Metso Nordberg GP200S Instruction Manual
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Metso Nordberg GP200S Instruction Manual

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RUGEHUJ *36
&RQH &UXVKHU
Instruction manual
0HWVR 0LQHUDOV
140548

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  • Page 1 RUGEHUJ *36 &RQH &UXVKHU Instruction manual 0HWVR 0LQHUDOV 140548...
  • Page 2 This instruction manual is valid for Nordberg GP200S-series secondary cone crushers manufactured by Metso Minerals from the year 1999 and the serial number of xxxx. The crusher is a high capacity cone crusher, which is intented to be used in secondary crushing applications in big and medium size crushing plants.

  • Page 3: Table Of Contents

    CRUSHER TERMINOLOGY ......... . 3-1 NORDBERG GP200S-SERIES CONE CRUSHER......3-2 OPERATING PRINCIPLE .
  • Page 4 GP200S Instruction Manual LUBRICATION ........... . . 6-1 COUNTERSHAFT.

  • Page 5: Preface

    Preface !# This instruction manual is intended to assist This instruction manual must be read and used owners and users of Nordberg products in the by each person wh o work s with the proper use of the equipment. equipment, typically: It includes important references to safe, —...

  • Page 6: Safety

    Safety  6$)(7< WARNING SYMBOLS not intended to replace safety codes, insurance The following symbols for particularly requirements, federal, state and local laws, important instructions are being used in the rules and regulations. instruction manual: SAFETY of the operator and maintenance Reference personnel is of prime concern.
  • Page 7 Safety Remember that on any job, YOU are the key READ THE MANUAL furnished with your to safety. Good safety practices not only equipment to learn its operating and protect the men around you, they are your own maintenance characteristics, capacities and best protection.
  • Page 8 Safety something that needs attention, THINK improper readings are observed. TWICE before deciding to "let it go this time". TEST all controls for proper Even minor mechanical defects can lead to functioning. personal injury and accidents. LISTEN for and report any unusual DO NOT allow unauthorized personnel noises.
  • Page 9 Safety Warning and caution plates provided on the WEAR SAFETY GLASSES AND machine. PROTECTIVE CLOTHING when using high pressure air. Warning and caution notes in the instruction manual. WEAR GOGGLES AND PROTECTIVE CLOTHING when Lubrication guides for periodic handling molten metals; zinc, babbitt, servicing in Section 6, LUBRICATION.
  • Page 10 Safety Save your back. what type of fire. Check regularly - at least monthly - to be sure it is in the Lower parts, do not drop them. working area. To prevent slipping, wipe hand levers PRESSURIZED SYSTEMS - and knobs clean of oil or grease. HYDRAULIC OR AIR Relieve ALL pressure before opening Do not use sheaves with cracked rims...
  • Page 11 Safety 5(0(0%(5 6$)(7<,68372<28 PLANT SAFETY The safety procedures mentioned here do not eliminate all safety hazards found in the area of crushing plants. However, they do highlight some of the procedures which have been found through long experience to improve safety conditions around Crushers and crushing plants.
  • Page 12 Safety automobile engine, the internal parts of a quickly vaporize the hydraulic fluid as it Cru sher sh ou ld b e assembled and reaches the atmosphere. This vaporized fluid disassembled with crane facilities that have the can quickly become a mass of flames, resulting capability of gently and slowly lifting and in severe burns for personnel in the immediate lowering the various parts that make up a...
  • Page 13 Safety LOCAL LAWS, ESPECIALLY ON cavity by hand. WEIGHT LIMITATIONS. When traveling on GENERAL MAINTENANCE WORK the highway make sure all headlights, A certain amount of work must be done in the clearance lights and tail lights are on. Use immediate area of the Crusher during the proper traffic warning flags and signs.

  • Page 14: General

    General GP200S  *(1(5$/ 3.1 CRUSHER TERMINOLOGY Feed opening (FO) = The largest distance between the top of the crushing members as Throughout this manual certain terms will be measured when the two crushing members are used in describing the crusher and its at their farthest relationship during one operation.

