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NORDBERG GP CONE CRUSHERS

INSTRUCTION MANUAL

MM0293378-EN REV-1.3

11/2011



11/2011 MM0293378-EN REV 1.3 INSTRUCTION MANUAL 0-1

GP CONE CRUSHERS CHAPTER 0

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

Because of the continuous development of the product, the manufacturer reserves a right to alter thetechnical 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.

Copyright © 2011 Metso. Printed in Tampere, Finland.

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]



0-2 INSTRUCTION MANUAL MM0293378-EN REV 1.3 11/2011

CHAPTER 0 - GP CONE CRUSHERS

This Page Left Intentionally Blank.



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




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




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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-166.12 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137.6 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19.3 STROKE CHANGE AND RE-ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.4 RETIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8




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

SAFETY, OPERATING, AND MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . .A-1

1. Intended purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

2. Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

3. Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

4. Commissioning and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

5. Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-16. Inspection and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

7. Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1




PREFACE CHAPTER 1

This instruction manual is intended to assist ownersand users of Metso products in the proper use of theequipment.

It includes important references to safe, proper andeconomical operation of the equipment. Followingthese instructions will help to avoid possible

danger, reduce repair costs and breakdowns and toincrease the reliability and life of the equipment.

This manual must be complemented by thoseinstructions necessary because of existing nationalmandatory rules relating to accident prevention andenvironmental protection.

A copy of this manual must be kept at theequipment's location and made available to theoperators as required.

In addition to this manual and accident preventionregulations mandatory in the country of use and atthe equipment's place of operation, generally

recognized rules for safe and professional operationmust be observed.

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

– operations, including installation, startup,operation, application engineering,materials handling, site labour,

environmental engineering and safetydepartments.

– maintenance, including inspection andrepair.

– transport, materials handling and rigging.

Note that this instruction manual containsinformation and instructions on alternative andoptional equipment. Normally the machines haveonly some of them. Before maintaining andservicing, find out which alternative and optionalequipment your machine has.

See separate instruction manuals for more detailedinstructions when servicing the main components.

There may be optional equipment which haveseparate instruction manuals. Those manuals must

be read and used by each person who works withthe equipment.




CHAPTER 1 - PREFACE





SAFETY CHAPTER 2

2.1 GENERAL

The instructions of the safety guide, these safetyinstructions and other manuals and safety labels forthe equipment must be read, understood and used

by each person who works with this equipment.

The following symbol is used in this manual and onthe machine to call attention to instructions, whichwill help prevent machine related injuries.

When you see this symbol on your machine or inthis manual, be alert to the potential for personalinjury.

Figure 2.1 Alert Symbol

This manual uses the alert symbol, with words suchas DANGER, WARNING or CAUTION, to alertyou and other Crushing Plant personnel of actionsor conditions that pose a potential safety hazard,with an attending risk of personal injury (including

death) or property damage. The machine alsodisplays safety signs, labels and tags at appropriate points to show safety risks that may exist.

Figure 2.2 Danger, warning, caution signs andtheir meaning

WARNING!

In addition to these unit-specific safetyinstructions, the operators of thisequipment must also read the safetyguide with instructions for generaloperational safety.

WARNING!

Read the instruction manual forLubrication and adjusting unit, and the

instruction manual for automationsystem before using the GP conecrusher.

Sign Description

DANGER

Immediate hazards or unsafe practicesthat will result in severe personal injuryor death.

WARNINGHazards or unsafe practices that couldresult in severe personal injury or death

CAUTION

Hazards or unsafe practices that couldresult in minor personal injury orequipment damage

DANGER

CAUTION

WARNING




CHAPTER 2 - SAFETY

2.1.1 General safety instructions

1. Ignoring the safety instructions or thewarning signs increases the risk of severeinjury or death.

2. GP cone crushers have been designed forsafe operation when used by professionalstaff in the operating situations included inthis instruction manual. All other serviceand repair procedures must be performed byspecially trained personnel or authorizedMetso service staff.

3. Never operate the crusher without propercovers and safety devices. If the covers orsafety devices have not been purchased fromMetso, a customer has to ensure that thecovers and safety devices are according tolaw and regulations.

4. Before starting the crusher make sure that noone is near the crusher.

5. It is prohibited to stay in the danger areaduring the crushing process. The crushingmaterial may be thrown into a few meters

distance from the crusher. Always usehelmet and safety glasses.

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

7. Ensure before performing any maintenance,that the crushing cavity is empty. Materialmay be thrown from the crusher even whenit is stopped.

8. Because the crusher is installed on rubberdampers, 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 duringcrushing. The movement may be as much as± 25mm (±1”).

9. Clearing a jammed cavity is extremelydangerous. Do not attempt to clear the cavityuntil the crusher has stopped completely.

10. The crusher does not stop immediately afterthe motor has been turned off. Make surethat the crusher has stopped completely

before opening any covers, performing anymaintenance, or adjusting the crusher.

11. The crushing plant and auxiliary equipmentsuch as chutes, transfer stations, screens,etc. can create dust and, if not contained, thedust can escape into the air. Metso highlyrecommends that dust protective devicessuch as an appropriate respirator be worn byanyone exposed to airborne dust to preventits inhalation. It is the responsibility of theOwner and Operator to determine thenecessity and adequacy of protectivedevices and warnings, to provide them, andto ensure that they are used and followed!

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

WARNING!

Before performing any maintenance or

repair work, make sure that the crusheris stopped and locked out.

LOCKOUT PROCEDURE of the dieselengine driven crushers

1. Switch off engine

2. Remove the ignition key and keep iton person during lockout

3. Place appropriate maintenancewarning signs (TAG OUT)

LOCKOUT PROCEDURE of theelectrical motor driven crushers

1. Switch off motor

2. Lock the main switch of the motorwith a padlock or make sure in someother way that the motor cannot bestarted (locking must be done by everymember of the work group)

3. Keep the keys on person duringlockout

4. Place appropriate maintenance

warning signs (TAG OUT).




CHAPTER 2 - SAFETY

13. Make sure that the main shaft is in down position before performing anymaintenance. The adjusting circuit maycontain high pressure even when the crusheris stopped.

14. Before performing any maintenance orrepair work, make sure that the crusher isstopped and locked out.

15. The surfaces of the crusher may become hotduring crushing. Hot surfaces can causesevere burn injuries. Make sure that thesurfaces have cooled before performing anymaintenance work.

16. The lubricating oil and grease may be hot.Make sure that hot oil and grease do notcome into contact with skin.

17. Before handling oil or grease refer to

Operational Safety Bulletin delivered by theoil manufacturer.

18. Before changing any wear parts of thecrusher, read chapter “Replacing wear parts”carefully.

19. Before lifting any wear parts, check theweight of the component and ensure thatlifting equipment being used is adequate tolift the weight.

20. Read the instructions regarding lifting andreplacing wear parts carefully beforereplacing any wear parts. Make sure that the

parts are adequately supported beforelifting. Never go under the suspended load.

21. Follow the occupational safety rules duringall maintenance and lifting procedures!

22. If the crusher is equipped with a pressureaccumulator, it may be charged only by a

professional. If the pressure accumulator ischarged incorrectly, it may explode. Do notcharge the accumulator yourself.

23. Release the pressure from the hydraulicsystem according to instructions before anymaintenance to the system.

24. The cooler blower of the lubricating devicestarts automatically during crushing. Do notgo near the blower or remove the coversduring crushing.

DANGER!

There are components made ofmanganese steel in the crusher, such as

liners and in some models protection plates of the upper frame arms. Weldingor flame cutting these componentsgenerates gas that is extremelyhazardous to health and causesmanganese poisoning. This kind ofwork must be done outdoors or inwell-ventilated premises equipped withlocal exhaust ventilation.




CHAPTER 2 - SAFETY

2.2 WARNING SIGNS

The warning signs attached to the equipment mustalways be kept readable and clean. Damaged orloose signs must be replaced at once before startingthe crusher. Make sure that the warning signs are

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

Figure 2.3 The locations of the warning signs

The number and exact locations of the warningsigns 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 warningsigns is used on your machine from theside of the machine or the spare partmanual.




CHAPTER 2 - SAFETY

Figure 2.4 Warning signs (ANSI)

1

2

3 4

65

7




CHAPTER 2 - SAFETY

2.2.1 Warning sign codes and texts (ANSI)

1. MM0229994WARNINGRead and understand instruction manual

before using or maintaining this machine.

Failure to follow operating instructions mayresult in death or serious injury.

DANGER Lung disease hazard.Dust protection required.

WARNINGRisk of eye injury.Use of eye protection required.

CAUTIONRisk of head injury.Use of a helmet required.

CAUTIONHazardous noise level.Use of ear protection required.

2. MM0229995DANGER Moving parts can crush and cut.Do not insert tools in the crusher cavitywhen the motor is running.

WARNINGMaterial can fall out.do not stand in the vicinity of the crusherwhen the motor is running.

3. MM0229997WARNINGExposed moving parts can cause severeinjury.Do not open drive guard before machine iscompletely stopped.

4. MM0229996WARNINGExposed moving parts can cause severeinjury.Do NOT operate this machine without

proper guards.5. MM0231186

WARNINGMoving parts can crush and cut.Do not open the hatch before machine iscompletely stopped.

6. MM0230002WARNINGServicing while pressurized can causesevere injury.Lock out source and relieve pressure beforeservicing.


before using or maintaining this machine.Failure to follow operating instructions mayresult in death or serious injury.

High voltage.

High pressure oil.

Failure to follow lockout procedure beforeservicing may result in death or seriousinjury.




CHAPTER 2 - SAFETY

Figure 2.5 Warning signs (ISO)

1

2

3

4

65

7




CHAPTER 2 - SAFETY

2.2.2 Warning sign codes and texts (ISO)


before using or maintaining this machine.

Failure to follow operating instructions mayresult in death or serious injury.

DANGER Lung disease hazard.Dust protection required.

WARNINGRisk of eye injury.Use of eye protection required.

CAUTIONRisk of head injury.Use of a helmet required.

CAUTIONHazardous noise level.Use of ear protection required.

2. MM0250251DANGER Moving parts can crush and cut.Do not insert tools in the crusher cavitywhen the motor is running.

WARNINGMaterial can fall out.do not stand in the vicinity of the crusherwhen the motor is running.

3. MM0250244WARNINGExposed moving parts can cause severeinjury.Do not open drive guard before machine iscompletely stopped.

4. MM0250244WARNINGExposed moving parts can cause severeinjury.Do NOT operate this machine without

proper guards.5. MM0252118

WARNINGMoving parts can crush and cut.Do not open the hatch before machine iscompletely stopped.

