Metso Nordberg GP200S Instruction Manual Download Page 4

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LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1

COUNTERSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2

TOP BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1

EVERY 8 RUNNING HOURS/EVERY WORKING SHIFT . . . . . . . . . . . . . . . . . . . 7-1

7.2

AFTER 40 HOURS OF OPERATION/ EVERY WEEK (1-SHIFT OPERATION). . 7-2

7.3

EVERY 300 HOURS OF OPERATION/ EVERY MONTH (2-SHIFT

OPERATION)/EVERY SECOND MONTH (1-SHIFT OPERATION) . . . . . . . . . . . . . . . . 7-3
7.4

EVERY 2000 HOURS OF OPERATION/EVERY YEAR (1-SHIFT

OPERATION)/EVERY HALF YEAR (2-SHIFT OPERATION). . . . . . . . . . . . . . . . . . . . . 7-4
7.5

SEASONAL MAINTENANCE (SUMMER/WINTER) . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.6

EVERY 20 000 HOURS OF OPERATION/EVERY 10 YEARS (1-SHIFT

OPERATION)/EVERY 5 YEARS (2-SHIFT OPERATION). . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.7

MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

REPLACEMENT OF LINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.2

DISMANTLING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.3

REPLACING THE CONCAVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.4

REPLACING THE MANTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8.5

ASSEMBLING THE CRUSHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8.6

AFTER TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

OTHER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2. REPLACING THE TOP BEARING SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.3

REPLACING THE DUST SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.4

THRUST BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.5

CHANGING THE STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.6

REPLACING THE TOP BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

9.7

REPLACING THE PROTECTIVE SLEEVE OF THE MAIN SHAFT . . . . . . . . . . . 9-8

9.8

GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

9.9

PROTECTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

9.10 REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

10.

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

GP200S

Instruction Manual

140548

12/99

Summary of Contents for Nordberg GP200S

Page 1: ... Instruction manual 140548 ...

Page 2: ...be used in secondary crushing applications in big and medium size crushing plants 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 This is the first edition published in December 1999 in Tampere Finland Manufacturer Metso Minerals P O Box 306 33101 Tampere Finland Tel ...

Page 3: ...NSIONS 4 2 4 3 SPACE REQUIREMENTS FOR MAINTENANCE 4 4 4 4 LIFTING THE CRUSHER AND ITS PARTS 4 5 4 5 FEEDING THE CRUSHER 4 6 4 6 REMOVAL OF CRUSHED MATERIAL 4 7 4 7 POWER TRANSMISSION 4 8 4 8 HOSES 4 10 4 9 OVERLOAD PROTECTION 4 11 4 10 TRANSPORT 4 12 4 11 SPECIAL TOOLS 4 12 4 12 WELDING 4 13 4 13 CORROSION PREVENTION 4 13 4 14 SERVICE PLATFORM 4 14 4 15 SETTING CONTROL 4 14 4 16 PRESSURIZED DUST S...

Page 4: ... EVERY 10 YEARS 1 SHIFT OPERATION EVERY 5 YEARS 2 SHIFT OPERATION 7 4 7 7 MAINTENANCE INTERVALS 7 5 8 REPLACEMENT OF LINERS 8 1 8 1 GENERAL 8 1 8 2 DISMANTLING THE CRUSHER 8 2 8 3 REPLACING THE CONCAVE 8 4 8 4 REPLACING THE MANTLE 8 6 8 5 ASSEMBLING THE CRUSHER 8 8 8 6 AFTER TIGHTENING 8 9 9 OTHER MAINTENANCE 9 1 9 1 GENERAL 9 1 9 2 REPLACING THE TOP BEARING SEAL 9 2 9 3 REPLACING THE DUST SEAL 9 ...

Page 5: ...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 t...

Page 6: ...ime concern These paragraphs are presented as a helpful guide to construction equipment personnel and shows some of the daily work problems which they may encounter It is the responsibility of the operator to know what specific requirements precautions and work area hazards exist and to discuss them with his supervisor A common understanding should be reached by all personnel to assure safe perfor...