  • Page 15: Nordberg Gp200S-Series Cone 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 Figure 3.3.1 Operating principle...

  • Page 16: Main Components

    General GP200S 3.4 MAIN COMPONENTS Upper frame Intermediate frame Drive motor Main shaft Lower frame Countershaft Lubrication and adjustment device Figure 3.4.1 Crusher main components 12/99 140548...

  • Page 17: Technical Specifications

    G200S General 3.5 TECHNICAL SPECIFICATIONS GP200S EC GP200S C Feed opening 330 mm / 13" 250 mm / 10" Max. feed size 280 mm / 11" 210 mm / 8-1/4" Min. setting* - stroke 18 mm / 3/4" 24 mm / 1" 22 mm / 7/8"...

  • Page 18: Spare And Wear Parts

    General GP200S 3.6 SPARE AND WEAR PARTS The original Nordberg parts are accurately To assure the immediate delivery of the spare manufactured to Nordberg specifications and and wear parts of the crusher, the following are made of the best quality material. The information should be included in the order: original parts ensure efficient, profitable and safe operation for your equipment.

  • Page 19: Applications

    G200S General 3.7 APPLICATIONS Concerning the use of cone crushers, the What is secondary GP-Cone not? following main guidelines should be kept in mind. — It is not a fine crusher, meaning that if final product’s topsize is like 20-40 mm What is secondary GP-Cone? (3/4"-1 1/2") the secondary GP-Cone to produce this is not the right choice.

  • Page 20: Capacity

    General GP200S 3.8 CAPACITY The capacity of a crusher is affected by a The capacity can be estimated from the tables number of factors e.g.: below, if you know the stroke and setting of the crusher. The actual capacity may differ —...

  • Page 21: Setting Range

    G200S General 3.9 SETTING RANGE Minimum setting, which can be used, depends among others on factors like: stroke used, reduction ratio, choke level, feeding rate fluctuation into the crusher, rock type (gravel or rock), feed gradation, cavity wear, etc. Allowable setting range varies depending on the stroke used.

  • Page 22: Cavity Selection

    General GP200S 3.10 CAVITY SELECTION When selecting the proper cavity type, please The type of crushing cavity must be contact Nordberg representative. To select the determined according to the feed material and appropriate cavity type, the following the requested end product. Because of the information is required: innumerable different applications, any exact instructions are about impossible to give.

  • Page 23: Installation

    Installation GP200S  ,167$//$7,21 4.1 FOUNDATION If the crusher has been delivered as mounted The crusher installation must be made on a on a steel frame (stationary or portable), the steel or concrete foundation strong enough by frame must be levelled so that all the rubber using rubber dampers between the crusher and dampers of the crusher are level.

  • Page 24: Installation Dimensions

    GP200S Installation 4.2 INSTALLATION DIMENSIONS Figure 4.2.1 Crusher installation dimensions (metric dimensions) 140548 12/99...
  • Page 25 Installation GP200S Figure 4.2.2 Crusher installation dimensions (imperial dimensions) 12/99 140548...

  • Page 26: Space Requirements For Maintenance

    GP200S Installation 4.3 SPACE REQUIREMENTS FOR MAINTENANCE When desig nin g cru sher in stallation 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 140548 12/99...

  • Page 27: Lifting The Crusher And Its Parts

    Installation GP200S 4.4 LIFTING THE CRUSHER AND ITS PARTS The weight of the crusher and its parts as well as the free space required for lifting must be determined when designing the foundation and lifting devices. A lifting device is necessary when erecting, dismantling and maintaining the crusher and also when replacing the liners.

  • Page 28: Feeding The Crusher

    GP200S Installation 4.5 FEEDING THE CRUSHER The material to be crushed can be fed straight — The feed must be directed so that there is into the crusher by using a belt conveyor, an equal load around the whole lower screen or different types of feeders or by using portion of crushing cavity.