6. MM0250241WARNINGServicing while pressurized can causesevere injury.Lock out source and relieve pressure beforeservicing.


before using or maintaining this machine.Failure to follow operating instructions mayresult in death or serious injury.

High voltage.

High pressure oil.

Failure to follow lockout procedure beforeservicing may result in death or seriousinjury.




GENERAL CHAPTER 3

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 intons per hour (mtph or STPH).

Feed opening (closed side) = The shortest distance between the top of the mantle and bowl liner asmeasured when the mantle and bowl liner are attheir closest position during mantle gyrating circle

Feed opening (open side) = The longest distance between the top of the mantle and bowl liner asmeasured when the mantle and bowl liner are attheir farthest position during mantle gyrating circle.As a general rule, the maximum size of feed should

be 60-80 % of the open side feed openingdepending on the crusher type and the raw materialto be crushed.

Liners= The members which perform the crushingare commonly referred to as liners. The linersconsist of mantle and bowl liner.

Mantle= Inner part of the liners, moveseccenterically in the crushing chamber

Bowl liner= Outer part of the liners, stationary

Crushing cavity = The internal contour formed bythe two crushing members.

Discharge setting = The distance between the bottom of the mantle and bowl liner as measured atthe point where the liners are at their closest

position during mantle gyrating circle (a.k.a. closedside setting, CSS). The discharge setting regulates product size.

Minimum discharge setting = The shortest permissible distance between the bottom of bowlliner and mantle as measured at the point where theliners are at their closest position during mantlegyrating circle.

Discharge opening = The distance between the bottom of the bowl liner and mantle as measured atthe point where the liners are at their farthest

position during mantle gyrating circle. This wideopening permits rapid discharge of the crushed

material.

Stroke = The difference of the maximum andminimum distance between the bottom of bowlliner and mantle during one revolution of theeccentric shaft.

Open circuit operation = The type of operationwhere precise uniformity of product size is notconsidered to be of prime importance and the feedis run through the crusher only once.

Closed circuit operation = The type of operationwhere 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 thecrusher. The closed circuit is used when the nextstage of process needs a precise product size orwhen crushing process needs to be balanced.

Choke feed = The crusher is fed so that thecrushing chamber is full all the time. It isrecommended to maintain the choke feed, as itensures good crushing quality and improves theefficiency of the crusher.

The recommended choke feed level for secondaryGP-cone is at the level of mantle fixing nut.

The recommended choke feed level for fineGP-cone crusher is max 1 meter above top bearingarrangement.

Circulation material = Oversize material, which isfed back into the crusher.




CHAPTER 3 - GENERAL

Figure 3.1 Terminology used in the instruction manual

Callout Description

1 Feed opening

2 Mantle

3 Bowl liner(s)

4 Discharge setting

5 Stroke

1

2

3

4

↔ 5




CHAPTER 3 - GENERAL

3.2 OPERATING PRINCIPLE AND MAINCOMPONENTS

The crushing takes place between the eccentricallymoving 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 themain shaft (6), which has bearings at the bottom (7)and top end (8). The material to be crushed is fedinto the crusher through the top, and the crushedmaterial exits through the bottom.

Figure 3.2 Operating principle of the crusher




CHAPTER 3 - GENERAL

Figure 3.3 GP-crusher with some optional devices

Callout Description

1 Feed hopper (option)

2 Cone crusher

3 Drive motor (option)

4 Belt guard (option)

5 Lubrication and adjusting unit6 Discharge chute (option)

7 Subframe (option)

8 Overpressure device




CHAPTER 3 - GENERAL

Figure 3.4 Main components of the secondary GP-cone crusher

Callout Description Callout Description

1 Upper frame protection 13 Main shaft

2 Intermediate frame 14 Head

3 Bowl liners 15 Thrust bearing

4 Mantle 16 Gear

5 Lower frame arm protection 17 Pinion

6 Lower frame 18 Countershaft

7 Setting sensor 19 Countershaft housing

8 Thrust bearing set 20 Frame bushing

9 Cylinder cover 21 Eccentric shaft

10 Main shaft protecting sleeve 22 Eccentric bushing

11 Top bearing 23 Piston

12 Upper frame

1

2

3

4

5

6

7

8

9

10

11

1213

14

15

16

1718

1920

21

2223




CHAPTER 3 - GENERAL

Figure 3.5 Main components of the fine GP-cone crusher

Callout Description Callout Description

1 Upper frame protection 12 Main shaft

2 Bowl liners 13 Head

3 Mantle 14 Thrust bearing

4 Lower frame arm protection 15 Gear

5 Lower frame 16 Pinion

6 Setting sensor 17 Countershaft

7 Thrust bearing set 18 Countershaft housing

8 Cylinder cover 19 Frame bushing

9 Main shaft protecting sleeve 20 Eccentric shaft

10 Top bearing 21 Eccentric bushing

11 Upper frame 22 Piston

1

2

3

4

5

6

7

8

9

1011

12

13

14

15

16 17

1819

2021

22




CHAPTER 3 - GENERAL

3.3 GP-SERIES CONE CRUSHER

The Nordberg GP-series cone crusher is intendedfor secondary and tertiary crushing at crushing

plants of different sizes.

GP200S, GP300S and GP500S are defined assecondary crushers. Secondary crushers haveseparate intermediate frame and the feed opening is

bigger than in fine crushers. Also the cavity islonger. Secondary crushers are mainly used as asecond crusher after the jaw or impactor.

GP200, GP300 and GP550 are designed for finecrushing purposes. Feed opening is not as big andcavity is not as long as in secondary crushers. Finecrushers are used for tertiary and quarternarycrushing.

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 TECHNICALSPECIFICATIONS chapter. If necessary, the strokemay be changed by turning or replacing theeccentric bushing and by replacing the top bearing(refer to chapter 9).

3.4 APPLICATION OPTIONS

The crusher operates in fixed crushing plant, in aLokotrack crushing plant or in a Nordwheeler

mobile crushing plant.

3.5 CRUSHER AUTOMATION

The crusher is automatically controlled by theautomation system. See the separate Instructionmanual.

3.6 SELECTION OF LINERS

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

If the liners are unsuitable for the crushingapplication, the liners may wear quicker, the

product quality may be worse or the yield of thewanted end product may decrease. In this kind ofsituation, the change of liner type to anothertypically improves the situation.

Feed material that is unsuitable for the liners causesthe mantle and bowl liner wear unevenly, whichmay lead to a machine breakdown.

When determining the suitable liner type, contactyour local construction expert at Metso. Thefollowing information is required to determine thesuitability 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




CHAPTER 3 - GENERAL

3.7 SPARE AND WEAR PARTS

Metso endeavors to carry an ample supply of partsin stock to provide prompt and efficient service onall orders for repairs and replacements.

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 isstamped on the crusher nameplate. Theserial number is also on the cover of thespare parts books.

3. Complete name and part code number asshown in the Spare Parts Book.

4. Exact quantity of each part ordered.

5. Complete shipping instructions.

If your crusher Spare Parts Books have been lost,destroyed or misplaced, an additional set can beordered.

3.8 SETTING RANGE

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.The allowable setting range depends on the strokeused. The minimum setting is limited by either the

power requirement or setting pressure, both ofwhich increase when the setting is decreased. Thus,selection of motor size is largely dependent on thestroke used.

In coarse crushing in particular, variation in the process can be a factor that prevents the use of theminimum setting. Accordingly, it is recommendedthat the minimum allowable setting be usedcontinuously only if the operating conditions arewell known and sufficiently stable.

IMPORTANT!

For proper operation, only genuinefactory parts should be installed. Theseare guaranteed as to accuracy,

workmanship and material. Using pirate parts may put your safety and that ofyour crusher at risk. Make sure youcompletely understand your crusher'sWarranty conditions at all times.




INSTALLATION CHAPTER 4

4.1 FOUNDATION

The crusher is to be installed on a sufficientlysteady steel or concrete foundation by using therubber 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 installationdimension drawing delivered in the installationdocuments indicates the static and dynamic forcesfrom the crusher to the foundation. When installing

the crusher on the foundation, ensure that all fourrubber dampers are equally affected by the weightof the crusher. This requires that all four supportsurfaces 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 thecrusher are level with each other. The steel frame(element or wagon) must be supported well on theground, and the vertical alignment of the crushermust be checked.

Figure 4.1 Examples of the GP crusher installations




CHAPTER 4 - INSTALL ATION

4.2 INSTALLATION CLEARANCEDIMENSIONS

A well planned installation is absolutely necessaryfor the success of the crusher. One of the majorconsiderations are crusher clearances.

In order to accurately determine crusher clearancesrefer to the Installation Drawings.

4.3 LIFTING THE CRUSHER

The weight of the crusher and its parts, as well asthe space required for lifting them, must be takeninto account in selection of the crusher foundationand lifting equipment. Lifting equipment must be

used when erecting, disassembling, and servicingthe crusher and replacing liners. The liftingequipment, wires, hooks and other componentsmust be dimensioned to withstand the weight of the

basic crusher without options (Figure 4.2). Themaximum weight of that basic assembly for eachcrusher type is shown in the Table 4-1.

Table 4-1 Maximum weights of the crusher

Figure 4.2 Lifting the crusher

Crusher Maximum weight

GP200 9500 kg

GP200S 10900 kg

GP300 13700 kg

GP300S 16500 kg

GP550 26000 kg

GP500S 33500 kg





4.4 FEEDING OF THE CRUSHER

The material to be crushed may be fed into thecrusher using a belt conveyor, screen, or variousfeeders, 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 wearto the liners can be achieved only if the feeder isdirectly above the crushing cavity and the materialis distributed evenly on both sides of the supportingarms of the upper frame. If necessary, the upperframe assy may be turned in steps of one bolt pitch.

Figure 4.3 Feeding the crusher

The following must be taken into account inarranging the feed:

– All fine material and material smaller than

the crusher setting must be separated fromthe feed material. These could cause

packing and damage the machine. Inaddition, any metal pieces must beremoved from the feed material using,e.g., a magnetic separator. Themanufacturer is not responsible fordamage resulting from the above causes.

– The feed must be directed such that thereis an equal load around the entire bottomedge of the crusher gap. This ensures moreeven loading and better lubrication for thecrusher bearings, as well as more uniform

wear to the liners. To achieve this, the feedcan be directed by changing the positionof the conveyors and feeding troughs and

by using barriers.