Page 7: ...ing and maintenance characteristics capacities and limitations Learn the location and function of ALL controls indicators warning devices and caution instructions DO YOU HAVE KNOWLEDGE OF WORKING AREAS Learn beforehand as much about your working area as possible Be a good housekeeper keep the floor clean free of oil grease rags cables chains buckets rocks and other hazards Keep loose parts in a to...

Page 8: ...tarted check all gauges and instruments to be sure that everything is operating properly 4 SHUT DOWN immediately if any improper readings are observed 5 TEST all controls for proper functioning 6 LISTEN for and report any unusual noises 7 RE CHECK alarms or other warning and safety devices 8 DO NOT stand on the Crusher while the Crusher is running 9 DO NOT lean or place your hands on or against th...

Page 9: ...ND SAFETY SHOES when required 7 WEAR GLOVES to protect your hands when changing cables 8 WEAR SAFETY GLASSES AND PROTECTIVE CLOTHING when using high pressure air 9 WEAR GOGGLES AND PROTECTIVE CLOTHING when handling molten metals zinc babbitt lead etc 10 WEAR EAR PROTECTIVE DEVICES when required or REDUCE exposure time as required ALCOHOLIC BEVERAGES AND MEDICATION 1 DO NOT use alcoholic beverages ...

Page 10: ... in a safe place 7 NEVER use an open flame to check fuel battery electrolyte or coolant levels or to look for hydraulic leaks anywhere on the equipment Use a flashlight 8 KNOW where fire extinguishers are kept and how they operate and for what type of fire Check regularly at least monthly to be sure it is in the working area PRESSURIZED SYSTEMS HYDRAULIC OR AIR 1 Relieve ALL pressure before openin...

Page 11: ...E MAINTENANCE MEN WHO MUST INSPECT AND WORK ON THE CRUSHER A good operator s platform constructed of solid floor plate should have hand railings toe plates and wire mesh or expanded metal between the platform and the top of the hand railing to prevent tools from dropping off the platform and hitting someone working below Do not fasten the operator s platform to the Crusher ELECTRICAL LOCKOUT THE E...

Page 12: ...red high pressure hydraulic lines will quickly vaporize the hydraulic fluid as it reaches the atmosphere This vaporized fluid can quicklybecomeamassofflames resulting in severe burns for personnel in the immediate area ALL MAINTENANCE PERSONNEL WHO NORMALLY USE TORCH CUTTING EQUIPMENT SHOULD BE ADVISED IF THERE ARE HYDRAULIC COMPONENTS IN THE IMMEDIATE AREA IN WHICH THEY ARE WORKING Then adequate ...

Page 13: ...ficiency in plant operation CLEARING A CRUSHER There are many unforseen events such as power failures sudden surge of materials etc which can cause a Crusher to become plugged with material and stall UNPLUGGING THE CRUSHER CAN BECOME A VERY SERIOUS POTENTIAL SOURCE OF ACCIDENTS In many instances the only way in which the Crusher can be restarted is to literally dig the material out of the crushing...

Page 14: ... opening FO The largest distance between the top of the crushing members as measured when the two crushing members are at their farthest relationship during one revolution of the eccentric As a general rule the maximum size of feed should be 60 80 of the open side feed opening depending of the crusher type and the raw material to be crushed Crushing cavity G The internal area formed by the two lin...

Page 15: ...s not pass through screen is returned to the crusher 3 2 NORDBERG GP200S SERIES CONE CRUSHER The Nordberg GP200S series cone crusher is designed for secondary crushing purposes either in small or medium size crushing plants There are two different crushing cavities available extra coarse EC and coarse C The crushing cavities are fully interchageable There are three different strokes 18 25 and 32 3...

Page 16: ...3 4 MAIN COMPONENTS Main shaft Lower frame Countershaft Lubrication and adjustment device Upper frame Drive motor Intermediate frame Figure 3 4 1 Crusher main components General GP200S 12 99 140548 3 3 ...

