This instruction manual applies to GP-series cone crushers, manufactured by Metso. These crushers are high-capacity cone crushers intended for secondary and tertiary crushing at crushing plants of different sizes.
Because of the continuous development of the product, the manufacturer reserves a right to alter the technical specifications written in this manual, without any advance information. In case of conflicts between different language versions, the English version of this manual is the original and prevails.
Manufacturer:
Metso Minerals, Inc., Tampere Works
Lokomonkatu 3, P.O. Box 306 33101 Tampere Finland Phone: +358 204 84 142 Fax: +358-204-84 143 email: [email protected] www.metso.com
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) /Table of Contents
6.11.5 Every 2,000 hours of operation / every year (one-shift operation) /
every six months (two-shift operation) . . . 6-14 6.11.6 Seasonal maintenance (summer/winter) . . . 6-16 6.11.7 Every 20,000 hours of operation / every 10 years (one-shift operation) /
every 5 years (two-shift operation) . . . 6-16 6.12 MAINTENANCE CHART . . . 6-17 6.13 OTHER MAINTENANCE . . . 6-18 6.13.1 General . . . 6-18 6.13.2 Replacing the main shaft dust seal. . . 6-18 6.13.3 Checking / replacing the top bearing . . . 6-20 6.13.4 Replacing the main shaft protective sleeve . . . 6-21 6.13.5 Checking / replacing thrust plates. . . 6-22 6.13.6 Replacing the top bearing seal . . . 6-23
REPLACING WEAR PARTS
7.1 GENERAL . . . 7-1 7.2 WELDING . . . 7-2 7.3 DISMANTLING THE UPPER FRAME ASSEMBLY . . . 7-3 7.4 REPLACING THE BOWL LINER. . . 7-6 7.4.1 Fine crushers . . . 7-6 7.4.2 Secondary crushers . . . 7-8 7.5 REPLACING THE MANTLE . . . 7-10 7.5.1 Removing the old mantle . . . 7-10 7.5.2 Installing the new mantle . . . 7-13 7.6 INSTALLING THE UPPER FRAME ASSEMBLY. . . 7-15 7.7 RE-TIGHTENING . . . 7-16 7.8 PROTECTION PLATES. . . 7-17
TROUBLESHOOTING
CHANGING THE STROKE
9.1 GENERAL . . . 9-1 9.2 DISMANTLING THE UPPER FRAME ASSEMBLY . . . 9-1 9.3 STROKE CHANGE AND RE-ASSEMBLING . . . 9-4 9.4 RETIGHTENING . . . . 9-8
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 . . . 10-6APPENDIX 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-1 6. Inspection and maintenance. . . .A-1 7. Operating instructions. . . .A-1
This instruction manual is intended to assist owners and users of Metso products in the proper use of the equipment.
It includes important references to safe, proper and economical operation of the equipment. Following these instructions will help to avoid possible danger, reduce repair costs and breakdowns and to increase the reliability and life of the equipment. This manual must be complemented by those instructions necessary because of existing national mandatory rules relating to accident prevention and environmental protection.
A copy of this manual must be kept at the equipment's location and made available to the operators as required.
In addition to this manual and accident prevention regulations mandatory in the country of use and at the equipment's place of operation, generally recognized rules for safe and professional operation must be observed.
This instruction manual must be read and used by each person who works with the equipment, typically:
– operations, including installation, startup, operation, application engineering, materials handling, site labour, environmental engineering and safety departments.
– maintenance, including inspection and repair.
– transport, materials handling and rigging. Note that this instruction manual contains information and instructions on alternative and optional equipment. Normally the machines have only some of them. Before maintaining and servicing, find out which alternative and optional equipment your machine has.
See separate instruction manuals for more detailed instructions when servicing the main components. There may be optional equipment which have separate instruction manuals. Those manuals must be read and used by each person who works with the equipment.
2.1 GENERAL
The instructions of the safety guide, these safety instructions and other manuals and safety labels for the equipment must be read, understood and used by each person who works with this equipment.
The following symbol is used in this manual and on the machine to call attention to instructions, which will help prevent machine related injuries.
When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
Figure 2.1 Alert Symbol
This manual uses the alert symbol, with words such as DANGER, WARNING or CAUTION, to alert you and other Crushing Plant personnel of actions or conditions that pose a potential safety hazard, with an attending risk of personal injury (including death) or property damage. The machine also displays safety signs, labels and tags at appropriate points to show safety risks that may exist.
Figure 2.2 Danger, warning, caution signs and their meaning
WARNING!
In addition to these unit-specific safety instructions, the operators of this equipment must also read the safety guide with instructions for general operational safety.
WARNING!
Read the instruction manual for Lubrication and adjusting unit, and the instruction manual for automation system before using the GP cone crusher.
Sign Description
DANGER
Immediate hazards or unsafe practices that will result in severe personal injury or death.
WARNING Hazards or unsafe practices that could result in severe personal injury or death CAUTION
Hazards or unsafe practices that could result in minor personal injury or equipment damage
DANGER
CAUTION
WARNING
2.1.1 General safety instructions
1. Ignoring the safety instructions or the warning signs increases the risk of severe injury or death.
2. GP cone crushers have been designed for safe operation when used by professional staff in the operating situations included in this instruction manual. All other service and repair procedures must be performed by specially trained personnel or authorized Metso service staff.
3. Never operate the crusher without proper covers and safety devices. If the covers or safety devices have not been purchased from Metso, a customer has to ensure that the covers and safety devices are according to law and regulations.
4. Before starting the crusher make sure that no one is near the crusher.
5. It is prohibited to stay in the danger area during the crushing process. The crushing material may be thrown into a few meters distance from the crusher. Always use helmet and safety glasses.
6. Do not look into the crushing cavity during crushing. Material may be thrown from the crusher during crushing and cause injuries. Always use a helmet and safety glasses. 7. Ensure before performing any maintenance,
that the crushing cavity is empty. Material may be thrown from the crusher even when it is stopped.
8. Because the crusher is installed on rubber dampers, it moves during crushing. This movement causes a crushing danger. Never put your hands or feet between the moving parts and the structure of the crusher during crushing. The movement may be as much as ± 25mm (±1”).