– The speed of the feed material uponentering the crusher must not exceed 5m/s, which corresponds to a free fall

height of 1.3 m. If necessary, the speedmust be limited by stone ledges.

– To ensure even wear to the liners, thecrushing cavity must be evenly filled tothe top.

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

– Feeding of the crusher when it is notrunning must be prevented. This can beachieved electrically by allowing startingof the feeding device only when thecrusher drive motor is running.

5 0 %

5 0 %





4.5 REMOVAL OF CRUSHED MATERIAL

The crushed material may be removed using a beltconveyor or different hoppers or silos, eitherdirectly or by using guiding troughs. The removalequipment should be easy to move, to enable quick

and easy maintenance of the crusher.The discharge opening of the crusher must becovered, or safety distances in accordance withapplicable national standards must be observed.

The following must be taken into account inremoving the crushed material:

– If the crushed material is removed fromunder the crusher with a conveyor orfeeder, the device feeding the crusher mustnot start before the removal device beginsrunning.

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

– The lubrication and adjusting oil hoses forthe crusher must be protected from thecrushed material exiting the crusher.

– Use the inspection hatches on thecrusher’s lower frame to remove any trees,stumps, plastic covers of explosives, andother debris from the protection plates ofthe lower frame to prevent theaccumulation of material. These objects

prevent the crushed material from exiting

freely, which might damage the crusher.

Figure 4.4 Removal of crushed material

IMPORTANT!

The crushed material must be allowed to exitfreely at all times. The removal equipment must

be built to prevent the accumulation of crushedmaterial. If the level of crushed material reachesthe bottom of the mantle, the seal under the mainshaft becomes damaged and dust enters thelubricating oil, possibly causing further damage.





4.6 MOTOR SIZE SELECTION

Table below will give max. recommended motor power for the different GP Cones. Table is valid fordry, medium-hard granite

NOTE: If you choose a nominal power for themotor bigger than the recommended Maximum

power, then the crusher automation system limitsthe 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





4.8 LUBRICATION AND ADJUSTING UNIT

4.8.1 Installation

The location of lubricating and adjusting equipmentshould be selected to be as dustless as possible

within the length of hoses.NOTE: It is highly recommended that originalhose lengths are used when installing thelubrication and adjusting unit

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

When choosing a location for lubricating andadjusting equipment, pay attention also to thefollowing:

– The water should never, in any conditions(spring flood etc.), enter the equipment,

because the electrical components of thedevices might be damaged.

– An adequate space should be reservedaround the equipment for the oil change.

– The air flow caused by the cooling fansthrough the coolers above the lubricatingdevice should not be prevented by anyobstacles on either side of the coolers. Theair 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). Thedirection of the air flow should bearranged according to the figure 4.8.

NOTE: If the lubrication and adjusting unit isinstalled in a closed space make sure that the airflow is sufficient.

A safe and capable route should be arranged to thelubricating and adjusting equipment, to allow thedaily (shiftly) inspection of proper functioning ofthe devices.

4.8.2 Hoses

The hoses between the lubricating and adjustingequipment and the crusher should be properlyfastened in every point, where they can be affected

by rubbing. Points affected by rubbing should be

covered with rubber plates etc. when necessary.

The minimum bending radius of hoses (R) are:

• Adjusting oil hose

– 1” => R = 310 mm (R =12")

• Lubricating oil hose

– 1 1/4” => R = 420 mm (R =16 ½")

• Return oil hose

– 4” => R = 450 mm (R = 18")

The return oil hose of circular lubrication shoulddescend all the way from the crusher to thelubricating equipment. The depression should be atleast 50 mm by every meter (2" by every yard) oflength of the hose.

NOTE: To prevent the splashing of the oil in thetank the depression of the hose should not be morethan 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 lubricatingequipment after having been stopped (Figure 4.8).

High sag acts like a water seal in return hosecompelling the crusher to breathe via the dust sealarea and to suck the silicious dust into the crusher.





4.8.3 Functions

Automation system controls the functions of thecrusher and the lubrication unit according to thetemperature limits shown in the table below.

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

Operation(with ISO VG150)

Temperature limit Sensor Control point

Fan starts +50°C (122°F) Temperature sensor 1 Return oil

Fan stops +45°C (113°F) Temperature sensor 1 Return oil

Feed stops +63°C (145°F) Temperature sensor 1 Return oil

Crusher stops +65°C (149°F) Temperature sensor 1 Return oil

Restart of the crusher orfeed

+55°C (131°F) Temperature sensor 1 Return oil

Stop the crusher (safety) +68°C (154°F) Temperature switch Return oil

Heaters on +20°C (68°F) Temperature sensor 2 Tank

Heaters off +30°C (86°F) Temperature sensor 2 Tank

Permission to start thepump

+15°C (59°F) Temperature sensor 2 Tank

Permission to start thecrusher

+10°C (50°F) Temperature sensor 1 Return oil





Figure 4.8 (A) Air flow to the cooler, (B) Minimum decline of the return oil hose 50 mm/m, (C) Maximumdecline 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





4.9 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 beenordered and supplied with the crusher, it must be

built by the operator.The crusher’s service platform must meet therequirements of ISO 2867 or a correspondingstandard. The appropriate height for the platform isthe level of the support brackets. The platform andsteps must be equipped with handrails to prevent

personnel from falling down.

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

4.10 PRESSURIZED DUST SEALINGThe crusher is equipped with pressurized dustsealing system. It should be noticed that the blowerunit must be installed as close to the crusher as

possible but not further than 10 m (30 ft) from thecrusher.

Mounting height is correct when the pressure portof the blower is higher than frame connectionflange of the lower frame.

4.11 STORAGE

To protect your crusher from rust corrosion duringseasonal shutdown, shipment or storage over 3months, the following protective measures have to

be taken. If you have further questions related tothe storage or safety at work, contact Metso.

• Remove the top cover, upper frame assemblyand main shaft assembly. Disconnect the oildrain 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 preventivelubricating oil to the flange connection of theframes. Using the paint brush, coat the

protection bushing and all the visible outersurfaces of the main shaft and the head. Thencoat all the visible surfaces of the slip ring.

Use lubricating oil which has a rust preventive blend that is designed for the protection of

internal parts of enclosed assemblies, such asengines, compressors, pumps, gear sets, andhydraulic assemblies. The rust preventivesfunction by displacing water from metalsurfaces, by forming strong water-resistantfilms on the surfaces, and by absorbing waterin the system into a water-in-oil emulsion.These products provide as much as 30 to 40times the protection against rust compared tohigh quality lubricating oils that have not beenespecially formulated to prevent rust.

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

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

• Then reinstall the main shaft assembly, upperframe assembly, and top cover into the crusherand cover the entire crusher with a sheet of 2mm polyethylene to prevent water fromseeping into the crusher. Black isrecommended as transparent sheeting willdeteriorate four times faster than black. Thecountershaft 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 machinedsurfaces of the various sub-assemblies must be

painted with rust preventive oil and coveredwith black polyethylene sheeting.

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





4.12 CRUSHER TRANSPORTATION

During transportation the crusher main shaft must be supported with wooden wedges (3 pcs) whichare placed equally to the crusher cavity (Figure4.10). After the transportation remove the wedges.

Figure 4.10 Wooden wedges





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OPERATION CHAPTER 5

5.1 BEFORE STARTING

Remove all transport latches. Remove wooden blocks (3 pcs) from the crusher cavity (see figure5.1). Check the condition of the machine.

Ensure that the crusher is operated only in a safemanner and is in good condition.

Use the crusher only when all necessary protectiveand safety devices – e.g., guards, emergency stopdevices, silencers, aspirators – are in place and inoperating condition.

Starting the crusher is possible when the lubricationoil is warm enough. Connect the control voltage towarm up the oil.

NOTE: Read the Instruction Manual beforestarting the crusher.

Figure 5.1 Remove the wooden blocks

5.2 GENERAL INFORMATION PRIOR TOCRUSHING

Crushing is most efficient when the crusher is fullof stones.

WARNING!

Before starting the crusher, ensure that

there are no persons in the area whosesafety may be endangered! Walk aroundthe crusher and ensure that there is nobodyon, by or below the crusher. Warneverybody in the vicinity before starting.

IMPORTANT!

Ensure that the crusher cavity is empty.

Do not climb on the crusher, when it is inoperation and do not touch any moving

parts.

Do not try to clear the blocked crushingcavity, when the crusher is running. Bealways very careful when clearing thecavity.

Do not try to clear the blocked crushingcavity alone.

IMPORTANT!

At least once per shift, visually check themachine for defects and deficiencies. Report anychanges (including changes in the operation ofthe machine) to the unit/person in charge

immediately. If necessary, the crusher must bestopped without delay and the necessary safety

precautions taken.

Immediately stop the crusher and takethe necessary safety precautions in theevent of a malfunction! Repair any faultsor have them repaired immediately!




CHAPTER 5 - OPERATION

NOTE: IF THE CRUSHER STOPSUNEXPECTEDLY, TAKE THE FOLLOWINGSTEPS:

Remove all personnel from the vicinity of themachine, and report the situation to the person incharge of the plant. Switch the crusher power off to

prevent unexpected starting.

NOTE: Never inspect a stopped crusher fromabove; use the inspection hatches on the hopper orcrusher instead. The pressure could cause a piece ofmaterial to fly out from the gap, causing an

accident.

Determine why the crusher stopped. If a carefulinspection indicates that the crusher did not stopdue to an electrical or hydraulic fault, it may havestopped because of a foreign, metal object in thecavity. In this case, the crusher may pose a threat tolife.

If the crusher stops when loaded, release the pressure from the adjusting system by opening themanual valve on the lubricating device until theadjusting system pressure gauge indicates zero.

Now there should be no pressure on any foreignobject, apart from the weight of the stones on top ofit.

After releasing of the pressure, the crushing cavitymay be inspected and the foreign object removedsafely.

If the main shaft must be lowered to empty thecrusher, one of the following methods may be used:

– Lower the main shaft by using the manualvalve (no electricity needed). Open themanual valve on the lubrication unit untilthe adjusting system pressure gaugeindicates zero. Shut down the valveimmediately after that.

– Fill the crushing cavity with stones, orcover it with a suitable, approved cover tomake it safe. Place a jack between theupper frame arm and shaft nut, and press

the main shaft down (be careful not tomake the shaft drop quickly).

– If the blockage is so bad that the above procedures do not help, remove the upperframe to release the pressure from the

main shaft.

When the main shaft is fully down, the foreignmetal object should fall out of the cavity, and it canthen be removed using the conveyor as usual. Thenensure that there are no more foreign objects in thecavity. The crusher may be started again when thereason for the foreign object in the crusher cavityhas been determined and possible damages have

been repaired.

