Instruction manual
140551

 
 Instruction manual GP300

1RUGEHUJ*3VHULHV
&RQH&UXVKHU

This instruction manual is valid for GP300-series crushers manufactured by Metso Minerals
from the year of 2001 and the serial number of 4658. The crusher is a high capacity cone crusher,
which is intented to be used in fine 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 second edition published in June 2002 in

Tampere, Finland. Manufacturer:

Metso Minerals (Tampere) Oy

P.O. Box 306
33101 Tampere
Finland

Tel. +358-(0) 20 484 142

Fax +358-(0) 20 484 143

6/02 140551
 Instruction Manual GP300

1RUGEHUJ*3VHULHV
&RQH&UXVKHU

1. PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 CRUSHER TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 NORDBERG GP300 SERIES CONE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.6 SPARE AND WEAR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.7 CAPACITY OF THE CRUSHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.8 SETTING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.9 CAVITY SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.10. MOTOR SIZE SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

4. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 FOUNDATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 INSTALLATION DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 SPACE REQUIREMENTS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 LIFTING THE CRUSHER AND ITS PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5 FEEDING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.6 REMOVAL OF CRUSHED MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.7 POWER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.8 HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.9 OVERLOAD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.10 TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.11 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.12 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.13 CORROSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.14 SERVICE PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.15 SETTING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.16 PRESSURIZED DUST SEALING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.17 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

5. CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 BEFORE STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.4 RUNNING-IN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.6 SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.7 STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

6/02 140551
GP300 Instruction Manual

6. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 COUNTERSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 TOP BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7. 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

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

8.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 DISMANTLING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 REPLACING THE CONCAVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 REPLACING THE MANTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 ASSEMBLING THE CRUSHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6 AFTER TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

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 SETTING OF BEVEL GEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.9 PROTECTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.10 AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.11 BOLT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

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

140551 6/02
 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 who works with the
proper use of the equipment. equipment, typically:
It includes important references to safe, — operations, including installation, startup,
proper and economical operation of the operation, application engineering,
equipment. Following these instructions will materials handling, site labour,
help to avoid possible danger, reduce repair environmental engineering and safety
costs and breakdowns and to increase the departments.
reliability and life of the equipment. — maintenance, including inspection and
repair.
This manual must be complemented by those — transport, materials handling and rigging.
instructions necessary because of existing
national mandatory rules relating to accident
prevention and environmental protection. Note that this instruction manual contains
information and instructions on alternative
A copy of this manual must be kept at the and optional equipment. Normally the
equipment’s location and made available to machines have only some of them. Before
the operators as required. maintaining and servicing, find out which
In addition to this manual and accident alternative and optional equipment your
prevention regulations mandatory in the machine has.
country of use and at the equipment’s place of See separate instruction manuals for more
operation, generally recognized rules for safe detailed instructions when servicing the main
and professional operation must be observed. 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.

1/95 1-00-B 1-1

 Safety

 6$)(7<
2.1 WARNING SYMBOLS 2.2 INTENDED USE

The following symbols for particularly impor- Metso Minerals’ products are designed with
tant instructions are being used in the instruc- safety as a major criteria and also manufactur-
tion manual: ed according to the state of art principals in
engineering and safety. Nevertheless, impro-
Reference per or careless operation can be dangerous.
Operating personnel and others must be made
aware of the inherent dangers in operating this
type of equipment.
The equipment shall be used only when in
proper mechanical condition, according to its
Refers to economical operation of the equip- "intended use", and careful consideration gi-
ment. ven to safe operation and possible danger.
Strict attention must be paid to this instruction
manual. Poor mechanical or site conditions
that would prejudice safety must be corrected
Attention immediately.
The equipment is intended to be used in ore,
rock or rock-based materials handling exclu-
sively. Any application different from above
or exceeding the design limitations of the
equipment will not be considered as intended.
Particular attention must be given to prevent The manufacturer will not be liable for any
possible incorrect or dangerous operating si- consequential or inconsequential damages re-
tuations from occurring. sulting from the product’s misuse. The user
only, shall incur these risks.
The "intended use" must also include: adhe-
Danger rence to all instructions in this manual, proper
and safe operation, and the observing of re-
sponsible inspection and maintenance proce-
dures.

Particular attention must be given to prevent

accidents or damage to personnel and/or pro- 2.3 INSTRUCTION MANUAL
perty.
Keep the instruction manual permanently ac-
cessible at the equipment’s location.
In addition to the following advise provided in
the instruction manual, observe and provide
instruction regarding all general legal and
mandatory regulations relating to safety, acci-
dental prevention and environmental protec-
tion.

5/95 2-00-B 2-1

 Safety

Such responsibilities also include: handling can only be fully guaranteed when original
and disposal of dangerous materials or con- manufacturer’s parts are used.
sumables, wearing of personal protection ap-
parel and other protective equipment, and ob- Replace hydraulic hoses and pipes at the indi-
serving of materials handling and transport cated or appropriate time intervals, even if no
regulations. safety-related defects are perceptible! Always
replace them immediately when there is any
Read the instruction manual completely. In- indication of unsafe, worn, damaged or faulty
itiate and institute proper training procedures parts.
for; operator instruction and education, repor-
ting and control procedures, supervision gui- Always follow the time period guidelines spe-
delines and procedures, personnel supervi- cified in the instruction manual for inspection
sion, etc. and maintenance.

Before starting assembly or site preparation, Always use tools and suitable for the work to
personnel in charge must read the instruction be performed.
manual and in particular the chapter on safety. Always know the location and proper use of
This is imperative. Particular attention must be fire extinguishers.
paid to the activities or safety of personnel not
familiar with the equipment and its applica- Always observe the proper procedures for fire
tion, for example those involved in assembly, alarms and fire fighting.
startup or maintenance.
Control must be exerted over work performed
on or near the equipment to ensure that strict 2.4 PERSONNEL
adherence to this manual is maintained.
Any work on the equipment must be perfor-
The personnel must not wear long hair, loose med by skilled and trained personnel only.
clothing or jewelry, because of possible dan- Observe the minimum legal age requirements.
ger or injury.
Clearly state and follow guidelines for person-
Use personal protection suits and other protec- nel skills and requirements necessary for the
tive equipment where mandatory. safe operation, installation, service, mainten-
ance and repair of the equipment.
Observe and follow any safety, danger or war-
ning signs on the equipment. Ensure that only personnel with these skills
and that meet these requirements work on the
Keep all safety, danger and warning signs on equipment.
the equipment in legible condition.
State clearly the responsibilities of the machi-
If safety-related modifications to the equip- ne operator. Authorize him to refuse any un-
ment or its performance are required, stop the safe instructions by third parties.
plant immediately and before beginning any
work notify the person responsible. Let personnel in training, in training on the job
or in general education work with the equip-
Do not make any modifications or repairs to ment only under permanent supervision of an
the equipment which would prejudice safety, experienced person.
without the supplier’s written approval. This
includes work on attached or remote safety Work on electrical controls and equipment
devices, control valves, as well as the welding must only be performed by a licenced electri-
of supporting structures, brackets, etc. cian or under the guidance and supervision of
an electrician, always according to applicable
Spare and wear parts must meet the manufac- regulations.
turer’s technical specifications. Conformity

2-2 2-00-B 5/95

 Safety

Only trained and experienced hydraulics tech- tion or touch the moving parts.
nicians should perform work on any hydraulic
system. All the moving parts relating to power trans-
mission ie. flywheels, shafts, couplings, V-
belt pulleys and V-belts must be covered gu-
arded properly to eliminate danger to person-
2.5 OPERATION nel.
Refrain from any work that would endanger Make sure that all the persons operating or
safety. maintaining the equipment know the location
of the emergency stop buttons or controls.
Before starting work, familiarize with the sur-
roundings of the work place, e.g. any possible Do not try to clear any blockings when the
hindrances (barriers/obstructions/ obstacles) equipment is running.
in the reach of work and traffic, soil bearing
capacity and necessary site protection towards Rock or other objects may fall from the machi-
the public road traffic area. ne. Always wear a helmet in the dangerous
area.
Take any necessary measures to ensure that the
equipment is operated in a safe manner and Be very careful near sharp corners, edges or
when in good mechanical condition. rough surfaces.

If the equipment is used alone, it must be

equipped with main switch and emergency 2.6 MAINTENANCE AND REPAIR
switch.
Only operate when all safety devices and safe- Observe all guidelines outlined in the instruc-
ty-related equipment, e.g. removable guards, tion manual regarding adjustment, maintenan-
emergency stops, sound insulation, dust col- ce and inspection schedules, as well as replace-
lector are in proper position and operative. ment of parts or equipment. Only trained tech-
nicians should perform this work.
Check the equipment at least once a shift for
visible damage and defects. Notify the respon- Inform the maintenance staff of any mainten-
sible person immediately of any problems in- ance or service work required. Ensure proper
cluding any deviations in normal operating supervision.
performance. In every case stop equipment In any work related to the operation, modifi-
immediately and resolve the problem! cation, conversion or adjustment of the equip-
In the case of any malfunction, stop and safe- ment and its safety devices including inspec-
guard the equipment immediately. Have the tion, maintenance and repair, observe all star-
problem immediately corrected. ting, stopping and maintenance procedures as
outlined in the instruction manual.
Observe starting and stopping procedures,
control devices and signals as specified in the Ensure as extensively as possible that the im-
instruction manual. mediate area is safe and secure.