9. Clearing a jammed cavity is extremely dangerous. Do not attempt to clear the cavity until the crusher has stopped completely. 10. The crusher does not stop immediately after
the motor has been turned off. Make sure that the crusher has stopped completely before opening any covers, performing any maintenance, or adjusting the crusher. 11. The crushing plant and auxiliary equipment
such as chutes, transfer stations, screens, etc. can create dust and, if not contained, the dust can escape into the air. Metso highly recommends that dust protective devices such as an appropriate respirator be worn by anyone exposed to airborne dust to prevent its inhalation. It is the responsibility of the Owner and Operator to determine the necessity and adequacy of protective devices and warnings, to provide them, and to ensure that they are used and followed! 12. The noise level is dangerously high near the
crusher. All personnel working near the crusher must wear hearing protection. The noise level is typically about 100-115 dB(A) next to the crusher during crushing.
WARNING!
Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.
LOCKOUT PROCEDURE of the diesel engine driven crushers
1. Switch off engine
2. Remove the ignition key and keep it on person during lockout
3. Place appropriate maintenance warning signs (TAG OUT)
LOCKOUT PROCEDURE of the electrical motor driven crushers 1. Switch off motor
2. Lock the main switch of the motor with a padlock or make sure in some other way that the motor cannot be started (locking must be done by every member of the work group)
3. Keep the keys on person during lockout
4. Place appropriate maintenance warning signs (TAG OUT).
13. Make sure that the main shaft is in down position before performing any
maintenance. The adjusting circuit may contain high pressure even when the crusher is stopped.
14. Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.
15. The surfaces of the crusher may become hot during crushing. Hot surfaces can cause severe burn injuries. Make sure that the surfaces have cooled before performing any maintenance work.
16. The lubricating oil and grease may be hot. Make sure that hot oil and grease do not come into contact with skin.
17. Before handling oil or grease refer to Operational Safety Bulletin delivered by the oil manufacturer.
18. Before changing any wear parts of the crusher, read chapter “Replacing wear parts” carefully.
19. Before lifting any wear parts, check the weight of the component and ensure that lifting equipment being used is adequate to lift the weight.
20. Read the instructions regarding lifting and replacing wear parts carefully before replacing any wear parts. Make sure that the parts are adequately supported before lifting. Never go under the suspended load. 21. Follow the occupational safety rules during
all maintenance and lifting procedures! 22. If the crusher is equipped with a pressure
accumulator, it may be charged only by a professional. If the pressure accumulator is charged incorrectly, it may explode. Do not charge the accumulator yourself.
23. Release the pressure from the hydraulic system according to instructions before any maintenance to the system.
24. The cooler blower of the lubricating device starts automatically during crushing. Do not go near the blower or remove the covers during crushing.
DANGER!
There are components made of manganese steel in the crusher, such as liners and in some models protection plates of the upper frame arms. Welding or flame cutting these components generates gas that is extremely hazardous to health and causes manganese poisoning. This kind of work must be done outdoors or in well-ventilated premises equipped with local exhaust ventilation.
2.2 WARNING SIGNS
The warning signs attached to the equipment must always be kept readable and clean. Damaged or loose signs must be replaced at once before starting the crusher. Make sure that the warning signs are
not covered during installation. If a part of the crusher with an attached a warning sign is replaced, always make sure that the required warning signs are included with the new part.
Figure 2.3 The locations of the warning signs
The number and exact locations of the warning signs may vary according to options (for example,
guards). IMPORTANT!
There are two different sets of warning signs depending on the delivery country. You can check which set of warning signs is used on your machine from the side of the machine or the spare part manual.
Figure 2.4 Warning signs (ANSI)
1
2
3
4
6
5
7
2.2.1 Warning sign codes and texts (ANSI)
1. MM0229994
WARNING
Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury.
DANGER
Lung disease hazard. Dust protection required.
WARNING
Risk of eye injury.
Use of eye protection required.
CAUTION
Risk of head injury. Use of a helmet required.
CAUTION
Hazardous noise level. Use of ear protection required. 2. MM0229995
DANGER
Moving parts can crush and cut.
Do not insert tools in the crusher cavity when the motor is running.
WARNING
Material can fall out.
do not stand in the vicinity of the crusher when the motor is running.
3. MM0229997
WARNING
Exposed moving parts can cause severe injury.
Do not open drive guard before machine is completely stopped.
4. MM0229996
WARNING
Exposed moving parts can cause severe injury.
Do NOT operate this machine without proper guards.
5. MM0231186
WARNING
Moving parts can crush and cut.
Do not open the hatch before machine is completely stopped.
6. MM0230002
WARNING
Servicing while pressurized can cause severe injury.
Lock out source and relieve pressure before servicing.
7. MM0230498
WARNING
Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury.
High voltage. High pressure oil.
Failure to follow lockout procedure before servicing may result in death or serious injury.
Figure 2.5 Warning signs (ISO)
1
2
3
4
6
5
7
2.2.2 Warning sign codes and texts (ISO)
1. MM0250258
WARNING
Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury.
DANGER
Lung disease hazard. Dust protection required.
WARNING
Risk of eye injury.
Use of eye protection required.
CAUTION
Risk of head injury. Use of a helmet required.
CAUTION
Hazardous noise level. Use of ear protection required. 2. MM0250251
DANGER
Moving parts can crush and cut.
Do not insert tools in the crusher cavity when the motor is running.
WARNING
Material can fall out.
do not stand in the vicinity of the crusher when the motor is running.
3. MM0250244
WARNING
Exposed moving parts can cause severe injury.
Do not open drive guard before machine is completely stopped.
4. MM0250244
WARNING
Exposed moving parts can cause severe injury.
Do NOT operate this machine without proper guards.
5. MM0252118
WARNING
Moving parts can crush and cut.
Do not open the hatch before machine is completely stopped.
6. MM0250241
WARNING
Servicing while pressurized can cause severe injury.
Lock out source and relieve pressure before servicing.
7. MM0265819
WARNING
Read and understand instruction manual before using or maintaining this machine. Failure to follow operating instructions may result in death or serious injury.
High voltage. High pressure oil.
Failure to follow lockout procedure before servicing may result in death or serious injury.