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

WARNING!

The foreign metal object in the crushermight be very hot. Do not touch it!





5.3 STARTING

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

• Start the process by pressing the “start” buttonat the control cabinet (refer to the automationsystem manual). Lubrication unit (2) starts.

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

• After process has given permission, start thefeeding device (4).

.

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

START





5.4 OPERATING THE NEW ORRENOVATED CRUSHER

• Operate new or renovated crusher for 1 hourwithout load before feeding material in. If therenovating is done at the customers facilities,

the operating time for an unloaded crusher is 4hours.

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

• Operate the crusher for 5 hours with amaximum 75% load.

• After this running-in period, the crusher can beoperated with the maximum load.

• Ensure that the pipes and hoses do not leak.

• Ensure that the upper and lower frame do notmove in relation to each other.

• Ensure that the cooling of lubricating oil worksas shown in the operating manual. Check thatthe oil temperature and the settings ofthermostats are according the oil viscosityused.

• Observe pressure and temperature of thelubricating oil.

• Check and clean regularly the magnetic plugsand 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 thecavity.

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

• Stop feeding sometimes and listen to thecrusher for any abnormal noise. Knockingsound may come from loose liner.

• Ensure that the top bearing does not leakgrease.

• Check oil level in the reservoir.

• Check that the setting keeps constant.





5.5 SETTING

Setting is the closest relation between the bowlliner and mantle during the work cycle. It must bemeasured at the lowest point of the mantle. Thesetting determines the maximum size of the

discharging material, crusher capacity and load.The setting may be measured by lowering a pieceof lead with a wire through the crushing cavitywhen the crusher is idling, then measuring thethickness of the compressed lead (Figure 5.3). A

piece of lead is delivered with the crusher in thetool box.

Since the liners could wear unevenly, measure thesetting at three or four different points and thencalculate the average of these measurement toobtain the crusher setting. Use of too small a settingincreases the crusher load considerably.

More accurate way to measure the setting is to perform contact calibration. For more detailedinstructions refer to automation system manual.

Automation keeps the crusher setting at the presetvalue. Overload situation opens the setting. Systemreturns the setting to preset value when theoverload situation is over.

Figure 5.3 Measuring the crusher setting

5.6 STROKE

For changing the stroke refer to chapter 9.

WARNING!

When measuring the setting the wire mustnot be wrapped around the hand.

IMPORTANT!

Contact calibration is possible ONLY for finecrushers.

IMPORTANT!

The crusher is equipped with cone crusherautomation system. Therefore the setting can not

be adjusted if the automation system isdisconnected. Normally the setting adjustment is performed from the automation system display(i.e. manual or setting mode). However thesetting can also be adjusted with the LCP (LocalControl Panel) in local mode with separate panel.

NOTE: For safety reasons the crusher must berunning before the automation system allows thesetting decrease.





5.7 STOPPING

• Stop the process by pressing the “stop” buttonat the control cabinet (refer to the automationsystem manual).

• Stop the feeding device (1).

• Crusher (2) stops.

• Stop the discharge conveyor (3).

• Lubrication unit (4) stops..

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

STOP





5.8 OVERLOAD PROTECTION

The crusher is equipped with a shock valve whichacts as an additional overload protection in extremeoverload 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 adjustingsystem reaches that pressure due to overload, thevalve opens, oil flows to the lubrication unit returnline and the setting increases. When the overloadsituation is over, automation system will adjust thesetting back to the preset value.

.

Table 5-1

Figure 5.5 Shock valve acts as an overloadprotection

Crusher Pressure level

bar (PSI)

GP200 30 (435)

GP200S 20 (290)

GP300 35 (510)

GP300S 26 (375)

GP550 35 (510)

GP500S 35 (510)




MAINTENANCE CHAPTER 6

6.1 GENERAL

The crusher repair and maintenance is allowed onlyfor reliable and qualified craftsmen.

When the equipment is switched off duringmaintenance and repair, the motor controls must belocked out/off. Secure the lock keys and attach ahazard notice at the main disconnect switch.

All service/repair, except those told in this manual,

are allowed only for the servicemen qualified byMetso, to keep the warranty valid.

WARNING!

Before performing any maintenance orrepair work, make sure that the crusher

is stopped and locked out.






1. Switch off motor



4. Place appropriate maintenancewarning signs (TAG OUT).

In any work related to the operation,modification, conversion or adjustmentof the equipment and its safety devicesincluding inspection, maintenance andrepair, observe all starting, stopping andmaintenance procedures as outlined inthe instruction manual.

IMPORTANT!

Ensure as extensively as possible that theimmediate area is safe and secure.




CHAPTER 6 - MAINTENANCE CHAPTER 6 - MAINTENANCE

6.2 LIFTING WEIGHTS

Figure 6.1 Lifting weights of assemblies (fine crushers)

1Countershaft Assy

kg (lbs)

2Main Shaft Assy

kg (lbs)

3Upper Frame Assy

kg (lbs)

4Lower Frame Assy(w/o countershaft)

kg (lbs)

GP200170

(375)1700

(3750)1600

(3530)4300

(9480)

GP200S170

(375)1950

(4300)2650

(5840)4300

(9480)

GP300260

(573)2540

(5600)2150

(4740)6820

(15000)

GP300S260

(573)2970

(6550)3850

(8200)6830

(15100)

GP550350

(772)5280

(11600)4600

(10100)11630

(25600)

GP500S350

(772)6600

(14600)8380

(18500)11550

(25500)




CHAPTER 6 - MAINTENANCE

Figure 6.2 Lifting weights of assemblies (secondary crushers)





6.3 SPACE REQUIREMENTS FORMAINTENANCE

When designing crusher installation remember thatthere must be enough space around the crusher forlifting and maintenance (figures 6.3 and 6.4).

Required measures are indicated in the table below. .

GP200 GP200S GP300 GP300S GP550 GP500S

A 1013 925 1199 1160 1380 1518

B 1853 2166 1873 2231 2380 2840

C 2620 2933 2603 2961 3237 3697

D 2581 3205 2590 3291 3326 4209

E 1881 2196 1901 2265 2456 2891

F 1428 1742 1411 1766 1802 2236

G 453 454 490 499 655 655

H 717 717 680 680 807 807

I 132 132 132 132 132 132

J 1103 1413 1130 1477 1475 1925

K 1540 1540 1820 1820 2280 2280

L 830 830 939 943 1150 1150

M 830 830 1029 922 1150 1134

N 1165 1165 1400 1297 1588 1587

O 1710 1710 2018 1915 2350 2334





Figure 6.3 Space requirements for maintenance (fine crushers)

Figure 6.4 Space requirements for maintenance (secondary crushers)





6.4 SPECIAL TOOLS FOR MAINTENANCE

The delivery of the crusher includes a tool boxcontaining tools and accessories necessary tomaintain 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 beenordered and supplied with the crusher, it must be

built by the operator.

The crusher’s service platform must meet therequirements of ISO 2867 or a correspondingstandard. The appropriate height for the platform isthe level of the support brackets. The platform andsteps must be equipped with handrails to prevent

personnel from falling down.All international and national regulations on service

platforms for crushing equipment must beobserved.

6.6 WELDING

When electric arc welding must be used to install ordisassemble wear parts etc., the ground cable must

be fastened directly to the part to be welded and asclose to the welding point as possible (Figure 6.5).

Figure 6.5 Welding arrangement

IMPORTANT!

Welding current must never pass through anyconnection or bearing.

IMPORTANT!

Before welding the crusher switch off the controlvoltage.

DANGER!

There are components made ofmanganese steel in the crusher, such asliners and in some models protection

plates of the upper frame arms. Weldingor flame cutting these componentsgenerates gas that is extremelyhazardous to health and causesmanganese poisoning. This kind ofwork must be done outdoors or inwell-ventilated premises equipped withlocal exhaust ventilation.





6.7 CORROSION PROTECTION

Corrosion occurs on iron and steel surfaces that areexposed to water and oxygen. Metal surfaces areexposed to oxygen and humidity practically all thetime. 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.

Corrosion can

– cause unnecessary downtime

– increase maintenance costs

– decrease the service life of equipment

– cause dangerous situations

To ensure economical and safe crushing, regularcorrosion-protection procedures must be used forthe equipment. Use only well-tried methods andsubstances.

Before long-term storage, the machine must be protected against corrosion, and a suitable storagelocation must be selected.

After long-term storage, the machine must beinspected for corrosion. Corrosion may occur, e.g.,

between the bronze bearings and the steel eccentricshaft and main shaft due to the materials differing.In this case, rust must be removed by grinding the

parts.

6.8 BLEEDING AIR FROM THE ADJUSTINGCYLINDER

Air must be bled from the adjusting cylinder whenthe adjusting oil hose has been connected. Bleedingis 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. Suitablehose is about 6 mm and it must be long enoughto reach to the collector tray. Open the bleedingscrew and close the manual valve in thelubrication unit.

• Start the lubrication pump and the crushermanually (refer to automation system manual).

Notice that there is 2 minutes delay before thecrusher 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.

Figure 6.6 The air bleeding screw.

IMPORTANT!

Use a collector tray so that the oil does not spill tothe ground.





6.9 TIGHTENING TORQUE FOR BOLTS

6.9.1 Cavity mounting bolts

The bowl liner bolts are to be tightened inaccordance 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.

6.9.2 Other bolts

Other bolts must be tightened in accordance withthe table below. The tightening torque indicated isfor a clean, unlubricated bolt. The threads are notsurface-treated. The bolts’ strength class is 8.8.

Crusher BoltTorque

Nm ft lbs

GP200 M30 579 426

GP200S M30 579 426

GP300 M30 579 426

GP300S M30 579 426

GP550 M36 1,010 744

GP500S M36 1,010 744

BoltTorque

Width acrossthe flats

Nm ft lbs mm in

M10 47 35 17 43/64

M12 81 60 19 3/4

M16 196 145 24 61/64

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





6.10 LUBRICATION

For the main lubrication see Instruction Manual forGP Lubrication System.

6.10.1 Countershaft system

The amount of oil in the countershaft system isshown in the table below. Oil is filled via the

breather hole on the countershaft housing, so the breather must be unscrewed before filling (A). Fordraining the oil, there is a drain plug on the bottomof the housing (B). The oil level should reach up tothe level plug hole (C).(Figure 6.7)

Use the same lubricating oil as in the lubricationand adjusting system; refer to separate instructions.