Before starting the equipment inspect the ge- When installing or replacing parts, incorrect
neral area to ensure that there are no personnel mounting may be hazardous. Always ensure
that may be endangered from starting. Walk that the parts are properly installed.
around the equipment and make sure that there When the equipment is switched off during
is nobody on, by or below the equipment. maintenance and repair, the motor controls
Warn all persons in the area before starting. must be locked out/off. Secure the lock keys
Do not climb on the equipment during opera- and attach a hazard notice at the main discon-
nect switch. Make sure that the equipment can

5/95 2-00-B 2-3

 Safety

not be started during maintenance and repair. Check all fuel, motor oil and hydraulic oil
hoses for leaks, loose screws, fasteners, bolts,
During replacement of parts or heavy structu- fittings, cuts, shearing or damage. Repair all of
ral components careful handling and hoisting these immediately.
procedures must be followed to eliminate any
possible danger. Only use appropriate, proper- After maintenance and/or repair work, tighten
ly designed lifting and handling equipment any loose fittings, bolts, fasteners, etc.
with sufficient capacity. Place the parts on
ground with sufficient bearing capacity. Never If any maintenance and repair procedures re-
stand or work underneath a suspended load. quire the dismantling of safety controls, they
must be re-assembled and checked immedi-
Use only approved lifting equipment and ately upon completion of the work.
slings when lifting components. Tighten any
lifting eyebolts before lifting. Care must be taken for the safe and environ-
mentally correct disposal of process materials,
Allow only skilled personnel to sling loads and parts and other consumables.
direct the crane operators. The hoisting person
in charge must keep in visual or voice contact Always attach a hazard notice to the main
with the crane operator. electrical disconnect switch and lock it out,
when starting the equipment may be hazardous
For any work above grade level, use appropria- or when maintaining or repairing the equip-
te stairs and working platforms. Do not use ment.
machine parts as platforms. For maintenance
work involving any height other than grade Always attach a hazard notice to the power
level use appropriate safety equipment and supply of electrical components and lock them
procedures. out, when starting the equipment/component
may be hazardous or when maintaining or
Due to small size and mobility of the machine, repairing the equipment/component.
the accesses may be different from the requi-
rements of the standards. Always be very
careful when walking on the machine. 2.7 OTHER SAFETY
Keep all handles, steps, railings, platforms, CONSIDERATIONS
stages and ladders free from dirt, snow, ice and
other hazards. Electricity

When cleaning hoppers or other hazardous Only use fuses of proper and recommended
places be very careful to prevent falling and capacity. Never use fuses of higher capacity
injuries. than indicated in the electrical drawings.

Prior to maintenance and repair work, clean In case of electrical problems, shut down the
the machine. In particularly clean all connec- equipment immediately.
tions and leads to remove oil, fuel or other Any work on electrical equipment must only
fluids. Do not use harsh cleansers. Use fibre- be performed by a licenced electrician or under
free cleaning rags. the guidance and supervision of a licenced
Before cleaning the machine with water, steam electrician, providing all codes and regulations
or high-pressure cleaning methods, cover and are followed.
protect all openings where water, steam or Prior to any inspection, maintenance and re-
cleanser must not penetrate, particularly elec- pair being performed, the equipment must, if
trical motors and controls. required, be secured electrically and switched
After cleaning remove any temporary covers voltage free. Follow all required safety proce-
or protection completely. dures and regulations.

2-4 2-00-B 5/95

 Safety

The electrical equipment must be inspected at Never search for leaks from the pressurized
regular intervals. Defects such as loose con- hoses with hand. High pressure fluid jet may
nections, damaged wiring must be repaired penetrate the skin and cause injury. Search for
immediately. The work must be performed by leaks with paper, etc.
a licenced electrician or equivalent as specified
by law. Gas, dust, steam, smoke

Should work be required on live electrical Perform welding, cutting and grinding work at
apparatus, a second person must be assigned the equipment only where allowed. Fire ha-
to actuate the emergency stop or disconnect the zard may exist and explosion hazard may oc-
main switch in case of emergency. Safeguard cur.
the working area with a red and white safety Before welding, cutting and grinding clean the
chain and "danger" sign. Use voltage isolated
tools only.
Where work is required on high voltage com-
ponents, connect the supply cable after voltage
clearance to mass, and short-circuit compo-
nents, e.g. capacitors, by an ground rod.
Use only proper parts in electrical appliances.
Electric cables should be properly sized and
protected, for example from falling rocks. Wi- equipment and site to remove dust and com-
ring should be long enough to provide for bustible materials. Take the necessary precau-
components requiring adjustment. tions in providing for sufficient ventilation.

Hydraulic, pneumatic Dust protection must be fitted to the machine

where necessary to prevent injury to personnel
Only persons with special knowledge and ex- or contamination of the environment. Airbor-
perience in hydraulics shall perform work on ne dust must be minimized while feeding,
the hydraulic equipment. moving or discharging the product. Recom-
mended methods for dust prevention are:
Check at specified intervals that all conduits,
hoses, lines and fittings are free of leaks or 1. Dust covers and dust extraction
visible defects. Repair any defects immedi- 2. Dust enclosures
ately. Spurting oil may cause injury and fire. 3. Water suppression
Prior to any repair work, depressurize any air Noise
or hydraulic system, including hoses, lines and
fittings to be opened. This must be done in a During operation, sound insulation, if availa-
safe, approved manner. ble, must be in its proper and safe location.

Assemble hydraulics and compressed-air pi- Wear ear protection.

ping carefully according to all proper proce- Oil, grease and other chemical materials
dures. Take precautions to not mix up any
connections. Fittings, length and quality of the When using oil, grease and other chemical
hoses and pipes must satisfy any requirements materials, observe the product safety guideli-
set. nes and warnings.
When replacing or repairing hydraulic parts, Be careful when using any hot materials to
make sure that only parts designed for the protect personnel from burning or scalding.
operating pressures of the system are used.
This also relates to any pressure hoses.

5/95 2-00-B 2-5

 Safety

Hot surfaces Transport or hoist components, and handle any

parts in accordance with the instructions and
During operation some surfaces become very advice provided herein.
hot (for example exhaust pipes and turbo-char-
gers). The wear parts of the crusher and me- Fasten the lifting equipment only to the points
tallic object which go through the crusher can meant for lifting.
also become hot.
Use only proper means of transport with ade-
Fire quate transporting capacity!
In case of fire near the equipment: Fasten the load carefully! For lifting, use only
the fastenings showed in instructions!
— Warn all persons in the dangerous area.
— Stop the equipment. Secure all component parts of the equipment
— Turn off the main disconnect switch. immediately after loading to avoid any acci-
— Make sure that all persons are in safe area. dental shifting. Attach required warning signs
— Start fire fighting and give the alarm if to the load.
necessary.
— If possible move the equipment away from Remove all temporary supporting structures or
the dangerous area. brackets before re-starting the equipment.
Carefully assemble all of the parts previously
In case of fire in the equipment: disassembled.

— Warn all persons in the dangerous area. Disconnect all external power supply before
— Stop the equipment using emergency stop. moving any part of the equipment and recon-
— Turn off the main disconnect switch (if nect it properly before re-starting.
possible). Perform any start-up in accordance with the
— Make sure that all persons are in safe area. instruction manual.
— Start fire fighting and give the alarm if
necessary.

Blasting
The use of the radio control device is strictly
forbidden during blasting operations, as it may
cause a premature explosion.
The equipment must be moved far enough
away from the dangerous area when blasting.
Explosives must be prevented from entering
the equipment.

2.8 TRANSPORTATION

Only use appropriate transportation and lifting

equipment with adequate capacity.
Provide a supervisor to direct lifting opera-
tions.

2-6 2-00-B 5/95

 General GP300

 *(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 opera- at their farthest relationship during one revo-
tion. In order that there will be no possibility lution of the eccentric. As a general rule, the
of confusion or misunderstanding, these terms maximum size of feed should be 60...80 % of
are defined as to their usage in the manual. the open side feed opening depending of the
crusher type and the raw material to be crus-
Feed = The raw material that is to be crushed. hed.

Product size = The size of the screened mate- Crushing cavity (G) = The internal area for-
rial after it has been crushed. med by the two liners.

Capacity = The output of the crusher compu- Discharge setting (S) = The distance between
ted in tons per hour (mtph). the bottom of the crushing members as mea-
sured at the point where the two crushing
Liners = The mantle (IM) and concave (OM) members are at their closest relationship du-
are the crushing members and are commonly ring their gyrating circle (= closed side setting,
referred to as liners. c.s.s.). The discharge setting regulates product
size.

Figure 3.1.1 Terms used in instruction manual

6/02 140551 3-1

GP300 General

Minimum discharge setting = The smallest GP300-series crusher. The stroke can be chan-
permissible distance between the bottom of ged by turning the eccentric bushing.
concave and mantle as measured at the point
where the two crushing members are at their
closest relationship during their gyrating cir-
cle. 3.3 OPERATING PRINCIPLE

Discharge opening = The distance between The crushing occurs between the fixed conca-
the bottom of the concave and mantle as mea- ve and eccentrically gyrating mantle (Figure
sured at the point where the two crushing 3.3.1). The countershaft of the crusher is dri-
members are at their farthest relationship du- ven by an electric motor via a V-belt and
ring their gyrating circle. This wide opening pulleys. The countershaft drives the eccentric
permits rapid discharge of the crushed materi- bush through a gear and pinion. The stroke is
al. generated by the eccentric bush, which gives
the main shaft a gyrating movement. The feed
Stroke (E) = The difference between open material enters the crusher via the feed ope-
side setting (o.s.s.) and closed side setting ning in the upper part of the crusher. The
(c.s.s.). crushed material leaves the crusher via disch-
arge opening below the crusher.
Open circuit operation = The type of opera-
tion 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 ope-

ration where precise uniformity of product
size is important and the product is screened
as it is being discharged and the material which
does not pass through screen is returned to the
crusher.

3.2 NORDBERG GP300 SERIES CONE

CRUSHER

Nordberg GP300-series crusher is designed

for fine crushing purposes either in big or
medium size crushing plants.

There are six different crushing cavities avai- Figure 3.3.1 Operating principle
lable: Extra Fine(EF), Fine(F), Medium
Fine(MF), Medium(M), Coarse(C) and Extra
Coarse(EC).

The crusher type can be changed any time by

replacing the liners with different types.

There are three different strokes, 25, 32 and

40 mm (1", 11/4 " and 19/16 ") available for the

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 General GP300

3.4 MAIN COMPONENTS

Figure 3.4.1 Crusher main components

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GP300 General

3.5 TECHNICAL SPECIFICATIONS

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

FEED OPENING 260 mm 180 mm 130 mm 100 mm 60 mm 40 mm
(10") (7") (5") (4") (21/2") (11/2")
MAX. FEED SIZE 210 mm 140 mm 120 mm 80 mm 50 mm 32 mm
(8") (51/2") (41/2") (3") (2") (11/4")
MIN.SETTING*)
— stroke 25 mm 22 mm 18 mm 15 mm 13 mm 8 mm 6 mm
(1") (7/8") (11/16") (19/32") (1/2") (5/16") (1/4")
— stroke 32 mm 26 mm 21 mm 17 mm 15 mm 11 mm 8 mm
1
(1 /4") (11/32") (27/32") (21/32") (19/32") (7/16") (5/16")
— stroke 40 mm 30 mm 24 mm 19 mm 17 mm 14 mm 10 mm
9
(1 /16") (13/16") (15/16") (3/4") (21/32") (9/16") (3/8")

MAX. SETTING **) 37 mm 34 mm 26 mm 26 mm 25 mm 19 mm

(17/16") (111/32") (11/32") (11/32") (1") (3/4")
COUNTER SHAFT 1233
rpm (motor 1480 rpm)
WEIGHT 12900 - 13400 kg
(28400 - 29500 lbs)

*) Dry, medium hard granite.

