GP11F/GP11M

Cone Crusher
Instruction manual

Metso Minerals Oy

140564
 Instruction manual GP11F/GP11M

Nordberg GP11F and GP11M

series Cone crusher

This instruction manual is valid for GP11F and GP11M-series fine and medium-fine crushers
manufactured by Metso Minerals beginning from the year of 2002 and the serial number of 2002.
The crusher is intented to be used in fine crushing applications in small and medium size crushing
plants.

Because of the continuous development of the product, the manufacturer reserves a right to alter
the technical specifications written in this manual, without any advance information.

This is the first edition published in september Manufacturer:

2002 in Tampere, Finland.
Metso Minerals (Tampere) Oy
P.O. Box 306
33101 Tampere
Finland

Tel. +358-(0)20 484 142

Fax +358-(0)20 484 143

09/02 140564
 Instruction manual GP11F/GP11M

GP11F and GP11M

Cone Crusher
Table of Contents

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

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

3. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 CRUSHER TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 GP11F AND GP11M-SERIES CONE CRUSHERS . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.9 CAVITY SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.10 MOTOR SIZE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

4. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 FOUNDATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 INSTALLATION DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 SPACE REQUIREMENTS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 LIFTING THE CRUSHER AND ITS PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.5 FEEDING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 REMOVAL OF CRUSHED MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.7 POWER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.8 HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.9 TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.10 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.11 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.12 CORROSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.13 SERVICE PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.14 SETTING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.15 PRESSURIZED DUST SEALING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.16 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.6 SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.7 STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

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GP11F/GP11M Instruction manual

6. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 COUNTERSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 TOP BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 DUST SEAL RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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). . 7-3
7.3 EVERY 300 HOURS OF OPERATION/ EVERY MONTH (2-SHIFT OPERATI
ON)/EVERY SECOND MONTH (1-SHIFT OPERATION) . . . . . . . . . . . . . . . . . . . 7-5
7.4 EVERY 2000 HOURS OF OPERATION/EVERY YEAR (1-SHIFT
OPERATION)/EVERY HALF YEAR (2-SHIFT OPERATION) . . . . . . . . . . . . . . . . 7-6
7.5 SEASONAL MAINTENANCE (SUMMER/WINTER) . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.6 EVERY 20 000 HOURS OF OPERATION/EVERY 10 YEARS (1-SHIFT
OPERATION)/EVERY 5 YEARS (2-SHIFT OPERATION) . . . . . . . . . . . . . . . . . . . 7-6
7.7 MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

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

8.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 DISMANTLING THE CRUSHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 REPLACING THE CONCAVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 REPLACING THE MANTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5 ASSEMBLING THE CRUSHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.6 AFTER TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

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

9.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 REPLACING THE TOP BEARING SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.3 REPLACING THE DUST SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.4 THRUST BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.5 CHANGING THE STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.6 REPLACING THE TOP BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.7 REPLACING THE PROTECTIVE SLEEVE OF THE MAIN SHAFT . . . . . . . . . . . 9-8
9.8 SETTING OF BEVEL GEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.9 PROTECTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.10 BOLT TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.10.1 CONCAVE BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.10.2 OTHER BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

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

140564 1/03
 Preface

1. 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

2. SAFETY
WARNING SYMBOLS not intended to replace safety codes, insurance
The following symbols for particularly requirements, federal, state and local laws,
important instructions are being used in the rules and regulations.
instruction manual:
SAFETY of the operator and maintenance
Reference personnel is of prime concern. These
paragraphs are presented as a helpful guide to
construction equipment personnel and shows
some of the daily work problems which they
may encounter.
It is the responsibility of the operator to know
what specific requirements, precautions and
Refers to economical operation of the work area hazards exist and to discuss them
equipment. with his supervisor. A common understanding
should be reached by all personnel to assure
safe performance in operating the equipment.
Attention
The operator is the key to safe job performance
and should study these safety tips to be aware
of basic safety precautions to help prevent
serious injury and damage to property.
STOP ACCIDENTS BEFORE THEY STOP
YOU!
Particular attention must be given to prevent
possible incorrect or dangerous operating In order to alert you, the user, and those
situations from occurring. entrusted as operators and maintenance
personnel, dangerous or hazardous operations
are shown in this instruction manual with
WARNING notes.
Danger

Particular attention must be given to prevent

accidents or damage to personnel and/or
property.

PERSONNEL SAFETY
This portion of the instruction manual is
intended to illustrate only basic safety The safest machine must still be operated with
procedures. Additional precautions may be care and with knowledge of its performance
necessary for the safe operation of a Crusher. capabilities. The most comprehensive safety
The information contained in this manual is program must still be followed.

12/97 2-01-B 2-1

 Safety

Remember that on any job, YOU are the key READ THE MANUAL furnished with your
to safety. Good safety practices not only equipment to learn its operating and
protect the men around you, they are your own maintenance characteristics, capacities and
best protection. Study this manual and any limitations. Learn the location and function of
manufacturer’s operator’s manuals covering ALL controls, indicators, warning devices and
your specific equipment. Read all warning and caution instructions.
caution instructions. Practice safe operation.
DO YOU HAVE KNOWLEDGE OF
INSIST THAT YOUR FELLOW WORKERS WORKING AREAS?
DO, TOO. BE ALERT TO POSSIBLE Learn - beforehand as much about your
HAZARDS BEFORE THEY CAUSE working area as possible:
TROUBLE, AND REMEMBER . . . SAFETY
IS UP TO YOU!!! Be a good housekeeper . . . keep the floor
clean, free of oil, grease, rags, cables, chains,
DO YOU KNOW YOUR EMPLOYER’S buckets, rocks and other hazards. Keep loose
SAFETY PROGRAM? parts in a tool box. Use only non-flammable
Company safety records show that the greatest solutions for cleaning.
percentage of accidents are caused by
disregard of simple safety rules. Know the weight limitations for any floors on
Know-observe!-the overall program . . . and which you will operate.
con sult y ou r su pervisor for specific Know the clearances in the work area. A little
instructions when starting a job. time spent checking side and overhead
ARE YOU DRESSED PROPERLY FOR clearances, including power lines, can save a
THE JOB? lot of trouble later.
You may need any number of special items - Be careful of dust, smoke or fog, which may
safety hat, safety shoes, safety glasses, obscure your vision.
goggles, heavy gloves, ear protective devices,
etc., - for your own protection. Find out what ARE YOU PREPARED FOR
items are required and wear them! EMERGENCIES?
Plan ahead - stay alert - operate sensibly - and
Loose clothing can catch in moving parts. you will avoid both having and causing
Keep sleeves buttoned, jackets belted and personal injury and accidental equipment
wear your special safety equipment. Keep damage. If a careless moment does cause an
warm without restricting your movement. emergency - react quickly with the tools and
Wrist watches and rings can be dangerous. skills at hand. Know the location of and how
Keep your pockets free of objects which may to use a fire extinguisher and a first aid kit.
fall out.
Know where to get prompt assistance.
DO YOU UNDERSTAND YOUR
MACHINERY? An emergency calls for fast action.
DON’T STOP YOUR SAFETY PROGRAM
WITH THESE GENERAL RULES. BE
EQUALLY CONSCIOUS THAT SPECIFIC
WORKING CONDITIONS AND YOUR
PARTICULAR EQUIPMENT - CAN
REQUIRE ADDITIONAL PRECAUTIONS.
BEFORE STARTING CHECK
Equipment not properly prepared for
operation is unsafe equipment. Run a careful
check at the beginning of your shift. If you find

2-2 2-01-B 12/97

 Safety

something that needs attention, THINK improper readings are observed.

TWICE before deciding to "let it go this time".
Even minor mechanical defects can lead to 5 TEST all controls for proper
personal injury and accidents. functioning.

1 DO NOT allow unauthorized personnel 6 LISTEN for and report any unusual
to operate the Crusher! noises.

2 MAKE SURE all guards and other 7 RE-CHECK alarms or other warning
protective devices are in place, secured and safety devices.
and not damaged. 8 DO NOT stand on the Crusher while
3 CHECK fluid systems: Are they at the the Crusher is running.
correct level and completely leak free? 9 DO NOT lean or place your hands on
4 CHECK every drain cock, valve and or against the tension spring while the
fitting to sure it is in place and secure Crusher is in operation.

5 Loss of pressure from low fluid levels 10 DO NOT take a chance with a defective
may lead to serious hydraulic failures. machine. REPORT IT TO YOUR
SUPERVISOR.
6 CRUSHER SEIZURE from lack of oil
or grease is a problem that may cause REPORT A DEFECTIVE MACHINE
accidents. Inspect your machine daily . . . check for loose,
worn or damaged parts. Report or correct any
7 NEVER tamper with safety devices. unsafe conditions immediately . . . and do not
operate the machine until they have been
8 CHECK the Crusher thoroughly for corrected.
visual defects, such as leaks, worn hoses
or loose parts. Even a minor defect can become serious . . .
report any machine defects to your supervisor.
9 INSPECT your machine according to
the operator’s manual and your STOPPING SAFELY
supervisor’s instructions. Be sure Crusher is stopped before . . . cleaning,
servicing, lubricating . . . checking belt tension
10 BEFORE STARTING walk completely . . . removing housing covers . . . working on
around your machine. Make sure there the hydraulic system . . . making repairs . . . or
is no one next to under or on the attempting to clear a plugged cavity. MAKE
machine. Warn any personnel nearby NO CHECKS, ADJUSTMENTS OR
that you are starting up. REPAIRS OF ANY KIND WHILE
REPORT ANY DEFECTS TO YOUR CRUSHER IS IN OPERATION.
SUPERVISOR TIPS FOR SAFE MAINTENANCE
START UP SAFELY Perform maintenance with care.
1 CHECK equipment for warning tags. READ AND UNDERSTAND
2 FOLLOW the recommended starting 1 Instruction manual furnished with the
procedure as outlined in Section 5 Crusher, especially Section 5,
OPERATION. OPERATION.