Table 6-1 The filling amount of oil in thecountershaft system

Figure 6.7 Draining and adding oil to thecountershaft

6.10.2 Top bearing

The top bearing grease capacity is shown in thetable 6-2. The usual filling has to be accomplishedat the liner change, when the crusher is dismantled.If the top bearing seal leaks, change the sealing andfill top bearing housing with grease. The housing ofthe bearing should be filled with grease, when themain shaft is fully lowered (figure 6.8). Suitablegrease quality is a semisolid EP (pressure-proof)grease.

Table 6-2

Crusher Oil amountliters (US gallons)

GP200 2,0 (0,5)

GP200S 2,0 (0,5)

GP300 2,0 (0,5)

GP300S 2,0 (0,5)

GP550 5,0 (1,3)

GP500S 5,0 (1,3)

Crusher Grease capasity

kg (lbs)

GP200 7 (15,4)

GP200S 7 (15,4)

GP300 8 (17,6)

GP300S 8 (17,6)

GP550 10 (22)

GP500S 10 (22)





Recommended brands are e.g.:

Table 6-3

NOTE: Oil brands listed above are suitable fortemperature range -25 - +40°C (-13 - +104 F). If thetemperature is outside this range, contact your localconstruction expert at Metso.

Figure 6.8 Fill top bearing housing with grease

Brand Type

BP Energrease LS-EPO

MOBIL Mobilith SCH 007PETRO CANADA Precision XL EP000

SHELL Alvania GC 00

NESTE Centergrease 00 EP

CALTEX Multifak EP 0





6.11 SCHEDULED MAINTENANCE

6.11.1 Scheduled maintenance for newcrusher

A new or renovated crusher has to be inspected and

the following maintenance should be accomplishedduring 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 afterchanging the wear parts

HOSES AND PIPES

Check all hose and pipe connections. Repair allleakages immediately.

V-BELTS

Check the tension of V-belts and tighten asnecessary.

Figure 6.9 Check the bowl liner bolts (finecrusher)

Figure 6.10 Check the bowl liner bolts(secondary crusher)





6.11.2 Every eight hours of operation /every shift

6.11.2.1 Lubricating and adjustingequipment

NOTE: For more maintenance information, referto the Lubrication unit manual

Check the oil amount in the lubrication tank. Theoil level should be above the middle of the scale.When the crusher is running, the oil level shouldnot descend below the minimum point in the scale(A, Figure 6.11). Add oil as necessary.

Check the return oil filter basket (B, behind thecover).

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

6.11.2.2 HosesCheck the hoses and fittings, and repair any leaksimmediately.

6.11.2.3 Top bearing seal

Check the condition of the top bearing seal. Theseal prevents grease from leaking out from the top

bearing housing. A leak is indicated by grease onthe main shaft, above the tightening nut

(Figure 6.12). A damaged seal must be replacedimmediately. For more detailed instructions, referto subsection 6.13.6.

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

AB





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

6.11.3.1 Entire crusher

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

6.11.3.2 Liners

Observe the possible uneven wear of the liners.Uneven wear of the liners may be caused byincorrect feeding of the crusher. In this case, thefeed must be adjusted. For instructions, refer tosubsection 4.4.

6.11.3.3 Lower frame arms

Open the inspection hatches (3 pcs.) on the lowerframe, and clean the arms and slip ring, removingcrushed rock and other accumulated material.Cleaning must be performed more frequently ifthere are tree roots, wires, iron bars, etc. among therock material.

If there is oil on the slip ring under the head, thecause must be determined and rectified.

6.11.3.4 V-belts

Check the tension and wear of the V-belts. Tensionas necessary, or replace the entire set of V-belts atthe same time. For tensioning instructions, refer tosubsection 4.7.

6.11.3.5 Electrical equipment

Check visually the condition of electrical cablesand components, ensuring that there are no cracksor signs of abrasion. Immediately repair any faults,and follow the regulations on electrical safety andinspections.





6.11.4 Every 400 hours of operation / everymonth (two-shift operation) / every twomonths (one-shift operation)

6.11.4.1 Main shaft dust sealCheck the clearance between the slip ring and themain shaft dust seal every 400 hours or alwaysduring the mantle change. For more informationrefer to section 6.13.2.

6.11.4.2 Lubricating oil of the countershaftsystem

Change the lubricating oil of the countershaftsystem. Drain the oil through the plug. Fill new oilthrough the breather hole (Figure 6.7). For theamount of oil, refer to Table 6-1. For the oil type,

refer to the lubricating and adjusting device manual

6.11.4.3 Feed and discharge hoppers andcrusher 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 pulleysand the lubrication unit.

6.11.4.5 Pressurized sealing system

Check the operation of the overpressure device andthe condition of the hose.

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

6.11.5.1 Thrust platesCheck the condition of the main shaft’s thrust

plates. If the oil grooves in the bronze plates areless than 2 mm deep, the plates must be replaced.The inspection is to be made during mantlereplacement. For more detailed instructions, referto subsection 6.13.5.

6.11.5.2 Checking the gear backlash

Check the countershaft and eccentric shaft gear backlash.

Figure 6.13 Checking the gear backlash





Table 6-4 Free movement on the outer diameterof 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 thefunction of the breather. Refer to figure below.

Figure 6.14 Breathers

Crusher Pulley[mm]

Lowerlimit[mm]

Upper limit[mm]

GP200

450 1,4 1,8

530 1,7 2,1

560 1,8 2,2

GP200S 530 1,7 2,1

GP300450 1,2 1,6

475 1,3 1,7

GP300S530 1,5 1,9

560 1,5 1,9

GP550 560 1,3 1,7

GP500S 560 1,3 1,7





6.11.6 Seasonal maintenance(summer/winter)

Change the lubricating oil. For oilrecommendations, refer to the lubricating andadjusting device manual. If necessary, also changethe filter and clean the lubricating oil tank.

Change top bearing grease every six months if notdone during mantle change

Replace the the air filter of the pressurized dustsealing.

6.11.7 Every 20,000 hours of operation /every 10 years (one-shift operation) / every5 years (two-shift operation)

Entire crusher is inspected. Special attention is paidto 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 shockvalve)

NOTE: This procedure is performed by the Metsospecialist.





6.12 MAINTENANCE CHART

More detailed instructions for each maintenance procedure are provided above.

8 h

4 0 h

4 0 0 h

2 , 0

0 0

h

s u m m

e r /

w i n t e

r

2 0 , 0 0

0 h

ELECTRICAL EQUIPMENT

Check the condition of cables and components. X

THRUST BEARINGS

Check the condition of the thrust bearings. X

COUNTERSHAFT SYSTEM

Change the lubricating oil of the countershaft system. X X

Check the clearance. X

TOP BEARING SEAL

Check the condition of the seal. X

MAIN SHAFT DUST SEALCheck the condition of the seal. X

PRESSURIZED SEALING

Check the operation of the overpressure device. X

Replace the air cleaner. X

CRUSHER

Check the tightness of the hydraulic hoses andconnections.

X

Check the tension and wear of the V-belts. X

Observe the possible uneven wear of the liners. X

Check the condition of the hoppers, guards, andprotective cap.

X

Clean the lower frame arms, removing debris. XCheck the overall condition. X

Overhaul the crusher. X

Remove dust from the crusher X

LUBRICATING AND ADJUSTING UNIT

Check the oil amount in the lubrication tank X

Check the return oil filter basket X





6.13 OTHER MAINTENANCE

6.13.1 General

The machine must be serviced and repaired byreliable professionals who are adequately

acquainted with it.The startup and shutdown instructions in theinstruction manual, and all applicable servicinginstructions, must be followed in all proceedingsconcerning the operation of the machine and itssafety devices, as well as inspection, servicing, andrepairing of the machine.

Reserve a large safety zone around the machine formaintenance.

When the crusher has been shut down for servicingor repairs, make sure that it cannot be restartedunintentionally. Open the main switch, and removethe ignition key. Attach a warning sign to the mainswitch, and lock the switch.

Maintenance procedures not described in thismanual must be performed by Metso authorizedtechnicians only; otherwise, the machine’s warranty

becomes void.

6.13.2 Replacing the main shaft dust seal

The condition of the main shaft must be checkedevery 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 theseal is heavily worn.

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

Lift the main shaft off. Screw an eye bolt (suppliedwith the tools and accessories) into the hole at theupper end of the shaft, and carefully lift the mainshaft up. For the main shaft weight, refer tosubsection 6.2.

NOTE: Intermediate thrust plate may shift whenyou lift up the shaft. Check and relocate (ifnecessary) intermediate thrust plate beforeinstalling main shaft back.

IMPORTANT!

Following maintenance operations may be doneduring the liner change





Figure 6.16 Lower the main shaft onto theground

Place the main shaft on its side, taking care not to

damage the bearing surfaces at its lower and upperend (Figure 6.16). Do not lower the thrust bearingat the lower end of the shaft onto the ground; use arubber 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 slidering out.

Protect the bearing surface on the shaft with, e.g., a board or rubber plate to prevent the slide ring fromdamaging 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 installthe new seal. The seal does not require greasing.

Lift the slide ring onto the seal. Fasten the slide ringin place with the mounting bolts. Do not forget thewashers. Ensure that the seal moves freely in thehousing (Figure 6.17). If necessary, shims may beused between the slide ring and head. Figure 6.17 Ensure that the seal moves freely in

the housing

Slide ringkg (lbs)

Sealkg (lbs)

GP20025

(55)3

(7)

GP200S26

(57)3

(7)

GP30064

(141)5

(11)

GP300S64

(141)5

(11)

GP550171

(377)12

(27)

GP500S130

(287)10

(22)





6.13.4 Replacing the main shaft protectivesleeve

If the protective sleeve at the upper end of the mainshaft is damaged or exceeds wear limits, it must bereplaced as well. The sleeve may be replaced only

when the upper frame has been lifted off.

Carefully clean the shaft and the new protectivesleeve.

Heat the new protective sleeve until thetemperature difference between it and the main

shaft is 160 °C. However, the temperature of thesleeve must not exceed 240 °C.

The protective sleeve is equipped with lifting holes(M8); use these to install the sleeve in one go. Ifyou fail to install the sleeve in one go, cut it off andtry again with a new sleeve.

Figure 6.20 Main shaft protective sleeve

IMPORTANT!

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





6.13.5 Checking / replacing thrust plates

The condition of the thrust plates must be checkedannually. It is easiest to perform the inspectionduring replacement of the liners.