**) With new liners at 32 mm (11/4") stroke

3-4 140551 6/02

 General GP300

3.6 SPARE AND WEAR PARTS To assure the immediate delivery of the spare
and wear parts of the crusher, the following
The original Nordberg parts are accurately information should be included in the order:
manufactured to Metso Minerals specifica-
tions and are made of the best quality material. — The serial number and model
The original parts ensure efficient, profitable identification of the crusher
and safe operation for your equipment. Their
use also ensures the validity of the warranty. — The spare parts number, description and
amount of the parts in order
The total costs will be lower when using Nord-
berg parts. Typical benefits: — The formal and complete name and postal
address of the remitter
— Parts are tested in practice.
— Exact forwarding instructions, method and
— Latest development available. address of delivery

— No unexpected breakdowns. Never use any other than original Nordberg

spare and wear parts to ensure the faultless and
— Fast and reliable delivery. safe operation of your crusher and the validity
of the warranty.
— All parts with a single order.
If the original spare parts manual has disappea-
red, you can order a new one from Metso
Minerals.

8VHRQO\
RULJLQDO
1RUGEHUJ
ZHDUDQG
VSDUHSDUWV

6/02 140551 3-5

GP300 General

3.7 CAPACITY OF THE CRUSHER

The capacity of a crusher is affected by a The capacity can be estimated from the table
number of factors e.g.: below, if you know the stroke and setting of
the crusher. The actual capacity may differ
— The characteristics of the feed material from the capacity estimated by the table de-
(size, hardness, toughness, moisture pending of the factors given before.
content, bulk density, etc.)
The given values are to be used as a guide
— The method of operation only, and are valid when crushing dry, medi-
um hard granite with a bulk density of 1.6 t/m3
— The setting and stroke of the crusher (100 lbs/ft3).

GP300 EC
SETTING c.s.s.
STROKE tons/ 22 mm 26 mm 30 mm 32 mm 33 mm 37 mm 41 mm
7 3 1 5 7
hour /8" 1" 1 /16" 1 /4" 1 /16" 1 /16" 15/8"
25 mm mtph 185 210 230 240 245 270 290
1" stph 205 225 255 265 275 295 320
32 mm mtph 265 290 305 315 340
11/4" stph 290 325 335 345 370
40 mm mtph 350 365 375
19/16" stph 385 400 415

GP300 C
SETTING c.s.s.
STROKE tons/ 18 mm 21 mm 24 mm 28 mm 30 mm 34 mm 37 mm
11 13 1 3 5
hour /16" /16" 1" 1 /8" 1 /16" 1 /16" 17/16"
25 mm mtph 170 185 200 225 235 255 270
1" stph 185 205 230 250 260 275 295
32 mm mtph 230 250 280 290 320
11/4" stph 250 285 310 325 350
40 mm mtph 310 345 360
19/16" stph 355 385 400

GP300 M
SETTING c.s.s.
STROKE tons/ 15 mm 17 mm 19 mm 20 mm 22 mm 26 mm 29 mm
5 11 3 13 7
hour /8" /16" /4" /16" /8" 1" 11/8"
25 mm mtph 150 165 175 180 190 215 230
1" stph 175 185 190 200 210 230 250
32 mm mtph 205 220 225 240 270
11/4" stph 230 240 255 270 295
40 mm mtph 265 275 290
19/16" stph 295 305 320

3-6 140551 6/02

 General GP300

GP300 MF
SETTING c.s.s.
STROKE tons/ 13 mm 15 mm 17 mm 19 mm 22 mm 26 mm 29 mm
1 5 11 3 7
hour /2" /8" /16" /4" /8" 1" 11/8"
25 mm mtph 145 155 165 175 195 215 230
1" stph 160 175 185 195 215 230 250
32 mm mtph 190 205 215 240 265

11/4" stph 215 230 240 265 290

40 mm mtph 245 260 285
19/16" stph 275 290 315

GP300 F
SETTING c.s.s.
STROKE tons/ 8 mm 11 mm 14 mm 17 mm 21 mm 25 mm 28 mm
5 7 9 11 13
hour /16" /16" /16" /16" /16" 1" 11/8"
25 mm mtph 120 135 150 165 185 205 220
1" stph 130 150 165 185 200 230 245
32 mm mtph 170 185 205 225 250
11/4" stph 190 210 230 250 280
40 mm mtph 230 250 280
19/16" stph 255 280 305

GP300 EF
SETTING c.s.s.
STROKE tons/ 6 mm 8 mm 10 mm 12 mm 15 mm 19 mm 22 mm
1 5 3 1 5 3 7
hour /4" /16" /8" /2" /8" /4" /8"
25 mm mtph 95 100 110 120 130 150 160
1" stph 105 110 120 135 150 165 175
32 mm mtph 130 140 150 170 190
11/4" stph 145 150 170 190 210
40 mm mtph 175 190 210
19/16" stph 190 215 240

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GP300 General

3.8 SETTING RANGE When selecting the proper cavity type, please
contact Metso Minerals representative. To se-
Minimum setting, which can be used, depends lect the appropriate cavity type, the following
among others on factors like: stroke used, information is required:
reduction ratio, choke level, feeding rate fluc-
tuation into the crusher, rock type (gravel or 1. Feed size (distribution)
rock), feed gradation, cavity wear, etc.
2. Feed type (rock type)
Allowable setting range varies depending on
the stroke used. Limiting factor for minimum 3. Final product (distribution)
setting is either power draw or adjustment
pressure, which both increase, when setting is 4. Capacity required
being squised tighter. Power draw increases
when stroke increases, and thus motor size
selection is much dependable on stroke used.

Especially in coarse crushing the fluctuation

in the process can be a factor, which causes
that minimum specified setting can not be
used. That is why it is recommended that
minimum allowed setting is used continuous-
ly only, if the running conditions are known
well and they are stable enough.

3.9 CAVITY SELECTION

The type of crushing cavity must be determin-

ed according to the feed material and the re-
quested end product. Because of the innume-
rable different applications, any exact instruc-
tions are about impossible to give.

If the cavity type is improperly selected for the

application, the result might be accelerated
and uneven wear of the liners, deterioration of
end product quality and decreased capacity.
Replacing the liners with proper ones normal-
ly 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. Figure 3.9.1 There are six different crushing
cavities available for GP300.

3-8 140551 6/02

 General GP300

3.10. MOTOR SIZE SELECTION

Maximum motor size is determined by chosen

stroke. Table below will give max. allowable
motor size for GP300 Cone.

Stroke Max. motor size

IEC/NEMA standards

(mm) (inch) (kW) (hp)

GP300 25 1 160 200
1
32 1 /4 200 300
(EC, C, M, MF, F, EF)
40 19/16 250 350

Note: If you choose a nominal power for the This method should always be used when final
motor bigger than the recommended Maxi- motor selection is being done.
mum size, then the crusher must have the
automatic setting control system. Example of motor size selection for
GP300C:
Power needed in the application depends on
setting to be used. If crusher is used in constant Crusher is being used in an application with
setting (doing constant product) motor size setting 26 mm (11/32"), and stroke 32 mm
should be selected accordingly. (11/4"") gives enough capacity. Reduction ra-
tio is normal (F80/P80 = max. 3…4), and rock
This selection can be done when application is Wi = max. 14…16, LosA = max. 25…30.
known and in most case results is that motor
can be smaller size than mentioned in item 1. In this case max. allowable motor size is 200

kW (250 hp), but due to setting used estimated power draw is about 150 kW (200 hp)

160 kW (250 hp) motor is the closest standard and to be selected.

6/02 140551 3-9

GP300 General

Power curves for the other GP300 cones:

GP300 EC

GP300 M

3-10 140551 6/02

 General GP300

GP300 MF

GP300 F

6/02 140551 3-11

GP300 General

GP300 EF

3-12 140551 6/02

 Installation GP300

 ,167$//$7,21
4.1 FOUNDATION must be checked to be equal. To accomplish
this, all four support points must be level. To
The crusher installation must be made on a level the supporting points, shims may be used
steel or concrete foundation strong enough by if necessary.
using rubber dampers between the crusher and
foundation. When running, the crusher is If the crusher has been delivered as mounted
oscillating about ± 2 mm (±5/64") on dampers. on a steel frame (element or portable), the
When starting or stopping, the oscillation is frame must be levelled so that all the rubber
about ±10mm(±3/8)". Becau se of the dampers of the crusher are level. The steel
oscillation, the clearance around the crusher frame (element or portable) must be well
must be at least 20 mm (3/4"). The static and supported on the ground and the vertical
dynamic forces per supporting point, see fig. alignment of the crusher must be checked.
4.1.1. When mounting the crusher on its
foundation the depression of all four rubber
dampers, caused by the weight of the crusher,

Figure 4.1.1 Crusher foundation (example)

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GP300 Installation

4.2 INSTALLATION DIMENSIONS

Figure 4.2.1 Crusher installation dimensions

4-2 140551 6/02

 Installation GP300

4.3 SPACE REQUIREMENTS FOR

MAINTENANCE

Wh en 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

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GP300 Installation

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. 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 12900 - 13400 kg
(28400 - 29500 lbs). The weights of separate
parts are given in the figure 4.4.1.

Figure 4.4.1. Lifting the crusher

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 Installation GP300

4.5 FEEDING THE CRUSHER The feed arrangement should be executed as

follows:
The material to be crushed can be fed straight
into the crusher by using a belt conveyor, — All material smaller than crusher setting
screen or different types of feeders or by using should be separated before feeding into the
guiding troughs. The feed arrangement should crusher. The fines might cause packing
be easily portable to make the maintenance of and overload in the crushing cavity. All
the crusher as easy and quick as possible. uncrushable objects like metal pieces have
to be removed from the feed e.g. with a
The maximum crushing capacity and the most magnetic separator. The manufacturer is
economical wear of the crushing liners can be not responsible for damage caused by the
achieved only with a right amount and even reasons above.
distribution of feed material around the
crushing cavity. The feed should be directed — The feed must be directed so that there is
to the crusher parallel with the supporting arms an equal load around the whole lower
of the upper frame. This arrangement helps the portion of crushing cavity. This ensures
feed’s even distribution in the cavity. The more even loading and better lubrication
upper frame can be rotated in 18° steps as for the bearings and also the wear of the
necessary. liners is more uniform. To accomplish this
the feed can be guided by the position of
the conveyor and feeding chutes or
barriers.