Page 17: ...30 mm 13 250 mm 10 Max feed size 280 mm 11 210 mm 8 1 4 Min setting stroke 18 mm 3 4 stroke 25 mm 1 stroke 32 mm 1 1 4 24 mm 1 28 mm 1 1 8 32 mm 1 1 4 22 mm 7 8 26 mm 1 30 mm 1 1 8 Max setting with new liners stroke 18 mm 3 4 52 mm 2 48 mm 1 7 8 Max adjustment pressure 13 bar 190 PSI Motor size dependable on stroke 132 160 kW 200 HP Countershaft rpm 1256 Weight 10600 kg 23400 lbs G200S General 3 4...

Page 18: ...o assure the immediate delivery of the spare and wear parts of the crusher the following information should be included in the order The serial number and model identification of the crusher The spare parts number description and amount of the parts in order The formal and complete name and postal address of the remitter Exact forwarding instructions method and address of delivery Never use any ot...

Page 19: ...roduct in cases where top size is about 60 120 mm 2 1 2 5 One typical product is railway ballast 25 65 mm 1 2 1 2 which will be produced by close circuiting through secondary GP Cone As a rule of thumb it can be said that the minimum setting is about 10 of feed opening This is valid with smallest stroke Minimum setting increases when stroke increases mainly due to increased power draw See performa...

Page 20: ...m the capacity estimated by the tables depending of the factors given before The given valuesare to beusedasaguideonly and are valid when crushing dry medium hard granite with a bulk density of 1 6 t m3 100 lbs ft3 Actual resultsmayvary dependingon feed grading moisture content etc Capacities MTPH GP200S EC Setting c s s Stroke 25 mm 30 mm 35 mm 40 mm 45 mm 50 mm 18 mm 140 163 186 209 233 256 25 m...

Page 21: ... setting is either power draw or adjustment pressure which both increase when setting is being set tighter Power draw increases when stroke increases and thus motor size selection is dependent on stroke used Especially in coarse crushing the fluctuation in the process can be a factor which means that minimum specified setting can not be used That is why it is recommended that minimum allowed setti...

Page 22: ...iners deterioration of end product quality and decreased capacity Replacing the liners with proper ones normally gives much better result The crusher might be damaged because of an uneven wear of the liners caused by the feed improper for the cavity formation in question When selecting the proper cavity type please contact Nordberg representative To select the appropriate cavity type the following...

Page 23: ...wing in chapter 4 2 When mounting the crusher on its foundation the depression of all four rubber dampers caused by the weight of the crusher must be checked to be equal To accomplish this all four support points must be level To level the supporting points shims may be used if necessary If the crusher has been delivered as mounted on a steel frame stationary or portable the frame must be levelled...

Page 24: ...4 2 INSTALLATION DIMENSIONS Figure 4 2 1 Crusher installation dimensions metric dimensions GP200S Installation 4 2 140548 12 99 ...

Page 25: ...Figure 4 2 2 Crusher installation dimensions imperial dimensions Installation GP200S 12 99 140548 4 3 ...

Page 26: ...AINTENANCE When designing crusher installation remember that there must be enough space around the crusher for lifting and maintenance fig 4 3 1 Figure 4 3 1 Space requirements for maintenance GP200S Installation 4 4 140548 12 99 ...

Page 27: ...ng device is necessary when erecting dismantling and maintaining the crusher and also when replacing the liners The lifting devices wires hooks etc must be dimensioned according to the weights of the parts to be lifted The total weight of the crusher is 10600 kg 23400 lbs The weights of separate parts are given in the figure 4 3 1 Figure 4 4 1 Lifting the crusher Installation GP200S 12 99 140548 4...

Page 28: ...ave to be removed from the feed e g with a magnetic separator The manufacturer is not responsible for damage caused by the reasons above The feed must be directed so that there is an equal load around the whole lower portion of crushing cavity This ensures more even loading and better lubrication for the bearings and also the wear of the liners is more uniform To accomplish this the feed can be gu...

Page 29: ... the lubrication oil possibly causing more serious damages When arranging the withdrawal of crushed material from the crusher pay attention to following When the crushed material is hauled away by conveyor or feeder the feeding device to the crusher must not be able to start if the crusher is not operating If there is a silo below the crusher a level indicator must be mounted into the silo to stop...