The bronze plates in the thrust plate assembly – (A)at the lower end of the main shaft and (C) in theadjusting cylinder – must be replaced when the oilgrooves are less than 2 mm deep (5 mm in new

plates), at the latest. Also check the condition of theintermediate thrust plate (B, steel).

NOTE: Change all plates at the same time.

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 liftinginstruction of the main shaft, refer to chapter 7.5.

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. Lockthe mounting bolt with the locking plate.

Screw an eye bolt into the hole on the lower thrust plate hub, and carefully lift the thrust plates and

bearing away. The diameter of the bearings is about1.5 mm smaller than that of the eccentric bushing.

Clean the lower thrust bearing housing, and installthe new bearing and thrust plate separately. Ensurethat the thrust bearing locking pin enters the hole

and the bearing is properly seated.Slide the thrust plate on top of the thrust bearing tothe eccentric side, to allow the thrust bearingassembly to settle as well as possible into placewhen the main shaft is lowered.

To check that the thrust plate is in the correct position, measure distance “K” between the slipring (A) and the dust seal (B) when the main shaft(piston) is fully down.

This distance should be 8 mm

.

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 beenoptimized correctly. Lift the main shaft, and correctthe position of the thrust plate.

IMPORTANT!

For replacement of the thrust plates, remove theoil from the crusher.





6.13.6 Replacing the top bearing seal

The condition of the top bearing seal must bechecked daily. If the seal is damaged, there isgrease 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 insubsection 7.3, “Dismantling the upper frameassembly” and lift the upper frame onto a stand.

Remove the old seal from the upper frame.

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 theseal to room temperature to make the mountingeasier and to avoid breakage of the seal. Bend theseal during mounting (Figure 6.24).

Figure 6.24 Bend the seal during mounting

Figure 6.25 Installing the top bearing seal

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




REPLACING WEAR PARTS CHAPTER 7

7.1 GENERAL

The wear of the liners may be checked bymeasuring the distance between the mantletightening nut and the bottom of the top bearinghousing (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 notmore than 20 mm (25/32”). If it is less than 3 mm,cut some material off from the bowl liner.

Figure 7.1 Distances to check the wear of theliners

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

The part numbers of wearing and spare partsneeded for replacing the liners are indicated in thespare parts manual.

Before installing the liners, carefully remove theanti-rust agent. Use a suitable hand tool to removeany transportation damage, rust, etc. as well.

WARNING!

Before performing any maintenance orrepair work, make sure that the crusher

is stopped and locked out.






1. Switch off motor



4. Place appropriate maintenancewarning signs (TAG OUT).

IMPORTANT!

The liners must not be worn through, since thiswould damage the liner mating surfaces on theframe or head, which would then require padwelding and machining.

A(with new

liners)

A(replacement

limit)

GP200168

(6 5/8")11

(7/16")

GP200S164

(6 1/2")10

(3/8")

GP300160

(6 5/16")11

(7/16")

GP300S167

(6 9/16")11

(7/16")

GP550 250(10”) 15(5/8”)

GP500S240

(9 1/2")15

(5/8”)

IMPORTANT!

Change the liners earlier if they wear out due touneven feed.




CHAPTER 7 - REPLACING WEAR PARTS

When you are changing the stroke and gap option,it may be useful to change the rotation speed of thecrusher as well, to optimize the capacity and

product quality. In such cases, contact your localconstruction expert at Metso.

7.2 WELDING

When electric welding equipment is used to fastenor disassemble wearing parts or other components,the ground cable must be fastened directly to one ofthe parts to be welded, as close to the welding point

as possible (Figure 7.2).

Figure 7.2 Welding the crusher

IMPORTANT!

To check the tightening torques of the bolts, referto subsection 6.9.

IMPORTANT!

The welding current must never pass through any bearing or joint surface!

IMPORTANT!

Before welding switch off the control voltage.DANGER!

There are components made ofmanganese steel in the crusher, such asliners and in some models protection

plates of the upper frame arms. Weldingor flame cutting these componentsgenerates gas that is extremelyhazardous to health and causesmanganese poisoning. This kind ofwork must be done outdoors or inwell-ventilated premises equipped withlocal exhaust ventilation.





Figure 7.4 Remove the bolts on the jointbetween the upper and lower frame (fine

crusher)

Figure 7.5 Remove the bolts on the jointbetween the intermediate and lower frame

(secondary crusher)

Figure 7.6 Separate the joint between the upperand lower frame by using four jacking bolts (fine

crusher)

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





Lift the upper frame assembly away (Figures 7.8 and 7.9). You can tie the hoisting ropes around theupper frame arms. Lower the upper frame assemblyonto a stand for removing the bowl liner.

Figure 7.8 Lift the upper frame away (finecrusher)

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

WARNING!

Do not open the bowl liner bolts beforelifting the upper frame assembly





7.4 REPLACING THE BOWL LINER

7.4.1 Fine crushers

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

Figure 7.10 Nuts on the bowl liner mountingbolts

If the bowl liner does not come loose, drive wedges between the bowl liner lugs and upper frame. SomeExtra fine (EF)…Medium (M) bowl liners mayhave the protection cone and/or intermediate cone.In these cases ensure that whole package can beremoved together out from the frame.

Lift the frame off the liner, and place it on a stand.

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

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, placetwo bolts in their holes.

NOTE: With short bowl liners (extra fine (EF) andfine (F)), check that the clearances between bowlliner lugs and the upper frame are equal.

Tighten the nuts on the two bolts, and insert the restof the bolts into their holes (Figure 7.11).

The bowl liner is mounted with six bolts and nuts.

See Figure 7.10.

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, makesure that the flat side of the bolt head is facingoutwards (Figure 7.12)

Remove the bowl liner from the upperframe by hitting the upper frame with asledgehammer from different sides. Becautious of the falling liner.

DANGER!

Do not use explosives for removing the bowl liner!

DANGER!

Watch out for the possibly falling ptotection cone and/or intermediatecone!





.

Figure 7.12

Tighten the nuts alternately, a little at a time. Forthe tightening torque, refer to subsection 6.9.1.

When tightening the bowl liner bolts, notice thatthere must be some clearance left between the bowlliner lug and the frame (clearance X in theFigure 7.12).

Check the top bearing seal, and replace it ifnecessary. Refer to subsection 6.13.6.

Check the condition of the upper frame protection plates. Repair or replace if necessary.

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

Table 7-3 Lifting weights for fine crusher bowl

liner

IMPORTANT!

There must be no gap between the bowl linerseating surface and the frame (Figure 7.13). Theservice life of the liner is reduced if it is allowedto move in the frame.

X

IMPORTANT!

If the contact surfaces in the frame have worn toomuch, i.e. there is gap between the bowl liner

seating surface and the frame, contact your localconstruction expert at Metso for moreinformation.

Bowl liner kg (lbs)

GP200654

(1442)

GP3001098

(2421)

GP5501892

(4171)





7.4.2 Secondary crushers

Replacing the lower part of the bowl liner is similarto the fine crusher. Refer to previous section.

When replacing the upper part of the bowl liner,remove the nuts from the connection between theintermediate and upper frame (Figure 7.14). Openthe connection with four jacking bolts (N,Figure 7.16). Leave four equally distributed boltsloose in the frame connection. Screw the nuts onthe bolts so that the connection can open about 10 -20 mm (3/8" - 3/4"). This ensures that the upperframe cannot jump away.

Figure 7.14 Remove the nuts from theconnection between the intermediate and upperframe

Remove the tightening wedges (L) by torch cuttingor grinding (Figure 7.16).

Lift the upper part of the bowl liner by using thelifting holes. If needed, insert wedges between thelower and upper part of the bowl liner to remove it.

Clean and inspect the liner seating surfaces in theframe as well as the conical mounting surfaces

between the frames.

Lift the new upper part of the bowl liner in place

and hammer it to seat it properly.

Figure 7.15 Check the distance B

Lift the upper frame in place so that the grooves forthe tightening wedges of the upper part of the bowlliner will stay below the supporting arms of theupper frame. Install the bolts and nuts between theupper and intermediate frame and tighten evenly,tightening torque see chapter 6.9.

Place the wedges under the supporting arms andensure the wedges will tighten the bowl liner to theframe. If necessary weld a flat bar to the bowl linergroove and cut the extra length of the wedge so thatdimension K is greater than 0 and M is greater than10 mm (3/8"). Hit the wedges tight and weld themto the bowl liner using stainless electrode(Figure 7.16).

NOTE: Do not use old wedges. Replace wedgesevery time the upper bowl liner is replaced.

IMPORTANT!

Distance B between the upper and lower bowlliner must be at least 6 mm (15/64”).

(Figure 7.15)





Figure 7.16 Tightening wedges

Table 7-4 Lifting weights for secondary crusherbowl liners

Bowl liner kg (lbs)

GP200SUpper 310 (684)

Lower 465 (1026)

GP300SUpper 472 (1041)

Lower 951 (2097)

GP500SUpper 1317 (2904)

Lower 1916 (4224)





7.5 REPLACING THE MANTLE

The mantle is replaced with the main shaft liftedoff. When the main shaft is lifted it is possible tocheck the thrust plates at the lower end of the shaft.

When you are going to lift the main shaft, screw theeye bolt (supplied with the tools and accessories)into the hole at the upper end of the shaft, andcarefully lift the main shaft away. For the weight ofthe main shaft refer to chapter 6.2.

Lower the main shaft onto a stand such that it issupported from the lower end of the head – NOT

THE SEAL, taking care not to damage the bearingsurfaces at the lower and upper end of the shaft. Donot lower the thrust bearing at the lower end of theshaft onto the ground; use a rubber plate as

protection (Figure 7.17).

Figure 7.17 Example of supporting the mainshaft

After the main shaft has been lifted away, check thecondition of the thrust plates. If the bronze plateshave been worn such that their oil grooves are lessthan 2 mm deep, the plates must be replaced. Theinspection must be made at least once a year. Referto 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 notdamage the main shaft.

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 equallydivided nuts (M16/ 5/8”) to the upper surface of thelocking nut. (Figure 7.19).

NOTE: Screw the eye bolts to the nuts beforewelding, to keep threads working properly.

WARNING!

The surface in the frame flange is greasyand slippery. Take care of occupationalsafety while standing on the surface!

WARNING!

Before replacing the mantle, the mainshaft must be supported properly

2 1





Figure 7.19 Lifting the locking nut

Clean and inspect the tightening nut. If it is in goodcondition it can be reused. Leave the welded arminto the nut. Also clean and inspect the thread in themain shaft.