— The speed of the feed material when

arriving at the crusher should not exceed 5
m/s (16ft/s), which corresponds to a free
fall height of 1.3 m (4.3ft). As necessary,
the speed must be limited by stone ledges
etc.

— To ensure even wear of liners, the crusher

should be evenly choke fed.

— The overfilling of the feed chute should be

prevented by a level indicator or similar
device.
Figure 4.5.1 Feeding the crusher
— Any feed into the crusher when it is
stationary, must be prevented. This can be
accomplished electrically through cutout
relays that will only allow the motor of the
feeding device to start when the crusher
and discharge conveyor/system are
running.

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GP300 Installation

4.6 REMOVAL OF CRUSHED When arranging the withdrawal of crushed

MATERIAL material from the crusher, pay attention to
following:
The crushed rock can be removed by using a
belt conveyor and/or different chutes or silos, — When the crushed material is hauled away
either directly or using guiding troughs. The by conveyor or feeder, the feeding device
arrangement should be easily portable to make to the crusher must not be able to start if
the maintenance of the crusher as easy and the crusher is stationary.
quick as possible.
— If there is a silo below the crusher, a level
The discharge opening of the crusher must be indicator must be mounted into the silo to
covered or built safety distances according to stop the feed into the crusher, when the
national standards (eg. EN 294). material level in the silo is too high.

The withdrawal of crushed rocks must all the — The lubrication and adjusting oil hoses for
time be unimpeded. The hauling away devices the crusher must be protected from falling
must be build in to prevent the accumulation rock.
of crushed material. In case the level of
crushed material reaches the lower part of — Use the inspection openings in the lower
mantle, the seal ring below the head might get frame to remove all material that may
damaged. This allows dust to enter the become lodged on the lower frame arm
lubrication oil possibly causing more serious guards. Any accumulation of material on
damages. these arms can impair the outflow from the
crusher and may result in serious damage
to crusher components.

Figure 4.6.1 Removal of crushed material

4-6 140551 6/02

 Installation GP300

4.7 POWER TRANSMISSION The power is transmitted from the driving

motor to the countershaft of the crusher by
The recommended driving motor is a slip ring using V-belts. The use of V-belts is most
motor with a nominal speed of rotation of 1500 recommended in this case, because they
rpm (1200 rpm). The motor power needed is prevent the shock loads from being conveyed
160-250 kW (200-350 hp) depending on the from the crusher to driving motor.
selected cavity and the material to be crushed,
see chapter 3.10. The V-belt pulley on the drive shaft of the
driving motor must be ruled to be accurately
In case the crusher driving motor is to be parallel with the V-belt pulley on the
mounted on fixed basement and the crusher is countershaft of the crusher. The drive shaft of
oscillating in regard to the motor, the motor the driving motor must be parallel with the
must be located directly above or below the countershaft of the crusher.
countershaft of the crusher. The max.
oscillation of V-belt line should not exceed 15° The type of V-belts is SPC/ISO4184. There is
when the crusher is standing still (fig. 4.7.1). a 8 pcs set of V-belts. When replacing V-belts,
The purpose of this arrangement is to avoid all of them must be replaced at a time. Never
additional stresses caused by the oscillating mix new and second hand V-belts. The V-belts
movement of the crusher. If driving motor and must also belong to the same length category
crusher are mounted on the same platform (= (stamped on V-belts) to ensure the equal
they are oscillating together), the location of power distribution on all of the V-belts. The
driving motor can be independently chosen. required center distance is shown in figure
4.7.2. Make provision that centers can be
moved closer together by 50 mm (2") to
facilitate installing belts without injury. Also,
the centers should be adjustable over the
distance by 40 mm (19/16") because of
manufacturing tolerance and possible stretch
Motor and wear of belt.

Crusher

Figure 4.7.1 Drive motor installation

Figure 4.7.2 Shaft distances

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GP300 Installation

The V-belts must be properly tightened. To The driving motor and the V-belts must be
inspect the proper tightness place a straight sheltered against the falling stones and also to
edge across the top of both sheaves. Measure prevent accidents. The V-belt guards should
the span length. Using a spring scale at right be open underneath to allow the dust outflow.
angles to the center of the span length, apply The size and location of the openings must
a force to the scale great enough to deflect one fulfill the commands of the health and safety
of belts the equivalent of 0.016 times legislation.
millimeters of span length (0.016 times inches
of span length. The force should be 90…120
N (20.4…27.0 lbs.) for a properly tensioned
drive (figure 4.7.3).

Figure 4.7.3 V-belt tension

Each V-belt should be inspected individually

and the average of 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.

4-8 140551 6/02

 Installation GP300

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:

— Adjusting oil hose R = 300 mm

(SAE 100R2T-16) (12")

— Lubricating oil hose R = 420 mm

(SAE 100 RIT-20) (16")

— Return oil hose R = 600 mm

(LVU 075) (24")

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 of Figure 4.8.1 Hang of return oil hose
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 in return hose compelling the
crusher to breathe via the dust seal area and to
suck the silicious dust into the crusher.

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GP300 Installation

4.9 OVERLOAD PROTECTION 4.10 TRANSPORT

The crusher is equipped with a pressure relief When transporting the crusher, which is
valve which acts as an overload protection (fig mounted on a mobile wagon, must be firmly
4.9.1). The pressure relief valve has been secured to the transporting frame to prevent
adjusted at 35 bar (508 PSI). When the any moving on the rubber dumpers during the
pressure in the adjusting system reaches 35 bar transportation (figure 4.10.1).
(508PSI) due to overload, the valve opens and
the setting increases.

Figure 4.9.1 A Pressure relief valve acts as an

overload protection
Figure 4.10.1 Transport latches

The transport latches must be removed before

starting the crusher.

An individual or Lokotrack-mounted crusher

will not be transported on the dampers. An
individual crusher must be properly secured to
the transport device.

4.11 SPECIAL TOOLS

The delivery of the crusher includes a tool box

containing tools and accessories necessary to
maintain the crusher.

4-10 140551 6/02

 Installation GP300

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.
part to be welded and as close to the welding
point as possible (figure 4.12.1). Corrosion can

— cause unnecessary breakdowns

— increase maintaining costs

— shorten useful life of equipment

— cause dangerous situations.

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.)
Figure 4.12.1 Welding arrangement

Before any long term storage the equipment

should be protected against corrosion. The
Welding current must never pass storage location as well should be considered.
th r ou gh a n y c o n n e c t i o n o r
bearing! After a long term storage, the equipment
should be inspected for corrosion.

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GP300 Installation

4.14 SERVICE PLATFORM 4.17 STORAGE

To make operation and maintenance as easy PUTTING THE CRUSHER IN STORAGE

and safe as possible the crusher should be
equipped with the service platform. If the This instruction applies also to long term
service platform has not been ordered and shut-down.
supplied with the crusher, it should be built by
the operator. Clean the crusher.

The service platform of the crushing Check the corrosion prevention and repair it if
equipment must be constructed according to necessary. Suitable anti-corrosive agent is e.g.
the ISO 2867 or corresponding standard. The Tectyl 506.
suitable level for the platform is the upper end
of the crusher. The platform must be at least Store the crusher on a firm support in upright
600 mm (2ft) wide, firm and safe to use. The position so that it does not touch the ground.
access (stairways or ladders) to the platform
must be firm enough. The platform, stairways MOVING
and ladders must be provided with handrail to
prevent personnel from falling. The crusher must be moved in accordance with
the following instructions at least every six
All the national regulations on the service months. If any disturbances or problems are
platforms of the crushing equipment must be found during the moving find out the reason
observed. and clear the problem.

Turn the countershaft nine rounds. During the

rotating control that the bearings turn. The
4.15 SETTING CONTROL crusher must in upright position during the
turning.
Setting control system
Control also the condition of the crusher. In
The crusher is equipped with a setting control case some disturbances occur or may occur,
system that keeps the setting at the desired take the necessary measures to prevent any
value. It returns the setting back to correct damage on the crusher.
value after an overload situation and decreases
the setting a certain amount if the overload is If the storage period is extended carry out the
continuous. See separate Instruction Manual. restorage as instructed above. Pay special
attention to corrosion protection and other
protective equipment.

4.16 PRESSURIZED DUST SEALING TAKING THE CRUSHER OUT OF THE

STORAGE
The crusher is equipped with pressurized dust
sealing system. It should be noticed that the Clean the crusher.
blower unit must be installed as close to the
crusher as possible but not further than 1 meter Check the condition of the painting. If it is
(3 ft) from the crusher. poor, re-paint.

Mounting height is correct when the pressure Check the corrosion prevention and repair it if
port of the blower is higher than frame necessary.
connection flange of the lower frame.

4-12 140551 6/02

 Installation GP300

Pay special attention to the protection that

have been removed or damaged during
operation or transport.

Remove the anti-corrosive agent from the con-

tact surfaces before assembling.

6/02 140551 4-13

 Crushing GP300

 &586+,1*
5.1 BEFORE STARTING 4
Remove any latches, brackets, devices, etc.
used for transport and check the condition of
the crusher. 3
Ensure that the crusher is operated only in a
safe manner and only in good mechanical
condition. 1
Operation of the crusher must only be allowed
when all necessary protective and safety devi-
ces, e.g. guards, emergency stop devices, si- 2
lencers, aspirators etc. are in place and in
operating condition. Figure 5.2.1 Starting order

Before starting the crusher, ensure that there

are no persons in the area whose safety may
be endangered ! Walk around the crusher and 5.3 STOPPING
ensure that there is nobody on, by or below the
crusher. Warn everybody in the vicinity befo- Stop the feeding conveyor (1).
re starting.
Stop the crusher (2).
Ensure that the crusher cavity is empty.
Stop the discharge conveyor (3).

Stop the lubricating equipment as necessary

5.2 STARTING (4).

Start the lubricating device (1) of the crusher 1

and check the function of safety devices for oil
pressure, oil temperature and oil flow.