3.1 TERMINOLOGY
Feed = The raw material to be crushed.
Product size = The size of the material after it has
been crushed.
Capacity = The output of the crusher computed in
tons per hour (mtph or STPH).
Feed opening (closed side) = The shortest distance
between the top of the mantle and bowl liner as measured when the mantle and bowl liner are at their closest position during mantle gyrating circle
Feed opening (open side) = The longest distance
between the top of the mantle and bowl liner as measured when the mantle and bowl liner are at their farthest position during mantle gyrating circle. As a general rule, the maximum size of feed should be 60-80 % of the open side feed opening
depending on the crusher type and the raw material to be crushed.
Liners= The members which perform the crushing
are commonly referred to as liners. The liners consist of mantle and bowl liner.
Mantle= Inner part of the liners, moves
eccenterically in the crushing chamber
Bowl liner= Outer part of the liners, stationary Crushing cavity = The internal contour formed by
the two crushing members.
Discharge setting = The distance between the
bottom of the mantle and bowl liner as measured at the point where the liners are at their closest position during mantle gyrating circle (a.k.a. closed side setting, CSS). The discharge setting regulates product size.
Minimum discharge setting = The shortest
permissible distance between the bottom of bowl liner and mantle as measured at the point where the liners are at their closest position during mantle gyrating circle.
Discharge opening = The distance between the
bottom of the bowl liner and mantle as measured at the point where the liners are at their farthest position during mantle gyrating circle. This wide opening permits rapid discharge of the crushed material.
Stroke = The difference of the maximum and
minimum distance between the bottom of bowl liner and mantle during one revolution of the eccentric shaft.
Open circuit operation = The type of operation
where precise uniformity of product size is not considered to be of prime importance and the feed is run through the crusher only once.
Closed circuit operation = The type of operation
where part of the crusher product is returned back to the crusher. The crusher output is fed to a screen, from which the oversize is returned back to the crusher. The closed circuit is used when the next stage of process needs a precise product size or when crushing process needs to be balanced.
Choke feed = The crusher is fed so that the
crushing chamber is full all the time. It is recommended to maintain the choke feed, as it ensures good crushing quality and improves the efficiency of the crusher.
The recommended choke feed level for secondary GP-cone is at the level of mantle fixing nut. The recommended choke feed level for fine GP-cone crusher is max 1 meter above top bearing arrangement.
Circulation material = Oversize material, which is
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
3.2 OPERATING PRINCIPLE AND MAIN COMPONENTS
The crushing takes place between the eccentrically moving mantle (1) and the stationary bowl liner (2). The motor rotates the countershaft (3) via V-belts, and the countershaft rotates the eccentric shaft (4) via pinion and a gear (5). The eccentric shaft causes
the crusher strokes by eccentrically moving the main shaft (6), which has bearings at the bottom (7) and top end (8). The material to be crushed is fed into the crusher through the top, and the crushed material exits through the bottom.
Figure 3.3 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 unit 6 Discharge chute (option) 7 Subframe (option) 8 Overpressure device
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 armprotection 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
12
13
14
15
16
17
18
19
20
21
22
23
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 armprotection 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
10
11
12
13
14
15
16
17
18
19
20
21
22
3.3 GP-SERIES CONE CRUSHER
The Nordberg GP-series cone crusher is intended for secondary and tertiarycrushing at crushing plants of different sizes.
GP200S, GP300S and GP500S are defined as secondary crushers. Secondary crushers have separate intermediate frame and the feed opening is bigger than in fine crushers. Also the cavity is longer. Secondary crushers are mainly used as a second crusher after the jaw or impactor. GP200, GP300 and GP550 are designed for fine crushing purposes. Feed opening is not as big and cavity is not as long as in secondary crushers. Fine crushers are used for tertiary and quarternary crushing.
There are different cavity options for the crusher. See the different options in the TECHNICAL SPECIFICATIONS chapter.
There are different stroke options for the crusher. See the options in the TECHNICAL
SPECIFICATIONSchapter. If necessary, the stroke may be changed by turning or replacing the eccentric bushing and by replacing the top bearing (refer to chapter 9).
3.4 APPLICATION OPTIONS
The crusher operates in fixed crushing plant, in a Lokotrack crushing plant or in a Nordwheeler mobile crushing plant.
3.5 CRUSHER AUTOMATION
The crusher is automatically controlled by the automation system. See the separate Instruction manual.
3.6 SELECTION OF LINERS
The appropriate liner type depends on the feed material used and the product size required. If the liners are unsuitable for the crushing application, the liners may wear quicker, the product quality may be worse or the yield of the wanted end product may decrease. In this kind of situation, the change of liner type to another typically improves the situation.
Feed material that is unsuitable for the liners causes the mantle and bowl liner wear unevenly, which may lead to a machine breakdown.
When determining the suitable liner type, contact your local construction expert at Metso. The following information is required to determine the suitability of various liner types:
1. Feed material size (distribution curve) 2. Feed material type (rock material type) 3. End product size
4. End product capacity 5. Crusher type and size
3.7 SPARE AND WEAR PARTS
Metso endeavors to carry an ample supply of parts in stock to provide prompt and efficient service on all 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 is stamped on the crusher nameplate. The serial number is also on the cover of the spare parts books.
3. Complete name and part code number as shown in the Spare Parts Book.
4. Exact quantity of each part ordered. 5. Complete shipping instructions.
If your crusher Spare Parts Books have been lost, destroyed or misplaced, an additional set can be ordered.
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 stroke used. The minimum setting is limited by either the power requirement or setting pressure, both of which increase when the setting is decreased. Thus, selection of motor size is largely dependent on the stroke used.
In coarse crushing in particular, variation in the process can be a factor that prevents the use of the minimum setting. Accordingly, it is recommended that the minimum allowable setting be used continuously only if the operating conditions are well known and sufficiently stable.
IMPORTANT!
For proper operation, only genuine factory parts should be installed. These are guaranteed as to accuracy,
workmanship and material. Using pirate parts may put your safety and that of your crusher at risk. Make sure you completely understand your crusher's Warranty conditions at all times.