Page 30: ...ently chosen The power is transmitted from the driving motor to the countershaft of the crusher by using V belts The use of V belts is most recommended in this case because they prevent the shock loads from being conveyed from the crusher to driving motor The V belt pulley on the drive shaft of the driving motor must be ruled to be accurately parallel with the V belt pulley on the countershaft of ...

Page 31: ...f individual forces causing the equal deflection should be calculated None of the belts must not deviate more than 20 of the average because in that case the lifetime of the belt will be halved The driving motor and the V belts must be sheltered against the falling stones and also to prevent accidents TheV beltguardsshouldbe openunderneathtoallowthedustoutflow The size and location of the openings...

Page 32: ...R 600 mm 24 LVU 075 The return oil hose of circulating lubrication should descend all the way from the crusher to the lubricating equipment The depression should be at least 50 mm by every meter 0 6 ft of length of the hose 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 1 High sag acts like a water seal i...

Page 33: ...ng system reaches 20 bar 290 PSI due to overload the valve opens and the setting increases If the crusher is equipped with Lokoset the setting will return automatically after pressure has decreased If the crusher is not equipped with Lokoset the adjusting pump must be operated to return to the original setting Figure 4 9 1 A pressure relief valve acts as an overload protection Installation GP200S ...

Page 34: ...he transport device 4 11 SPECIAL TOOLS A lockable toolbox is included with the crusher It contains tools and acessories thet are needed when servicing the crusher There are wrenches for hexagonal socket head screws and for hexagonal screws hit wrenches eyebolts for lifting the main shaft slide ring eccentric shaft and piston There is also a lead piece for measuring the setting two filters and o ri...

Page 35: ...s Corrosion is expensive and dangerous To ensure the most economical and safe operating of the equipment it should be regularly protected against corrosion Only accepted methods and materials should be used Factors affecting the speed of corrosion humidity of air impurities in the air physical factors such as temperature rain wind etc Before any long term storage the equipment should be protected ...

Page 36: ...ice platforms of the crushing equipment must be observed 4 15 SETTING CONTROL Setting control system standard The crusher is equipped with a setting control system that keeps the setting at the desired value It returns the setting back to correct value after an overload situation and decreases the setting a certain amount if the overload is continuous Lokoset option When using Lokoset the normal c...

Page 37: ...n the vicinity before starting Ensure that the crusher cavity is empty 5 2 STARTING Start the lubricating device 1 of the crusher and check the function of safety devices for oil pressure oil temperature and oil flow Bleed air from the adjusting equipment before starting the crusher for the first time Start the discharge conveyor 2 Start the crusher 3 when the oil circulation is functioning proper...

Page 38: ...ir all leakages immediately After 25 hours of operation ADJUSTING CYLINDER Tighten the cylinder head bolts figure 5 4 2 10 pcs M36 keyhole 55 mm tightening torque 2314 Nm 236 kpm 1710 ft lbs FRAME CONNECTION Tighten the frame bolts between lower and intermediate frame figure 5 4 3 20 pcs M36 keyhole 55 mm tightening torque 2314 Nm 236 kpm 1710 ft lbs and the frame bolts between upper and intermedi...

Page 39: ...pressure and temperature of the lubricating oil to make sure that they are within allowable limits Check and clean regularly the magnetic plugs and strainer located in the oil reservoir It is normal 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 red button of the pressure filter...

Page 40: ...ation there appears to be no electrical or mechanical reason why the crusher has stalled it would indicate that the crusher is jammed by the ingress of foreign matter and is in hazardous state If a crusher stalls under load open the manual valve which is located in the lubricating device until the pressure gauge shows zero pressure Now there should be no more stored energy in the mechanism except ...

Page 41: ...t wear unevenly measure the setting in three or four points around the cavity and use the average as a setting Too small of a setting increases the load of the crusher remarkably For minimum setting see chapter 3 5 When the crusher is equipped with automatic control system Lokoset or equivalent the crusher should not be used without it When adjusting the setting main shaft position the control sys...