3 AFTER Crusher has been started, check 2 Instructions for inspection and
all gauges and instruments to be sure maintenance located in Section 5
that everything is operating properly. OPERATION and 7 PERIODICAL
MAINTENANCE.
4 SHUT DOWN immediately if any

12/97 2-01-B 2-3

 Safety

3 Warning and caution plates provided on the 8 WEAR SAFETY GLASSES AND
machine. PROTECTIVE CLOTHING when
using high pressure air.
4 Warning and caution notes in the
instruction manual. 9 WEAR GOGGLES AND
PROTECTIVE CLOTHING when
5 Lubrication guides for periodic handling molten metals; zinc, babbitt,
servicing in Section 6, LUBRICATION. lead, etc.
WARNING TAGS 10 WEAR EAR PROTECTIVE DEVICES
Before working inside a Crusher, be sure to tag when required or REDUCE exposure
and lockout the electrical controls so no one time as required.
else will start it.
ALCOHOLIC BEVERAGES AND
Attach warning tags to prevent accidents: MEDICATION
1 If Crusher is unsafe for operation. 1 DO NOT use alcoholic beverages
before coming to work or while on the
2 If controls are being serviced. job.
3 If machine is being repaired. 2 BEWARE of medicines, tranquilizers
or other drugs which can make you
LOCKOUT ELECTRICAL SERVICE sleepy or less alert.
1 Always lockout all electrical controls
before performing any type of WORK AREA
maintenance work on the Crusher. 1 PROMOTE GOOD HOUSEKEEPING,
keep the floor clean and dry, free of
2 Provide each maintenance man with debris and tools. Oily and wet floors,
his own personal padlock and ONE key. steps and hand rails are slippery. In
CLOTHING - SAFE PRACTICE winter watch out for ice and snow. Wet
1 KEEP HANDS AND CLOTHING spots, especially near electrical
AWAY FROM MOVING PARTS. Do equipment, are dangerous.
not take chances by wearing loose 2 DO NOT let material lay and build up
sleeves, floppy ties, watches and rings. on or around the Crusher.
2 WEAR EYE PROTECTION when 3 STORE dangerous fluids in a suitable
handling fuel, cleaning fluid, oil or place - away from unauthorized
brake fluid. THESE MATERIALS CAN personnel. ALLOW NO SMOKING IN
DAMAGE YOUR EYES. THE AREA!
3 WEAR A RESPIRATOR when 4 NEVER start a diesel or gasoline engine
required. within an enclosed area unless there is
4 WEAR SAFETY GLASSES when adequate ventilation. Exhaust fumes can
drilling, grinding or hammering metal. kill!

5 KEEP YOUR POCKETS FREE of EQUIPMENT

objects which can fall out and into 1 Use the proper tools; handle tools and
machinery. heavy parts sensibly.

6 WEAR HARD HAT AND SAFETY 2 Keep all tools and equipment free of
SHOES, when required. dirt, oil and grease. Do not drop or toss
them.
7 WEAR GLOVES to protect your
hands when changing cables. 3 Use hoisting equipment for heavy lifting.

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 Safety

Save your back. what type of fire. Check regularly - at

least monthly - to be sure it is in the
4 Lower parts, do not drop them. working area.
5 To prevent slipping, wipe hand levers PRESSURIZED SYSTEMS -
and knobs clean of oil or grease. HYDRAULIC OR AIR
6 Do not use sheaves with cracked rims 1 Relieve ALL pressure before opening
or spokes. or removing any hydraulic or air
pressure lines, valves, fittings, etc.
7 Check for missing, cracked or frayed
V-belts. 2 Check for worn hoses or damaged lines.

8 Check for broken, defective or missing 3 High pressure oil can be dangerous.
parts and replace them. Keep equipment USE QUALITY PARTS
clean and free of dirt and oil so you can A replacement part for any item should always
spot loose or defective parts. be of comparable SIZE, TYPE AND
9 When using cables to move a load, be QUALITY - as the part being discarded.
sure cables are of adequate size and REPORT NECESSARY REPAIRS
replace any worn, badly frayed, broken If your daily check uncovers any item that
or kinked ones. Check end connections need attention - repair, replacement or
for wear. adjustment - REPORT IT NOW!
FIRE HAZARDS The most minor defect could result in more
1 DO NOT smoke while refueling - or serious trouble - IF THE MACHINE IS
when handling fuel containers. OPERATED.
2 SHUT OFF engine when refueling - Only perform the work you’re authorized to
and use extra caution if engine is hot. do. Do not attempt repairs you do not
3 WHEN pouring fuel into the tank, understand.
ground the funnel or spout against the Only work on equipment you thoroughly
filler neck to avoid static electric spark. understand - a pressure-loaded part, if
4 DO NOT use gasoline or diesel fuel carelessly released could injure anyone in its
for cleaning parts. Good commercial, path.
non-flammable solvents are preferred. Remember you are entrusted with the
5 DO NOT smoke while using cleaning operation and maintenance of a highly
solvents. valuable piece of equipment TREAT IT AS
SUCH!
6 DO NOT let greasy, oily rags
accumulate in poorly ventilated area.
Store oily rags and other combustible
material in a safe place.
7 NEVER use an open flame to check
fuel, battery electrolyte or coolant levels
. . . or to look for hydraulic leaks
anywhere on the equipment.
Use a flashlight!
8 KNOW where fire extinguishers are
kept - and how they operate - and for

12/97 2-01-B 2-5

 Safety

REMEMBER -
SAFETY IS UP TO YOU
PLANT SAFETY
The safety procedures mentioned here do not
eliminate all safety hazards found in the area
of crushing plants. However, they do highlight
some of the procedures which have been found
through long experience to improve safety
conditions around Crushers and crushing
plants. Nordberg will welcome inquiries
regarding other suggested safety procedures
for use around their Crushers and related
equipment.
DRIVE GUARDS
Proper safety precautions start with the initial
installation of the Crusher. Crushers are driven someone working below. Do not fasten the
either by V-belts or by direct couplings to operator’s platform to the Crusher.
motors. THE BELT DRIVE OR COUPLING
SHOULD HAVE A PROTECTIVE GUARD ELECTRICAL LOCKOUT
THE ELECTRICAL POWER SOURCE FOR
AROUND IT.
THE CRUSHING EQUIPMENT SHOULD
Crusher-sheaves in particular are designed for BE LOCKED OUT WHENEVER ANYONE
maximum rim speeds. If these speeds are IS WORKING ON IT. Each maintenance man
exceeded it is possible that the sheave could who normally works on a Crusher should be
explode and cause severe injury or even death. provided with his own personal padlock with
only one key. When he works on any assembly
Since the speed of the Crusher is quite of the Crusher, he should use this padlock to
important for proper operation, most V-belt lock out the electrical controls for the Crusher.
drive guards usually have a small opening It is most important that only one key be
immediately opposite the center of the crusher provided for the lock and that key must be in
drive shaft so that a tachometer can be inserted the pocket of the person who is working on the
to occasionally check the speed of the Crusher. If more than one person works on the
eccentric shaft. This opening should be Crusher, each should have his own lock and
covered with an access door or hatch. key at separate lockout stations for the controls
OPERATOR’S PLATFORM of the Crusher. Accidental start-up of crushing
Since periodic inspection and maintenance equipment with men in the immediate area can
must be performed on each Crusher, IT IS be responsible for many accidents on what was
IMPORTANT THAT SOME TYPE OF supposedly a "clear" machine.
PLATFORM BE ERECTED AT A LEVEL CRANES
CONVENIENT FOR THE MAINTENANCE Crushers, like any other type of mechanical
MEN WHO MUST INSPECT AND WORK equipment, require normal periodic
ON THE CRUSHER. A good operator’s maintenance if the operator is to get the most
platform constructed of "solid" floor plate for his money from the use of the machine.
should have hand railings, toe plates and wire One of the most flagrant Crusher safety
mesh or expanded metal between the platform violations is the use of inadequate and unsafe
and the top of the hand railing to prevent tools lifting equipment. Although a Crusher is not a
from dropping off the platform and hitting finely tuned piece of equipment, such as an

