.

For dismantling the upper frame assembly refer to subsection 7.3. Remove the top bearing housing cover bolts and lift the cover off. Remove the grease from the upper section of the top bearing housing (Figure 6.18).

Figure 6.19 Pulling out the bearing

Figure 6.18 Remove the grease from the upper section of the top bearing housing

Unscrew the top bearing mounting bolts. Pull the top bearing out by using jacking bolts (Figure 6.19). If the bearing does not come loose, heat the housing. Lift the bearing away. Install the new top bearing. Heat the housing slightly, to facilitate installation. Install the top bearing bolts; refer to subsection 6.9 for the tightening torque. Fill the top bearing housing with grease (Figure 6.18). For lubrication instructions, refer to subsection 6.10. Check the condition of the cover, and repair or replace if necessary. Lift the cover into place, and

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6.13.4 Replacing the main shaft protective sleeve If the protective sleeve at the upper end of the main shaft is damaged or exceeds wear limits, it must be replaced as well. The sleeve may be replaced only when the upper frame has been lifted off.

IMPORTANT! Carefully cut the protective sleeve with a grinder. Be careful not to damage the shaft.

Carefully clean the shaft and the new protective sleeve. Heat the new protective sleeve until the temperature difference between it and the main shaft is 160 °C. However, the temperature of the sleeve must not exceed 240 °C. The protective sleeve is equipped with lifting holes (M8); use these to install the sleeve in one go. If you fail to install the sleeve in one go, cut it off and try again with a new sleeve.

Figure 6.20 Main shaft protective sleeve

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6.13.5 Checking / replacing thrust plates

bearing away. The diameter of the bearings is about 1.5 mm smaller than that of the eccentric bushing.

The condition of the thrust plates must be checked annually. It is easiest to perform the inspection during replacement of the liners. The bronze plates in the thrust plate assembly – (A) at the lower end of the main shaft and (C) in the adjusting cylinder – must be replaced when the oil grooves are less than 2 mm deep (5 mm in new plates), at the latest. Also check the condition of the intermediate thrust plate (B, steel). NOTE: Change all plates at the same time.

Clean the lower thrust bearing housing, and install the new bearing and thrust plate separately. Ensure that the thrust bearing locking pin enters the hole and the bearing is properly seated. Slide the thrust plate on top of the thrust bearing to the eccentric side, to allow the thrust bearing assembly to settle as well as possible into place when the main shaft is lowered. To check that the thrust plate is in the correct position, measure distance “K” between the slip ring (A) and the dust seal (B) when the main shaft (piston) is fully down. This distance should be 8 mm .

Figure 6.21 Thrust plates on the main shaft

For replacement of the plates, the main shaft must be lifted off and placed on its side. For lifting instruction of the main shaft, refer to chapter 7.5.

Figure 6.22 Distance between the slip ring (A) and dust seal (B) should be 8 mm.

If the value is higher, the thrust plates have not been optimized correctly. Lift the main shaft, and correct the position of the thrust plate.

Remove the locking plate of the bearing mounting bolt at the end of the main shaft, and unscrew the bolt. Remove the thrust plate. Clean the thrust plate and its position on the shaft, and reinstall the plate. Notice the locking pin. Lock the mounting bolt with the locking plate.

IMPORTANT! For replacement of the thrust plates, remove the oil from the crusher. Screw an eye bolt into the hole on the lower thrust plate hub, and carefully lift the thrust plates and

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6.13.6 Replacing the top bearing seal The condition of the top bearing seal must be checked daily. If the seal is damaged, there is grease on the main shaft, above the tightening nut (Figure 6.23). A damaged seal must be replaced immediately. Dismantle the upper frame assy as described in subsection 7.3, “Dismantling the upper frame assembly” and lift the upper frame onto a stand. Remove the old seal from the upper frame.

Figure 6.25 Installing the top bearing seal

After this, replace the mantles (if necessary) and assemble the crusher as described in subsection 7.6

Figure 6.23 Is there grease on the main shaft?

Insert the new seal with the groove up (Figure 6.25). In subzero conditions, first warm the seal to room temperature to make the mounting easier and to avoid breakage of the seal. Bend the seal during mounting (Figure 6.24).

Figure 6.24 Bend the seal during mounting

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7

7.1 GENERAL WARNING! Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out. LOCKOUT PROCEDURE of the diesel engine driven crushers 1. Switch off engine 2. Remove the ignition key and keep it on person during lockout 3. Place appropriate maintenance warning signs (TAG OUT) Figure 7.1 Distances to check the wear of the liners

LOCKOUT PROCEDURE of the electrical motor driven crushers 1. Switch off motor 2. Lock the main switch of the motor with a padlock or make sure in some other way that the motor cannot be started (locking must be done by every member of the work group)

GP200 GP200S

3. Keep the keys on person during lockout

GP300

4. Place appropriate maintenance warning signs (TAG OUT).

GP300S GP550

IMPORTANT!

GP500S

The liners must not be worn through, since this would damage the liner mating surfaces on the frame or head, which would then require pad welding and machining. The wear of the liners may be checked by measuring the distance between the mantle tightening nut and the bottom of the top bearing housing (distance “A”, Figure 7.1). The liners must be replaced, when distance “A” reaches the value indicated in the Table 7-1. With secondary crushers control the distance between the upper and lower bowl liner (“B”, Figure 7.1). It must be at least 3 mm (1/8”) but not more than 20 mm (25/32”). If it is less than 3 mm, cut some material off from the bowl liner.

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A (with new liners) 168 (6 5/8") 164 (6 1/2") 160 (6 5/16") 167 (6 9/16") 250 (10”) 240 (9 1/2")

A (replacement limit) 11 (7/16") 10 (3/8") 11 (7/16") 11 (7/16") 15 (5/8”) 15 (5/8”)

Table 7-1 The liners must be replaced at the latest when the distance "A" is reached

IMPORTANT! Change the liners earlier if they wear out due to uneven feed. The part numbers of wearing and spare parts needed for replacing the liners are indicated in the spare parts manual. Before installing the liners, carefully remove the anti-rust agent. Use a suitable hand tool to remove any transportation damage, rust, etc. as well.

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When you are changing the stroke and gap option, it may be useful to change the rotation speed of the crusher as well, to optimize the capacity and product quality. In such cases, contact your local construction expert at Metso.

IMPORTANT! To check the tightening torques of the bolts, refer to subsection 6.9.