Page 42: ...ng 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 2 1 There is also a plugged hole at the cover for checking refilling of the grease Suitable grease quality is a semisolid EP pressu...

Page 43: ...R SETTING Check if the crusher setting keeps constant during crushing If the setting increases during crushing and returns when load decreases air should be bled from the system If the crusher setting increases continuously the reason might be a leakage of adjusting cylinder seal pressure relief valve needle valve direction valve or shock valve Find the leakage and repair it A reason for the setti...

Page 44: ...r part of the frame find out the reason and repair it At cold temperature the crusher may be so cold and the lubricating oil gets so cool and stiff that it does not have enough time to flow down by the normal return channels but floats over the slip ring on the dust seal and between the dust seal and the slip ring on the center part of the frame The overflowing during a cold start up can be preven...

Page 45: ... mm tightening torque 2314 Nm 236 kpm 1710 ft lbs figure 7 3 2 DRIVE SHAFT BACKLASH Check the drive shaft and the eccentric shaft gear backlash The backlash must be approx 0 7 mm 0 028 The free movement of the crusher V belt which corresponds to the backlash should be 1 9 2 2 mm 0 075 0 087 on a pulley diameter of 530 mm 21 See chapter 9 8 FEED AND DISCHARGE HOPPERS AND PROTECTIVE GUARDS Checkthec...

Page 46: ...as to be made during the liner replacement See further instructions in chapter 9 4 PRESSURIZED SEALING SYSTEM Change the air cleaner Also check the operation of the blower and condition of the hose 7 5 SEASONAL MAINTENANCE SUMMER WINTER COUNTERSHAFT Change oil See oil recommendations in chapter 6 7 6 EVERY 20 000 HOURS OF OPERATION EVERY 10 YEARS 1 SHIFT OPERATION EVERY 5 YEARS 2 SHIFT OPERATION W...

Page 47: ...P BEARING SEAL Check condition of top bearing seal X CRUSHER DUST SEAL Check dust seal X PRESSURIZED SEALING SYSTEM Check the blower X Change air cleaner X CRUSHER Check if crusher setting keeps constant X Check tightness of hydraulic hoses and connections X Loosen and tighten the concave bolts X Check tension and wear of V belts X Observe wear of liners X Check condition of chutes guards and prot...

Page 48: ...rts manual The concave consists of two parts When changing to different cavity both parts must be replaced With new liners the distance B is about 16 mm 5 mm 5 8 3 16 figure 8 1 1 measured from machined surfaces When changing new liner due to wear it may be necessary only to replace the lower part of the concave and the mantle Then secure that distance B is greater than 3 mm 1 8 There must always ...

Page 49: ...kg 220 lbs away Remove grease from the upper part of the top bearing housing figure 8 2 3 Remove the bolts between the intermediate and lower frames 20 bolts B figure 8 2 2 M36 keyhole 55 mm figure 8 2 2 Separate the intermediate and lower frame by using the four jacking bolts C figure 8 2 2 M48 keyhole 75 mm The separation can be helped by mounting lifting ropes on the upper frame and tensioning ...

Page 50: ...e lifting ropes can be mounted under the supporting arms of the frame Lower the upper frame on a stand for liner removal The total weight of parts is roughly 3500 kg 7700 lbs Figure 8 2 4 Lift the upper and intermediate frames together away Liner replacement GP200S 12 99 140548 8 3 ...

Page 51: ...unting surfaces between the frames If there is severe wear the surfaces must be filled by welding and machined Clean the seating surface of the concave Lift the frame on the concave so that the mounting bolt holes meet each other Use two bolts to direct the holes Tighten two bolts in the opposite sides of the frame and put the others in the holes figure 8 3 2 Mount the concave with 6 bolts and nut...

Page 52: ...he new upper part of the concave in place and hammer it to seat it properly Lift the upper frame in place so that the grooves for the tightening wedges of the upper part of the concave will stay below the supporting arms of the upper frame Install the bolts and nut between the upper and intermediate frame 10 pcs and tighten evenly M36 keyhole 55 mm tightening torque 2314 Nm 236 kpm 1710 ft lbs Pla...