2-6 2-01-B 12/97

 Safety

automobile engine, the internal parts of a quickly vaporize the hydraulic fluid as it
Crusher sh ou ld b e assembled and reaches the atmosphere. This vaporized fluid
disassembled with crane facilities that have the can quickly become a mass of flames, resulting
capability of gently and slowly lifting and in severe burns for personnel in the immediate
lowering the various parts that make up a area. ALL MAINTENANCE PERSONNEL
Crusher. WHEN USING A CRANE, WHO NORMALLY USE TORCH
ALWAYS OPERATE WITHIN THE CUTTING EQUIPMENT SHOULD BE
RATED CAPACITY OF THE CRANE. THE ADVISED IF THERE ARE HYDRAULIC
SAFE RATED CAPACITY INCLUDES COMPONENTS IN THE IMMEDIATE
WEIGHT OF HOOK, BLOCK AND ANY AREA IN WHICH THEY ARE WORKING.
MATERIALS HANDLING DEVICES Then adequate precautions be made to avoid
SUCH AS CABLES, SLINGS, SPREADER contact with these components. Rubber lined
BARS, ETC. SUBTRACT THE WEIGHT OF hoses are not immune to the torch cutting
ALL THESE TO FIND THE TRUE WEIGHT equipment which is used in normal plant
OF THE LOAD THAT CAN BE HANDLED maintenance procedures.
SAFELY. Chain falls should be considered
only as a last resort to assemble and CONVEYOR BELTS
disassemble a Crusher. When it comes to DO NOT USE CONVEYOR BELTS AS
safety, the best should be used. WALKWAYS. Conveyor belts leading to and
from the Crusher should be provided with
MOBILE CRANES walkways alongside the conveyor. Always
WHEN USING A MOBILE CRANE, provide hand rails along the conveyor belt
ALWAYS OPERATE WITHIN THE walkway as an added safety precaution.
RATED CAPACITY OF THE MACHINE
TO AVOID BUCKLING THE BOOM OR PORTABLE PLANTS
TIPPING. Safe ratings are based on operating If the crushing plant consists of portable
the crane on firm, level ground; outriggers equipment, that is, crushing and screening
should be properly extended and/or lowered equipment mounted on trailers, trailer footing
whenever possible. Avoid fast swings, hoists or cribbing is extremely important for safe
or sudden braking; these can cause overloads. operation. Check your footing. Your machine
Do not handle large, heavy loads in strong should be on a solid and level a footing as
winds. possible. Use heavy timber mats as needed.
Trailers must be raised so that trailer wheels
When moving your crane, check bridges do not touch the ground. Place screw jacks at
before crossing, make sure they will support each corner of the trailer or as near the corner
the weight of the machine. Check clearances as possible. All four jacks must be an equal
under bridges for overhead electrical lines or distance from each end. Adjust each jack until
any overhead obstruction. the unsupported portion of the trailer beams
stop vibrating or until vibrations are reduced
Check your hitcher, be sure he’s clear before to a minimum. NEVER leave your trailer in a
starting lift. Make certain he securely attaches low spot where rains may wash out your
the load. footing.
TORCH CUTTING EQUIPMENT PERIODICALLY RECHECK TRAILER
One of the most frequently used tools around FOOTING FOR STABILITY
the Crusher is the cutting torch. Crushers
wh ich are equipped with hydraulic When moving your trailer, check bridges
components should have these components before crossing, make sure they will support
depressurized and adequately covered with the weight of the machine. Check clearances
flame-proof material so that sparks, weld under bridges, for overhead lines or any
spatter, etc., cannot reach these areas. overhead obstruction. NEVER TRAVEL
Ruptured high pressure hydraulic lines will WITH NEAR-CAPACITY LOADS, CHECK

12/97 2-01-B 2-7

 Safety

LOCAL LAWS, ESPECIALLY ON cavity by hand.

WEIGHT LIMITATIONS. When traveling on
the highway make sure all headlights, GENERAL MAINTENANCE WORK
clearance lights and tail lights are on. Use A certain amount of work must be done in the
proper traffic warning flags and signs. immediate area of the Crusher during the
normal course of operations on a day-to-day
CRUSHING PLANT "NOISE" basis. The following are some of the do’s and
Crushing equipment by its very nature is noisy don’ts to be followed as part of normal crusher
and the auxiliary equipment found in and operating procedures.
around crushing equipment such as chutes,
transfer stations, screens, etc., can at times be 1 DO NOT perform maintenance on
noisier than the Crusher itself. EAR moving machinery. This includes such
PROTECTIVE DEVICES MAY BE items as adding lubricating oil or
REQUIRED IF NOISE LEVELS ARE greasing parts of the Crusher while it is
HIGHER THAN THOSE ALLOWED BY in operation.
LAW. If ear protective devices are 2 DO NOT put hands or feet on the
undesireable, consideration should be given to tension springs which project from the
reducing the amount of noise exposure that an rear of the Crusher while the Crusher is
operator or maintenance man may be in operation.
subjected to. In other words, shorter working
hours. 3 DO check the manufacturer’s
recommendations for periodic
Although alteration of the machinery to maintenance procedures. These
change its noise characteristics may be maintenance procedures are designed to
economically impossible, many operators not only avoid damage to the equipment
have found that the installation of a relatively but also avoid harm to the operator as
inexpensive operator’s station can improve well.
noise conditions. The operator can see the
equipment in operation and still be protected 4 DO avoid spillage around the Crusher.
from the noise through the installation of Crushers seem to attract odd size pieces
acou stical tile double windows, air of rock, gravel, etc. Plant operators
conditioning equipment, etc. These working should make it a habit to keep the area
conditions will normally result in a more immediately adjacent to the Crusher free
efficient operation and reduce potential from this type of spillage which could
injuries from noise. cause unsuspecting personnel to trip and
fall.
Many plant operators are finding that an
operator’s tower erected at an elevation above 5 NEVER look into the crushing cavity
most of the equipment provides both safety while the Crusher is in operation
features for the operator and increased without protection from possible flying
efficiency in plant operation. material.
CLEARING A CRUSHER
There are many unforseen events such as
power failures, sudden surge of materials, etc.,
which can cause a Crusher to become plugged
with material and stall. UNPLUGGING THE
CRUSHER CAN BECOME A VERY
SERIOUS POTENTIAL SOURCE OF
ACCIDENTS. In many instances, the only
way in which the Crusher can be restarted is to
literally dig the material out of the crushing

2-8 2-01-B 12/97

 General GP11F/GP11M

3. GENERAL
3.1 CRUSHER TERMINOLOGY Feed opening (FO) (open side) = The largest
distance between the top of the crushing mem-
Throughout this manual certain terms will be bers as measured when the two crushing mem-
used in describing the crusher and its opera- bers are at their farthest relationship during
tion. In order that there will be no possibility their gyrating circle. 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 to be crushed. hed.

Product size = The size of the screened mate- Liners = The members which perform the
rial after it has been crushed. crushing are commonly referred to as liners.
The liners consist of mantle (IM) and conca-
Capacity = The output of the crusher compu- ve (OM).
ted in tons per hour (mtph).
Crushing cavity (G) = The internal contour
Feed opening (FO) (closed side) = The smal- formed by the two crushing members.
lest distance between the top of the crushing
members as measured when the two crushing Discharge setting (S) = The distance between
members are at their closest relationship dur- the bottom of the inner and outer mantles as
ing their gyrating circle. measured at the point where the two crushing
members are at their closest relationship dur-
ing their gyrating circle (= closed side setting,
c.s.s.). The discharge setting regulates product
size.

Figure 3.1.1 The terms used in this instruction manual

1/03 140564 3-1

GP11F/ GP11M General

Minimum discharge setting = The smallest interchangeable. See table 3.5 to ensure inter-
permissible distance between the bottom of changeablity.
concave and mantle as measured at the point
where the two crushing members are at their In GP11 the crusher type can be changed any
closest relationship during their gyrating time by replacing the liners with different ty-
circle. pes.

Discharge opening = The distance between the There are three different strokes available: 20,
bottom of the concave and mantle as measured 25 and 30 mm. The stroke can be changed by
at the point where the two crushing members changing the eccentric bushing.
are at their farthest relationship during their
gyrating circle. This wide opening permits 3.3 OPERATING PRINCIPLE
rapid discharge of the crushed material.
The crushing occurs between the fixed conca-
Stroke (E) = The difference of the maximum ve and eccentrically gyrating mantle (Figure
and minimum distance between the bottom of 3.3.1). The countershaft of the crusher is run
concave and mantle during one revolution of by an electric motor via a V-belt drive. The
the eccentric shaft. countershaft drives the eccentric shaft via gear
transmission. The stroke is generated by the
Open circuit operation = The type of operation eccentric shaft, which gives the main shaft a
where precise uniformity of product size is not gyrating movement. The feed material enters
considered to be of prime importance and the the crusher via feed opening in the upper part
feed is run through the crusher only once. of the crusher. The crushed material leaves the
crusher via discharge opening below the crus-
Closed circuit operation = The type of opera- her.
tion 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 GP11F AND GP11M-SERIES CONE

CRUSHERS

The GP11F and GP11M-series Cone crushers

are designed for fine crushing purposes either
in small or medium size crushing plants.

There are four different crushing cavities avai-

lable for GP11F: GP11F EF, GP11F MF,
GP11F M and GP11F C.

There are three different crushing cavities

available for GP11M: GP11M C, GP11M EC
and GP11M EC LS.