4.1 FOUNDATION
The crusher is to be installed on a sufficiently steady steel or concrete foundation by using the rubber dampers (4 pcs.). During normal operation, the crusher oscillates horizontally about ±2 mm (±0,08”) on the dampers. During starting and stopping, the oscillation is about ±10 mm (±0,39”). Due to this, the clearance around the crusher must be at least 20 mm (0,79”). The installation dimension drawing delivered in the installation documents indicates the static and dynamic forces from the crusher to the foundation. When installing
the crusher on the foundation, ensure that all four rubber dampers are equally affected by the weight of the crusher. This requires that all four support surfaces be level with each other. If necessary, shims may be used to level the support surfaces. If the crusher has been delivered mounted on a steel frame (element or mobile wagon), the frame must be installed so that the rubber dampers of the crusher are level with each other. The steel frame (element or wagon) must be supported well on the ground, and the vertical alignment of the crusher must be checked.
4.2 INSTALLATION CLEARANCE DIMENSIONS
A well planned installation is absolutely necessary for the success of the crusher. One of the major considerations are crusher clearances.
In order to accurately determine crusher clearances refer to the Installation Drawings.
4.3 LIFTING THE CRUSHER
The weight of the crusher and its parts, as well as the space required for lifting them, must be taken into account in selection of the crusher foundation and lifting equipment. Lifting equipment must be used when erecting, disassembling, and servicing the crusher and replacing liners. The lifting equipment, wires, hooks and other components must be dimensioned to withstand the weight of the basic crusher without options (Figure 4.2). The maximum weight of that basic assembly for each crusher type is shown in the Table 4-1.
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 the crusher using a belt conveyor, screen, or various feeders, either directly or by using guiding troughs. The feeding equipment should be easy to move, to enable quick and easy maintenance of the crusher.
The maximum crushing capacity and optimal wear to the liners can be achieved only if the feeder is directly above the crushing cavity and the material is distributed evenly on both sides of the supporting arms of the upper frame. If necessary, the upper frame assy may be turned in steps of one bolt pitch.
Figure 4.3 Feeding the crusher
The following must be taken into account in arranging the feed:
– All fine material and material smaller than the crusher setting must be separated from the feed material. These could cause packing and damage the machine. In addition, any metal pieces must be removed from the feed material using, e.g., a magnetic separator. The manufacturer is not responsible for damage resulting from the above causes. – The feed must be directed such that there
is an equal load around the entire bottom edge of the crusher gap. This ensures more even loading and better lubrication for the crusher bearings, as well as more uniform wear to the liners. To achieve this, the feed can be directed by changing the position of the conveyors and feeding troughs and by using barriers.
– The speed of the feed material upon entering the crusher must not exceed 5 m/s, which corresponds to a free fall height of 1.3 m. If necessary, the speed must be limited by stone ledges. – To ensure even wear to the liners, the
crushing cavity must be evenly filled to the top.
– Overfilling of the feed hopper must be prevented by using, e.g., level controls. – Feeding of the crusher when it is not
running must be prevented. This can be achieved electrically by allowing starting of the feeding device only when the crusher drive motor is running.
50%
4.5 REMOVAL OF CRUSHED MATERIAL
The crushed material may be removed using a belt conveyor or different hoppers or silos, either directly or by using guiding troughs. The removal equipment should be easy to move, to enable quick and easy maintenance of the crusher.
The discharge opening of the crusher must be covered, or safety distances in accordance with applicable national standards must be observed.
The following must be taken into account in removing the crushed material:
– If the crushed material is removed from under the crusher with a conveyor or feeder, the device feeding the crusher must not start before the removal device begins running.
– If there is a silo below the crusher, it must be equipped with a level control that stops the feeding device if the level of crushed material in the silo is too high.
– The lubrication and adjusting oil hoses for the crusher must be protected from the crushed material exiting the crusher. – Use the inspection hatches on the
crusher’s lower frame to remove any trees, stumps, plastic covers of explosives, and other debris from the protection plates of the lower frame to prevent the
accumulation of material. These objects prevent the crushed material from exiting freely, which might damage the crusher.
Figure 4.4 Removal of crushed material
IMPORTANT!
The crushed material must be allowed to exit freely at all times. The removal equipment must be built to prevent the accumulation of crushed material. If the level of crushed material reaches the bottom of the mantle, the seal under the main shaft becomes damaged and dust enters the lubricating oil, possibly causing further damage.
4.6 MOTOR SIZE SELECTION
Table below will give max. recommended motor power for the different GPCones. Table is valid for dry, medium-hard granite
NOTE: If you choose a nominal power for the
motor bigger than the recommended Maximum power, then the crusher automation system limits the power.
Max. motor power IEC/NEMA standards (kW) (hp) GP200 160 215 GP200S 160 215 GP300 250 340 GP300S 250 340 GP550 350 475 GP500S 315 430
4.7 POWER TRANSMISSION
The crusher is driven by the drive motor, from which power is transmitted through V-belts to the crusher countershaft. The V-belt is recommended for this purpose since it prevents the transmission of impact loads from the crusher to the drive motor. The V-belt pulley on the drive motor shaft must be aligned precisely with the V-belt pulley on the crusher countershaft. The drive motor shaft and crusher countershaft must be parallel. In replacing V-belts, all belts must be replaced at the same time. Never mix new and used belts. The belts must also belong to the same length category (this
information is stamped on the belts) to ensure equal power distribution on all belts.
If the crusher drive motor is installed on a fixed platform and the crusher oscillates in relation to the motor, the motor must be located directly above or below the crusher countershaft or at a maximum angle of 15° from this position (Figure 4.5). This is to prevent additional strain caused by crusher oscillation. If the drive motor and crusher are installed on the same foundation (i.e., oscillate together), the location of the drive motor may be selected freely.
The V-belts must be tightened to the correct tension. This can be checked by pulling or pressing the V-belt halfway between the shafts with a force indicated in the Table 4-2. The belt deflection should be 16 mm per meter of the belt span (center distance) (Figure 4.6).
Table 4-2 Required forces for proper V-belt tensioning
Each belt is measured separately, and the average force needed to produce the deflection is then calculated. A single belt must not deviate from the average value by more than 20%, since this causes the service life of the belt to be halved.