Page 53: ...d mantle carefully to remove the mantle Turn the tightening nut B figure 8 4 2 clockwise by hammering it with a sledge hammer until it gets loose If needed weld a hit plate on the nut If the nut does not get loose torch cut it in two pieces Do not damage the thread in the shaft Lift the mantle and the nut away together Before lifting ensure that the lifting hooks are in safe condition Repair them ...

Page 54: ... seating hammer the mantle to ensure tight seating Continue tightening until the mantle does not clang when hammered After tightening weld the nut the torch ring and the mantle together with six 50 mm 2 long welds equally distributed figure 8 4 4 Use stainless steel electrode If the main shaft has been removed Check that the intermediate plate of the thrust bearing has not moved from it s location...

Page 55: ...tween the frames Fill the top bearing housing with grease figure 8 5 3 See the lubricating instructions in chapter 6 2 Check the condition of the o ring and cover Repair or replace as necessary Install the cover and with bolts 4 pcs M20 keyhole 30 mm tightening torque 382 Nm 39 kpm 280 ft lbs Check the condition of the feed chute and repair as necessary Install the chute with bolts 8 pcs M20 keyho...

Page 56: ...hours tighten the mounting bolts between the lower and intermediate frame 20 pcs M36 keyhole 55 mm tightening torque 2314 Nm 236 kpm 1710 ft lbs and the bolts between the intermediate and upper frame 10 pcs M36 keyhole 55 mm tightening torque 2314 Nm 236 kpm 1710 ft lbs Figure 8 6 1 Tightening after liner replacement 10 h 25 h Liner replacement GP200S 12 99 140548 8 9 ...

Page 57: ...and maintenance procedures as outlined in the instruction manual Ensure as extensively as possible that the immediate area is safe and secure 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 ...

Page 58: ...r and intermediate frames together on the stand Remove the used seal from the upper frame Place a new seal with the groove upwards If the weather is cold first warm up the seal to room temperature to make the mounting easier and to avoid the damage of the seal Bend the seal to ease mounting figure 9 2 2 Replace the liners if necessary and assemble the crusher according to chapter 8 5 Figure 9 2 1 ...

Page 59: ... Do not drop the thrust bearing against the ground but use a piece of rubber as a protection in between figure 9 3 2 Remove the mounting bolts of the slide circle figure 9 3 1 6 pcs M16 Remove the slide circle by screwing 4 pcs of the mounting bolts in the threaded holes and forcing it away Protect the bushing faces of the main shaft e g with a rubber plate to avoid the slide circle to damage the ...

Page 60: ... the end of the main shaft and unscrew the bolt M16 Remove the thrust bearing Clean the new bearing the seating surfaces and install the bearing Note the locking pin Secure the mounting bolt with the locking washer Drain the oil from the crusher to replace the intermediate plate and the lower bronze bearing Remove the slipring and lift the hub eccentric shaft combination away Screw a ringbolt M30 ...

Page 61: ... SEAL or turn it on the side taking care not to damage the upper and lower bearing surfaces of the shaft Do not drop the thrust bearing against the ground but use a piece of rubber as a protection in between figure 9 5 1 Remove the wear cover from the slipring by unscrewing three bolts M16 locating radially under the wear cover Unscrew the fastening bolts and loosen the slipring of its guidance by...

Page 62: ... of the thrust bearing has not moved from its location when removing the main shaft out of the crusher See chapter 8 4 Before installing the main shaft slide the intermediate plate steel on the bearing plate bronze to the eccentric side to allow the thrust bearing to settle as well as possible Lubricate the main shaft and eccentric bushing well with the lubricating oil used in the crusher Lift the...

Page 63: ...ter 9 7 Install the new top bearing Heat the housing to ease the mounting Lift the upper and intermediate frames together and place on lower frame see chapter 8 5 Fill the top bearing housing with grease figure 9 6 1 and grease the bearing See the lubricating instructions in chapter 6 2 Check the condition of the o ring and cover and repair or replace if necessary Lift the cover on its place and i...