  • Page 29: Removal Of Crushed Material

    Installation GP200S 4.6 REMOVAL OF CRUSHED MATERIAL When arranging the withdrawal of crushed The crushed rock can be removed by using a material from the crusher, pay attention to belt conveyor and/or different chutes or silos, following: either directly or using guiding troughs. The arrangement should be easily portable to make —...

  • Page 30: Power Transmission

    GP200S Installation 4.7 POWER TRANSMISSION The recommended driving motor is a slip ring The power is transmitted from the driving motor with a nominal speed of rotation of 25 motor to the countershaft of the crusher by 1/s (1500 rpm) or 30 1/s (1800 rpm). The using V-belts.
  • Page 31 Installation GP200S The V-belts must be properly tightened. To inspect the proper tightness pull or push the V-belt in the middle of the shaft distance by the force of 90...120 N (20-27 lbf). The V-belt should yield 16 mm (5/8") per each meter (1 yd) of belt span (shaft spacing) (figure 4.7.3).

  • Page 32: Hoses

    GP200S Installation 4.8 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: —...

  • Page 33: Overload Protection

    Installation GP200S 4.9 OVERLOAD PROTECTION The crusher is equipped with a pressure relief valve which acts as overload protection (fig 4.9.1). The pressure relief valve has been adjusted at 20 bar (290 PSI). When the pressure in the adjusting system reaches 20 bar (290 PSI) due to overload, the valve opens and the setting increases.

  • Page 34: Transport

    GP200S Installation 4.10 TRANSPORT 4.11 SPECIAL TOOLS When transporting the crusher, which is A lockable toolbox is included with the mounted on a mobile wagon, it must be firmly crusher. It contains tools and acessories thet secured to the transporting frame to prevent are needed when servicing the crusher.

  • Page 35: Welding

    Installation GP200S 4.12 WELDING 4.13 CORROSION PREVENTION When electric arc welding must be used to Corrosion occurs naturally on iron and steel install or disassemble wear parts etc., the surfaces. The equipment must be regularly ground cable must be fastened directly to the protected from it.

  • Page 36: Service Platform

    GP200S Installation 4.14 SERVICE PLATFORM 4.16 PRESSURIZED DUST SEALING To make operation and maintenance as easy The crusher is equipped with pressurized dust and safe as possible the crusher should be sealing system. It should be noticed that the equipped with the service platform. If the blower unit must be installed as close to the service platform has not been ordered and crusher as possible but not further than 1 meter...

  • Page 37: Crushing

    Crushing GP200S  &586+,1* 5.1 BEFORE STARTING Remove any latches, brackets, devices, etc. used for transport and check the condition of the crusher. Ensure that the crusher is operated only in a safe manner and only in good mechanical condition. Operation of the crusher must only be allowed when all necessary protective and safety devices, e.g.

  • Page 38: Running-In

    GP200S Crushing 5.4 RUNNING-IN After 25 hours of operation A new or renovated crusher has to be inspected ADJUSTING CYLINDER and the following maintenance should be Tighten the cylinder head bolts (figure 5.4.2), accomplished during the first 100 hours of operation.
  • Page 39 Crushing GP200S DURING RUNNING-IN PERIOD NOTE THE FOLLOWING: Operate new or renovated crusher for 4 hours without load before feeding material in. Do not load the crusher more than 50 % out of the maximum motor power or hydraulic pressure during first 40 operating hours. Keep the crusher setting 50 % larger than shortest allowed setting during first 100 operating hours.

  • Page 40: Operation

    GP200S Crushing 5.5 OPERATION matter and is in hazardous state. The crusher operates most efficiently, when If a crusher stalls under load, open the manual the crushing cavity is full. valve which is located in the lubricating device until the pressure gauge shows zero Do not climb on the crusher, when it is in pressure.

  • Page 41: Setting

    Crushing GP200S 5.6 SETTING The setting is the minimum distance between the concave 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.

  • Page 42: Countershaft

    Lubrication GP200S  /8%5,&$7,21 6.1 COUNTERSHAFT The countershaft housing is filled with oil to provide lubrication of the countershaft bearings. The oil amount is approximately 2 liters (1/2 Gal). Unscrew the breather (A) on the top of the housing and pour oil into the housing (figure 6.1.1).