To avoid damage caused by falling stones and to prevent accidents, the drive motor and V-belts must be protected. The size and location of the openings must meet occupational safety requirements.
Figure 4.5 Installation of the drive motor
Figure 4.6 V-belt tension
IMPORTANT!
In the subframe delivered by the Metso, location of the drive motor and the alignment of the V-belts is guaranteed to be correct.
Belt Section Min.Tension N (lbf) Max.Tension N (lbf) SPB 50 (11) 65 (15) SPC 60 (13) 100 (22) 8V 80 (18) 120 (27)
4.8 LUBRICATION AND ADJUSTING UNIT 4.8.1 Installation
The location of lubricating and adjusting equipment should be selected to be as dustless as possible within the length of hoses.
NOTE: It is highly recommended that original
hose lengths are used when installing the lubrication and adjusting unit
Lubricating and adjusting equipment should be separated from the shaking frame construction and lay down on a stand on ground. By doing this, the life time of the components of lubricating and adjusting equipment can be significantly increased. When choosing a location for lubricating and adjusting equipment, pay attention also to the following:
– The water should never, in any conditions (spring flood etc.), enter the equipment, because the electrical components of the devices might be damaged.
– An adequate space should be reserved around the equipment for the oil change. – The air flow caused by the cooling fans
through the coolers above the lubricating device should not be prevented by any obstacles on either side of the coolers. The air flow is approximately 100 m3/min (3530 ft3/min) and the speed of the air through cells is about 5 m/s (16 ft/s). The direction of the air flow should be arranged according to the figure 4.8.
NOTE: If the lubrication and adjusting unit is
installed in a closed space make sure that the air flow is sufficient.
A safe and capable route should be arranged to the lubricating and adjusting equipment, to allow the daily (shiftly) inspection of proper functioning of the devices.
4.8.2 Hoses
The hoses between the lubricating and adjusting equipment and the crusher should be properly fastened in every point, where they can be affected by rubbing. Points affected by rubbing should be covered with rubber plates etc. when necessary.
The minimum bending radius of hoses (R) are: • Adjusting oil hose
– 1” => R = 310 mm (R =12") • Lubricating oil hose
– 1 1/4” => R = 420mm (R =16 ½") • Return oil hose
– 4” => R = 450 mm (R = 18")
The return oil hose of circular lubrication should descend all the way from the crusher to the lubricating equipment. The depression should be at least 50 mm by every meter (2" by every yard) of length of the hose.
NOTE: To prevent the splashing of the oil in the
tank the depression of the hose should not be more than 50 mm (2”) in the last meter before the tank. The sag of the hose should not exceed 50 mm (2"), to allow the crusher to breathe via lubricating equipment after having been stopped (Figure 4.8). High sag acts like a water seal in return hose compelling the crusher to breathe via the dust seal area and to suck the silicious dust into the crusher.
4.8.3 Functions
Automation system controls the functions of the crusher and the lubrication unit according to the temperature limits shown in the table below.
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 or
feed +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 the
pump +15°C (59°F) Temperature sensor 2 Tank Permission to start the
Figure 4.8 (A) Air flow to the cooler, (B) Minimum decline of the return oil hose 50 mm/m, (C) Maximum decline 50 mm in the last meter before the tank
.
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 been ordered and supplied with the crusher, it must be built by the operator.
The crusher’s service platform must meet the requirements of ISO 2867 or a corresponding standard. The appropriate height for the platform is the level of the support brackets. The platform and steps must be equipped with handrails to prevent personnel from falling down.
All international and national regulations on service platforms for crushing equipment must be
observed.
4.10 PRESSURIZED DUST SEALING
The crusher is equipped with pressurized dust sealing system. It should be noticed that the blower unit must be installed as close to the crusher as possible but not further than 10 m (30 ft) from the crusher.
Mounting height is correct when the pressure port of the blower is higher than frame connection flange of the lower frame.
4.11 STORAGE
To protect your crusher from rust corrosion during seasonal shutdown, shipment or storage over 3 months, the following protective measures have to be taken. If you have further questions related to the storage or safety at work, contact Metso. • Remove the top cover, upper frame assembly
and main shaft assembly. Disconnect the oil drain line at the bottom of the lower frame. Make sure that all piping is sealed with pipe plugs. Clean the crusher.
• Use a paint brush to paint rust preventive lubricating oil to the flange connection of the frames. Using the paint brush, coat the protection bushing and all the visible outer surfaces of the main shaft and the head. Then coat all the visible surfaces of the slip ring. Use lubricating oil which has a rust preventive blend that is designed for the protection of
internal parts of enclosed assemblies, such as engines, compressors, pumps, gear sets, and hydraulic assemblies. The rust preventives function by displacing water from metal surfaces, by forming strong water-resistant films on the surfaces, and by absorbing water in the system into a water-in-oil emulsion. These products provide as much as 30 to 40 times the protection against rust compared to high quality lubricating oils that have not been especially formulated to prevent rust.
In most applications, the residual rust
preventive film left by these products need not be flushed away or otherwise removed when the crusher is to be filled with lubricating oil and put into normal service. The viscosity of the oil should be in the 32 to 66 cSt at 38°C (100°F) range.
• Fill countershaft housing with lubricating oil. When crusher is put into normal service remove the oil that exceeds the normal limit. • Then reinstall the main shaft assembly, upper
frame assembly, and top cover into the crusher and cover the entire crusher with a sheet of 2 mm polyethylene to prevent water from seeping into the crusher. Black is
recommended as transparent sheeting will deteriorate four times faster than black. The countershaft assembly should also be covered. Steel strapping or banding is an ideal method of holding the polyethylene sheeting in place. • Where it is necessary that the crusher is being
shipped or stored dismantled, all the machined surfaces of the various sub-assemblies must be painted with rust preventive oil and covered with black polyethylene sheeting.
• When crusher is put into normal service check the condition of the painting. If it is poor, re-paint.
4.12 CRUSHER TRANSPORTATION
During transportation the crusher main shaft must be supported with wooden wedges (3 pcs) which are placed equally to the crusher cavity (Figure 4.10). After the transportation remove the wedges.