7.2 WELDING When electric welding equipment is used to fasten or disassemble wearing parts or other components, the ground cable must be fastened directly to one of the parts to be welded, as close to the welding point as possible (Figure 7.2).

IMPORTANT! The welding current must never pass through any bearing or joint surface! Figure 7.2 Welding the crusher

IMPORTANT! Before welding switch off the control voltage.

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DANGER! There are components made of manganese steel in the crusher, such as liners and in some models protection plates of the upper frame arms. Welding or flame cutting these components generates gas that is extremely hazardous to health and causes manganese poisoning. This kind of work must be done outdoors or in well-ventilated premises equipped with local exhaust ventilation.

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7.3 DISMANTLING THE UPPER FRAME ASSEMBLY Bearing housing cover kg (lbs) 100 (220) 100 (220) 130 (287) 130 (287) 320 (705) 410 (904)

Feed hopper kg (lbs)

DANGER! When working high, e.g. on the top of the crusher, wear the safety harness! Remove the gravel and stones from on top of the slip ring inside the crusher, so that the main shaft can move freely down.

GP200 GP200S GP300

450 (992) 530 (1170 530 (1170) 600 (1320) 950 (2090) 1640 (3620)

Lower the main shaft by opening the magnetic valve or manual valve on the lubricating and adjusting device. When the main shaft has been lowered, close the valve.

GP300S

Remove the feed hopper bolts, and lift the hopper away.

GP500S

Remove the top bearing housing cover bolts and lift the cover away.

Table 7-2 Lifting weights

GP550

Upper Frame Assy kg (lbs) 1500 (3310) 2550 (5620) 2020 (4450) 3720 (8200) 4600 (10100) 7970 (17600)

NOTE: If the old lifting points have worn out, weld new lifting lugs to the cover Remove the grease from the upper section of the top bearing housing (Figure 7.3). Remove the bolts on the joint between the upper and lower frame (Figure 7.4) or the intermediate and lower frame (Figure 7.5). Separate the joint between the upper and lower frame by using four jacking bolts (Figures 7.6 and 7.7). The separation can be assisted by attaching hoisting ropes to the upper frame and tensioning them with the crane. In this case, leave three bolts loosely attached to the frame joint (equally spaced). The bolts must have nuts on them such that the joint can be separated 10–20 mm. This is to ensure that the upper frame does not jump off when it comes loose.

Figure 7.3 Remove the grease from the upper section of the top bearing housing

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Figure 7.4 Remove the bolts on the joint between the upper and lower frame (fine crusher)

Figure 7.6 Separate the joint between the upper and lower frame by using four jacking bolts (fine crusher)

Figure 7.5 Remove the bolts on the joint between the intermediate and lower frame (secondary crusher)

Figure 7.7 Separate the joint between the intermediate and lower frame by using four jacking bolts (secondary crusher)

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Lift the upper frame assembly away (Figures 7.8 and 7.9). You can tie the hoisting ropes around the upper frame arms. Lower the upper frame assembly onto a stand for removing the bowl liner. WARNING! Do not open the bowl liner bolts before lifting the upper frame assembly

Figure 7.8 Lift the upper frame away (fine crusher)

Figure 7.9 Lift the upper and intermediate frames together away (secondary crusher)

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7.4 REPLACING THE BOWL LINER

Clean and inspect the bowl liner mounting surface on the upper frame and the conical mounting surfaces of the frame joint. If they are badly worn, they must be pad-welded and machined.

7.4.1 Fine crushers Remove the nuts from the bowl liner mounting bolts (Figure 7.10).

Clean the bowl liner mounting surface. If a protection cone is used, place it on top of the bowl liner. Lift the frame onto the liner such that the mounting bolt holes are aligned. To facilitate alignment, place two bolts in their holes. NOTE: With short bowl liners (extra fine (EF) and fine (F)), check that the clearances between bowl liner lugs and the upper frame are equal. Tighten the nuts on the two bolts, and insert the rest of the bolts into their holes (Figure 7.11). The bowl liner is mounted with six bolts and nuts. See Figure 7.10

Figure 7.10 Nuts on the bowl liner mounting bolts

.

Remove the bowl liner from the upper frame by hitting the upper frame with a sledgehammer from different sides. Be cautious of the falling liner.

DANGER! Do not use explosives for removing the bowl liner! If the bowl liner does not come loose, drive wedges between the bowl liner lugs and upper frame. Some Extra fine (EF)…Medium (M) bowl liners may have the protection cone and/or intermediate cone. In these cases ensure that whole package can be removed together out from the frame.

Figure 7.11 Tighten the nuts on the two bolts, and insert the rest of the bolts into their holes

NOTE: When placing the bowl liner bolts, make sure that the flat side of the bolt head is facing outwards (Figure 7.12)

DANGER! Watch out for the possibly falling ptotection cone and/or intermediate cone! Lift the frame off the liner, and place it on a stand.

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. IMPORTANT! If the contact surfaces in the frame have worn too much, i.e. there is gap between the bowl liner seating surface and the frame, contact your local construction expert at Metso for more information. Check the top bearing seal, and replace it if necessary. Refer to subsection 6.13.6. Check the condition of the upper frame protection plates. Repair or replace if necessary.

X

Figure 7.12

Tighten the nuts alternately, a little at a time. For the tightening torque, refer to subsection 6.9.1. When tightening the bowl liner bolts, notice that there must be some clearance left between the bowl liner lug and the frame (clearance X in the Figure 7.12).

Figure 7.13 There must be no gap between the bowl liner and the frame

IMPORTANT!

GP200

There must be no gap between the bowl liner seating surface and the frame (Figure 7.13). The service life of the liner is reduced if it is allowed to move in the frame.

GP300 GP550

Bowl liner kg (lbs) 654 (1442) 1098 (2421) 1892 (4171)

Table 7-3 Lifting weights for fine crusher bowl liner

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7.4.2 Secondary crushers Replacing the lower part of the bowl liner is similar to the fine crusher. Refer to previous section. When replacing the upper part of the bowl liner, remove the nuts from the connection between the intermediate and upper frame (Figure 7.14). Open the connection with four jacking bolts (N, Figure 7.16). Leave four equally distributed bolts loose in the frame connection. Screw the nuts on the bolts so that the connection can open about 10 20 mm (3/8" - 3/4"). This ensures that the upper frame cannot jump away.