  • Page 43: Periodical Maintenance

    Periodical maintenance GP200S  3(5,2',&$/0$,17(1$1&( 7.1 EVERY 8 RUNNING HOURS/EVERY WORKING SHIFT CRUSHER SETTING HOSES Check, if the crusher setting keeps constant Check the tightness of all the hoses and during crushing. If the setting increases during connections. Repair all leakages immediately. crushing and returns when load decreases, air should be bled from the system.

  • Page 44: After 40 Hours Of Operation/ Every Week (1-Shift Operation)

    GP200S Periodical maintenance 7.2 AFTER 40 HOURS OF OPERATION/ EVERY WEEK (1-SHIFT OPERATION) LOWER FRAME ARMS LINERS Open the inspection hatches of the lower frame Observe the wear of the liners. The reason for (3 pcs) and remove all stone chips and other uneven wear of the liners might be an incorrect material jammed on the arms or slip ring.

  • Page 45: Every 300 Hours Of Operation/ Every Month

    Periodical maintenance GP200S 7.3 EVERY 300 HOURS OF OPERATION/ EVERY MONTH (2-SHIFT OPERATION)/EVERY SECOND MONTH (1-SHIFT OPERATION) DRIVE SHAFT BACKLASH LUBRICATION OIL OF COUNTERSHAFT Check the drive shaft and the eccentric shaft Change the lubricating oil in the countershaft gear backlash. The backlash must be approx. housing (figure 7.3.1).

  • Page 46: Every 2000 Hours Of Operation/Every Year (1-Shift Operation)/Every Half Year (2-Shift Operation)

    GP200S Periodical maintenance 7.4 EVERY 2000 HOURS OF 7.5 SEASONAL MAINTENANCE OPERATION/EVERY YEAR (1-SHIFT (SUMMER/WINTER) OPERATION)/EVERY HALF YEAR (2-SHIFT OPERATION) COUNTERSHAFT THRUST BEARING Change oil. See oil recommendations in chapter 6. Check the condition of the thrust bearings of the main shaft. If the oil grooves in the bronze bearings are lower than 3 mm (1/8"), the 7.6 EVERY 20 000 HOURS OF bearings should be replaced.

  • Page 47: Maintenance Intervals

    Periodical maintenance GP200S 7.7 MAINTENANCE INTERVALS More detailed maintenance instructions are shown in previous pages. 40 h 300 h 2000 h 20000h Summer Winter ELECTRICAL COMPONENTS Check condition of cables and components ADJUSTING CYLINDER Retighten cylinder head bolts THRUST BEARING Check condition of thrust bearing COUNTERSHAFT Change countershaft box oil...

  • Page 48: General

    Liner replacement GP200S  5(3/$&(0(172)/,1(56 8.1 GENERAL The part numbers of wear and spare parts needed for liner change are shown in the spare Do not wear the liners through. It may damage parts manual. the surfaces in the crusher frame and head. These surfaces can only be repaired by The concave consists of two parts.

  • Page 49: Dismantling The Crusher

    GP200S Liner replacement 8.2 DISMANTLING THE CRUSHER Separate the intermediate and lower frame by using the four jacking bolts (C, figure 8.2.2) Remove the gravel and stones from above the (M48/ keyhole 75 mm). The separation can be slip ring, so the main shaft can freely move helped by mounting lifting ropes on the upper down.
  • Page 50 Liner replacement GP200S Lift the upper and intermediate frames together away with concave (figure 8.2.4.). The 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).

  • Page 51: Replacing The Concave

    GP200S Liner replacement 8.3 REPLACING THE CONCAVE Remove the nuts of the mounting bolts of the lower part of the concave, 6 nuts M30/keyhole 46 mm (figure 8.3.1). Remove the lower part of the concave from the frame e.g. by hammering wedges between the flange and intermediate frame.
  • Page 52 Liner replacement GP200S There must be no clearance between the liner necessary. See chapter 9.2. and frame (figure 8.3.3). Hammer the liner to seat it properly. If the liner can move against Check the condition of protection plates of the the frame, their life shortens.