5.1 BEFORE STARTING
Remove all transport latches. Remove wooden blocks (3 pcs) from the crusher cavity (see figure 5.1). Check the condition of the machine. Ensure that the crusher is operated only in a safe manner and is in good condition.
Use the crusher only when all necessary protective and safety devices – e.g., guards, emergency stop devices, silencers, aspirators – are in place and in operating condition.
Starting the crusher is possible when the lubrication oil is warm enough. Connect the control voltage to warm up the oil.
NOTE: Read the Instruction Manual before
starting the crusher.
Figure 5.1 Remove the wooden blocks
5.2 GENERAL INFORMATION PRIOR TO CRUSHING
Crushing is most efficient when the crusher is full of stones.
WARNING!
Before starting the crusher, ensure that there are no persons in the area whose safety may be endangered! Walk around the crusher and ensure that there is nobody on, by or below the crusher. Warn everybody in the vicinity before starting.
IMPORTANT!
Ensure that the crusher cavity is empty.
Do not climb on the crusher, when it is in operation and do not touch any moving parts.
Do not try to clear the blocked crushing cavity, when the crusher is running. Be always very careful when clearing the cavity.
Do not try to clear the blocked crushing cavity alone.
IMPORTANT!
At least once per shift, visually check the machine for defects and deficiencies. Report any changes (including changes in the operation of the machine) to the unit/person in charge immediately. If necessary, the crusher must be stopped without delay and the necessary safety precautions taken.
Immediately stop the crusher and take the necessary safety precautions in the event of a malfunction! Repair any faults or have them repaired immediately!
NOTE: IF THE CRUSHER STOPS
UNEXPECTEDLY, TAKE THE FOLLOWING STEPS:
Remove all personnel from the vicinity of the machine, and report the situation to the person in charge of the plant. Switch the crusher power off to prevent unexpected starting.
NOTE: Never inspect a stopped crusher from
above; use the inspection hatches on the hopper or crusher instead. The pressure could cause a piece of material to fly out from the gap, causing an accident.
Determine why the crusher stopped. If a careful inspection indicates that the crusher did not stop due to an electrical or hydraulic fault, it may have stopped because of a foreign, metal object in the cavity. In this case, the crusher may pose a threat to life.
If the crusher stops when loaded, release the pressure from the adjusting system by opening the manual valve on the lubricating device until the adjusting system pressure gauge indicates zero. Now there should be no pressure on any foreign object, apart from the weight of the stones on top of it.
After releasing of the pressure, the crushing cavity may be inspected and the foreign object removed safely.
If the main shaft must be lowered to empty the crusher, one of the following methods may be used:
– Lower the main shaft by using the manual valve (no electricity needed). Open the manual valve on the lubrication unit until the adjusting system pressure gauge indicates zero. Shut down the valve immediately after that.
– Fill the crushing cavity with stones, or cover it with a suitable, approved cover to make it safe. Place a jack between the upper frame arm and shaft nut, and press
the main shaft down (be careful not to make the shaft drop quickly).
– If the blockage is so bad that the above procedures do not help, remove the upper frame to release the pressure from the main shaft.
When the main shaft is fully down, the foreign metal object should fall out of the cavity, and it can then be removed using the conveyor as usual. Then ensure that there are no more foreign objects in the cavity. The crusher may be started again when the reason for the foreign object in the crusher cavity has been determined and possible damages have been repaired.
If the crusher stops when loaded, it may pose a hazard to life and safety.
WARNING!
The foreign metal object in the crusher might 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” button at the control cabinet (refer to the automation system manual). Lubrication unit (2) starts. • Crusher (3) starts. NOTE! Bleed air from the
setting adjustment system before starting the crusher for the first time. Refer to chapter 6.8. • After process has given permission, start the
feeding device (4).
.
Figure 5.2 Starting steps (example arrangement with the IC50 automation system)
5.4 OPERATING THE NEW OR RENOVATED CRUSHER
• Operate new or renovated crusher for 1 hour without load before feeding material in. If the renovating is done at the customers facilities, the operating time for an unloaded crusher is 4 hours.
• After the unloaded operating time, the crusher is operated for 2 hours with a 50% load. • Operate the crusher for 5 hours with a
maximum 75% load.
• After this running-in period, the crusher can be operated with the maximum load.
• Ensure that the pipes and hoses do not leak. • Ensure that the upper and lower frame do not
move in relation to each other.
• Ensure that the cooling of lubricating oil works as shown in the operating manual. Check that the oil temperature and the settings of thermostats are according the oil viscosity used.
• Observe pressure and temperature of the lubricating oil.
• Check and clean regularly the magnetic plugs and strainer located in the oil reservoir. It is possible that there are some steel and bronze particles in them during running-in period. • Ensure that the feed distributes evenly in the
cavity.
• Observe the cleanliness indicator of the pressure filter in the lubricating device. • Stop feeding sometimes and listen to the
crusher for any abnormal noise. Knocking sound may come from loose liner.
• Ensure that the top bearing does not leak grease.
• Check oil level in the reservoir. • Check that the setting keeps constant.
5.5 SETTING
Setting is the closest relation between the bowl liner and mantle during the work cycle. It must be measured at the lowest point of the mantle. The setting determines the maximum size of the discharging material, crusher capacity and load. The setting may be measured by lowering a piece of lead with a wire through the crushing cavity when the crusher is idling, then measuring the thickness of the compressed lead (Figure 5.3). A piece of lead is delivered with the crusher in the tool box.
Since the liners could wear unevenly, measure the setting at three or four different points and then calculate the average of these measurement to obtain the crusher setting. Use of too small a setting increases the crusher load considerably.
More accurate way to measure the setting is to perform contact calibration. For more detailed instructions refer to automation system manual.
Automation keeps the crusher setting at the preset value. Overload situation opens the setting. System returns the setting to preset value when the overload situation is over.
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 must not be wrapped around the hand.
IMPORTANT!
Contact calibration is possible ONLY for fine crushers.
IMPORTANT!
The crusher is equipped with cone crusher automation system. Therefore the setting can not be adjusted if the automation system is
disconnected. Normally the setting adjustment is performed from the automation system display (i.e. manual or setting mode). However the setting can also be adjusted with the LCP (Local Control Panel) in local mode with separate panel.