Bleed air from the lubricating device before

starting the crusher for the first time. 2
Start the discharge conveyor (2).
4
Start the crusher (3), when the oil circulation
is functioning properly. Make sure that the
crusher is operating properly and that the
countershaft is rotating in right direction. 3
Check the crusher setting, see chapter 5.6. Figure 5.3.1 Stopping order
Start the feeding conveyor (4).

6/02 140551 5-1

GP300 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 ac-
complished during the first 100 hours of ope- Tighten the cylinder head bolts (figure 5.4.2),
ration. See detailed instructions for the each 12 pcs M42, see chapter 9.11.2.
individual maintenance operation in the chap-
ter 7 "Periodical maintenance".

After 10 hours of operation

LINERS

Loosen and tighten the concave bolts (figure

5.4.1), 6 pcs M30, see chapter 9.11.1.

Figure 5.4.2 Tighten the cylinder head bolts

FRAME CONNECTION

Tighten the frame bolts between lower and

upper frame (figure 5.4.3), 20 pcs, M48 tighte-
ning torque, see chapter 9.11.2.

Figure 5.4.1 Tighten the concave bolts

HOSES AND PIPES

Figure 5.4.3 Tighten the frame bolts between
Tighten all hose and pipe connections. Repair lower and upper frames
all leakages immediately.

5-2 140551 6/02

 Crushing GP300

V-BELTS Ensure that the top bearing does not leak grea-
se.
Check the tension of V-belts and tighten as
necessary. Check oil level in the reservoir.

DURING RUNNING-IN PERIOD NOTE Check that the setting keeps constant.
THE FOLLOWING:

Operate new or renovated crusher for 4 hours

without load before feeding material in.

Do not load the crusher more than 70 % out of

the maximum motor power or hydraulic pres-
sure during first 40 operating hours.

Keep the crusher setting larger than shortest

allowed setting during first 100 operating
hours.

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.

Observe pressure and temperature of the lubri-

cating oil.

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 of the pres-

sure filter in the lubricating device, see In-
struction Instruction Manual for GP Lubrica-
tion system.

Stop feeding sometimes and listen to the crus-

her for any abnormal noise. Knocking sound
may come from loose liner.

6/02 140551 5-3

GP300 Crushing

5.5 OPERATION 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 setting device
until the pressure gauge shows no more pres-
Do not climb on the crusher, when it is in sure. Now there should be no more stored
operation and do not touch any moving parts. energy in the mechanism except the weight of
the stones.
Do not try to clear the blocked crushing cavity,
when the crusher is running. Be always very After releasing the pressure the tramp metal
careful when clearing the cavity. can be safely removed.

When crushing there must be all the time at If the main shaft must be lowered to remove
least 5 mm (3/16")oil under the main shaft the tramp metal, use the following methods:
(adjusting piston).
— Lower the main shaft by using the switch
Verify at least once a shift, that there are no in the setting device. NOTE! Lower the
faults or problems with the crusher! Report all shaft only few seconds so that the space
changes in the crusher operation to the person between the main shaft and the piston
in charge immediately! will not increase too much. When the
main shaft falls down the pressure plate
Stop the crusher without delay and take neces- can centralized itself. If the main shaft
sary precautions if any problems appear! Re- does not go down it means that only
pair any faults prior to starting up! adjusting piston goes down. In this case
move the adjusting piston up again until
pressure increases a little. Open the
manual valve which is located in the
SHOULD THE CRUSHER STALL UN- setting device until the pressure gauge
DER LOAD PROCEED AS FOLLOWS: shows no more pressure and try the next
method.
A stalled crusher MUST be treated as possibly
being jammed and therefore a potential ha- — Fill the cavity with rocks or use an
zard. approved cover to make it safe. Place a
hydraulic jack between the upper frame
Clear the plant area of all personnel. Notify the support and shaft nut. Push the main shaft
manager or his deputy of a stalled crusher down. Be careful, the shaft may fall
situation. Switch off the crusher to make sure rapidly.
it will not start.
— If none of the procedures above helps,
NOTE! Any inspection of the crushing cavity remove the upper frame to release the
must be carried out from inspection doors of pressure.
the hopper and crusher, not from above. A
tramp metal could be ejected from the crus- When the main shaft is in lowest position the
hing cavity and cause serious damage. tramp metal should fall out of the cavity and
it can be removed. After that ensure that there
Find out why the crusher stalled. If, after is no more tramp metal in the cavity. Then
careful examination, there appears to be no restart the crusher.
electrical or mechanical reason why the crus-
her has stalled, it would indicate that the crus-
her is jammed by the ingress of foreign matter

5-4 140551 6/02

 Crushing GP300

5.6 SETTING When the crusher is equipped with auto-

matic control system, the crusher must not
Setting is the minimum distance between the be used without it. When adjusting the set-
concave and mantle during the work cycle. It ting (main shaft position), the control sy-
must be measured at the lowest point of the stem must be connected and in use. Only
mantle. The setting determines the maximum during maintenance the setting may be ad-
size of the discharging material, crusher capa- justed without the control system, using the
city and load. switch located in the setting device.

The easiest and most accurate way to measure

the setting is to lower a piece of lead with a
wire through the crushing cavity when the 5.7 STROKE
crusher is idling, lift it up again and check the
thickness of the compressed lead (figure The stroke length has effect on crusher capa-
5.6.1). A piece of lead is delivered with the city (the longer stroke, the higher capacity)
crusher in the accessory box. and quality of the product.

There are 3 different strokes available, see

chapter 3.5 and changing the stroke, see chap-
ter 9.5.

Figure 5.6.1 Measuring the crusher setting

Because the liners might wear unevenly, mea-

sure the setting in three or four points around
the cavity and use the average as a setting. Too
small setting increases the load of the crusher
remarkably. Never use setting smaller than
given in the chapter 3.5.

6/02 140551 5-5

 Lubrication GP300

 /8%5,&$7,21
For the main lubrication see Instruction Ma- 6.2 TOP BEARING
nual for GP Lubrication System.
The top bearing grease capacity approx. 8 kg
(17.6 lbs). The filling has to be accomplished
6.1 COUNTERSHAFT at the liner change, when the crusher is dis-
mantled. The housing of the bearing should be
The countershaft housing oil amount is appro- filled with grease, when the main shaft is fully
ximately 2 liters (0.5 U.S. gallons) with the lowered (figure 6.2.1). Suitable grease quality
standard housing and 2.5 liters (0.7 U.S. gal- is a semisolid EP (pressure-proof) grease.
lons) with the housing for mobile solutions.
Unscrew the breather (A) on the top of the Suitable commercial qualities are e.g.:
housing and pour oil into the housing (figure
6.1.1). Remove the plug (B) on the side of the BP Energrease LS-EPO
housing to check the oil level. To drain oil ESSO Fliesfett S 420 (synthetic
from the housing, remove the plug (C) provi- grease)
ded on the bottom of the casting. ESSO Getriebefliess fett 330
MOBIL Mobilux EP 004 (very cold
Use the same type of oil in the countershaft areas only)
housing as in the lubrication and adjustment MOBIL Mobilith SCH 007
system, see separate instruction. PETRO CANADA Semi-Fluid Grease EP
SHELL Special getriebefett H
NESTE Centergrease 00 EP
CALTEX Multifak EP 0

grease level

Figure 6.1.1. Countershaft oil drain and filling

Figure 6.2.1. Fill top bearing housing with

grease

6/02 140551 6-1

 Periodical maintenance GP300

 3(5,2',&$/0$,17(1$1&(
7.1 EVERY 8 RUNNING HOURS/ CRUSHER SETTING
EVERY WORKING SHIFT
Check, if the crusher setting keeps constant
HOSES during crushing. If the setting increases during
crushing and returns when load decreases, air
Check the tightness of hoses and connections should be bled from the system.
and repair all leakages immediately.
If the crusher setting increases continuously,
TOP BEARING SEAL the reason might be a leakage of adjusting
cylinder seal, pressure relief valve, needle val-
Check the condition of the top bearing seal. ve, direction valve or shock valve. Find the
The seal prevents the grease from flowing into leakage and repair it. A reason for the setting
the crusher. A possible leakage can be noticed increase might also be overload, which opens
when grease appears on the main shaft above the pressure relief valve. To restore the setting,
the shaft nut (figure 7.1.1.). A damaged seal the adjusting pump must be started.
must be replaced as soon as possible (at least
at the next liner change). See more detailed
instructions in chapter 9.2.

Figure 7.1.1. Replace top bearing seal, if there

is grease on the main shaft

6/02 140551 7-1

GP300 Periodical maintenance

7.2 AFTER 40 HOURS OF LOWER FRAME ARMS

OPERATION/ EVERY WEEK
(1-SHIFT OPERATION) Open the inspection hatches of the lower frame
(3 pcs) and remove all macadam and other
LINERS material jammed on the arms or slip ring. The
cleaning should be accomplished more often,
Observe the wear of the liners. The reason for if there are roots, wires, bars etc. in the feed
uneven wear of the liners might be an incorrect material.
feed to the crusher. In that case the feed arran-
gement should be modified. See further in- If there is any oil on the slip ring and the center
structions in chapter 4.5. part of the frame, find out the reason and repair
it. At cold temperature the crusher may be so
The wear of the liners can be checked by the cold, that the oil gets so cool and stiff, that it
distance between the mantle tightening nut and does not have time enough to flow down by
the bottom of the top bearing housing. With the normal return channels, but floats over the
new liners the distance "A" about 160 mm slip ring on the dust seal, and between the dust
(65/16").The liners should be replaced latest seal and the slip ring on the center part of the
when the distance "A" is 11 mm (7/16") (figure frame. The overflowing during a cold start up
7.2.1). can be prevented by starting the pumps peri-
odically few times. Periods: pump running for
10 s, pause for 30 s. etc.

V-BELTS

Check the tension and wear of the V-belts.

Tighten as needed or replace the whole V-belt
set. See the tightening instruction in chapter
4.7.

WHOLE CRUSHER

Examine the overall condition of the crusher

(the tightness of bolts, leakages, wear, possible
breakages, etc.). Repair any faults immedi-
ately.

ELECTRICAL COMPONENTS

Check the condition of the electric cables and

Figure 7.2.1 Liners should be replaced latest components, to avoid breakages and abrasion.
when distance "A" is 11 mm (7/16") Repair any faults immediately. Follow the
electrical safety and inspection regulations.