  • Page 53: Replacing The Mantle

    GP200S Liner replacement 8.4 REPLACING THE MANTLE The mantle can be replaced after removing the upper and intermediate frame, without removing the main shaft. The thrust bearings should be inspected at least once a year. To inspect the thrust bearings, the main shaft should be lifted out of the crusher.
  • Page 54 Liner replacement GP200S Check the condition of the thrust bearing, if the After tightening, weld the nut, the torch ring main shaft has been removed. If the bronze and the mantle together with six 50 mm (2") plates of the bearing are worn out so, that the long welds, equally distributed (figure 8.4.4).

  • Page 55: Assembling The Crusher

    GP200S Liner replacement 8.5 ASSEMBLING THE CRUSHER Lift the upper and intermediate frame (together ab. 3500 kg / 7700 lbs) and place on lower frame. Be careful not to damage the top bearing seal (figure 8.5.1). Place the mounting bolts and nuts (figure 8.5.2) (20 pcs), M36/keyhole 55 mm, tightening torque 2314 Nm (236 kpm / 1710 ft lbs), between the intermediate and lower frame...

  • Page 56: After Tightening

    Liner replacement GP200S 8.6 AFTER TIGHTENING After 10 operating hours, loosen and tighten the concave bolts (6 pcs) M30/keyhole 46 mm, tightening torque 440 Nm (45 kpm / 325 ft lbs). After 25 operating 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...

  • Page 57: Other Maintenance

    Other maintenance GP200S  27+(50$,17(1$1&( 9.1 GENERAL The crusher repair and maintenance is allowed When the equipment is switched off during only for reliable and qualified craftsmen. maintenance and repair, the motor controls must be locked out/off. Secure the lock keys In any work related to the operation, and attach a hazard notice at the main modification, conversion or adjustment of the...

  • Page 58: Replacing The Top Bearing Seal

    GP200S Other maintenance 9.2. REPLACING THE TOP BEARING SEAL The condition of the top bearing seal must be inspected daily. If the seal has been damaged, grease appears on the main shaft above the tightening nut of the mantle (figure 9.2.1). The failed seal must be replaced during the next mantle change.

  • Page 59: Replacing The Dust Seal

    Other maintenance GP200S 9.3 REPLACING THE DUST SEAL Put the shaft on the stand supported under the The condition of the dust seal (figure 9.3.1) head - NOT THE DUST SEAL - or turn it on must be inspected every time when replacing its side taking care not to damage the upper the liners.

  • Page 60: Thrust Bearing

    GP200S Other maintenance 9.4 THRUST BEARING The condition of the thrust bearing must be bronze bearing to the eccentric side, to allow inspected every year. The most convenient the thrust bearing to settle as much as possible. time to check them is when replacing the liners.

  • Page 61: Changing The Stroke

    Other maintenance GP200S 9.5 CHANGING THE STROKE General There are three strokes available for the Remove the eccentric bushing with the special tool (figure 9.5.2). The key comes out crusher: 18, 25 and 32 mm (3/4", 1" and 1-1/4"). The stroke can be changed by turning with the bushing.
  • Page 62 GP200S Other maintenance Mounting around the slip ring. Check the condition of the eccentric bushing, Inspect the top bearing seal and replace if key and eccentric shaft. Clean if necessary. necessary. See the chapter 9.2. Place the key in the groove of the desired Install the upper and intermediate frames stroke in the eccentric bushing and lower the together according to the chapter 8.5.

  • Page 63: Replacing The Top Bearing

    Other maintenance GP200S 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 install with bolts (4 pcs) M20/keyhole 30 mm, tightening torque 382 Nm (39 kpm / 280 ft lbs).

  • Page 64: Replacing The Protective Sleeve Of The Main Shaft

    GP200S Other maintenance 9.7 REPLACING THE PROTECTIVE SLEEVE OF THE MAIN SHAFT The protective sleeve (figure 9.7.1) of the main shaft must be replaced when damaged or worn. To replace the sleeve, the upper and intermediate frames together must be removed.