NOTE: For safety reasons the crusher must be
running before the automation system allows the setting decrease.
5.7 STOPPING
• Stop the process by pressing the “stop” button at the control cabinet (refer to the automation system manual).
• Stop the feeding device (1). • Crusher (2) stops.
• Stop the discharge conveyor (3). • Lubrication unit (4) stops.
.
Figure 5.4 Stopping order (example arrangement with the IC50 automation system)
5.8 OVERLOAD PROTECTION
The crusher is equipped with a shock valve which acts as an additional overload protection in extreme overload situations (fig 5.5). The shock valve has been adjusted at the pressure level indicated in the Table 5-1. When the pressure in the adjusting system reaches that pressure due to overload, the valve opens, oil flows to the lubrication unit return line and the setting increases. When the overload situation is over, automation system will adjust the setting back to the preset value.
.
Table 5-1
Figure 5.5 Shock valve acts as an overload protection
Crusher Pressure level bar (PSI) GP200 30 (435) GP200S 20 (290) GP300 35 (510) GP300S 26 (375) GP550 35 (510) GP500S 35 (510)
6.1 GENERAL
The crusher repair and maintenance is allowed only for reliable and qualified craftsmen.
When the equipment is switched off during maintenance and repair, the motor controls must be locked out/off. Secure the lock keys and attach a hazard notice at the main disconnect switch. All service/repair, except those told in this manual, are allowed only for the servicemen qualified by Metso, to keep the warranty valid.
WARNING!
Before performing any maintenance or repair work, make sure that the crusher is stopped and locked out.
LOCKOUT PROCEDURE of the diesel engine driven crushers
1. Switch off engine
2. Remove the ignition key and keep it on person during lockout
3. Place appropriate maintenance warning signs (TAG OUT)
LOCKOUT PROCEDURE of the electrical motor driven crushers 1. Switch off motor
2. Lock the main switch of the motor with a padlock or make sure in some other way that the motor cannot be started (locking must be done by every member of the work group)
3. Keep the keys on person during lockout
4. Place appropriate maintenance warning signs (TAG OUT).
In any work related to the operation, modification, conversion or adjustment of the equipment and its safety devices including inspection, maintenance and repair, observe all starting, stopping and maintenance procedures as outlined in the instruction manual.
IMPORTANT!
6.2 LIFTING WEIGHTS
Figure 6.1 Lifting weights of assemblies (fine crushers) 1
Countershaft Assy kg (lbs)
2 Main Shaft Assy
kg (lbs)
3
Upper Frame Assy kg (lbs)
4
Lower Frame Assy (w/o countershaft) kg (lbs) GP200 170 (375) 1700 (3750) 1600 (3530) 4300 (9480) GP200S 170 (375) 1950 (4300) 2650 (5840) 4300 (9480) GP300 260 (573) 2540 (5600) 2150 (4740) 6820 (15000) GP300S 260 (573) 2970 (6550) 3850 (8200) 6830 (15100) GP550 350 (772) 5280 (11600) 4600 (10100) 11630 (25600) GP500S 350 (772) 6600 (14600) 8380 (18500) 11550 (25500)
6.3 SPACE REQUIREMENTS FOR MAINTENANCE
When designing crusher installation remember that there must be enough space around the crusher for lifting and maintenance (figures 6.3 and 6.4).
Required measures are indicated in the table below. .
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
6.4 SPECIAL TOOLS FOR MAINTENANCE
The delivery of the crusher includes a tool box containing tools and accessories necessary to maintain the crusher.
6.5 SERVICE PLATFORM
To make maintenance and operation easy and safe, the crusher should be equipped with a service platform. If the service platform has not been ordered and supplied with the crusher, it must be built by the operator.
The crusher’s service platform must meet the requirements of ISO 2867 or a corresponding standard. The appropriate height for the platform is the level of the support brackets. The platform and steps must be equipped with handrails to prevent personnel from falling down.
All international and national regulations on service platforms for crushing equipment must be
observed.
6.6 WELDING
When electric arc welding must be used to install or disassemble wear parts etc., the ground cable must be fastened directly to the part to be welded and as close to the welding point as possible (Figure 6.5).
Figure 6.5 Welding arrangement
IMPORTANT!
Welding current must never pass through any connection or bearing.
IMPORTANT!
Before welding the crusher switch off the control voltage.
DANGER!
There are components made of manganese steel in the crusher, such as liners and in some models protection plates of the upper frame arms. Welding or flame cutting these components generates gas that is extremely hazardous to health and causes manganese poisoning. This kind of work must be done outdoors or in well-ventilated premises equipped with local exhaust ventilation.
6.7 CORROSION PROTECTION
Corrosion occurs on iron and steel surfaces that are exposed to water and oxygen. Metal surfaces are exposed to oxygen and humidity practically all the time. On account of this, corrosion occurs
constantly unless the equipment is sufficiently protected.
The corrosion rate is influenced by the following: – humidity
– impurities in the air
– physical conditions (temperature, rain, wind)
Corrosion can be expensive and dangerous. Corrosion can
– cause unnecessary downtime – increase maintenance costs
– decrease the service life of equipment – cause dangerous situations
To ensure economical and safe crushing, regular corrosion-protection procedures must be used for the equipment. Use only well-tried methods and substances.
Before long-term storage, the machine must be protected against corrosion, and a suitable storage location must be selected.
After long-term storage, the machine must be inspected for corrosion. Corrosion may occur, e.g., between the bronze bearings and the steel eccentric shaft and main shaft due to the materials differing. In this case, rust must be removed by grinding the parts.
6.8 BLEEDING AIR FROM THE ADJUSTING CYLINDER
Air must be bled from the adjusting cylinder when the adjusting oil hose has been connected. Bleeding is done via bleed screw which is located on the lower frame.
NOTE: Before bleeding the system, the oil must
be at least +20°C (68°F)
• Fix the hose to the bleeding screw. Suitable hose is about 6 mm and it must be long enough to reach to the collector tray. Open the bleeding screw and close the manual valve in the lubrication unit.