7-2 140551 6/02

 Periodical maintenance GP300

7.3 EVERY 300 HOURS OF ADJUSTING CYLINDER

OPERATION/ EVERY MONTH
(2-SHIFT OPERATION)/EVERY Tighten the bolts of the adjusting cylinder head
SECOND MONTH (1-SHIFT (M42, 12 pcs), tightening torque (figure 7.3.2),
OPERATION) see chapter 9.11.2.

LUBRICATION OIL OF COUNTERSHAFT

Change the lubricating oil in the countershaft.

The oil amount, see chapter 6.1. The counters-
haft housing is filled with oil to provide lubri-
cation of the countershaft bearings. Unscrew
the breather (A) on the top of the housing and
pour oil into the housing (figure 7.3.1). Remo-
ve the plug (B) on the side of the housing to
check the oil level. To drain oil from the hou-
sing, remove the plug (C) provided on the
bottom of the casting.

Figure 7.3.2 Tightening of the adjusting

cylinder head bolts

DRIVE SHAFT BACKLASH

Check drive shaft and the eccentric shaft gear

backlash. The backlash must be approx. 0.7
mm (0.028"). See chapter 9.8.

FEED AND DISCHARGE HOPPERS AND

PROTECTIVE GUARDS

Check the condition of the hoppers, guards and

protective cap. Repair or replace the parts if
needed.

PRESSURIZED SEALING SYSTEM

Check the operation of the blower. Remove

the blower hose from the crusher. If there is no
Figure 7.3.1 Filling and draining countershaft air flow from the hose, make sure that the
box oil blower is running and change the air cleaner.

6/02 140551 7-3

GP300 Periodical maintenance

7.4 EVERY 2000 HOURS OF 7.5 SEASONAL MAINTENANCE

OPERATION/EVERY YEAR (SUMMER/WINTER)
(1-SHIFT OPERATION)/EVERY
HALF YEAR (2-SHIFT OPERATION) Change oil. See Instruction Manual for GP
Lubrication system.
THRUST BEARING

Check the condition of the thrust bearings of

the main shaft. If the oil grooves in the bronze 7.6 EVERY 20 000 HOURS OF
bearings are lower than 2 mm (5/64"), the OPERATION/EVERY 10 YEARS
bearings should be replaced. The inspection (1-SHIFT OPERATION)/EVERY
has to be made during the liner replacement. 5 YEARS (2-SHIFT OPERATION)
See further instructions in chapter 9.4.
WHOLE CRUSHER
PRESSURIZED SEALING SYSTEM
Recondition the whole crusher.
Change the air cleaner. Also check the opera-
tion of the blower.

7-4 140551 6/02

 Periodical maintenance GP300

7.7 MAINTENANCE INTERVALS

More detailed maintenance instructions are shown in previous pages.

8h 40 h 300 h 2000 h Summer/ 20000h

Winter
ELECTRICAL COMPONENTS

Check condition of cables and components X

ADJUSTING CYLINDER

Retighten cylinder head bolts X

THRUST BEARING

Check condition of thrust bearing X

COUNTERSHAFT

Change countershaft box oil X X

Check backlash X
TOP 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 X
connections
Check tension and wear of v-belts X
Observe wear of liners X
Check condition of chutes, guards and X
protective cap
Remove material from lower frame supporting X
arms
Examine overall crusher condition and X
tightening of bolts.
Recondition crusher X

6/02 140551 7-5

 Replacement of liners GP300

 5(3/$&(0(172)/,1(56
8.1 GENERAL There are six cavity shapes the crusher:

Do not wear the liners through. It may damage CRUSHER FEED OPENING
the surfaces in the crusher frame and head.
GP300 EC 260 mm
These surfaces can only be repaired by wel-
(10")
ding and machining.
GP300 C 180 mm
(7")
The wear of the liners can be checked by the
GP300 M 130 mm
distance between the mantle tightening nut and
(5")
the bottom of the top bearing housing. With
GP300 MF 100 mm
new liners the distance "A" about 160 mm (4")
(65/16"). The liners should be replaced latest 60 mm
when the distance "A" is 11 mm (7/16")or less GP300 F
(21/2")
(figure 8.1.1). 40 mm
GP300 EF
(11/2")
Change the liners earlier if they wear out due
to uneven feed.

The part numbers of wear and spare parts

needed for liner change are shown in the spare
parts manual.

Before installing the liner, remove the anti-rust

compound properly from the machined surfa-
ces. Use suitable hand tool (scraper or grinding
machine with sandpaper-type tool) to remove
excessive paine or dirt stuck in the paint. Re-
move possible transport damages, rust, etc.,
with a grinding tool.
A

Figure 8.1.1 Replace liners if distance "A" is Figure 8.1.2 There are six cavity shapes for the
11 mm ( (7/16") or less. crusher: EC, C, M, MF, F and EF.

6/02 140551 8-1

GP300 Replacement of liners

8.2 DISMANTLING THE CRUSHER Remove the bolts between the upper and lower
frames, 20 bolts M48 (figure 8.2.2).
Remove the gravel and stones from above the
slip ring, so the main shaft can freely move
down.

Lower the main shaft by opening either the

magnetic valve or the manual valve located in
the setting equipment. When the main shaft is
in its lowest position, close the valve.

Remove the bolts from the feeding chute and

lift the chute (530 kg(1170 lbs)) away. The
standard chute has 8 bolts, M16.

Remove the bolts from the top bearing housing

cover, 4 bolts M20 and lift the cover (123 kg
(271 lbs)) away.

Remove grease from the upper part of the top

bearing housing (figure 8.2.1). Figure 8.2.2 Remove the bolts between the
upper and lower frames
Separate the upper and lower frame by using
the four jacking bolts (M48) (figure 8.2.3).
The separation can be helped by mounting
grease lifting ropes on the upper frame and tensioning
them with the crane. In this case leave three
equally distributed bolts loose in the frame
connection. Screw the nuts on the bolts so that
the connection can open about 10 - 20 mm
(3/8" - 3/4"). This ensures, that the upper frame
cannot jump away.

Figure 8.2.1 Remove grease from the upper part

of the top bearing housing

Figure 8.2.3 Separate rame parts by using

jacking bolts

8-2 140551 6/02

 Replacement of liners GP300

Lift the upper frame away with concave (figure Lift the upper frame away and put it on the
8.2.4). The lifting ropes can be mounted under stand.
the supporting arms of the frame. Lower the
upper frame on a stand for liner removal. The Clean and inspect the liner seating surfaces in
total weight of parts is roughly (2730 - 3040 the frame as well as the conical mounting
kg (4560 - 6700 lbs)). 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 and put the others in the

holes.

Mount the concave with 6 bolts and nuts

(M30), see figure 8.3.1. Tighten the nuts one
by one evenly. The tightening torque, see
chapter 9.11.1.
Figure 8.2.4 Lift the upper frame away There must be no clearance between the liner
and frame (figure 8.3.2). Hammer the liner to
seat it properly. If the liner can move against
8.3 REPLACING THE CONCAVE the frame, their life shortens.

Remove the nuts of the mounting bolts of the

concave, 6 nuts M30 (figure 8.3.1).

Figure 8.3.2 There must be no clearance

between the liner and frame

Check and replace the top bearing seal as

necessary. See chapter 9.2.
Figure 8.3.1 The concave mounting bolts Check the condition of protection plates of the
upper frame. Repair or replace as necessary.
Remove the concave from the frame e.g. by
hammering wedges between the bracket and
frame. Mind the falling liner.

6/02 140551 8-3

GP300 Replacement of liners

8.4 REPLACING THE MANTLE Torch cut or grind away the torch ring between
the nut and mantle carefully to remove the
The mantle can be replaced after removing the mantle (figure 8.4.2).
upper frame, without removing the main shaft.
To inspect the thrust bearings, the main shaft
should be lifted out of the crusher sometimes.
The thrust bearings should be inspected at least
once a year. See the chapter 9.4.

If you are going to remove the main shaft,

screw the ringbolt M48, which belongs to the
accessories of the crusher, in the hole on the
top of the main shaft and lift the shaft (3200 -
3300 kg(7055 - 7275 lbs)) away carefully.

Put the shaft on the stand supported under the

head - NOT THE DUST 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 Figure 8.4.2 Torch ring and fastening nut
use a piece of rubber as a protection in between
(figure 8.4.1).
Turn the tightening nut clockwise by hamme-
ring it with a sledge hammer, until it gets loose.
If needed, weld a hit plate in 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 by welding as
necessary. If the mantle does not get loose, use
a sledge hammer. Move the mantle out of the
way.

Clean and inspect the mantle seating surfaces

in the head and repair as necessary.

Check the condition of the dust seal and repla-

Figure 8.4.1 Lower the main shaft on ground ce it as necessary. The clearance between the
dust seal and slip ring must not exceed 1.5 mm
(1/16"). See the instructions in chapter 9.3.

Check the condition of the thrust bearing, if

the main shaft has been removed. If the bronze
plates of the bearing are worn out so, that the
depth of the oil grooves is less than 2 mm
(5/64"), the bronze plates must be replaced.
The inspection of thrust bearing must be made
at least once a year. See chapter 9.4.

8-4 140551 6/02

 Replacement of liners GP300

Check the condition of the protection plates of

the lower frame. Repair or replace as necessa-
ry.

Clean the seating surfaces of a new mantle.

Lift the mantle on the head. Secure, that the

lower edge of the mantle is tightly against the
head. No clearance is allowed between the
mantle and head (figure 8.4.3).

Figure 8.4.4 Weld nut, torch ring and mantle

together

If the main shaft has been removed:

— Check, that the intermediate plate of the

thrust bearing has not moved from it’s
location, when lifting the main shaft.

— Before lowering the main shaft, slide the

Figure 8.4.3 No clearance is allowed between intermediate plate (steel) on the bearing
the liner and head plate (bronze) to the eccentric side, to
allow the thrust bearing to settle as well as
Place the new torch ring and nut on the mantle. possible.
The old nut can be used, if it is still in good
condition. Grind smooth the nut surface which — Lift the main shaft carefully into the
is against the torch ring. crusher. Note, that the hole of the eccentric
bushing is inclined, Be careful not to
Lubricate the nut thread and screw the nut damage the bushing surfaces. Also, be
down counterclockwise. Tighten it by hamme- careful not to damage the dust seal ring,
ring. To help the seating, hammer the mantle when it slides around the slip ring (figure
to ensure the tight seating. Continue tighte- 8.4.5).
ning, until the mantle is no more clanging
when hammering.

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).