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 fromISO-EN10025-S355 (ASTM A 572/572M-04 Gr.50) or similar. Weld the lugs to the mantleaccording to Figure 7.21. Use the followingwelding procedure:

a. Use austenitic stainless steel electrodes:AWS A5.4: E 307-16EN 1600: E 18 8 Mn R26(e.g. ESAB OK 67.45)

b. Do not preheat the mantle. Interpasstemperature must remain under 200°C(392°F). Observe the temperature closelyand let the mantle cool down if

necessary.

c. Carefully grind the surfaces to bewelded.

d. Weld the lugs to the mantle by a filletweld (a=6 mm (1/4")) around the lug.

WARNING!

Do not try to lift the worn mantle fromthe lifting hooks cast onto the mantle.They are suitable for lifting only in newmantles. Weld new lifting lugs to the

worn mantle.

Item Measure)

12345

100 mm (4”)50 mm (2”)50 mm (2”)

R50 mm (2”)50 mm (2”)





e. Fill any craters!

Figure 7.21 Lifting lugs welded on the mantle

Figure 7.22 Lift the protection cone (1) andmantle (2) together

Table 7-5 Lifting weights for mantles

WARNING!

Before lifting the mantle using weldedlifting lugs make sure that the lugs arestrong enough and welding is performed

properly. NEVER GO UNDER THESUSPENDED LOAD.

WARNING!

If the mantle has the protection cone DO NOT try to lift it separately. Weld thelifting lugs to the mantle and lift the

protection cone and the mantle together.(Figure 7.22)

Lift the mantle away. If the mantlecannot be lifted, hit it with asledgehammer from different directions.

Mantlekg (lbs)

GP200479

(1056)

GP200S578

(1274)

GP300755

(1664)

GP300S930

(2050)

GP5501218

(2685)

GP500S2330

(5137)





7.5.2 Installing the new mantle

Clean and inspect the mantle mounting surface ofthe head, and repair it if necessary.

Check the condition of the main shaft dust seal, andreplace it if necessary. The clearance between thedust seal and slip ring must not exceed 1.5 mm. Formore detailed instructions, refer to subsection6.13.2.

Check the condition of the lower frame protection plates. Repair or replace if necessary.

Clean the mounting surface of the new mantle.

Lift the mantle into place. Ensure that the bottomedge of the mantle mounting surface rests tightly onthe 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 7.23 There must be no gap between themantle and the head

Tighten the nut by turning it counterclockwise.Notice the left-hand thread. Tighten the nut byhitting the welded arm with a sledgehammer. At thesame time, you can also knock the mantle with thesledgehammer to make it settle more tightly into

place. Continue tightening until the mantle nolonger clangs when knocked with the

sledgehammer.

After tightening the nut, weld the nut, torch ring,and mantle / protective cone with six, equallyspaced, 50...70 mm (2...2 ¾”) long welds(Figure 7.24). Also weld the protection cone andmantle together with six, equally spaced, 50 mm(2”) welds. Remove the welded arm.

NOTE: Start the welding by closing the cap in thetorch ring

.

Figure 7.24 Weld the torch ring, nut and mantletogether





Installing the main shaft

– Ensure that the intermediate thrust bearinghas not moved out of position duringlifting 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 theeccentric side, to allow the thrust bearingassembly to settle into place as well as

possible when the main shaft is lowered.

– Carefully lift the main shaft into thecrusher. Remember that the hole of theeccentric shaft is slightly askew, and payspecial attention to the bearing surfaces.Also, be careful not to damage the dustseal 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 hatchesto control the lowering process.





7.6 INSTALLING THE UPPER FRAMEASSEMBLY

Lubricate the top bearing seal. Use the same greaseas in the top bearing.

Lift the upper frame assy into place, taking care notto damage the top bearing seal (Figure 7.26).

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 andlower 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 islowered onto the lower frame, there must be aclearance of 2–4 mm between the frame flanges,which is then closed by tightening the bolts.

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

Figure 7.28 Insert the mounting bolts and nutson the joint between the intermediate and lower

frame (secondary crusher)





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

Figure 7.29 Fill the top bearing housing withgrease

Check the condition of the cover, and repair orreplace if necessary. Lift the cover into place.

NOTE: Notice the correct position of the coverand the breather.

Check the condition of the feed hopper, and repairif necessary. Lift the hopper into place.

Test run the crusher without load for a while, toensure that it is operating properly.

7.7 RE-TIGHTENING

After 10 hours of operation, tighten the bowl linermounting bolts; refer to subsection 6.9.1 for thetightening torque.

After 25 hours of operation, tighten the bolts onthe joint between the lower and upper frame; referto subsection 6.9.2 for the tightening torque.

.

Figure 7.30 Re-tightening after replacement ofthe liners

CAUTION

After tightening no clearance is allowed between the frames.

Failure to tighten frame bolts properlywill cause damage to the tapered jointsand will need a major repair.

25 h10 h




TROUBLESHOOTING CHAPTER 8

Equipment malfunction may occur for a number ofreasons: incorrect operation of the equipment (fromoverloading, carelessness, or inexperience), or anormal wearing out of parts. Electrical controlsshould be designed so, that these possiblemalfunctions do not allow any additional damage.

For troubleshooting see also instruction manualsfor GP Lubrication System and the automationsystem.

Some typical malfunctions and the possiblesolutions follow:

MALFUNCTION CAUSE REMEDY

THE PROCESS WILL NOTSTART

• Emergency stop is activated • Deactivate the emergency stop

button

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

• 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

THE CRUSHER WILL NOTSTART

• There is feed material in the

crusher

• Remove the feed material

• If the cavity is empty, check the

level detector

• Oil pump is not running • As above

• There might be a mechanical

problem in the pump. Check the

pump.

• 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




CHAPTER 8 - TROUBLESHOOTING

• 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 DURINGSTARTING SEQUENCE

• The crusher power is too high

for too long

• Crusher motor is damaged

• Faulty starting resistor/ soft

starter

• The crusher is damaged • Contact Metso

THE FEEDER WILL NOT START • Crusher is not running • As above

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

• Dump valve is open. Close thevalve

• Check the setting sensor

• No pressure in the setting circuit.

Check the setting unit.

MALFUNCTION CAUSE REMEDY





OTHER POSSIBLEMALFUNCTIONS:

CRUSHER STOPS DURING

CRUSHING

• Return oil temperature is too

high

• Let the oil cool down. Determine

the reason for excessivetemperature.

• 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

crusher is overloaded and the

protection system of the motor

has been activated. The

lubricating pump is still running.

• Empty the crusher cavity,

remove the reason for overload

and restart the crusher after the

motor has cooled down. It might

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 NOTMAINTAIN THE PRESETSETTING 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 moreinformation contact Metso.





• 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.

LINERS ARE WEARINGUNEVENLY

• Feed is distributed unevenly to

the crusher

• Adjust the feed

• Replace liners as necessary

• Contact Metso

CRUSHER PERFORMANCE ISPOOR

• Contact Metso

PROCESS WILL NOT STOP • 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




CHANGING THE STROKE CHAPTER 9

9.1 GENERAL

There are several stroke options for the crusher. Tochange 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. Thecrusher stroke is caused by the eccentricity of the

bearing. For the stroke change, the upper frameassy and main shaft must first be lifted off the lowerframe.

When changing the stroke and gap option, in somecases it may be useful to change the rotation speedof the crusher as well, to optimize the capacity and

product quality. For more information contact yourlocal construction expert at Metso.

9.2 DISMANTLING THE UPPER FRAMEASSEMBLY

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

Lower the main shaft by opening the magnetic

valve or manual valve on the lubricating andadjusting device. When the main shaft has beenlowered, close the valve.

Remove the feed hopper bolts, and lift the hopperaway.

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

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

Figure 9.1 Remove the top bearing housing

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

IMPORTANT!

The following information is not valid for thecrushers equipped with the SteplessStroke

system. For SteplessStroke information refer toSteplessStroke Instruction Manual (delivered, ifyour crusher is equipped with the SteplessStrokesystem).

IMPORTANT!

Before changing the stroke contact your localconstruction expert at Metso.

IMPORTANT!

Wait until the crusher has cooled down beforechanging the stroke.

When the crusher is used, the eccentric bushingmade of bronze expands more than the main shaftmade of steel. Therefore the eccentric bushing ismore difficult to remove and re-install.




CHAPTER 9 - CHANGING THE STROKE

Figure 9.2 Remove the bolts on the jointbetween the upper and lower frame

Separate the joint between the upper frame assy andlower frame by using four jacking bolts(Figure 9.3). The separation can be assisted byattaching hoisting ropes to the upper frame andtensioning them with the crane. In this case, leavethree equally spaced bolts loosely on the frame

joint. The bolts must have nuts on them such thatthe joint can be separated 10–20 mm. This is toensure that the upper frame does not jump off whenit comes loose.

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

Lift the upper frame assy away (Figure 9.4). Youcan tie the hoisting ropes around the upper framearms. Lower the upper frame onto a stand.

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 thehole at the upper end of the shaft, and carefully liftthe main shaft away.

Lower the main shaft onto a stand such that it issupported from the lower end of the head – NOTTHE SEAL – or place it on its side, taking care notto damage the bearing surfaces at its lower andupper 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 9.7 Lift the eccentric bushing away

9.3 STROKE CHANGE ANDRE-ASSEMBLING

Check the condition of the new eccentric bushing.Clean if necessary.

Place the key in the keyway of the desired stroke inthe eccentric bushing and lower the bushing in its

place. The stroke lengths are marked on the top ofthe eccentric bushing above every keyway(Figure 9.8). The bushing must slide in, do not hitit.

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

keyway

Secure the eccentric bushing with the screw (M10).

Lock the bolt with locking compound, e.g. Loctite242.

Eccentric bushingkg (lbs)

GP200 76 (168)

GP200S 78 (172)

GP300 79 (174)

GP300S 82 (181)

GP550 144 (318)

GP500S 152 (335)

IMPORTANT!

Head of the screw must be lower than the insidediameter of the eccentric bushing.





Lock the eccentric bushing into place with theAllen 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 (30lbs)) and put the counterweight to the correct

position (Figure 9.9) according the stroke. Thearrow on the counterweight and the stroke digits onthe hub must be against each other. Screw the hexsocket-head screws M16 (3 pcs).

Figure 9.9 Position of the counterweight

Figure 9.10

Ensure that the intermediate thrust plate has notmoved out of position while lifting the main shaft.

Carefully lower the main shaft into the crusher.Remember that the hole of the eccentric shaft isslightly askew, and pay special attention to the

bearing surfaces. Also, be careful not to damage thedust seal ring when it slides onto the slip ring(Figure 9.11).