IMPORTANT! Distance B between the upper and lower bowl liner must be at least 6 mm (15/64”). (Figure 7.15)

Figure 7.15 Check the distance B

Figure 7.14 Remove the nuts from the connection between the intermediate and upper frame

Remove the tightening wedges (L) by torch cutting or grinding (Figure 7.16). Lift the upper part of the bowl liner by using the lifting holes. If needed, insert wedges between the lower and upper part of the bowl liner to remove it. Clean and inspect the liner seating surfaces in the frame as well as the conical mounting surfaces between the frames.

Lift the upper frame in place so that the grooves for the tightening wedges of the upper part of the bowl liner will stay below the supporting arms of the upper frame. Install the bolts and nuts between the upper and intermediate frame and tighten evenly, tightening torque see chapter 6.9. Place the wedges under the supporting arms and ensure the wedges will tighten the bowl liner to the frame. If necessary weld a flat bar to the bowl liner groove and cut the extra length of the wedge so that dimension K is greater than 0 and M is greater than 10 mm (3/8"). Hit the wedges tight and weld them to the bowl liner using stainless electrode (Figure 7.16). NOTE: Do not use old wedges. Replace wedges every time the upper bowl liner is replaced.

Lift the new upper part of the bowl liner in place and hammer it to seat it properly.

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Figure 7.16 Tightening wedges

GP200S GP300S GP500S

Upper Lower Upper Lower Upper Lower

Bowl liner kg (lbs) 310 (684) 465 (1026) 472 (1041) 951 (2097) 1317 (2904) 1916 (4224)

Table 7-4 Lifting weights for secondary crusher bowl liners

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7.5 REPLACING THE MANTLE The mantle is replaced with the main shaft lifted off. When the main shaft is lifted it is possible to check the thrust plates at the lower end of the shaft. When you are going to lift the main shaft, screw the eye bolt (supplied with the tools and accessories) into the hole at the upper end of the shaft, and carefully lift the main shaft away. For the weight of the main shaft refer to chapter 6.2.

After the main shaft has been lifted away, check the condition of the thrust plates. If the bronze plates have been worn such that their oil grooves are less than 2 mm deep, the plates must be replaced. The inspection must be made at least once a year. Refer to subsection 6.13.5. 7.5.1 Removing the old mantle For removing the mantle, burn open the torch ring between the locking welds (Figure 7.18). Do not damage the main shaft.

WARNING! The surface in the frame flange is greasy and slippery. Take care of occupational safety while standing on the surface!

2

1

Lower the main shaft onto a stand such that it is supported from the lower end of the head – NOT THE SEAL, taking care not to damage the bearing surfaces at the lower and upper end of the shaft. Do not lower the thrust bearing at the lower end of the shaft onto the ground; use a rubber plate as protection (Figure 7.17). WARNING! Before replacing the mantle, the main shaft must be supported properly

Figure 7.18 Torch ring (1) and locking nut (2)

Weld an arm (e.g. flatbar 25x100-250) to the nut. Hit the arm with a sledgehammer clockwise until the nut comes loose. Note the left-hand thread. To lift the locking nut away, weld two equally divided nuts (M16/ 5/8”) to the upper surface of the locking nut. (Figure 7.19). NOTE: Screw the eye bolts to the nuts before welding, to keep threads working properly.

Figure 7.17 Example of supporting the main shaft

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Figure 7.19 Lifting the locking nut

Clean and inspect the tightening nut. If it is in good condition it can be reused. Leave the welded arm into the nut. Also clean and inspect the thread in the main shaft.

Item 1 2 3 4 5

WARNING! Do not try to lift the worn mantle from the lifting hooks cast onto the mantle. They are suitable for lifting only in new mantles. Weld new lifting lugs to the worn mantle.

Measure) 100 mm (4”) 50 mm (2”) 50 mm (2”) R50 mm (2”) 50 mm (2”)

Figure 7.20 Measures of the lifting lug

Make two lifting lugs according to Figure 7.20. Use 10mm (3/8") thick steel plate made from ISO-EN10025-S355 (ASTM A 572/572M-04 Gr. 50) or similar. Weld the lugs to the mantle according to Figure 7.21. Use the following welding procedure: a. Use austenitic stainless steel electrodes: AWS A5.4: E 307-16 EN 1600: E 18 8 Mn R26 (e.g. ESAB OK 67.45) b. Do not preheat the mantle. Interpass temperature must remain under 200°C (392°F). Observe the temperature closely and let the mantle cool down if necessary. c. Carefully grind the surfaces to be welded. d. Weld the lugs to the mantle by a fillet weld (a=6 mm (1/4")) around the lug.

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e. Fill any craters!

Figure 7.21 Lifting lugs welded on the mantle

WARNING! Figure 7.22 Lift the protection cone (1) and mantle (2) together

Before lifting the mantle using welded lifting lugs make sure that the lugs are strong enough and welding is performed properly. NEVER GO UNDER THE SUSPENDED LOAD.

Lift the mantle away. If the mantle cannot be lifted, hit it with a sledgehammer from different directions.

WARNING! If the mantle has the protection cone DO NOT try to lift it separately. Weld the lifting lugs to the mantle and lift the protection cone and the mantle together. (Figure 7.22) GP200 GP200S GP300 GP300S GP550 GP500S

Mantle kg (lbs) 479 (1056) 578 (1274) 755 (1664) 930 (2050) 1218 (2685) 2330 (5137)

Table 7-5 Lifting weights for mantles

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7.5.2 Installing the new mantle Clean and inspect the mantle mounting surface of the head, and repair it if necessary. Check the condition of the main shaft dust seal, and replace it if necessary. The clearance between the dust seal and slip ring must not exceed 1.5 mm. For more detailed instructions, refer to subsection 6.13.2. Check the condition of the lower frame protection plates. Repair or replace if necessary.

After tightening the nut, weld the nut, torch ring, and mantle / protective cone with six, equally spaced, 50...70 mm (2...2 ¾”) long welds (Figure 7.24). Also weld the protection cone and mantle together with six, equally spaced, 50 mm (2”) welds. Remove the welded arm. NOTE: Start the welding by closing the cap in the torch ring .

Clean the mounting surface of the new mantle. Lift the mantle into place. Ensure that the bottom edge of the mantle mounting surface rests tightly on the head; there must not be a gap between these (Figure 7.23). Install the protection cone, if any. Install a new torch ring on the mantle. The nut must be replaced at least after every fifth mantle change. Clean the surface of the nut that is against the ring.