Figure 8.4.5 Take care of dust seal when

assembling main shaft

6/02 140551 8-5

GP300 Replacement of liners

8.5 ASSEMBLING THE CRUSHER Fill the top bearing housing with grease (figure
8.5.3). See the lubricating instructions in chap-
Lift the upper frame (2730 - 3040 kg(4560 - ter 6.2.
6700 lbs)) on place. Be careful not to damage
the top bearing seal (figure 8.5.1).

grease level

Figure 8.5.3 Fill the top bearing housing with

grease
Figure 8.5.1 Lift the intermediate and upper
frame together on the crusher Check the condition of the O-ring and cover
and repair or replace as necessary. Install the
When lowering the upper frame on the lower cover and with bolts (4 pcs) M20, tightening
frame, the gap of 2...4 mm (5/64" - 5/32")should torque, see chapter 9.11.2.
remain between the frame flanges. This gap
must then be closed by tightening the bolts. No Check the condition of the feed chute and
clearance is allowed between the frames. repair as necessary. Install the chute with bolts
(8 pcs) M16, tightening torque, see chapter
Place the mounting bolts and nuts (20 pcs), 9.11.2.
M48, tightening torque, see chapter 9.11.2
(figure 8.5.2) and tighten them evenly. Test operate the crusher for some hours wit-
hout load to check, that it is running properly.

Figure 8.5.2 Frame mounting bolts and nuts

8-6 140551 6/02

 Replacement of liners GP300

8.6 AFTER TIGHTENING

After 10 operating hours, loosen and tighten

the concave bolts (6 pcs) M30, tightening
torque, see chapter 9.11.1.

After 25 operating hours, tighten the moun-

ting bolts between the lower and upper frame
(20 pcs) M48, tightening torque, see chapter
9.11.2.

Figure 8.6.1 Tightening after liner replacement

6/02 140551 8-7

 Other maintenance GP300

 27+(50$,17(1$1&(
9.1 GENERAL When the equipment is switched off during
maintenance and repair, the motor controls
The crusher repair and maintenance is allowed must be locked out/off. Secure the lock keys
only for reliable and qualified craftsmen. and attach a hazard notice at the main discon-
nect switch.
In any work related to the operation, modifi-
cation, conversion or adjustment of the equip- All service/repair, except those told in this
ment and its safety devices including inspec- manual, are allowed only for the servicemen
tion, maintenance and repair, observe all star- qualified by Metso Minerals, to keep the war-
ting, stopping and maintenance procedures as ranty valid.
outlined in the instruction manual.

Ensure as extensively as possible that the im-

mediate area is safe and secure.

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GP300 Other maintenance

9.2. REPLACING THE TOP BEARING Place a new seal with the groove upwards. If
SEAL the weather is cold, first warm up the seal to
the room temperature to make the mounting
The condition of the top bearing seal must be easier and to avoid the breakage of the seal.
inspected daily. If the seal has been damaged, Bend the seal to ease mounting (figure 9.2.2).
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.

Figure 9.2.2 Bend seal to ease mounting

Replace the liners (if necessary) and assemble

the crusher according to the chapter 8.5.
Figure 9.2.1 Replace the top bearing seal if
grease appears on main shaft

Dismantle the crusher as told in the chapter 8.2

and lift the upper frame on the stand.

Remove the used seal from the upper frame.

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 Other maintenance GP300

9.3 REPLACING THE DUST SEAL

The condition of the dust seal (A, figure 9.3.1)

must be inspected every time when replacing
the liners. Replace the seal, when it is dama-
ged, or when the clearance between the seal
and the slip ring is more than 1.5 mm
(1/16")(figure 9.3.1), or when the upper and/or
the lower surface of the seal has been worn.

Figure 9.3.2 Lift the main on the ground

Remove the mounting bolts of the slide circle
(B, figure 9.3.1) (8 pcs, M20).

Remove the slide circle by screwing 4 pcs of

the mounting bolts (M20) in the threatened
holes and forcing it away.

Protect the bushing faces of the main shaft e.g.

with a piece of board to avoid the slide circle
to damage the bearing surface when removing.
Figure 9.3.1 Replace dust seal if gap between
seal and slip ring is more than 1.5 mm (1/16"). Remove the slide circle (64 kg (141 lbs)) and
Remove the main shaft. Screw the ringbolt the old dust seal (9 kg(20 lbs)).
M48, which belongs to the accessory box, in
the hole on top of the main shaft and carefully Clean the new seal and the housing and place
lift the main shaft (3200 - 3300 kg ( 7055 - the seal. The seal needs no lubrication.
7275 lbs)) away from the crusher. If you lift
too fast, the intermediate plate of the thrust Lift the slide circle on the seal. Install the slide
bearing may follow the upper bearing and fall circle with bolts (M20) (8 pcs). Do not forget
back down thus damaging the eccentric bus- the washers. Make sure that the seal can freely
hing. move in the housing (figure 9.3.3). Shims may
be used between the slide circle and head if
Put the shaft on the stand supported under the necessary.
head - NOT THE DUST 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 9.3.2).

Figure 9.3.3 Inspect seal movement in housing

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GP300 Other maintenance

9.4 THRUST BEARING Slide the intermediate plate (B) on the lower
bearing (C) to the eccentric side, to allow the
The condition of the thrust bearing must be thrust bearing to settle as well as possible.
inspected every year. The most convenient
time to check them is when replacing the li- After installing the upper bearing (A) lower
ners. the main shaft in place.

The bronze plates of the bearing (one mounted

below the main shaft and the other on the
adjusting piston) must be replaced when the
depth of the oil grooves is 2 mm (5/64") or less
(new grooves 5 mm (13/64")). The condition of
the intermediate plate (steel) must also be
checked, and replaced as necessary. Note !
Never make the grooves deeper.

To replace the thrust bearing plates, put the

main shaft on the side taking care not to
damage the upper (A) and lower bearing (C)
surfaces of the shaft. Do not drop the thrust
bearing against the ground, but use a piece of
rubber as a protection in between.

Remove the locking washer of the mounting

bolt at the end of the main shaft and unscrew
the bolt (M16). Remove the thrust bearing A, Figure 9.4.1 Thrust bearing
(19 kg, (42 lbs)).

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 (B) and the lower bronze
bearing (C).

Screw a ringbolt (M48) in the hole in center of

the lower bearing plate and carefully remove
the bearing (C) and intermediate plates (B)
together (total weight 49 kg (108 lbs)). The
diameter of bearing plates is about 1.5 mm
(1/16") less the diameter of the eccentric bus-
hing.

Clean the lower bearing housing and place a

new bearing plate (C) and the intermediate
plate (B) separately. Lubricate the bearing sur-
faces before installing. Ensure, that the locking
pin of the bearing plate goes into the hole and
the bearing is properly seated.

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 Other maintenance GP300

9.5 CHANGING THE STROKE Unscrew the mounting bolt (M10) of the ec-
centric bushing (figure 9.5.2). The bolt is se-
General cured with locking compound, which can be
softened by heating.
There are three strokes available for the crus-
her: 25 mm, 32 mm and 40 mm (1", 11/4" and
19/16") . The stroke can be changed by turning
the eccentric bushing of the crusher. The stro-
ke is generated by the eccentricity of the ec-
centric bushing. To change the stroke, the up-
per frame and the main shaft must be removed.
The top bearing needs not to be replaced, it is
the same for all strokes.

Dismounting the crusher

Remove the upper frame according to the

chapter 8.2 and lift it on the stand.

Remove the main shaft. Screw the ringbolt

M48, which belongs to the accessory box, in Figure 9.5.2 Unscrew the mounting bolt
the hole on the top of the main shaft and
carefully lift the main shaft (3200 - 3300 kg Remove the eccentric bushing (82 kg (181
(7055 - 7275 lbs)) from the crusher. lbs)) with the special tool A (figure 9.5.3). The
key comes out with the bushing. Place the
Put the shaft on the stand supported under the bushing away.
head - NOT THE DUST SEAL - or turn it on
the side taking care not to damage the upper
and lower bearing surfaces of the shaft (figure
9.5.1). Do not drop the thrust bearing against
the ground, but use a piece of rubber as a
protection in between.

Figure 9.5.3 Remove the eccentric bushing with

the special tool (A).
Check the thrust bearings (one mounted below
the main shaft and the other on the adjusting
piston). They must be replaced when the depth
of the oil grooves is 2 mm (5/64") or less (new
grooves 5 mm, (13/64")). The condition of the
Figure 9.5.1 Put the shaft on the stand intermediate plate (steel) must also be chek-
ked, and replaced as necessary. See chapter
9.4.

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GP300 Other maintenance

Mounting Before installing the main shaft, slide the in-

termediate plate (steel) on the bearing plate
Check the clearance between the eccentric (bronze) to the eccentric side, to allow the
bushing and slip ring (Figure 9.5.4). The clea- thrust bearing to settle as well as possible.
rance must be 0.5-0.6 mm (0.020 - 0.024").
Adjust clearance by adding or removing shims Lubricate the main shaft and new eccentric
between the eccentric bushing and slip ring. bushing well with the oil used in the crusher.

Lift the main shaft (3200 - 3300 kg (7055 -

7275 lbs)) carefully into the crusher. Note, that
the hole of the eccentric bushing is inclined,
Be careful not to damage the bushing surfaces.
Also, be careful not to damage the dust seal
ring, when it slides around the slip ring (figure
9.5.5).

Figure 9.5.4 Adjust clearance by adding or

removing shims (25) between the eccentric
bushing (14) and slip ring

Check the condition of the new eccentric bus- Figure 9.5.5 Be careful not to damage the dust
hing, key and eccentric shaft. Clean as neces- seal ring, when it slides around the slip ring
sary.
Inspect the top bearing seal and replace as
Place the key in the groove of the desired necessary. See the chapter 9.2.
stroke in the eccentric bushing and lower the
bushing in its place. The stroke lengths are Install the upper frame according to the chap-
marked on the top of the eccentric bushing ter 8.5.
above every groove. The bushing must slide
in, do not hit it. After tightening
Secure the eccentric bushing with the screw After 25 operating hours, tighten the moun-
(M10). Lock the bolt with locking compound, ting bolts between the lower and upper frame
e.g. Loctite 270. Note ! The head of the screw (20 pcs) M48, tightening torque, see chapter
must be fully inside the eccentric bushing. 9.11.2.
Make sure, that the intermediate plate of the
thrust bearing has not moved from its location,
when removing the main shaft out of the crus-
her, see chapter 8.4.