Figure 3.3.1 Operating principle

NOTE! GP11F and GP11M cavities are non-

3-2 140564 1/03

 General GP11F/GP11M

3.4 MAIN COMPONENTS

Figure 3.4.1 Crusher main components

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GP11F/ GP11M General

3.5 TECHNICAL SPECIFICATIONS

GP11F C GP11F M GP11F F GP11F EF

200 mm 120 mm 80 mm 40 mm
FEED OPENING
(8") (5") (3") (11/2")
170 mm 100 mm 80 mm 32 mm
MAX. FEED SIZE
(63/4") (4") (3") (11/8")
[Link]*)
— stroke 20 mm 15 mm 14 mm 7 mm 5 mm
3 9 9 5
( /4") ( /16") ( /16") ( /16") (3/16")
— stroke 25 mm 17 mm 16 mm 9 mm 7 mm
11 5 3
(1") ( /16") ( /8") ( /8") (5/16")
— stroke 30 mm 19 mm 18 mm 11 mm 9 mm
3 3 11 7
(1 /16") ( /4") ( /16") ( /16") (3/8")
27 mm 26 mm 21 mm 21 mm
MAX. SETTING **)
(11/16") (11/32") (13/16") (13/16")
COUNTERSHAFT rpm 1040

MOTOR rpm 1470 rpm

GP11M EC-LS GP11M EC GP11M C

220 mm 220 mm 180 mm
FEED OPENING
(9") (9") (7")
210 mm 190 mm 150 mm
MAX. FEED SIZE
(81/4") (71/2") (6")
[Link]*)
— stroke 20 mm 20 mm 18 mm 15 mm
3 25 11
( /4") ( /32") ( /16") (9/16")
— stroke 25 mm 25 mm 20 mm 17 mm
25
(1") (1") ( /32") (11/16")
— stroke 30 mm 30 mm 22 mm 19 mm
3 3 7
(1 /16") (1 /16") ( /8") (3/4")
49 mm 30 mm 27 mm
MAX. SETTING **)
(115/16") (13/16") (11/16")
COUNTER SHAFT 1040
rpm (motor 1470 rpm)
10500 kg
WEIGHT
(23200 lbs)
*) Dry, medium hard granite

**) With new liners at 25 mm (1") stroke

3-4 140564 1/03

 General GP11F/GP11M

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 made of the best possible 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. Some 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.

Use only
original
Nordberg
spare and
wear parts

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GP11F/ GP11M General

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

— The stroke of the crusher

3-6 140564 1/03

 General GP11F/GP11M

GP11F C
SETTING c.s.s.
STROKE tons/ 15 mm 17 mm 19 mm 22 mm 24 mm 27 mm 29 mm
5 11 3 7 15 1
hour /8" /16" /4" /8" /16" 1 /16" 11/8"
20 mm mtph 120 130 135 145 155 165 175
3
/4" stph 135 145 150 160 170 180 190
25 mm mtph 160 170 185 195 210
1" stph 175 190 205 215 230
30 mm mtph 205 220 230
11/8" stph 225 245 255

GP11F M
SETTING c.s.s.
STROKE tons/ 14 mm 16 mm 18 mm 20 mm 23 mm 26 mm 28 mm
9 5 11 3 7
hour /16" /8" /16" /4" /8" 1" 11/8"
20 mm mtph 115 125 130 140 150 165 170
3
/4" stph 125 135 145 150 165 175 185
25 mm mtph 155 165 170 190 205
1" stph 170 180 185 205 220
30 mm mtph 195 210 225
11/8" stph 215 220 245

GP11F F
SETTING c.s.s.
STROKE tons/ 7 mm 9 mm 11 mm 15 mm 19 mm 21 mm 24 mm
5 3 7 5 3 13 15
hour /16" /8" /16" /8" /4" /16" /16"
20 mm mtph 90 95 105 120 135 145 155
3
/4" stph 100 110 115 135 150 155 170
25 mm mtph 125 130 150 170 175
1" stph 135 145 170 185 195
30 mm mtph 155 180 205
11/8" stph 170 205 225

GP11F EF
SETTING c.s.s.
STROKE tons/ 5 mm 7 mm 9 mm 14 mm 18 mm 21 mm 23 mm
3 5 3 9 11 13 7
hour /16" /16" /8" /16" /16" /16" /8"
20 mm mtph 80 85 95 115 130 140 145
3
/4" stph 85 100 105 130 135 150 155
25 mm mtph 110 120 145 160 175
1" stph 125 135 155 175 190
30 mm mtph 145 170 190
11/8" stph 160 185 210

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GP11F/ GP11M General

GP11M EC-LS and GP11M EC

SETTING c.s.s.
STROKE tons/ 20 mm 25 mm 30 mm 38 mm 46 mm 49 mm 50 mm
7 1 1 3 7
hour /8" 1" 1 /4" 1 /2" 1 /4" 1 /8" 2"
20 mm mtph 140 160 180 210 245 255 265
3
/4" stph 160 175 205 230 260 275 290
25 mm mtph 200 225 265 305 320
1" stph 220 255 290 325 345
30 mm mtph 270 315 365
11/8" stph 310 345 390

Note! The max. setting for GP11M EC with new mantles by 20 mm (3/4") stoke is 32 mm
(11/4") and by 25 mm (1") stoke 30 mm (13/16"). Don’t use the 30 mm (11/8") stroke when
new mantles.

GP11M C
SETTING c.s.s.
STROKE tons/ 15 mm 17 mm 19 mm 22 mm 24 mm 27 mm 29 mm
5 11 3 7 15 1
hour /8" /16" /4" /8" /16" 1 /16" 11/8"
20 mm mtph 120 130 135 145 155 165 175
3
/4" stph 135 145 150 160 170 180 190
25 mm mtph 160 170 185 195 210
1" stph 175 190 205 215 230
30 mm mtph 205 220 230
11/8" stph 225 245 255

3.8 SETTING RANGE Especially in coarse crushing the fluctuation in

the process can be a factor, which causes that
Minimum setting, which can be used, depends minimum specified setting can not be used.
among others on factors like: stroke used, re- That is why it is recommended that minimum
duction ratio, choke level, feeding rate fluctua- allowed setting is used continuously only, if
tion into the crusher, rock type (gravel or rock), the running conditions are known well and
feed gradation, cavity wear, etc. they are stable enough.

Allowable setting range varies depending on

the stroke used. Limiting factor for minimum
setting is either power draw or adjustment
pressure, which both increase, when setting is
being squised tighter. Power draw increases
when stroke increases, and thus motor size
selection is much dependable on stroke used.

3-8 140564 1/03

 General GP11F/GP11M

3.9 CAVITY SELECTION

The type of crushing cavity must be determi-

ned according to the feed material and the
requested 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. Rep-
lacing the liners with proper ones normally
gives much better result.

The crusher might be damaged because of an

uneven wear of the liners caused by the feed
improper for the cavity formation in question.

When selecting the proper cavity type, please

contact Metso Minerals representative. When
inquiring the right cavity type following infor- Figure 3.9.1 There are four different crushing
mation is needed: cavities for GP11F.

1. Feed size (distribution)

2. Feed type (type of the stone)

3. End product distribution

4. Capacity required

Figure 3.9.2 There are three different crushing

cavities for GP11M.

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GP11F/ GP11M General

3.10 MOTOR SIZE SELECTION Power needed in the application depends on

setting to be used. If crusher is used in constant
Maximum motor size is determined by chosen setting (doing constant product) motor size
stroke. Table below will give max. allowable should be selected accordingly. This selection
motor size for GP11F and GP11M Cone. can be done when application is known and in
most case results is that motor can be smaller
Note: If you choose a nominal power for the size than mentioned in item 1. This method
motor bigger than the recommended Max- should always be used when final motor
imum size, then the crusher must have the selection is being done.
automatic setting control system.

Stroke Max. motor size

IEC/NEMA standards
(mm) (inch) (kW) (hp)
GP11F 3
(C, M, F, EF) 20 /4 132 200
GP11M 25 1 160 250
(EC-LS, EC, C) 1
30 1 /8 160 250

3-10 140564 1/03

 General GP11F/GP11M

Example of motor size selection for GP11F C: In this case max. allowable motor size is 160
kW (250 hp), but due to setting used estimated
Crusher is being used in an application with power draw is about 117 kW (159 hp)
setting 21 mm (13/16"), and stroke 25 mm (1")
gives enough capacity. Reduction ratio is nor- 132 kW (200 hp) motor is the closest standard
mal (F80/P80 = max. 3...4), and rock Wi = max. and to be selected.
14...16, LosA = max. 25...30.