Figure 7.24 Weld the torch ring, nut and mantle together

Figure 7.23 There must be no gap between the mantle and the head

Tighten the nut by turning it counterclockwise. Notice the left-hand thread. Tighten the nut by hitting the welded arm with a sledgehammer. At the same time, you can also knock the mantle with the sledgehammer to make it settle more tightly into place. Continue tightening until the mantle no longer clangs when knocked with the sledgehammer.

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–

Installing the main shaft –

Ensure that the intermediate thrust bearing has not moved out of position during lifting of the main shaft.

–

When reinstalling the main shaft, slide the (steel) thrust plate on top of the (bronze) thrust bearing under the main shaft to the eccentric side, to allow the thrust bearing assembly to settle into place as well as possible when the main shaft is lowered.

Carefully lift the main shaft into the crusher. Remember that the hole of the eccentric shaft is slightly askew, and pay special attention to the bearing surfaces. Also, be careful not to damage the dust seal ring when it slides onto the slip ring. When lowering the main shaft, control the process through the inspection hatches. (Figure 7.25)

.

Figure 7.25 Be mindful of the dust seal ring when installing the main shaft. Use the inspection hatches to control the lowering process.

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7.6 INSTALLING THE UPPER FRAME ASSEMBLY Lubricate the top bearing seal. Use the same grease as in the top bearing. Lift the upper frame assy into place, taking care not to damage the top bearing seal (Figure 7.26).

Figure 7.27 Insert the mounting bolts and nuts on the joint between the upper and lower frame (fine crusher)

Figure 7.26 Lift the upper frame into place

Insert the mounting bolts and nuts on the joint between the upper and lower frame in fine crusher (Figure 7.27) and between the intermediate and lower frame in the secondary crusher (Figure 7.28). Tighten the joint evenly, refer to subsection 6.9.2 for the tightening torque. When the upper frame is lowered onto the lower frame, there must be a clearance of 2–4 mm between the frame flanges, which is then closed by tightening the bolts.

Figure 7.28 Insert the mounting bolts and nuts on the joint between the intermediate and lower frame (secondary crusher)

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7.7 RE-TIGHTENING CAUTION After tightening no clearance is allowed between the frames. Failure to tighten frame bolts properly will cause damage to the tapered joints and will need a major repair.

After 10 hours of operation, tighten the bowl liner mounting bolts; refer to subsection 6.9.1 for the tightening torque. After 25 hours of operation, tighten the bolts on the joint between the lower and upper frame; refer to subsection 6.9.2 for the tightening torque. .

Fill the top bearing housing with grease (Figure 7.29). For lubrication instructions, refer to subsection 6.10.2.

10 h

25 h

Figure 7.30 Re-tightening after replacement of the liners Figure 7.29 Fill the top bearing housing with grease

Check the condition of the cover, and repair or replace if necessary. Lift the cover into place. NOTE: Notice the correct position of the cover and the breather. Check the condition of the feed hopper, and repair if necessary. Lift the hopper into place. Test run the crusher without load for a while, to ensure that it is operating properly.

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7.8 PROTECTION PLATES The protection plates protect the crusher frame from being hit by rocks. The plates are made of wear resistant steel, and they may be replaced as necessary. There are protection plates on the upper frame arms, in the crusher cap, and on the lower frame arms. Regularly check the condition of the protection plates. Worn-out plates are to be removed and replaced with new plates, which are mounted by welding.

IMPORTANT! The protection plates must not be worn through in any circumstances. Change the plates if there is a possibility that they might worn through before next liner change.

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CHAPTER

Equipment malfunction may occur for a number of reasons: incorrect operation of the equipment (from overloading, carelessness, or inexperience), or a normal wearing out of parts. Electrical controls should be designed so, that these possible malfunctions do not allow any additional damage. MALFUNCTION THE PROCESS WILL NOT START

8

For troubleshooting see also instruction manuals for GP Lubrication System and the automation system. Some typical malfunctions and the possible solutions follow:

CAUSE • Emergency stop is activated

THE OIL PUMP WILL NOT START • Stop sequence is running.

REMEDY • Deactivate the emergency stop button • Wait until the stop sequence is finished • Check the electric connections • For more information contact Metso

• There is not enough oil in the tank.

• Add oil.

• Tank oil temperature is too low.

• Wait until the oil is warm enough.

• Tank oil temperature is too high. • Let the oil cool down. Determine the reason for excessive temperature.

THE CRUSHER WILL NOT START

• Pressure switch contact closed before start

• Check pressure switch setting

• No electricity on the pump motor.

• Check and repair the electric connections and system.

• Winter mode is on

• Switch off the winter mode

• There is feed material in the crusher

• Remove the feed material

• Oil pump is not running

• As above

• If the cavity is empty, check the level detector

• There might be a mechanical problem in the pump. Check the pump.

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• Return oil temperature is too low.

• Wait until the oil is warm enough.

• Lubrication pressure is not within limits

• Check the pressure sensor

• Discharge conveyor (if equipped) is not running

• Deactivate the discharge conveyor safety switch and start the conveyor

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MALFUNCTION

CAUSE • The V-belts are slipping

• Tighten the belts or replace as necessary.

• The V-belts are broken

• Empty the crushing cavity, trace the reason for breakage and replace the belts.

• Return oil temperature sensor does not give signal.

• Check the sensor. Replace as necessary.

THE CRUSHER STOPS DURING • The crusher power is too high STARTING SEQUENCE for too long

THE FEEDER WILL NOT START

REMEDY

• Crusher motor is damaged • Faulty starting resistor/ soft starter

• The crusher is damaged

• Contact Metso

• Crusher is not running

• As above

• The main shaft is at the bottom (below safety limit)

• Dump valve is open. Close the valve • Check the setting sensor • No pressure in the setting circuit. Check the setting unit.

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OTHER POSSIBLE MALFUNCTIONS: CRUSHER STOPS DURING CRUSHING

• Return oil temperature is too high

• Let the oil cool down. Determine the reason for excessive temperature.

• Automation system excessive power limit exceeded

• Crusher motor is damaged

• There is a foreign, metal object in the crusher

• Remove the object. Refer to chapter 5.2 for detailed information.

• There is no pressure in the lubrication circuit.