• Start the lubrication pump and the crusher manually (refer to automation system manual). Notice that there is 2 minutes delay before the crusher starts. Run the crusher until only oil is coming through the hose to the collector tray. Do not run the crusher more than 30 seconds. Stop the crusher.
• After the crusher has stopped, tighten the bleeding screw and remove the hose.
IMPORTANT!
Use a collector tray so that the oil does not spill to the ground.
6.9 TIGHTENING TORQUE FOR BOLTS 6.9.1 Cavity mounting bolts
The bowl liner bolts are to be tightened in accordance with the table below. The tightening torque indicated is for a clean, unlubricated bolt. The threads are not surface-treated. The bolts must be tightened according to class 5.6.
6.9.2 Other bolts
Other bolts must be tightened in accordance with the table below. The tightening torque indicated is for a clean, unlubricated bolt. The threads are not surface-treated. The bolts’ strength class is 8.8.
Crusher Bolt Torque 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 Bolt Torque Width across the 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 for GP Lubrication System.
6.10.1 Countershaft system
The amount of oil in the countershaft system is shown in the table below. Oil is filled via the breather hole on the countershaft housing, so the breather must be unscrewed before filling (A). For draining the oil, there is a drain plug on the bottom of the housing (B). The oil level should reach up to the level plug hole (C).(Figure 6.7)
Use the same lubricating oil as in the lubrication and adjusting system; refer to separate instructions.
Table 6-1 The filling amount of oil in the countershaft system
Figure 6.7 Draining and adding oil to the countershaft
6.10.2 Top bearing
The top bearing grease capacity is shown in the table 6-2. The usual filling has to be accomplished at the liner change, when the crusher is dismantled. If the top bearing seal leaks, change the sealing and fill top bearing housing with grease. The housing of the bearing should be filled with grease, when the main shaft is fully lowered (figure 6.8). Suitable grease quality is a semisolid EP (pressure-proof) grease.
Table 6-2 Crusher Oil amount
liters (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 for
temperature range -25 - +40°C (-13 - +104 F). If the temperature is outside this range, contact your local construction expert at Metso.
Figure 6.8 Fill top bearing housing with grease
Brand Type
BP Energrease LS-EPO MOBIL Mobilith SCH 007 PETRO 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 new crusher
A new or renovated crusher has to be inspected and the following maintenance should be accomplished during the first 100 hours of operation.
After first 10 hours of operation
LINERS
Check the bowl liner bolt tightening torques (Figure 6.9 and 6.10).
NOTE: This check must also be performed after
changing the wear parts
HOSES AND PIPES
Check all hose and pipe connections. Repair all leakages immediately.
V-BELTS
Check the tension of V-belts and tighten as necessary.
Figure 6.9 Check the bowl liner bolts (fine crusher)
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 adjusting equipment
NOTE: For more maintenance information, refer
to the Lubrication unit manual
Check the oil amount in the lubrication tank. The oil level should be above the middle of the scale. When the crusher is running, the oil level should not descend below the minimum point in the scale (A, Figure 6.11). Add oil as necessary.
Check the return oil filter basket (B, behind the cover).
Figure 6.11 Check the oil level (A) and the return oil filter basket (B)
6.11.2.2 Hoses
Check the hoses and fittings, and repair any leaks immediately.
6.11.2.3 Top bearing seal
Check the condition of the top bearing seal. The seal prevents grease from leaking out from the top bearing housing. A leak is indicated by grease on the main shaft, above the tightening nut
(Figure 6.12). A damaged seal must be replaced immediately. For more detailed instructions, refer to subsection 6.13.6.
Figure 6.12 If there is grease on the main shaft, the top bearing seal must be replaced
6.11.3 Every 40 hours of operation / every week (one-shift operation)
6.11.3.1 Entire crusher
Check visually the overall condition of the crusher (bolt tightness, leaks, wear, any cracks, etc.). Repair any faults immediately.
6.11.3.2 Liners
Observe the possible uneven wear of the liners. Uneven wear of the liners may be caused by incorrect feeding of the crusher. In this case, the feed must be adjusted. For instructions, refer to subsection 4.4.
6.11.3.3 Lower frame arms
Open the inspection hatches (3 pcs.) on the lower frame, and clean the arms and slip ring, removing crushed rock and other accumulated material. Cleaning must be performed more frequently if there are tree roots, wires, iron bars, etc. among the rock material.
If there is oil on the slip ring under the head, the cause must be determined and rectified.
6.11.3.4 V-belts
Check the tension and wear of the V-belts. Tension as necessary, or replace the entire set of V-belts at the same time. For tensioning instructions, refer to subsection 4.7.
6.11.3.5 Electrical equipment
Check visually the condition of electrical cables and components, ensuring that there are no cracks or signs of abrasion. Immediately repair any faults, and follow the regulations on electrical safety and inspections.
6.11.4 Every 400 hours of operation / every month (two-shift operation) / every two months (one-shift operation)
6.11.4.1 Main shaft dust seal
Check the clearance between the slip ring and the main shaft dust seal every 400 hours or always during the mantle change. For more information refer to section 6.13.2.
6.11.4.2 Lubricating oil of the countershaft system
Change the lubricating oil of the countershaft system. Drain the oil through the plug. Fill new oil through the breather hole (Figure 6.7). For the amount of oil, refer to Table 6-1.For the oil type, refer to the lubricating and adjusting device manual
6.11.4.3 Feed and discharge hoppers and crusher protecting guards
Check the condition of the hoppers, guards, and protective cap. If necessary, replace the wear part.
Check the protection plates. Refer to 7.8.
6.11.4.4 Dust removal
Remove dust from the V-belt guards, v-belt pulleys and the lubrication unit.
6.11.4.5 Pressurized sealing system
Check the operation of the overpressure device and the condition of the hose.
6.11.5 Every 2,000 hours of operation / every year (one-shift operation) / every six months (two-shift operation)
6.11.5.1 Thrust plates
Check the condition of the main shaft’s thrust plates. If the oil grooves in the bronze plates are less than 2 mm deep, the plates must be replaced. The inspection is to be made during mantle replacement. For more detailed instructions, refer to subsection 6.13.5.
6.11.5.2 Checking the gear backlash
Check the countershaft and eccentric shaft gear backlash.