180

160

Power Limit
Stroke 30 mm
140 Stroke 25 mm
Stroke 20 mm

120
Power (kW)

100

80

60

40
14 16 18 20 22 24 26 28 30
Setting (mm)

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GP11F/ GP11M General

Power curves for the other GP11F cones:

GP11F M

180

160

Power Limit
Stroke 30 mm
140
Stroke 25 mm
Stroke 20 mm

120
Power (kW)

100

80

60

40
12 14 16 18 20 22 24 26 28 30
Setting (mm)

GP11F F

180

160

Power Limit
Stroke 30 mm
140
Stroke 25 mm
Stroke 20 mm

120
Power (kW)

100

80

60

40

20
6 8 10 12 14 16 18 20 22 24 26
Setting (mm)

3-12 140564 1/03

 General GP11F/GP11M

GP11F EF

180

160

Power Limit
Stroke 30 mm
140 Stroke 25 mm
Stroke 20 mm

120
Power (kW)

100

80

60

40
4 6 8 10 12 14 16 18 20 22 24
Setting (mm)

Power curves for the GP11M cones:

GP11M EC-LS and GP11M EC

180
Power Limit
170 Stroke 30 mm
Stroke 25 mm
160
Stroke 20 mm

150

140

130

120
Power (kW)

110

100

90

80

70

60

50

40
18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52
Setting (mm)

Note!The max. setting for GP11M EC with (13/16"). Do not use the 30 mm (11/8") stroke
new mantles by 20 mm (3/4") stoke is 32 mm when new mantles.
(11/4") and by 25 mm (1") stoke 30 mm

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GP11F/ GP11M General

GP11M C

180

160

Power Limit
Stroke 30 mm
140
Stroke 25 mm
Stroke 20 mm

120
Power (kW)

100

80

60

40
14 16 18 20 22 24 26 28 30
Setting (mm)

3-14 140564 1/03

 Installation GP11F/GP11M

4. INSTALLATION
4.1 FOUNDATION four rubber dampers, caused by the weight of
the crusher, must be checked to be equal. To
The crusher installation must be made on a accomplish this, all four support points must
steel or concrete foundation strong enough by be level. To level the supporting points, shims
using rubber dampers between the crusher and may be used if necessary.
foundation. When running, the crusher is os-
cillating about ± 2 mm (± 5/64") on dampers. If the crusher has been delivered as mounted
When starting or stopping, the oscillation is on a steel frame (element or portable), the
about ± 10 mm (± 3/8"). Because of the oscil- frame must be levelled so that all the rubber
lation, the clearance around the crusher must dampers of the crusher are level. The steel
be at least 20 mm ( 3/4"). The static and dyna- frame (element or portable) must be well
mic forces per supporting point, see figures supported on the ground and the vertical
4.1.1 and 4.1.2. When mounting the crusher alignment of the crusher must be checked.
on its foundation the depression of all

Figure 4.1.1 Crusher GP11F foundation (example)

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GP11F/GP11M Installation

Figure 4.1.2 Crusher GP11M foundation (example)

4-2 140564 1/03

 Installation GP11F/GP11M

4.2 INSTALLATION DIMENSIONS

Figure 4.2.1 Crusher GP11F installation dimensions

1/03 140564 4-3

GP11F/GP11M Installation

Figure 4.2.2 Crusher GP11M installation dimensions

4-4 140564 1/03

 Installation GP11F/GP11M

4.3 SPACE REQUIREMENTS FOR

MAINTENANCE

When designing crusher installation remem-

ber that there must be enough space around the
crusher for lifting and maintenance (fig. 4.3.1
and 4.3.2).

Figure 4.3.1 GP11F Space requirements for maintenance

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GP11F/GP11M Installation

Figure 4.3.2 GP11M Space requirements for maintenance

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 GP11F is 10430-10700
kg (23000-23600 lbs) and the total weight of
the crusher GP11M is 10500 kg (23200 lbs).
The weights of separate parts are given in
figures 4.3.1 and 4.3.2..

Figure 4.4. Lifting the crusher

4-6 140564 1/03

 Installation GP11F/GP11M

4.5 FEEDING THE CRUSHER — The excess filling of the feed chute should
be prevented by level indicators etc.
The material to be crushed can be fed straight
into the crusher by using a belt conveyor, — When at a standstill, the feed into the
screen or different types of feeders or by using crusher must be prevented. This is possible
guiding troughs. The feed arrangement should to accomplish e.g. by electrically
be easily portable to make the maintenance of preventing the start up of the feeding
the crusher as easy and quick as possible. device to the crusher, before the driving
motor of the crusher is running.
The maximum crushing capacity and the most
economical wear of the crushing liners can be
achieved only with a right amount and even
distribution of feed material around the
crushing cavity. The feed should be directed
to the crusher parallel with the supporting arms
of the upper frame. This arrangement helps the
feed’s even distribution in the cavity. The
upper frame can be rotated in 18 steps as
necessary.

The feed arrangement should be executed as

follows:

— All material smaller than crusher setting

should be separated before feeding into the
crusher. The fines might cause packing
and overload in the crushing cavity. All
uncrushable objects like metal pieces have
Figure 4.5.1 Feeding the crusher
to be removed from the feed e.g. with a
magnetic separator. The manufacturer is
not responsible for damages caused by the
reasons above.

— The feed must be directed so that there is

an equal load around the whole lower
portion of crushing cavity. This ensures
more even load and better lubrication for
the bearings and also the wear of the 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 the crusher should not exceed 5
m/s (16 ft/s), which corresponds a free fall
height of 1.3 m (4.3 ft). As necessary, the
speed must be limited by stone chatters etc.

— To ensure even wear of liners, the crusher

should be evenly choke fed.

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GP11F/GP11M Installation

4.6 REMOVAL OF CRUSHED crusher and might cause serious damages

MATERIAL to the crusher.

The crushed rock can be removed by using a

belt conveyor and/or different chutes or silos,
either directly or using guiding troughs. The
arrangement should be easily portable to make
the maintenance of the crusher as easy and
quick as possible.

The discharge opening of the crusher must be

covered or built safety distances according to
national standards (eg. EN 294).

The withdrawal of crushed rocks must all the

time be unimpeded. The hauling away devices
must be build in to prevent the accumulation
of crushed material. In case the level of
crushed material reaches the lower part of
mantle, the seal ring below the head might get
damaged. This allows dust to enter the
lubrication oil possibly causing more serious
damages.

When arranging the withdrawal of crushed

material from the crusher, pay attention to
following:
Figure 4.6.1 Removal of crushed material
— When the crushed material is hauled away
by using conveyor or feeder, the feeding
device to the crusher must not be able to
be started if the crusher is not running.

— In case there is a silo below the crusher, a

level indicator must be mounted into the
silo to halt the feed into the crusher,
supposing the material in the silo reaches
too high level.

— The hoses for lube and adjusting oil of the

crusher must be well sheltered against the
material flow.

— Use the inspection openings in lower

frame to remove all stumps, timber, plastic
packages of explosives and other stuff
from above the guards of lower frame
arms, to prevent material accumulation on
arms. The accumulation of excess material
on arms prevent the outflow from the

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 Installation GP11F/GP11M

4.7 POWER TRANSMISSION The V-belt pulley on the drive shaft of the
driving motor must be ruled to be accurately
The recommended driving motor is a slip ring parallel with the V-belt pulley on the
motor with a nominal speed of rotation of 1500 countershaft of the crusher. The drive shaft of
rpm (1200 rpm). The motor power needed is the driving motor must be parallel with the
132-160 kW (200-250 hp) depending on the countershaft of the crusher.
selected cavity and the material to be crushed.
The type of V-belts is SPC/ISO4184. There is
In case the crusher driving motor is to be a 8 pcs set of V-belts. When replacing V-belts,
mounted on fixed basement and the crusher is all of them must be replaced at a time. Never
oscillating in regard to the motor, the motor mix new and second hand V-belts. The V-belts
must be located directly above or below the must also belong to the same length category
countershaft of the crusher. The max. (stamped on V-belts) to ensure the equal
oscillation of V-belt line should not exceed 15° power distribution on all of the V-belts. The
when the crusher is standing still (fig. 4.7.1). required center distance is shown in table 4.7.2
The purpose of this arrangement is to avoid and figure 4.7.3. Make provision that centers
additional stresses caused by the oscillating can be moved closer together by 50 mm (2")
movement of the crusher. If driving motor and to facilitate installing belts without injury.
crusher are mounted on the same platform (= Also, the centers should be adjustable
they are oscillating together), the location of
driving motor can be independently chosen.
The
The power is transmitted from the driving lenght
Crusher ÆD e
motor to the countershaft of the crusher by of the
using V-belts. The use of V-belts is most V-belt
recommended in this case, because they 685
prevent the shock loads from being conveyed GP11F C 2800
GP11F M (27.0")
from the crusher to driving motor.
530 861
GP11M EC-LS (20.9") 3150 (33.9")
GP11M EC
GP11M C (1061)
(3550)
(41.8")
(601)
(2500)
(23.7")
Motor 450 751
GP11F F
(17.7") 2800 (29.7")
926
3150
(36.5")
641
2500
(25.2")
400 791
Crusher GP11F EF
(15.7") 2800 (31.1")
966
(3150)
(38.0)

Figure 4.7.1 Drive motor installation Table 4.7.2 Shaft Distances

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GP11F/GP11M Installation

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.

The driving motor and the V-belts must be

sheltered against the falling stones and also to
prevent accidents. The V-belt guards should
be open underneath to allow the dust outflow.
The size and location of the openings must
fulfill the commands of the health and safety
legislation.

Figure 4.7.3 Shaft distances

4.8 HOSES
over the distance by 40 mm (1 9/16") because
of manufacturing tolerance and possible The hoses between the lubricating and
stretch and wear of belt. adjusting equipment and the crusher should be
properly fastened in every point, where they
The V-belts must be properly tightened. To can be affected by rubbing. Points affected by
inspect the proper tightness place a straight rubbing should be covered with rubber plates
edge across the top of both sheaves. Measure etc. when necessary.
the span length. Using a spring scale at right
angles to the center of the span length, apply The minimum bending radius of hoses (R) are:
a force to the scale great enough to deflect one
of belts the equivalent of 0.016 times — Adjusting oil hose R = 560 mm
millimeters of span length (0.016 times inches (LOS 5-4 KP31.5) (22")
of span length. The force should be 90¼120
N (20.4¼27.0 lbs.) for a properly tensioned — Adjusting oil hose R = 160 mm
drive (figure 4.7.4) (LOS 5-2UU16) (6")

— Lubricating oil hose R = 245 mm

(LOS 5-1AA25) (10")

— Return oil hose R = 600 mm

(LVU 063) (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 (2") by every meter
(3 ft) of length of the hose. The sag of the hose
should not exceed 50 mm (2"), to allow the
crusher to breathe via lubricating equipment
after having been stopped (figure 4.8.1). High
sag acts like a water seal in return hose
Figure 4.7.4 V-belt tension compelling the crusher to breathe via the dust

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 Installation GP11F/GP11M

seal area and to suck the silicious dust into the secured to the transporting frame to prevent
crusher. any moving on the rubber dumpers during the
transportation (figure 4.9.1).