• Check the lubrication circuit.

• The electric drive motor of the • Empty the crusher cavity, crusher is overloaded and the remove the reason for overload and restart the crusher after the protection system of the motor has been activated. The motor has cooled down. It might lubricating pump is still running. also be possible to restart the crusher without having the cavity been emptied by simultaneously starting the motor and opening the magnetic or manual valve to increase the setting. • The V-belts are slipping

• Tighten the belts or replace as necessary.

• The V-belts are broken

• Empty the crushing cavity, trace the reason for breakage and replace the belts.

THE CRUSHER DOES NOT MAINTAIN THE PRESET SETTING VALUE • The setting of the crusher increases during crushing, but reverts when the crusher is idling.

• Check the following crusher data: –

setting

–

stroke

–

cavity

–

feed material

–

power

–

pressure

• There are separate checking instructions available. For more information contact Metso.

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A SMALL ENOUGH SETTING VALUE CANNOT BE REACHED

• High power

• Check the power sensor signal • Check the process, i.e. is the feed material appropriate • Liners have worn too much. Replace new liners. • Liners are unsuitable. Replace the correct set of liners. • Stroke is too big. Change the stroke

• High pressure

• Check the pressure sensor signal • Check the process, i.e. is the feed material appropriate. • Liners have worn too much. Replace new liners. • Liners are unsuitable. Replace the correct set of liners. • Stroke is too big. Change the stroke

THE CRUSHER IS OVERHEATING

• The crusher has been operated • Increase the crusher setting with too small setting thus causing the bearings to be overloaded generating excess heat. • The material to be crushed is accumulating in the crushing cavity.

• Scalp clay and the rest fine material below setting from the feed. • Examine that the discharge opening of the crusher has not been clogged. Clear as necessary. • Inspect that the liners are not worn as a "bag shape". Replace liners as necessary.

• Insufficient cooling of the lubricating oil.

• Check the function of the cooler fan. • Clean the cooler from outside and also from inside as necessary. • Ambient temperature is too high.

• Insufficient oil flow.

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• Check the float switch operation and the pump output.

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LINERS ARE WEARING UNEVENLY

• Crusher is damaged.

• Check if an unusual amount of metal exists in the return oil sump or in the magnetic plug. Contact Metso.

• Check valve is jammed open

• Replace the check valve.

• Feed is distributed unevenly to the crusher

• Adjust the feed • Replace liners as necessary • Contact Metso

CRUSHER PERFORMANCE IS POOR PROCESS WILL NOT STOP

• Contact Metso • Power of the crusher does not drop below the idling limit

• Ensure that there is no material in the crusher • Stop the crusher from the emergency stop button

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CHANGING THE STROKE

CHAPTER

9

9.2 DISMANTLING THE UPPER FRAME ASSEMBLY

9.1 GENERAL

Remove the gravel and stones from on top of the slip ring inside the crusher, so that the main shaft can move freely downward.

IMPORTANT! The following information is not valid for the crushers equipped with the SteplessStroke system. For SteplessStroke information refer to SteplessStroke Instruction Manual (delivered, if your crusher is equipped with the SteplessStroke system).

Lower the main shaft by opening the magnetic valve or manual valve on the lubricating and adjusting device. When the main shaft has been lowered, close the valve. Remove the feed hopper bolts, and lift the hopper away.

IMPORTANT!

Remove the top bearing housing cover bolts and lift the cover away.

Before changing the stroke contact your local construction expert at Metso.

Remove the grease from the upper section of the top bearing housing (Figure 9.1).

There are several stroke options for the crusher. To change the stroke, turn/change the eccentric bushing on the lower frame. If you change the bushing, change the top bearing at the same time. There are bushings for different stroke lengths. The crusher stroke is caused by the eccentricity of the bearing. For the stroke change, the upper frame assy and main shaft must first be lifted off the lower frame. When changing the stroke and gap option, in some cases it may be useful to change the rotation speed of the crusher as well, to optimize the capacity and product quality. For more information contact your local construction expert at Metso.

IMPORTANT! Wait until the crusher has cooled down before changing the stroke. When the crusher is used, the eccentric bushing made of bronze expands more than the main shaft made of steel. Therefore the eccentric bushing is more difficult to remove and re-install.

11/2011

Figure 9.1 Remove the top bearing housing

Remove the bolts on the joint between the upper frame assy and lower frame (Figure 9.2).

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Lift the upper frame assy away (Figure 9.4). You can tie the hoisting ropes around the upper frame arms. Lower the upper frame onto a stand.

Figure 9.2 Remove the bolts on the joint between the upper and lower frame

Separate the joint between the upper frame assy and lower frame by using four jacking bolts (Figure 9.3). The separation can be assisted by attaching hoisting ropes to the upper frame and tensioning them with the crane. In this case, leave three equally spaced bolts loosely on the frame joint. The bolts must have nuts on them such that the joint can be separated 10–20 mm. This is to ensure that the upper frame does not jump off when it comes loose.

Figure 9.4 Lift the upper frame assy away

Lift the main shaft away. Screw an eye bolt (supplied with the tools and accessories) into the hole at the upper end of the shaft, and carefully lift the main shaft away. Lower the main shaft onto a stand such that it is supported from the lower end of the head – NOT THE SEAL – or place it on its side, taking care not to damage the bearing surfaces at its lower and upper end (Figure 9.5). Do not lower the thrust plates at the lower end of the shaft onto the ground; use a rubber plate as protection.

Figure 9.3 Separate the joint between the upper and lower frame by using jacking bolts

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Remove the Allen screw (M10) that holds the eccentric bushing in place (Figure 9.6).

Figure 9.5 Place the main shaft either onto a stand or on its side

Figure 9.6 Remove the Allen screw that holds the eccentric bushing in place

Lift the eccentric bushing away using a special tool, and move it aside (Figure 9.7).

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GP200 GP200S GP300 GP300S GP550 GP500S

Eccentric bushing kg (lbs) 76 (168) 78 (172) 79 (174) 82 (181) 144 (318) 152 (335)

9.3 STROKE CHANGE AND RE-ASSEMBLING Check the condition of the new eccentric bushing. Clean if necessary. Place the key in the keyway of the desired stroke in the eccentric bushing and lower the bushing in its place. The stroke lengths are marked on the top of the eccentric bushing above every keyway (Figure 9.8). The bushing must slide in, do not hit it.