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 Other maintenance GP300

9.6 REPLACING THE TOP BEARING The protective sleeve of the main shaft has to
be replaced, if damaged. See the instructions
The top bearing must be replaced, if it is da- in the chapter 9.7.
maged or worn. Check also the seal and repla-
ce it if necessary. Install the new top bearing. Heat the housing
to ease the mounting.
Replace the top bearing when the upper frame
is removed, e.g. when replacing the liners. Install the top bearing with bolts (4 pcs) M20,
tightening torque, see chapter 9.11.2.
Remove the bolts of the cover of top bearing
housing, 4 bolts M20, and lift the cover (123 Lift the upper frame on place, see chapter 8.5.
kg (271 lbs)) away.
Fill the top bearing housing with grease (figure
Remove the grease from upper part of the top 9.6.1) and grease the bearing. See the lubrica-
bearing housing (figure 9.6.1). ting instructions in chapter 6.2.

Check the condition of the cover and repair or

replace as necessary. Lift the cover on its place
and install with bolts (4 pcs) M20 tightening
grease torque, see chapter 9.11.2.

Test operate the crusher for few hours without

load to check, that the crusher is running pro-
perly.

Figure 9.6.1 Remove grease from the top

bearing

Remove the top bearing bolts, 4 bolts M20.

Remove the top bearing (45 kg (100lbs)) by

using four screws M20. (figure 9.6.2).

Figure 9.6.2 Removing the top bearing

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GP300 Other maintenance

9.7 REPLACING THE PROTECTIVE 9.8 SETTING OF BEVEL GEARING

SLEEVE OF THE MAIN SHAFT
GENERAL
The protective sleeve (figure 9.7.1) of the
main shaft must be replaced when damaged or The Zyklo-Palloid bevel gears are used for
worn. To replace the sleeve, the upper frame transmitting the operating force from the drive
must be removed. shaft to the eccentric shaft. During the manu-
facturing 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.

To ensure proper function of the gear, the

tooth contact must be correct. It is not impor-
tant whether the ends of the gears match toget-
her 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 the contact area move to
the toe of the tooth.

Figure 9.7.1 Main shaft protection sleeve

Cut the sleeve carefully with grinding machi-

ne. Be careful not to damage the shaft.

Carefully clean the shaft and the new protec-

tive sleeve.

Heat the new sleeve to a temperature of 160°C

(288°F) above the temperature of the main
shaft. When heating, the temperature of the
sleeve must not exceed 240°C (464°F).

Using the lifting holes (M8), place the sleeve

(39 kg, (86 lbs)) at once. If the mounting fails,
cut the sleeve away and try again with a new
sleeve.
Figure 9.8.1 The tooth contact

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 Other maintenance GP300

SETTING The smaller gear can be adjusted horizontally

by adding and removing shims (A) between
For setting the tooth contact and the clearance, the lower frame (B) and the countershaft hou-
the larger gear (crown wheel) can be lifted up sing (C) (figure. 9.8.3.). Also here the shim
or lowered down by adding or removing shims piles must be of equal thickness.
(A) between the bearing (B) and the lower
frame (C) (figure 9.8.2.).

Figure 9.8.3 The smaller gear can be adjusted

Figure 9.8.2 The tooth contact can be adjusted horizontally by adding and removing shims (A)
by adding or removing shims (A) between the between the lower frame and the countershaft
bearing (B) and the lower frame (C) housing

To ensure the correct position of the crown Check the tooth contact by applying thinly
wheel, it is important that all shim piles (4 pcs) contact colour on the crown wheel teeth (3 or
are of equal thickness. To adjust the crown 4 adjacent teeth). Rotate the smaller gear by
wheel, disassemble the crushes as when chan- the belt pulley to spread out the colour also to
ging the stroke, see chapter 9.5. After that the smaller gear. The tooth contact can be
remove the slip ring (218 kg (480 lbs)) to make adjusted with the help of the contact marks
it able to lift the eccentric shaft with crown according to figure 9.8.4.
wheel (610 kg (1340 lbs)).
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 mini-
mum 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 of 0.7
mm (0.028") is equivalent to a free movement
of 1.2 - 1.6 mm (0.047 - 0.063") measured on
a dia 450 mm (17 23/32") ring (figure 9.8.5).

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GP300 Other maintenance

Figure 9.8.4 With the contact as in the drawing on the left, turn the gear as in the drawing on
the right

Figure 9.8.5 Check the backlash by turning the pulley and measuring the free movement

9-10 140551 6/02

 Other maintenance GP300

9.9 PROTECTION PLATES 9.11 BOLT TORQUE VALUES

The plates protect the crusher frame against 9.11.1 CONCAVE BOLTS
the hits of rocks. The plates are made of hard,
wear resistant steel and they must be replaced Concave bolts must be tightened according to
as necessary. table below. Correct pretightening is possible
only with clean, unlubricated screw threads
There are protection plates above the sup- that are not surface treated. The table applies
porting arms of the upper frame, in the cavity to bolts with property class 5.6.
and above the supporting arms of the lower
frame.

Check the condition of the guards regularly. Bolt Torque

Worn out guards must be replaced with new Nm ft lbs
ones, which will be welded, according to the
instructions in chapter 4.12. M30 579 426

9.10 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 crus-
her for about 3 sec. Repeat this for 4 to 5 times
until no air is coming through the screw. Then
close the screw.

Figure 9.10.1 The air bleeding screw.

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GP300 Other maintenance

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

Nm ft lbs mm in
43
M10 47 35 17 /64
3
M12 81 60 19 /4
61
M16 196 145 24 /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

9-12 140551 6/02

 Trouble shooting GP300

 7528%/(6+227,1*
Equipment malfunction may occur for a num- For trouble shooting see also for Instruction
ber of reasons: incorrect operation of the Manual for GP Lubrication System.
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. See chapters 4.5
and 4.6.

THE OIL PUMP WILL NOT START

The temperature of the oil is less than +20°C

(+68°F). Warm up the oil.

No electricity on the pump motor. Check and repair the electric connections and
system.

THE SETTING OF THE CRUSHER VARIES

The setting of the crusher 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.

THE SETTING OF THE CRUSHER HAS INCREASED/ INCREASES CONSTANTLY.

Leaking adjusting piston seal, directional

control valve, check valve or manual control
valve. Trace the defective part and repair or replace
it.

The crusher has been/is overloaded and the

pressure relief valve has operated/is opera-
ting. Remove the reason for overload (uncrushable
particle, too small setting) and switch on the
adjusting pump to reset setting.

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GP300 Trouble shooting

THE CRUSHER HALTS AND THE MOTOR OF THE CRUSHER IS HOT

The electric drive motor of the crusher is overloaded and the protection system of the motor has
been activated. The lubricating pump is still running.

Empty the crusher cavity, remove the reason for overload and restart the crusher after the motor
has cooled down. It might also be possible to restart the crusher without having the cavity been
emptied by simultaneously starting the motor and opening the magnetic or manual valve to
increase the setting. Note! If the motor does not start, close the valve immediately.

The voltage level of the crushing plant has

dropped, so the electric current needed for
power has increased and caused the motor to
overheat. The voltage drop can be caused by
too long and/or thin supply cables, insuffi-
cient 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 250 kW (350 hp)).

Uncrushable material, i.e. excavator tooth

etc. has entered the cavity. Inspect the operation of the magnetic separa-
tor (if available) of feed conveyor.

The material to be crushed is accumulating in

the crushing cavity thus causing packing and
increasing power demand of the crusher. Scalp clay and the rest of the fine material
below the setting from the feed.

Examine that the discharge opening of the

crusher has not been clogged. Clear as neces-
sary

Inspect that the liners are not worn as a "bag

shape". Replace liners as necessary.

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 Trouble shooting GP300

THE CRUSHER HALTS AND AND THE CONTROL DEVICE GIVES WARNING
"OIL TEMPERATURE HIGH"

The temperature of the return oil or oil in the tank has exceeded +65°C (+149°F), thus activating
the return oil sensor or the tank oil sensor to halt the crusher. The lubricating pump is still running.
Empty the crushing cavity and remove the reason for overheating. The crusher cannot be restarted
before the oil temperature has dropped down to + 55°C (+131°F).

The crusher has been operated with too small

setting thus causing the bearings to be over-
loaded generating excess heat. Increase the crusher setting.

The material to be crushed 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 neces-
sary.

Inspect that the liners are not worn as a "bag

shape". Replace liners as necessary.

Insufficient cooling of the lubricating oil. Check the function of the cooler fan.

Clean the cooler from outside and also from

inside as necessary.

Insufficient oil flow. Check output of the lubricating oil pump.

Crusher bearing is getting damaged. Check if an unusual amount of metal exists

in the return oil sump or in the magnetic plug.
Check the condition of the bearings.

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GP300 Trouble shooting

THE CRUSHER HALTS AND THE CONTROL DEVICE GIVES WARNING "OIL
PRESSURE LOW"

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 pump is running and the

manometer is indicating pressure, the oil hose
to the crusher may be damaged. Stop the pump immediately and replace the
hose.

If the lubricating pump is running and the

manometer indicates no pressure, the pump
or pump coupling has been damaged. Repair or replace pump/ coupling.

If the pump is running, the manometer indi-

cates pressure and the hoses are undamaged,
the pressostat may be defective. Inspect the function of the pressostate and
repair/replace as necessary.

If the lubricating pump is not running and it

will not restart, the motor has overloaded and
the protection device operated halting the
motor. Trace the fault and repair it.

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 Trouble shooting GP300

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 FILTER IS CLOGGING VERY RAPIDLY.

The filter of the lubricating oil is clogged rapidly due to dust entering the lubrication system. If
an excessive amount of dust is in the system, drain the oil, wash the necessary parts of system
(reservoir, cooler etc.). Replace the filter and fill the system with clean oil.

Wear of the main shaft dust seal. Check the seal condition and replace as ne-
cessary.

Latches of lubricating equipment are open. See that the latches are always carefully clo-
sed.

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 crusher, trace the fault immediately and cure the problem.

Damaged gear. Replace the gear.

Loosened liners. Fix the liners.

Interference between the liners. (Setting is 0). Increase the setting.

"Living" frame joint. Tighten the bolts or repair the frame.

If the sound is heard only when idling, the top

bearing is worn out. Replace the top bearing and/or the main shaft
sleeve.

6/02 140551 10-5