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.

Figure 4.8.1 Hang of return oil hose 4.10 SPECIAL TOOLS

The delivery of the crusher includes a tool box

containing tools and accessories necessary to
maintain the crusher.
4.9 TRANSPORT

When transporting the crusher, which is

mounted on a mobile wagon, must be firmly

Figure 4.9.1 Transport latches

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GP11F/GP11M Installation

4.11 WELDING 4.12 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 4.11.1). 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

Figure 4.11.1 Welding arrangement — impurities in the air

— physical factors (such as temperature, rain,

wind, etc.)

Before any long term storage the equipment

The welding current must never pass should be protected against corrosion. The
through any connection or bearing! storage location as well should be considered.

After a long term storage, the equipment

should be inspected for corrosion.

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 Installation GP11F/GP11M

4.13 SERVICE PLATFORM 4.16 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 (2 ft) 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
4.14 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.

4.15 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.

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GP11F/GP11M Installation

Pay special attention to the protection that have

been removed or damaged during operation or
transport.

Remove the anti-corrosive agent from the

contact surfaces before assembling.

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 Crushing GP11F/GP11M

5. CRUSHING
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 2
devices, e.g. guards, emergency stop devices,
silencers, 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 Stop the feeding conveyor (1).
before 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

and check the function of safety devices for oil 1
pressure, oil temperature and oil flow.

Bleed air from the adjusting equipment 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 5.2.1 Stopping order
Start the feeding conveyor (4).

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GP11F/GP11M Crushing

5.4 RUNNING-IN

A new or renovated crusher has to be inspected

and the following maintenance should be
accomplished during the first 100 hours of
operation. See detailed instructions for the
each individual maintenance operation in the
chapter 7 "Periodical maintenance".

After 10 hours of operation

LINERS

Loosen and tighten the concave bolts (figure Figure 5.4.2 Tighten the cylinder head bolts
5.4.1), 6 pcs, M 30, tightening torque see
chapter 9.10.1. FRAME CONNECTION

HOSES AND PIPES Tighten the frame bolts between lower and
upper frame (figure 5.4.3), 10 pcs, M48,
Tighten all hose and pipe connections. Repair tightening torque see chapter 9.10.2.
all leakages immediately.

Figure 5.4.1 Tighten the concave bolts Figure 5.4.3 Tighten the frame bolts between
lower and upper frame
After 25 hours of operation
V-BELTS
ADJUSTING CYLINDER
Check the tension of V-belts and tighten as
Tighten the cylinder head bolts (figure 5.4.2), necessary.
12 pcs, M42, tightening torque see chapter
9.10.2.

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 Crushing GP11F/GP11M

DURING RUNNING-IN PERIOD NOTE 5.5 OPERATION

THE FOLLOWING:
The crusher operates most efficiently, when
Operate new or renovated crusher for 4 hours the crushing cavity is full.
without load before feeding material in.
Do not climb on the crusher, when it is in
Do not load the crusher more than 70 % out of operation and do not touch any moving parts.
the maximum motor power or hydraulic
pressure during first 40 operating hours. Do not try to clear the blocked crushing cavity,
when the crusher is running. Be always very
Keep the crusher setting larger than shortest careful when clearing the cavity.
allowed setting during first 100 operating
hours. When crushing, there must be all the time at
least 5 mm (3/16") oil under the main shaft
Ensure that the pipes and hoses do not leak. (adjusting piston).

Ensure that the upper, intermediate and lower Verify at least once a shift, that there are no
frame do not move in relation to each other. faults or problems with the crusher! Report all
changes in the crusher operation to the person
Ensure that the cooling of lubricating oil in charge immediately!
works as shown in the operating manual.
Stop the crusher without delay and take
Observe pressure and temperature of the necessary precautions if any problems appear!
lubricating oil. Repair any faults prior to starting up!

Check and clean regularly the magnetic plugs

and strainer located in the oil reservoir. It is
normal that there are some steel and bronze SHOULD THE CRUSHER STALL UNDER
particles in them during running-in period. LOAD PROCEED AS FOLLOWS:

Ensure that the feed distributes evenly in the A stalled crusher MUST be treated as possibly
cavity. being jammed and therefore a potential
hazard.
Observe the cleanliness indicator (red button)
of the pressure filter in the lubricating device. Clear the plant area of all personnel. Notify the
manager or his deputy of a stalled crusher
Stop feeding sometimes and listen to the situation. Switch off the crusher to make sure
crusher for any abnormal noise. Knocking it will not start.
sound may come from loose liner.
NOTE ! Any inspection of the crushing cavity
Ensure that the top bearing does not leak must be carried out from inspection doors of
grease. the hopper and crusher, not from above. A
tramp metal could be ejected from the
Check oil level in the reservoir. crushing cavity and cause serious damage.

Check that the setting keeps constant. Find out why the crusher stalled. If, after
careful examination, there appears to be no
electrical or mechanical reason why the
crusher has stalled, it would indicate that the
crusher is jammed by the ingress of foreign

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GP11F/GP11M Crushing

matter and is in hazardous state. 5.6 SETTING

If a crusher stalls under load, open the manual Setting is the minimum distance between the
valve which is located in the lubricating concave and mantle during the work cycle. It
device until the pressure gauge shows no more must be measured at the lowest point of the
pressure. Now there should be no more stored mantle. The setting determines the maximum
energy in the mechanism except the weight of size of the discharging material, crusher
the stones. capacity and load.

After releasing the pressure the tramp metal The easiest and most accurate way to measure
can be safely removed. the setting is to lower a piece of lead with a
wire through the crushing cavity when the
If the main shaft must be lowered to remove crusher is idling, lift it up again and check the
the tramp metal, use the following methods: thickness of the compressed lead (figure
5.6.1). A piece of lead is delivered with the
— Lower the main shaft by using the switch crusher in the accessory box.
in the setting device. NOTE! Lower the
shaft only few seconds so that the space
between the main shaft and the piston
will not increase too much. When the
main shaft falls down the pressure plate
can centralized itself. If the main shaft
does not go down it means that only
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
setting device until the pressure gauge
shows no more pressure and try the next
method.

— Fill the cavity with rocks or use an

approved cover to make it safe. Place a
hydraulic jack between the upper frame
support and shaft nut. Push the main shaft
down. Be careful, the shaft may fall
rapidly. Figure 5.6.1 Measuring the crusher setting

— If none of the procedures above helps,

remove the upper frame to release the Because the liners might wear unevenly,
pressure. measure the setting in three or four points
around the cavity and use the average as a
When the main shaft is in lowest position the setting. Too small setting increases the load of
tramp metal should fall out of the cavity and the crusher remarkably. Never use setting
it can be removed. After that ensure that there smaller than given in the chapter 3.5.
is no more tramp metal in the cavity. Then
restart the crusher. When the crusher is equipped with automatic
control system, the crusher must not be used
without it. When adjusting the setting (main
shaft position), the control system must be
connected and in use. Only during

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 Crushing GP11F/GP11M

maintenance the setting may be adjusted

without the control system, using the switch
located in the setting device.

5.7 STROKE

The stroke length has effect on crusher

capacity (the longer stroke, the higher
capacity) and quality of the product.

There are 3 different strokes available, see

chapter 3.5 and changing the stroke, see
chapter 9.5.

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 Lubrication GP11F/GP11M

6. LUBRICATION
For the main lubrication see Instruction lowered to the bottom (figure 6.2.1). Suitable
Manual for Lubrication and Adjusting grease quality is a lithium-based EP
Equipment. (pressure-proof) grease which contains at least
3 % molybdensulphide (MoS2). The viscosity
of the base oil must be at least 200 cSt at +40°C
6.1 COUNTERSHAFT (1000 SUS at +100°F)and NLGI-class 2.
The countershaft housing oil amount is
approximately 1,2 liters (0.3 U.S. gallons)
with the standard housing and 1.5 liters (0.4
U.S. gallons) with the housing for mobile
solutions. Unscrew the breather (A) on the top
of the housing and pour oil into the housing
(figure 6.1.1). Remove the plug (B) on the side
of the housing to check the oil level. To drain
oil from the housing, remove the plug (C)
provided on the bottom of the casting.

Figure 6.2.1. Fill the top bearing housing with

grease

Recommended brands are e.g.:

BP Energrease L21-M
CALTEX Molytex EP 2
KLÜBER Unimoly GL 402
MOLUB ALLOY 777/2
MOLUB ALLOY 787
Figure 6.1.1. Countershaft oil drain and filling SHELL Retinax EPX 2
SKF Alfalub LGEM 2
MOBIL Mobilgrease Special
Use the same type of oil in the countershaft MOBIL Mobilgrease SHC 1000
housing as in the lubrication and adjustment Special
system, see separate instruction. NESTE Molygrease
ESSO Multipurpose Grease
6.2 TOP BEARING Moly 2
The top bearing grease capacity is approx. 9 There are two grease nipples under the frame
kg (20 lbs). The filling has to be accomplished arms for greasing. Add grease 20 g (0.7
at the mantle change, when the crusher is ounces)/nipple every 8 operating hours. If the
dismantled. The housing of the bearing should top bearing seal leaks (there is grease on the
be filled with grease, when the main shaft is main shaft or tightening nut), add more grease.