Figure 9.7 Lift the eccentric bushing away

Figure 9.8 The stroke lengths are marked on the top of the eccentric bushing above every keyway

Secure the eccentric bushing with the screw (M10). IMPORTANT! Head of the screw must be lower than the inside diameter of the eccentric bushing. Lock the bolt with locking compound, e.g. Loctite 242.

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Lock the eccentric bushing into place with the Allen screw (M10) (Figure 9.6). Note for GP200/GP200S crushers: You must change the position of the counterweight (D, Figure 9.9) if you have changed the stroke. Open the hex socket-head screws M16 (3 pcs) (F, Figure 9.10), lift the counterweight (13.4 kg (30 lbs)) and put the counterweight to the correct position (Figure 9.9) according the stroke. The arrow on the counterweight and the stroke digits on the hub must be against each other. Screw the hex socket-head screws M16 (3 pcs).

Figure 9.10

STROKE 40 mm

STROKE 32 mm

Ensure that the intermediate thrust plate has not moved out of position while lifting the main shaft. Carefully lower the main shaft into the crusher. Remember that the hole of the eccentric shaft is slightly askew, and pay special attention to the bearing surfaces. Also, be careful not to damage the dust seal ring when it slides onto the slip ring (Figure 9.11).

STROKE 25 mm

STROKE 18 mm

Figure 9.9 Position of the counterweight

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Figure 9.11 Be mindful of the dust seal ring when installing the main shaft. Use the inspection hatches to control the lowering process.

Lift the upper frame assy into place, taking care not to damage the top bearing seal (Figure 9.12). Insert the mounting bolts and nut on the joint between the upper and lower frame, and tighten the joint evenly; refer to subsection 6.9 for the tightening torque. When the upper frame assy is lowered onto the lower frame, there must be a clearance of 2–4 mm between the frame flanges, which is then closed by tightening the bolts (Figure 9.13).

Figure 9.12 Lift the upper frame into place

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Fill the top bearing housing with grease (Figure 9.14). For lubrication instructions, refer to subsection 6.10. Lift the cover into place, and mount using bolts (refer to subsection 6.9 for the tightening torque). Lift the hopper into place, and mount using bolts (refer to subsection 6.9 for the tightening torque). After the stroke change automation system needs a new configuration. For more information contact your local construction expert at Metso. Test run the crusher without load, ensuring that it is operating properly.

Figure 9.13 Tighten the clearance between the frames

Figure 9.14 Fill the top bearing housing with grease

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9.4 RETIGHTENING After 25 hours of operation, tighten the bolts on the joint between the lower and upper frame. Refer to subsection 6.9 for the tightening torque. .

25 h

Figure 9.15 Tighten the bolts on the joint between the lower and upper frame

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TECHNICAL SPECIFICATIONS

CHAPTER

10

10.1 CAVITY OPTIONS There are six different crushing cavities available: –

Extra Fine (EF)

–

Fine (F)

–

Medium Fine (MF)

–

Medium (M)

–

Coarse (C)

–

Extra Coarse (EC)

Typical Secondary Crushing

Typical Fine Crushing

Extra Fine (EF)

Fine (F)

Medium Fine (MF)

Medium (M)

Coarse (C)

Extra Coarse (EC)

Coarse (C)

Extra Coarse (EC)

Figure 10.1 Typical cavity options for GP cones

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10.2 STROKE OPTIONS

Stroke

Stroke options for the different GP cone crushers are shown in the table below.

(mm)

Stroke (mm) 18

GP300S

10-2

/64

1

28

7

1 /64

32

1 17/64

36

1 27/64

40

1 9/16

45

1 49/64

1

28

7

1 /64

18

32

1 17/64

25

1

36

1 27/64

28

1 7/64

40

1 9/16

32

1 17/64

36

1 27/64

40

1 9/16

18

GP300

45

GP550

25

25

GP200

GP200S

(inch)

(inch)

45

/64

25

1

28

1 7/64

32

1 17/64

36

1 27/64

25

1

28

1 7/64

32

1 17/64

36

1 27/64

40

1 9/16

18

45/ 64

25

1

28

1 7/64

32

1 17/64

36

1 27/64

40

1 9/16

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10.3 TECHNICAL DATA NOTE: Setting values apply with dry, medium hard granite. Max. setting with new liners, varies by the manufacturing tolerances GP200 EC

GP200 M

GP200 F

GP200 EF

FEED OPENING

210 mm (8½”)

130 mm (5”)

70 mm (2¾”)

40 mm (1½”)

MAX. FEED SIZE

170 mm (6¾”)

105 mm (4”)

70 mm (2¾”)

35 mm (13/8”)

• stroke 18 mm (45/64”)

12 mm (15/32”)

10 mm (25/64”)

7 mm(9/32”)

8 mm (5/16”)

• stroke 25 mm (1”)

17 mm (43/64”)

13 mm (33/64”)

10 mm (25/64”)

11 mm (7/16”)

• stroke 32 mm (1 17/64”)

24 mm (15/16”)

15 mm (19/32”)

13 mm (33/64”)

14 mm (19/32”)

MIN. SETTING

• stroke 40 mm (1 9/16“) MAX. SETTING With new liners at 25 mm (1”) stroke

COUNTERSHAFT rpm WEIGHT

16 mm (5/8”) 32 mm (1 17/64”) 26 mm (11/32”) 1190

26 mm (11/32”)

1257

24 mm (15/16”) 1480

9000 - 9300 kg (19800 - 20500 lbs)

GP200S EC

GP200S C

FEED OPENING

330 mm (13”)

250mm (10”)

MAX. FEED SIZE

280 mm (11”)

210 mm (81/4”)

• stroke 18mm (45/64”)

26 mm (11/32”)

24 mm (15/16”)

• stroke 25 mm (1”)

29mm (19/64”)

27mm (11/16”)

32 mm (117/64”)

30 mm (13/16”)

49mm (15/16”)

43 mm (1111/16”)

MIN. SETTING

• stroke 32mm (117/64”) MAX. SETTING With new liners at 25 mm (1") stroke

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COUNTERSHAFT rpm

1257

WEIGHT

10800-10900 kg (23800-24000 lbs)

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GP300 EC FEED OPENING

GP300 C

GP300 M

GP300 MF

GP300 F

GP300 EF

260 mm (10”) 180 mm (7”) 130 mm (5”) 100 mm (4”) 60 mm (2½”) 40 mm (1½”) 210 mm (8”)