  • Page 65: Gear Backlash

    Other maintenance GP200S 9.8 GEAR BACKLASH GENERAL The Zyklo-Palloid bevel gears are used for transmitting the operating force from the drive shaft to the eccentric shaft. During the manufacturing stage the gears are finished in pairs, so that if one of the gears is damaged or worn out, both gears have to be changed.
  • Page 66 GP200S Other maintenance ADJUSTING The tooth contact and the gear backlash can be Check the tooth contact by applying thinly adjusted by moving the pinion (smaller gear). contact colour on the crown wheel teeth (3 or 4 adjacent teeth). Rotate the smaller gear by Vertical movement happens by turning the the belt pulley to spread out the colour also to countershaft housing with adjusting screws...
  • Page 67 Other maintenance GP200S If the tooth contact is this Move the pinion this way Figure 9.8.4 With the contact as in the drawing on the left, turn the pinion as in the drawing on the right. Figure 9.8.5 Check the backlash by turning the pulley and measuring the free movement 12/99 140548 9-11...

  • Page 68: Protection Plates

    GP200S Other maintenance 9.9 PROTECTION PLATES 9.12 BOLT TORQUE VALUES The plates protect the crusher frame against 9.12.1 CONCAVE BOLTS the hits of rocks. The plates are made of hard, Concave bolts must be tightened according to wear resistant steel and they must be replaced if necessary.
  • Page 69 Other maintenance GP200S 9.11.2 OTHER BOLTS All other bolts must be tightened according to table below. Correct pretightening is possible only with clean, unlubricated screw threads that are not surface treated. The table applies to bolts with property class 8.8. Bolt Torque Width across the flats...

  • Page 70: Trouble Shooting

    Trouble Shooting GP200S  7528%/(6+227,1* Equipment malfunction may occur for a number of reasons: incorrect operation of the equipment (from overloading, carelessness, or inexperience), or a normal wearing out of parts. Electrical controls should be designed so, that these possible malfunctions do not allow any additional damage.
  • Page 71 GP200S Trouble Shooting THE CRUSHER HALTS AND THE SIGNAL LIGHT "OVERLOADING/ MOTOR OVERHEATED" IS ILLUMINATED. The electric drive motor of the crusher is overloaded and the protection system of the motor has been activated. The lubricating pumps are still running. Empty the crusher cavity, remove the reason for overload and restart the crusher after the motor has cooled down.
  • Page 72 Trouble Shooting GP200S THE CRUSHER HALTS AND SIGNAL LIGHT "LUBRICATING OIL/ HOT" IS ILLUMINATED. The temperature of the oil returning from the crusher has exceeded +68°C (154°F), thus activating the return oil thermostat to halt the crusher. The lubricating pumps are still running. Empty the crushing cavity and remove the reason for overheating.
  • Page 73 GP200S Trouble Shooting THE CRUSHER HALTS AND THE SIGNAL LIGHT "OIL PRESSURE/ LOW" IS ILLUMINATED. There is a fault in the lubricating oil supply and the pressostat has stopped the crusher. Empty the crushing cavity, trace and repair the fault. If the lubricating pumps are running and the manometer is indicating pressure, the oil hose to the crusher may be damaged.
  • Page 74 Trouble Shooting GP200S THE CRUSHER HALTS AND THE SIGNAL LIGHT "NO OIL FLOW" IS ILLUMINATED. The float switch in the return oil sump has been activated stopping the motor. The lubricating pumps are still running. Stop the pumps immediately. Empty the crushing cavity trace the fault and repair it.
  • Page 75 GP200S Trouble Shooting THE CRUSHER HALTS, NO FAULT IN LUBRICATION SYSTEM. The V-belts are slipping. Tighten the belts or replace as necessary. The V-belts are broken. Empty the crushing cavity, trace the reason for breakage and replace the belts. THE OIL FILTERS ARE CLOGGING VERY RAPIDLY. The filters of the lubricating oil are clogged rapidly due to dust entering the lubrication system.

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