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GP11F/GP11M Lubrication

6.3 DUST SEAL RING

The purpose of the dust seal ring is to prevent

dust from getting into the crusher. The grease
prefill of the seal ring housing is approx. 0,65
kg (1.4 lbs). The grease must be added every
40 running hours by pressing a total amount of
100 g (3.5 ounces) of grease from two opposite
grease nipples (figure 6.3.1).

Suitable grease quality is a multi-purpose

grease with a good water and corrosion
resistance, e.g lithium-based greases with a
NLGI-class of 2, penetration of min. 260 and
operational temperature range beginning from
-30 C. The grease may contain also
EP-additives.
Figure 6.3.1. Dust seal ring
Suitable commercial qualities are e.g.:

BP Energrease LS 2
CALTEX Starplex EP 2
ESSO Beacon EP 2
MOBIL Mobilux EP 2
SHELL Alvania Grease EP 2
NESTE EP 2

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 Periodical maintenance GP11F/GP11M

7. PERIODICAL MAINTENANCE
7.1 EVERY 8 RUNNING Check the readings of temperature and
HOURS/EVERY WORKING SHIFT pressure gauges (figure 7.1.2). When starting
the crusher, oil temperature should be at least
LUBRICATING AND ADJUSTING +25°C (+77°F) and it should not exceed
EQUIPMENT +65°C (+149°F) during the operation. Oil
pressure should be between 1-5 bar
Check the oil amount in the reservoir. The oil (14.5...72.5 psi) with the oil temperature of
level should be above the middle of the scale. +40...+50°C (+104...+122°F). If the pressure
When the crusher is running, the oil level rises to 4.5-5.5 bar (65.3...79.8 psi) in the
should not descend below the minimum point temperature of +40...+50°C (+104...+122°F),
in the scale (figure 7.1.1). Add oil as necessary. the filter is getting clogged. The starting of the
cooling fan increases the pressure 1-2 bar
(14.5...29.0 psi). At special conditions check
the oil temperatures, see chapter 3.3 at the
Lubricating and Adjustning Equipment
Instruction Manual.

Figure 7.1.1 Oil level inspection

Figure 7.1.3 Filter cleanliness indicator

Check the filter cleanliness indicator (figure

7.1.3). If the red button comes out in a normal
operation temperature (+40...+50°C
(+104...+122°F)), the filter is getting clogged,
and should be replaced.

Check the operation of the cooler. The cooling

fan should start, when the oil temperature
reaches +55°C (+131°F) and stop, when it
drops to +50°C (+122°F).
Fig ure 7.1.2 Check the readings of
temperature and pressure gauges

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GP11F/GP11M Periodical maintenance

At special conditions check the oil CRUSHER SETTING

temperature, see chapter 3.3 at Instruction
Manual for Lubrication and Adjusting Check, if the crusher setting keeps constant
Equipment. during crushing. If the setting increases during
crushing and returns when load decreases, air
HOSES should be bled from the system.

Check the tightness of hoses and connections If the crusher setting increases continuously,
and repair all leakages immediately. the reason might be a leakage of adjusting
cylinder seal, pressure relief valve, needle
TOP BEARING SEAL valve, direction valve or shock valve. Find the
leakage and repair it. A reason for the setting
Add grease and check the condition of the top increase might also be overload, which opens
bearing seal. Add grease 20 g (0.7 the pressure relief valve. To restore the setting,
ounces)/nipple. The seal prevents the grease the adjusting pump must be started.
from flowing into the crusher. A possible
leakage can be noticed when grease appears on
the main shaft above the shaft nut (figure
7.1.4.). If the seal is leaking, add some more

Figure 7.1.4 Replace top bearing seal, if there

is grease on main shaft

grease accordingly. A damaged seal must be

replaced as soon as possible (at least at the next
liner change). See more detailed instructions
in chapter 9.2.

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 Periodical maintenance GP11F/GP11M

7.2 AFTER 40 HOURS OF LINERS

OPERATION/ EVERY WEEK (1-SHIFT
OPERATION) Observe the wear of the liners. The reason for
uneven wear of the liners might be an
LUBRICATION AND ADJUSTMENT incorrect feed to the crusher. In that case the
DEVICE feed arrangement should be modified. See
further instructions in chapter 4.5.
Check and clean the strainer and the magnetic
plugs in the return oil trough (figure 7.2.1). The wear of the liners can be checked by the
The unusual amount of metal particles or distance between the mantle tightening nut
impurities in the strainer or magnetic plugs is and the bottom of the top bearings housing.
a sign of a problem in the crusher. Find the With new liners the distance "A" is about 156
reason before going on with crushing. mm (6.1") for GP11F and about 162 mm
(6.4") for GP11M. The liners should be
replaced latest when the distance "A" is 10
mm (3/8") (figure 7.2.3).

Figure 7.2.1 Check return oil sump strainer

and magnetic plugs

DUST SEAL

Add grease in the dust seal by pressing a total

amount of 100 g (3.5 ounces) of grease from Figure 7.2.3 Liners should be replaced latest
two opposite grease nipples (figure 7.2.2). when distance "A" is 10 mm (3/8")
There are four nipples. See the grease quality
in chapter 6.3.

Figure 7.2.2 Grease the dust seal

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GP11F/GP11M Periodical maintenance

LOWER FRAME ARMS

Open the inspection hatches of the lower frame

(3 pcs) and remove all macadam and other
material jammed on the arms or slip ring. The
cleaning should be accomplished more often,
if there are roots, wires, bars etc. in the feed
material.

If there is any oil on the slip ring and the center

part of the frame, find out the reason and repair
it. At cold temperature the crusher may be so
cold, that the oil gets so cool and stiff, that it
does not have time enough to flow down by
the normal return channels, but floats over the
slip ring on the dust seal, and between the dust
seal and the slip ring on the center part of the
frame. The overflowing during a cold start up
can be prevented by starting the pumps
periodically 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
break ag es, etc. ). Repair any faults
immediately.

ELECTRICAL COMPONENTS

Check the condition of the electric cables and

components, to avoid breakages and abrasion.
Repair any faults immediately. Follow the
electrical safety and inspection regulations.

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 Periodical maintenance GP11F/GP11M

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 (12 pcs, M42, tightening torque see chapter
OPERATION) 9.10.2) (figure 7.3.2).

LUBRICATION OIL OF COUNTERSHAFT

Change the lubricating oil in the countershaft.

The oil amount, see chapter 6.1. The
countershaft housing is filled with oil to
provide lubrication of the countershaft
bearings. Unscrew the breather (A) on the top
of the housing and pour oil into the housing
(figure 7.3.1). Remove the plug (B) on the side
of the housing to check the oil level. To drain
oil from the housing, remove the plug (C)
Figure 7.3.2 Tightening of the adjusting
provided on the bottom of the casting.
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 further instructions in
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
air flow from the hose, make sure that the
blower is running and change the air cleaner.

Figure 7.3.1 Filling and draining countershaft

box oil

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GP11F/GP11M Periodical maintenance

7.4 EVERY 2000 HOURS OF 7.5 SEASONAL MAINTENANCE

OPERATION/EVERY YEAR (1-SHIFT (SUMMER/WINTER)
OPERATION)/EVERY HALF YEAR
(2-SHIFT OPERATION) LUBRICATING AND ADJUSTING
EQUIPMENT AND COUNTERSHAFT
THRUST BEARING
Change oil. See Instruction Manual for
Check the condition of the thrust bearings of Lubricating and Adjusting Equipment.
the main shaft. If the oil grooves in the bronze
bearings are lower than 2 mm (5/64"), the
bearings should be replaced. The inspection
has to be made during the liner replacement. 7.6 EVERY 20 000 HOURS OF
See further instructions in chapter 9.4. OPERATION/EVERY 10 YEARS
(1-SHIFT OPERATION)/EVERY 5
PRESSURIZED SEALING SYSTEM YEARS (2-SHIFT OPERATION)

Change the air cleaner. Also check the WHOLE CRUSHER

operation of the blower.
Recondition the whole crusher.

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 Periodical maintenance GP11F/GP11M

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

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 Liner change GP11F/GP11M

8. REPLACEMENT OF LINERS
8.1 GENERAL Before installing the liner, remove the anti-rust
compound properly from the machined
Do not wear the liners through. It may damage surfaces. Use suitable hand tool (scraper or
the surfaces in the crusher frame and head. grinding machine with sandpaper-type tool) to
These surfaces can only be repaired by remove excessive paine or dirt stuck in the
welding and machining. paint. Remove possible transport damages,
rust, etc., with a grinding tool.
The wear of the liners can be checked by the
distance between the mantle tightening nut and There are four cavity shapes available for
the bottom of the top bearings housing. With GP11F
new liners the distance "A" is about 156 mm
(6.1") for GP11F and about 162 mm (6.4") for
GP11M. The liners should be replaced latest CRUSHER FEED OPENING
when the distance "A" is 10 mm (3/8") (figure 180 mm
8.1.1). GP11F C
(7")
120 mm
GP11F M
(5")
80 mm
GP11F F
(3")
40 mm
GP11F EF
(11/2")

Figure 8.1.1 The liners should be replaced

latest when the distance "A" is 10 mm (3/8")

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.