140 mm (5½”)

120 mm (4½”)

80 mm (3”)

50 mm (2”)

32 mm (1¼”)

• stroke 25 mm (1”)

22 mm (55/64”)

18 mm (45/64”)

15 mm (19/32”)

13 mm (33/64”)

8 mm (5/16”)

6 mm (1/4”)

• stroke 32 mm (1 17/64”)

26 mm (11/32”)

21 mm (53/64”)

17 mm (43/64”)

15 mm (19/32”)

11 mm (7/16”)

8 mm (5/16”)

• stroke 40 mm (19/16”)

30 mm (13/16”)

24 mm (15/16”)

19 mm (3/4”)

17 mm (43/64”)

14 mm (9/16”)

10 mm (25/64”)

37 mm (1 (17/16”)

34 mm (111/32”)

26 mm (11/32”)

26 mm (11/32”)

25 mm (1”)

19 mm (3/4”)

MAX. FEED SIZE MIN. SETTING

MAX. SETTING With new liners at 32 mm (117/64”) stroke

COUNTERSHAFT rpm

1233

WEIGHT

12900 - 13400 kg (28400 - 29500 lbs)

GP300S EC

GP300S C

FEED OPENING

380m (15”)

280 mm (11”)

MAX. FEED SIZE

320 mm (121/2”)

240 mm (91/2”)

28 mm(17/64”)

25mm (1”)

• stroke 25 mm (1”)

32 mm (117/64”)

29mm (19/64”)

• stroke 32mm (117/64”)

36 mm (127/64”)

35 mm (13/8”)

• stroke 40mm (19/16”)

40mm (19/16”)

39mm (19/16”)

50 mm (2”)

44 mm (147/64”)

MIN. SETTING • stroke 18mm (11/16”)

MAX. SETTING With new liners at 25mm (1”) stroke

10-4

COUNTERSHAFT rpm

985

WEIGHT

16000 kg (35600 lbs)

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GP550 EC FEED OPENING

GP550 C

GP550 M

GP550 MF

GP550 F

GP550 EF

280 mm (11”) 220 mm (9”) 180 mm (7”) 130 mm (5”) 90 mm (3½”) 40 mm (1½”) 240 mm (9½”)

190 mm (7½”)

150 mm (6”)

110 mm (41/3”)

70 mm (23/4””)

35 mm (11/3””)

• stroke 25 mm (1”)

22 mm (55/64”)

18 mm (45/64”)

15 mm (19/32”)

13 mm (33/64”)

8 mm (5/16”)

6 mm (15/64”)

• stroke 32 mm (117/64”)

26 mm (11/32”)

21 mm (53/64”)

17 mm (43/64”)

15 mm (19/32”)

11 mm (7/16”)

8 mm (5/16”)

• stroke 40 mm (19/16”)

30 mm (13/16”)

24 mm (15/16”)

19 mm (3/4”)

17 mm (43/64”)

14 mm (35/64”)

10 mm (25/64”)

43 mm (111/16”)

39 mm (19/16”)

38 mm (11/2”)

35 mm (13/8”)

32 mm (117/64”)

24 mm (15/16”)

MAX. FEED SIZE MIN. SETTING

MAX. SETTING With new liners at 32 mm (117/64”) stroke

COUNTERSHAFT rpm

1205

WEIGHT

25800 - 26400 kg (56900 - 58200 lbs)

GP500S EC

GP500S C

FEED OPENING

500mm (20”)

380 mm (15”)

MAX. FEED SIZE

420 mm (16 1/2”)

320 mm (12 1/2”)

50 mm(2”)

40mm (19/16”)

• stroke 25 mm(1”)

55 mm(211/64”)

45mm (149/64”)

• stroke 32mm (117/64”)

60 mm (223/64”)

50 mm (2”)

MAX. SETTING

79 mm (37/64”)

74 mm (229/32")

MIN. SETTING • stroke 18mm (45/64”)

With new liners at 25mm (1”) stroke

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COUNTERSHAFT rpm

990

WEIGHT

32100-32800 kg (70800-72300 lbs)

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10.4 CRUSHER CAPACITY The capacity of a crusher is affected by a number of factors e.g.: –

The characteristics of the feed material (size, hardness, toughness, moisture content, bulk density, etc.)

–

The method of operation

–

The setting of the crusher

–

The stroke of the crusher

–

The cavity of the crusher

The capacity can be estimated from the tables below, if you know the stroke and setting of the crusher. The actual capacity may differ from the capacity estimated by the table depending of the factors given before. The given values are to be used as a guide only, and are valid when crushing dry, medium hard granite with a bulk density of 1.6 t/m³ (100 lbs/ft³). For values in parenthesis, contact your local construction expert at Metso.

SETTING c.s.s. STROKE

tons/ hour

10 mm

8 mm 5/

16”

15 mm

13/ ” 32

19/

20 mm 32”

13/

25 mm 16”

1”

30 mm 35 mm 13/16” 13/8”

18 mm 3/ ” 4

mtph stph

60-70 70-90 80-105 100-125 135-150 160-175 185-200 65-80 80-100 90-115 110-140 150-165 175-190 200-215

25 mm 1”

mtph stph

90-110 110-130 130-155 160-180 185-210 100-120 120-140 145-170 180-200 200-230

32 mm 11/4”

mtph stph

140-160 170-190 190-220 155-175 185-205 210-240

40 mm 15/8”

mtph stph

200-220 220-240 210-240 230-260

Table 10-1 GP200

SETTING c.s.s. STROKE

tons/ hour

20 mm 3/ ” 4

25 mm 1”

30 mm 35 mm 40 mm 50 mm 45 mm 2” 11/4” 11/2” 13/4” 21/4”

18 mm 3 /4”

mtph stph

110-140 140-170 160-190 180-210 200-230 230-260 130-160 170-220 180-210 200-230 250-280

25 mm 1”

mtph stph

110-130 190-240 210-260 230-280 200-250 225-275 250-275

32 mm 11/4”

mtph stph

230-280 270-320 280-350 260-310 310-380

Table 10-2 GP200S

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SETTING c.s.s. STROKE

tons/ hour

10 mm

8 mm 5

/16”

15 mm

13

/32”

19

20 mm /32”

25 mm

13

1”

/16”

30 mm 35 mm 13/16” 13/8”

