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TitleGP Instruction Manual
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Total Pages112
Table of Contents
                            GP CONE CRUSHERS
PREFACE
SAFETY
	2.1 GENERAL
		2.1.1 General safety instructions
	2.2 WARNING SIGNS
		2.2.1 Warning sign codes and texts (ANSI)
		2.2.2 Warning sign codes and texts (ISO)
GENERAL
	3.1 TERMINOLOGY
	3.2 OPERATING PRINCIPLE AND MAIN COMPONENTS
	3.3 GP-SERIES CONE CRUSHER
	3.4 APPLICATION OPTIONS
	3.5 CRUSHER AUTOMATION
	3.6 SELECTION OF LINERS
	3.7 SPARE AND WEAR PARTS
	3.8 SETTING RANGE
INSTALLATION
	4.1 FOUNDATION
	4.2 INSTALLATION CLEARANCE DIMENSIONS
	4.3 LIFTING THE CRUSHER
	4.4 FEEDING OF THE CRUSHER
	4.5 REMOVAL OF CRUSHED MATERIAL
	4.6 MOTOR SIZE SELECTION
	4.7 POWER TRANSMISSION
	4.8 LUBRICATION AND ADJUSTING UNIT
		4.8.1 Installation
		4.8.2 Hoses
		4.8.3 Functions
	4.9 SERVICE PLATFORM
	4.10 PRESSURIZED DUST SEALING
	4.11 STORAGE
	4.12 CRUSHER TRANSPORTATION
OPERATION
	5.1 BEFORE STARTING
	5.2 GENERAL INFORMATION PRIOR TO CRUSHING
	5.3 STARTING
	5.4 OPERATING THE NEW OR RENOVATED CRUSHER
	5.5 SETTING
	5.6 STROKE
	5.7 STOPPING
	5.8 OVERLOAD PROTECTION
MAINTENANCE
	6.1 GENERAL
	6.2 LIFTING WEIGHTS
	6.3 SPACE REQUIREMENTS FOR MAINTENANCE
	6.4 SPECIAL TOOLS FOR MAINTENANCE
	6.5 SERVICE PLATFORM
	6.6 WELDING
	6.7 CORROSION PROTECTION
	6.8 BLEEDING AIR FROM THE ADJUSTING CYLINDER
	6.9 TIGHTENING TORQUE FOR BOLTS
		6.9.1 Cavity mounting bolts
		6.9.2 Other bolts
	6.10 LUBRICATION
		6.10.1 Countershaft system
		6.10.2 Top bearing
	6.11 SCHEDULED MAINTENANCE
		6.11.1 Scheduled maintenance for new crusher
		6.11.2 Every eight hours of operation / every shift
			6.11.2.1 Lubricating and adjusting equipment
			6.11.2.2 Hoses
			6.11.2.3 Top bearing seal
		6.11.3 Every 40 hours of operation / every week (one-shift operation)
			6.11.3.1 Entire crusher
			6.11.3.2 Liners
			6.11.3.3 Lower frame arms
			6.11.3.4 V-belts
			6.11.3.5 Electrical equipment
		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
			6.11.4.2 Lubricating oil of the countershaft system
			6.11.4.3 Feed and discharge hoppers and crusher protecting guards
			6.11.4.4 Dust removal
			6.11.4.5 Pressurized sealing system
		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
			6.11.5.2 Checking the gear backlash
			6.11.5.3 Breathers
		6.11.6 Seasonal maintenance (summer/winter)
		6.11.7 Every 20,000 hours of operation / every 10 years (one-shift operation) / every 5 years (two-shift operation)
	6.12 MAINTENANCE CHART
	6.13 OTHER MAINTENANCE
		6.13.1 General
		6.13.2 Replacing the main shaft dust seal
		6.13.3 Checking / replacing the top bearing
		6.13.4 Replacing the main shaft protective sleeve
		6.13.5 Checking / replacing thrust plates
		6.13.6 Replacing the top bearing seal
REPLACING WEAR PARTS
	7.1 GENERAL
	7.2 WELDING
	7.3 DISMANTLING THE UPPER FRAME ASSEMBLY
	7.4 REPLACING THE BOWL LINER
		7.4.1 Fine crushers
		7.4.2 Secondary crushers
	7.5 REPLACING THE MANTLE
		7.5.1 Removing the old mantle
		7.5.2 Installing the new mantle
	7.6 INSTALLING THE UPPER FRAME ASSEMBLY
	7.7 RE-TIGHTENING
	7.8 PROTECTION PLATES
TROUBLESHOOTING
CHANGING THE STROKE
	9.1 GENERAL
	9.2 DISMANTLING THE UPPER FRAME ASSEMBLY
	9.3 STROKE CHANGE AND RE-ASSEMBLING
	9.4 RETIGHTENING
TECHNICAL SPECIFICATIONS
	10.1 CAVITY OPTIONS
	10.2 STROKE OPTIONS
	10.3 TECHNICAL DATA
	10.4 CRUSHER CAPACITY
APPENDIX A
	SAFETY, OPERATING, AND MAINTENANCE INSTRUCTIONS
		1. Intended purpose
		2. Transport and storage
		3. Safe operation
		4. Commissioning and operating conditions
		5. Technical specifications
		6. Inspection and maintenance
		7. Operating instructions
                        
Document Text Contents
Page 1

NORDBERG GP CONE CRUSHERS
INSTRUCTION MANUAL

MM0293378-EN REV-1.3
11/2011

Page 56

CHAPTER 6 - MAINTENANCECHAPTER 6 - MAINTENANCE
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
6-10 INSTRUCTION MANUAL MM0293378-EN REV 1.3 11/2011

Page 57

CHAPTER 6 - MAINTENANCE
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)
11/2011 MM0293378-EN REV 1.3 INSTRUCTION MANUAL 6-11

Page 111

APPENDIX A A

LIFTING DEVICE FOR NORDBERG GP
SERIES ECCENTRIC SLEEVES

SAFETY, OPERATING, AND MAINTENANCE
INSTRUCTIONS

1. Intended purpose

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

2. Transport and storage

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

3. Safe operation

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

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

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

• Do not overload the lifting device.

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

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

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

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

• Work carefully and avoid unnecessary rush.

4. Commissioning and operating
conditions

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

• No external power connections are required.

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

5. Technical specifications

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

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

6. Inspection and maintenance

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

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

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

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

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

• Lubricate the threads and joints during
inspection if necessary.

7. Operating instructions

1. Wait until the crusher has cooled down
sufficiently after use.

2. Check that the engagement points on both
the lifting device and the work piece to be
lifted are intact, and ensure that the periodic
EN N11449569 LIFTING DEVICE FOR GP SERIES ECCENTRIC SLEEVES A-1

Page 112

APPENDIX A
inspections for the lifting device are
performed.

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

Figure 1 Installing the lifting device in the sleeve
groove

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

5. Fasten the hoist hook, sling or
corresponding lifting equipment to the
lifting device and ensure that the fastening
mechanism of the lifting equipment is
secure.

6. Recheck all fastening points.

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

8. Perform the lifting operation carefully,
anticipating potential hazard situations.

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

10. Inspect the lifting device after the lifting
operation.

11. Do not store a damaged or otherwise faulty
lifting device.

WARNING!

Ensure that there are no persons under
the item to be lifted and that nobody
enters the lifting area during the lifting
operation.
A-2 LIFTING DEVICE FOR GP SERIES ECCENTRIC SLEEVES N11449569 EN

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