STROKE 40 mm STROKE 32 mm

STROKE 25 mm STROKE 18 mm





Figure 9.11 Be mindful of the dust seal ringwhen installing the main shaft. Use the

inspection hatches to control the loweringprocess.

Lift the upper frame assy into place, taking care notto 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 islowered onto the lower frame, there must be aclearance 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





Figure 9.13 Tighten the clearance between theframes

Fill the top bearing housing with grease(Figure 9.14). For lubrication instructions, refer tosubsection 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 anew configuration. For more information contactyour local construction expert at Metso.

Test run the crusher without load, ensuring that it isoperating properly.

Figure 9.14 Fill the top bearing housing withgrease





9.4 RETIGHTENING

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

.

Figure 9.15 Tighten the bolts on the jointbetween the lower and upper frame

25 h




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)

Figure 10.1 Typical cavity options for GP cones

Typical Secondary Crushing Typical Fine Crushing

Coarse (C)

Extra Coarse (EC)

Extra Fine (EF) Fine (F)

Medium Fine (MF) Medium (M)

Coarse (C) Extra Coarse (EC)




CHAPTER 10 - TECHNICAL SPECIFICATIONS

10.2 STROKE OPTIONS

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

Stroke

(mm) (inch)

GP200

18 45/64

25 1

28 1 7/64

32 1 17/64

36 1 27/64

40 1 9/16

GP200S

18 45/64

25 1

28 1 7/64

32 1 17/64

36 1 27/64

GP300

25 1

28 1 7/64

32 1 17/64

36 1 27/64

40 1 9/16

GP300S

18 45/64

25 1

28 1 7/64

32 1 17/64

36 1 27/64

40 1 9/16

GP550

25 1

28 1 7/64

32 1 17/64

36 1 27/64

40 1 9/16

45 1 49/64

GP500S

18 45/64

25 1

28 1 7/64

32 1 17/64

36 1 27/64

40 1 9/16

Stroke

(mm) (inch)





10.3 TECHNICAL DATA

NOTE: Setting values apply with dry, mediumhard granite.

Max. setting with new liners, varies by themanufacturing 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”)

MIN. SETTING

• 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”)

• stroke 40 mm (1 9/16“) 16 mm (5/8”)

MAX. SETTINGWith new liners at 25 mm (1”)

stroke32 mm (1 17/64”) 26 mm (11/32”) 26 mm (11/32”) 24 mm (15/16”)

COUNTERSHAFTrpm

1190 1257 1480

WEIGHT 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”)

MIN. SETTING

• stroke 18mm (45/64”) 26 mm (11/32”) 24 mm (15/16”)

• stroke 25 mm (1”) 29mm (19/64”) 27mm (11/16”)

• stroke 32mm (117/64”) 32 mm (117/64”) 30 mm (13/16”)

MAX. SETTINGWith new liners at 25 mm (1")

stroke49mm (15/16”) 43 mm (1111/16”)

COUNTERSHAFTrpm

1257

WEIGHT10800-10900 kg

(23800-24000 lbs)





GP300 EC GP300 C GP300 M GP300 MF GP300 F GP300 EF

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

MAX. FEED SIZE

210 mm

(8”)

140 mm

(5½”)

120 mm

(4½”)

80 mm

(3”)

50 mm

(2”)

32 mm

(1¼”)

MIN. SETTING

• 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”)

MAX. SETTINGWith new liners at 32

mm (117

/64”) stroke

37 mm (1

(17/16”)

34 mm

(111/32”)

26 mm

(11/32”)

26 mm

(11/32”)25 mm

(1”)

19 mm

(3/4”)

COUNTERSHAFTrpm

1233

WEIGHT 12900 - 13400 kg (28400 - 29500 lbs)

GP300S EC GP300S C

FEED OPENING 380m (15”) 280 mm (11”)

MAX. FEED SIZE320 mm

(121/2”)

240 mm

(91/2”)

MIN. SETTING

• stroke 18mm (11/16”) 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”)

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

50 mm (2”) 44 mm (147/64”)

COUNTERSHAFTrpm

985

WEIGHT 16000 kg (35600 lbs)





GP550 EC GP550 C GP550 M GP550 MF GP550 F GP550 EF

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

MAX. FEED SIZE 240 mm(9½”) 190 mm(7½”) 150 mm(6”) 110 mm(41/3”)70 mm(23/4””)

35 mm(11/3””)

MIN. SETTING

• 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”)

MAX. SETTINGWith new liners at 32

mm (117/64”) stroke

43 mm

(111

/16”)

39 mm

(19

/16”)

38 mm

(11

/2”)

35 mm

(13

/8”)

32 mm

(117

/64”)

24 mm

(15

/16”)

COUNTERSHAFTrpm

1205

WEIGHT 25800 - 26400 kg (56900 - 58200 lbs)

GP500S EC GP500S C

FEED OPENING 500mm (20”)380 mm

(15”)

MAX. FEED SIZE420 mm

(16 1/2”)

320 mm

(12 1/2”)MIN. SETTING

• stroke 18mm (45/64”) 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. SETTINGWith new liners at 25mm (1”) stroke

79 mm (37/64”) 74 mm (229/32")

COUNTERSHAFTrpm

990

WEIGHT 32100-32800 kg (70800-72300 lbs)





10.4 CRUSHER CAPACITY

The capacity of a crusher is affected by a number offactors e.g.:

– The characteristics of the feed material(size, hardness, toughness, moisturecontent, 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 thecrusher. The actual capacity may differ from thecapacity estimated by the table depending of the

factors given before.

The given values are to be used as a guide only, andare valid when crushing dry, medium hard granitewith a bulk density of 1.6 t/m³ (100 lbs/ft³). Forvalues in parenthesis, contact your localconstruction expert at Metso.

Table 10-1 GP200

Table 10-2 GP200S

STROKEtons/hour

SETTING c.s.s.

8 mm5/16”

10 mm13/32”

15 mm19/32”

20 mm13/16”

25 mm1”

30 mm

13/16”

35 mm

13/8”

18 mm3 /4”

mtphstph

60-7065-80

70-9080-100

80-10590-115

100-125110-140

135-150150-165

160-175175-190

185-200200-215

25 mm1”

mtphstph

90-110100-120

110-130120-140

130-155145-170

160-180180-200

185-210200-230

32 mm

11 /4”mtphstph

140-160155-175

170-190185-205

190-220210-240

40 mm

15 /8”mtphstph

200-220210-240

220-240230-260

STROKEtons/hour

SETTING c.s.s.

20 mm3/4”

25 mm1”

30 mm

11/4”

35 mm

11/2”

40 mm

13/4”45 mm

2”

50 mm

21/4”

18 mm3 /4”

mtphstph

110-140130-160

140-170170-220

160-190180-210

180-210200-230

200-230250-280

230-260

25 mm1”

mtphstph

110-130200-250

190-240225-275

210-260250-275

230-280

32 mm

11 /4”mtphstph

230-280260-310

270-320310-380

280-350





Table 10-3 GP300

Table 10-4 GP300S

STROKEtons/hour

SETTING c.s.s.

8 mm5/16”

10 mm13/32”

15 mm19/32”

20 mm13/16”

25 mm1”

30 mm

13/16”

35 mm

13/8”

25 mm1”

mtphstph

100-120110-130

110-130120-145

135-155150-170

160-180175-195

190-210210-230

210-235230-260

240-260255-285

32 mm

11 /4”mtphstph

110-130120-145

120-150135-165

165-195180-215

195-225210-245

230-260250-285

265-295295-325

300-330320-355

40 mm

15 /8”mtphstph

150-170165-185

205-235220-255

245-275270-300

290-320315-355

325-355360-390

STROKEtons/hour

SETTING c.s.s.20 mm

3/4”25 mm

1”

30 mm

11/4”

35 mm

11/2”

40 mm

13/4”45 mm

2”

50 mm

21/4”

18 mm3 /4”

mtphstph

170-190200-220

170-210190-240

190-230225-270

210-255255-300

235-275285-320

255-295

25 mm1”

mtphstph

220-270260-320

255-315300-350

290-345350-400

320-350370-390

330-350

32 mm

11 /4”mtphstph

360-400380-430

380-420430-480

400-440

40 mm

15 /8”

mtph

stph

450-500

500-550

480-530

STROKEtons/hour

SETTING c.s.s.

10 mm13/32”

15 mm19/32”

20 mm13/16”

25 mm1”

30 mm

13/16”

35 mm

13/8”

40 mm

19/16”

25 mm1”

mtphstph

140-160150-180

160-180180-200

190-210210-230

240-260260-290

270-290300-325

310-330340-360

350-370390-410

32 mm

11 /4”mtphstph

230-250250-270

270-290300-320

310-330340-360

340-370370-410

380-410420-450

430-450470-500

40 mm

15 /8”mtphstph

290-310320-340

320-340350-370

380-410420-450

430-460470-510

480-510530-560





Table 10-5 GP550

Table 10-6 GP500S

STROKEtons/hour

SETTING c.s.s.

45 mm

11/2”

50 mm

13/4”55 mm

2”

60 mm

21/4”

65 mm

21/2”

70 mm

23/4”75 mm

3”

18 mm3 /4”

mtphstph

300-350 325-375330-380

375-425350-400

400-450400-460

425-475460-520

450-500520-580

500-550560-620

25 mm1”

mtphstph

500-550 550-600550-600

600-650620-680

650-700680-740

700-750750-810

750-800840-900

32 mm

11 /4”mtphstph

650-700 700-750(720-780)

750-800800-860

825-875890-920

900-950940-1000

40 mm

15 /8”mtphstph

900-950930-990

975-10501030-1100



APPENDIX A

inspections for the lifting device are performed.

3. Install the lifting device in the groove on theupper edge of the eccentric sleeve by turningthe turnbuckle to spread the device's legs

(tightening by hand is sufficient).

Figure 1 Installing the lifting device in the sleevegroove

4. Ensure that the lifting device is firmly in place and that the outer edge of the liftingdevice's leg sits properly in the base of thesleeve groove.

5. Fasten the hoist hook, sling or

corresponding lifting equipment to thelifting device and ensure that the fasteningmechanism of the lifting equipment issecure.

6. Recheck all fastening points.

7. Reserve sufficient space for lifting and alert people in the vicinity.

9. Abort lifting if the eccentric sleeve does notcome loose easily.

10. Inspect the lifting device after the liftingoperation.

11. Do not store a damaged or otherwise faultylifting device.

WARNING!

244159132 gp instruction manual

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