25 mm 1”

mtph stph

100-120 110-130 135-155 160-180 190-210 210-235 240-260 110-130 120-145 150-170 175-195 210-230 230-260 255-285

32 mm 11/4”

mtph stph

110-130 120-150 165-195 195-225 230-260 265-295 300-330 120-145 135-165 180-215 210-245 250-285 295-325 320-355

40 mm 15/8”

mtph stph

150-170 205-235 245-275 290-320 325-355 165-185 220-255 270-300 315-355 360-390

Table 10-3 GP300

SETTING c.s.s. STROKE

tons/ hour

20 mm 3/

25 mm 1”

4”

35 mm 40 mm 30 mm 50 mm 45 mm 2” 11/2” 13/4” 11/4” 21/4”

18 mm 3/ ” 4

mtph stph

170-190 170-210 190-230 210-255 235-275 255-295 200-220 190-240 225-270 255-300 285-320

25 mm 1”

mtph stph

220-270 255-315 290-345 320-350 330-350 260-320 300-350 350-400 370-390

32 mm 11/4”

mtph stph

360-400 380-420 400-440 380-430 430-480

40 mm 15/8”

mtph stph

450-500 480-530 500-550

Table 10-4 GP300S

SETTING c.s.s. STROKE

tons/ hour

10 mm 13

15 mm /32”

20 mm

19

/32”

13

25 mm /16”

1”

30 mm 35 mm 40 mm 13/16” 13/8” 19/16”

25 mm 1”

mtph stph

140-160 160-180 190-210 240-260 270-290 310-330 350-370 150-180 180-200 210-230 260-290 300-325 340-360 390-410

32 mm 11/4”

mtph stph

230-250 270-290 310-330 340-370 380-410 430-450 250-270 300-320 340-360 370-410 420-450 470-500

40 mm 15/8”

mtph stph

290-310 320-340 380-410 430-460 480-510 320-340 350-370 420-450 470-510 530-560

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Table 10-5 GP550 SETTING c.s.s. STROKE

tons/ hour

18 mm 3 /4”

mtph stph

25 mm 1”

mtph stph

500-550

550-600 600-650 650-700 700-750 750-800 550-600 620-680 680-740 750-810 840-900

32 mm 11/4”

mtph stph

650-700

700-750 750-800 825-875 900-950 (720-780) 800-860 890-920 940-1000

40 mm 15/8”

mtph stph

45 mm 50 mm 60 mm 65 mm 70 mm 55 mm 75 mm 2” 3” 11/2” 13/4” 21/4” 21/2” 23/4” 300-350

325-375 375-425 400-450 425-475 450-500 500-550 330-380 350-400 400-460 460-520 520-580 560-620

900-950 975-1050 930-990 1030-1100

Table 10-6 GP500S

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A

APPENDIX A

LIFTING DEVICE FOR NORDBERG GP SERIES ECCENTRIC SLEEVES SAFETY, OPERATING, AND MAINTENANCE INSTRUCTIONS

4. Commissioning and operating conditions

1. Intended purpose

•

The lifting device is supplied fully assembled and ready to use.

•

No external power connections are required.

•

The device operates in at least the same conditions as the crusher itself, irrespective of climatic conditions.

The lifting device is intended to facilitate lifting operations during installation and removal of the eccentric sleeves of cone crushers. The lifting device is installed between the hoist and eccentric sleeve to facilitate engagement with the sleeve. The lifting device is designed, tested, and intended only for lifting eccentric sleeves of the type supplied with the device.

5. Technical specifications •

The lifting device may be subjected to a maximum load of 200 kg.

Keep the device sufficiently clean and do not store a damaged or otherwise faulty product. The device can be transported and stored in any position.

•

The weight of the eccentric sleeve to be lifted varies from 50 to 152 kg depending on the cone crusher model.

3. Safe operation

6. Inspection and maintenance

•

Familiarize yourself with the operating instructions of the lifting device and ensure that the periodic inspections are performed.

•

The lifting device must be inspected before each lifting operation and at least once a year.

•

•

Carefully ensure that the device properly engages with the work piece to be lifted.

Inspections must be documented for internal purposes and carried out by the appropriate authorities.

•

Use of the lifting device for any other than its intended purpose is prohibited.

•

•

Do not overload the lifting device.

Do not operate a damaged or faulty unit (e.g. deformation, cracks). A damaged or faulty unit must be repaired or scrapped.

•

Perform lifting only after the crusher has cooled down ss the sleeve attachment may be tight due to differences in material thermal expansion.

•

Pay special attention to the condition of threads, welds, and bolted joints.

•

Keep the lifting device clean to enable detection of possible deformation or cracks.

•

Abort lifting if the eccentric sleeve does not come loose easily.

•

Lubricate the threads and joints during inspection if necessary.

•

Load the lifting device evenly and perform the lift maneuvers carefully and smoothly.

•

Keep a safe distance from other people and objects during lifting.

•

Work carefully and avoid unnecessary rush.

2. Transport and storage

EN

N11449569

7. Operating instructions 1. Wait until the crusher has cooled down sufficiently after use. 2. Check that the engagement points on both the lifting device and the work piece to be lifted are intact, and ensure that the periodic

LIFTING DEVICE FOR GP SERIES ECCENTRIC SLEEVES

A-1

APPENDIX A

inspections for the lifting device are performed. 3. Install the lifting device in the groove on the upper edge of the eccentric sleeve by turning the turnbuckle to spread the device's legs (tightening by hand is sufficient).

9. Abort lifting if the eccentric sleeve does not come loose easily. 10. Inspect the lifting device after the lifting operation. 11. Do not store a damaged or otherwise faulty lifting device.

Figure 1 Installing the lifting device in the sleeve groove

4. Ensure that the lifting device is firmly in place and that the outer edge of the lifting device's leg sits properly in the base of the sleeve groove. 5. Fasten the hoist hook, sling or corresponding lifting equipment to the lifting device and ensure that the fastening mechanism of the lifting equipment is secure. 6. Recheck all fastening points. 7. Reserve sufficient space for lifting and alert people in the vicinity. WARNING! Ensure that there are no persons under the item to be lifted and that nobody enters the lifting area during the lifting operation. 8. Perform the lifting operation carefully, anticipating potential hazard situations.

A-2

LIFTING DEVICE FOR GP SERIES ECCENTRIC SLEEVES

N11449569

EN