Page 64: ...ng machine Be careful not to damage the shaft Carefully clean the shaft and the new protective sleeve Heat the new sleeve to a temperature of 160 C 320 F above the temperature of the main shaft When heating the temperature of the sleeve must not exceed 240 C 460 F Using the holes place the sleeve at once If the mounting fails cut the sleeve away and try again with a new sleeve Figure 9 7 1 Main sh...

Page 65: ...fthegear thetooth contact must be correct It is not important whether the ends of the gears match together in the length of the teeth direction or not The tooth contact is correct when the contact pattern is in the middle of the driving side V of the tooth in an unloaded condition and on the adjacent opposite side R somewhat on the heel of the tooth figure 9 8 1 The higher the load the more will t...

Page 66: ...er gear The tooth contact can be adjusted with the help of the contact marks according to figure 9 8 4 The backlash must be correct It is approx 0 7 mm 0 028 To check the backlash turn the eccentric shaft to a position where the minimum setting of the crusher is perpendicularly against the countershaft The backlash can now be measured as the free movement of the V belt pulley where by the backlash...

Page 67: ...he pulley and measuring the free movement Figure 9 8 4 With the contact as in the drawing on the left turn the pinion as in the drawing on the right If the tooth contact is this Move the pinion this way Other maintenance GP200S 12 99 140548 9 11 ...

Page 68: ...ase of damages in frame parts main shaft and head 9 11 AIR BLEEDING The adjusting system has to be air bled when the adjusting oil hoses are connected Loosen the air bleeding screw located on the lower frame see fig 9 10 1 and start the crusher for about 3 sec Repeat this for 4 to 5 times until no air is coming through the screw Then close the screw 9 12 BOLT TORQUE VALUES 9 12 1 CONCAVE BOLTS Con...

Page 69: ... not surface treated The table applies to bolts with property class 8 8 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 Other maintenance GP200S 12 99 140548 9 13 ...

Page 70: ...sher increases during crushing but reverts when the crusher is idling This is most probably caused by an air lock in the highest component of the adjustment system i e the adjusting cylinder Bleed the system by opening the bleeding screw at the bottom edge of the cylinder THE SETTING OF THE CRUSHER HAS INCREASED INCREASES CONSTANTLY Leaking adjusting piston seal directional control valve check val...

Page 71: ...e motor to overheat The voltage drop can be caused by too long and or thin supply cables insufficient overall power etc Inspect cables and or supply and replace as necessary The crusher has been operated with too small a setting causing a considerably higher power need Increase the setting or replace the motor with a more efficient one max 160 kW 200 HP Uncrushable material i e excavator tooth etc...

Page 72: ...d is accumulating in the crushing cavity Scalp clay and the rest fine material below setting from the feed Examine that the discharge opening of the crusher has not been clogged Clear as necessary Inspect that the liners are not worn as a bag shape Replace liners as necessary Insufficient cooling of the lubricating oil Check the function and the setting of cooler thermostat Check the function of t...

Page 73: ...place the hose If the lubricating pumps are running and the manometer indicates no pressure the pump or pump coupling has been damaged Repair or replace pump coupling If the pumps are running the manometer indicates pressure and the hoses are undamaged the pressostat may be defective Inspect the function of the pressostat and repair replace as necessary If the lubricating pump is not running and i...

Page 74: ...HTS OIL PRESSURE LOW AND NO OIL FLOW ARE ILLUMINATED There is a fault in the lubrication oil supply and the pressostat has stopped the crusher The return oil flow has ended before the signal light has been checked The flow continues for a while even though the pumps have been stopped Empty the crushing cavity trace and repair the fault If the lubricating pumps are running and the manometer indicat...

Page 75: ...ace as necessary Pressure air sealing system doesn t work Check that the blower is running replace the filter if necessary and check the hose Latches of lubricating equipment are open See that the latches are always carefully closed Lubricating oil is dirty and or contains an excessive amount of water Replace the oil UNUSUAL SOUND IS HEARD FROM THE CRUSHER If an unusual sound is heard from the cru...

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Metso Nordberg GP200S, Instruction Manual

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