In GP11F F and GP11F EF the concave consist

of two parts, the concave itself and a protection
above them. Replace the protections when
they have worn 5 mm (3/16").
Figure 8.1.2 There are four cavity shapes
available for GP11F: C, M, F and EF

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GP11F/GP11M Liner change

There are three cavity shapes available for 8.2 DISMANTLING THE CRUSHER
GP11M
Remove the gravel and stones from above the
slip ring, so the main shaft can freely move
CRUSHER FEED OPENING down.
220 mm
GP11M EC-LS*) Lower the main shaft by opening the magnetic
(9")
valve or the manual needle valve located in the
220 mm lubricating and adjusting equipment. When
GP11M EC
(9") the main shaft is in its lowest position, close
200 mm the valve.
GP11M C
(8")
Remove the bolts from the feeding chute and
lift the chute (500 kg (1100 lbs) for GP11F and
530 kg (1170 lbs) for GP11M) away. The
*) the cavity EC-LS for larger settings standard chute has 6 bolts, M16.

Remove the bolts from the top bearing housing

cover, 2 bolts M20, and lift the cover (105 kg
(231 lbs)) away.

Remove grease from the upper part of the top

bearing housing (figure 8.2.1).

Figure 8.1.3 There are three cavity shapes

available for GP11M: EC-LS, EC and C
Figure 8.2.1 Remove grease from the upper
part of the top bearing housing.

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 Liner change GP11F/GP11M

Remove the bolts between the upper and lower equally distributed bolts loose in the frame
frames, 10 bolts M48 (figure 8.2.2). 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.

Lift the upper frame away with convave

(figure 8.2.4). The lifting ropes can be
mounted under the supporting arms of the
frame. Lower the upper frame on a stand for
liner removal. The weight is approx.
2620-2930 kg (5780-6460 lbs) for GP11F and
approx. 3000 kg (6610 lbs) for GP11M.

Figure 8.2.2 Remove the bolts between the

upper and lower frames

Separate the upper and lower frame by using

the three jacking bolts (M48) (figure 8.2.3).
The separation can be helped by mounting
lifting ropes on the upper frame and tensioning
them with the crane. In this case leave three Figure 8.2.4 Lift the upper frame away

Figure 8.2.3 Separate frames by using jacking

bolts

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GP11F/GP11M Liner change

8.3 REPLACING THE CONCAVE

Remove the nuts from the concave mounting

bolts, 6 nuts M30 (figure 8.3.1).

Figure 8.3.2 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
Figure 8.3.1 Remove the nuts from the concave chapter 9.10.1.
mounting bolts
There must be no clearance between the liner
Remove the concave from the frame e.g. by and frame (figure 8.3.3). Hammer the liner to
hammering wedges between the bracket and seat it properly. If the liner can move against
frame. Mind the falling liner. the frame, their life shortens.

In GP11F F and GP11F EF the concave consist Check and replace the top bearing seal as
of two parts, the concave itself and a protection necessary. See chapter 9.2.
above it. Replace the protection when it has
worn 5 mm (3/16").

Lift the upper frame away and put it on the

stand.

Clean and inspect the liner seating surfaces in

the frame as well as the conical mounting
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.

Figure 8.3.3 There must be no clearance
Lift the frame on the concave so, that the between the liner and frame
mounting bolt holes meet each other. Use two
bolts to direct the holes. Check the condition of protection plates of the
upper frame. Repair or replace as necessary.
Tighten two bolts and put the others in the
holes (figure 8.3.2).

8-4 140564 12/02

 Liner change GP11F/GP11M

8.4 REPLACING THE MANTLE

The mantle can be replaced after removing the

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 (2600 Figure 8.4.2 Torch cut or grind away the torch
kg (5730 lbs) ) away carefully. Put the shaft on ring between the nut and mantle
the stand supported under the head - NOT THE
DUST SEAL - or turn it on the side taking care Turn the tightening nut anticlockwise by
not to damage the upper and lower bearing hammering it with a sledge hammer, until it
surfaces of the shaft. Do not drop the thrust gets loose. If needed, welt a hit plate in the nut.
bearing against the ground, but use a piece of If the nut does not get loose, torch cut it in two
rubber as a protection in between (figure pieces. There are two holes in the nut for torch
8.4.1). cutting. 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

replace 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.
Figure 8.4.1 Lift the main shaft away carefully
Check the condition of the thrust bearing, if
Torch cut or grind away the torch ring between the main shaft has been removed. If the bronze
the nut and mantle carefully to remove the plates of the bearing are worn out so, that the
mantle (figure 8.4.2). 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.

Check the condition of the protection plates of

the lower frame. Repair or replace as
necessary.

Clean the seating surfaces of the new mantle.

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GP11F/GP11M Liner change

Lift the mantle on the head. Secure, that the

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

Figure 8.4.4 Weld the nut, the torch ring and

the mantle together

If the main shaft has been removed:

— Check, that the intermediate plate of the

Figure 8.4.3 No clearance is allowed between thrust bearing has not moved from it’s
the mantle and head location, when lifting the main shaft.
Place the new torch ring and nut on the mantle. — Before lowering the main shaft, slide the
The old nut can be used, if it is still in good intermediate plate (steel) on the bearing
condition. Grind smooth the nut surface which plate (bronze) to the eccentric side, to
is against the torch ring. allow the thrust bearing to settle as well as
possible.
Lubricate the nut thread and screw the nut
down clockwise. Tighten it by hammering. To — Lift the main shaft carefully into the
help the seating, hammer the mantle to ensure crusher. Note, that the hole of the eccentric
the tight seating. Continue tightening, until the bushing is inclined, Be careful not to
mantle is no more clanging when hammering. damage the bushing surfaces. Also, be
careful not to damage the dust seal ring,
After tightening, weld the nut, the torch ring when it slides around the slip ring (figure
and the mantle together with six 50 mm (2") 8.4.5).
long welds, equally distributed (figure 8.4.4).

Figure 8.4.5 Be careful not to damage the dust

seal ring

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 Liner change GP11F/GP11M

8.5 ASSEMBLING THE CRUSHER lowering the upper frame on the lower frame,
the gap of 2...4 mm (5/64...5/32") should remain
Lift the upper frame (2620-2930 kg between the frame flanges. This gap must then
(5780-6460 lbs) for GP11F and 3000 kg (6010 be closed by tightening the bolts. No clearance
lbs) for GP11M) on place. Be careful not to is allowed between the frames.
damage the top bearing seal (figure 8.5.1).
Fill the top bearing housing with grease (figure
8.5.3). See the lubricating instructions in
chapter 6.2.

Figure 8.5.1 Lift the upper frame on place

Place the mounting bolts and nuts (10 pcs),

M48, tightening torque see chapter 9.10.2, Figure 8.5.3 Fill the top bearing housing with
between the lower and upper frame (figure grease
8.5.2) and tighten them evenly. When
Check the condition of the cover and repair or
replace as necessary. Install the cover and with
bolts (2 pcs) M20, tightening torque see
chapter 9.10.2.

Check the condition of the feed chute and

repair as necessary. Install the chute with bolts
(6 pcs) M16, tightening torque see chapter
9.10.2.

Test operate the crusher for some hours

without load to check, that it is running
properly.

Figure 8.5.2 Place the mounting bolts and nuts

between the lower and upper frame

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GP11F/GP11M Liner change

8.6 AFTER TIGHTENING

After 10 operating hours, loosen and tighten

the concave bolts (6 pcs) M30, tightening
torque see chapter 9.10.1.

After 25 operating hours, tighten the mounting

bolts between the lower and upper frame (10
pcs) M48, tightening torque see chapter
9.10.2.

Figure 8.6.1 Tightening after liner

replacement

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 Other maintenance GP11F/GP11M

9. OTHER MAINTENANCE
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
disconnect switch.
In any work related to the operation,
modification, conversion or adjustment of the All service/repair, except those told in this
equipment and its safety devices including manual, are allowed only for the servicemen
inspection, maintenance and repair, observe qualified by Metso Minerals, to keep the
all starting, stopping and maintenance warranty valid.
procedures as outlined in the instruction
manual.

Ensure as extensively as possible that the

immediate area is safe and secure.

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GP11F/GP11M Other maintenance

9.2. REPLACING THE TOP BEARING Replace the liners (if necessary) and assemble
SEAL the crusher according to the chapter 8.5.

The condition of the top bearing seal must be

inspected daily. If the seal has been damaged,
grease appears on the main shaft above the
tightening nut of the mantle (figure 9.2.1). The
failed seal must be replaced during the next
mantle change.

Figure 9.2.1 If the seal has been damaged,

grease appears on the main shaft above the
tightening nut of the mantle

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.

Place a new seal with the groove upwards. If

the weather is cold, first warm up the seal to
the room temperature to make the mounting
easier and to avoid the breakage of the seal.
Bend the seal to ease mounting (figure 9.2.2).

Figure 9.2.2 Bend the seal when installing

9-2 140564 2/03

 Other maintenance GP11F/GP11M

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
damaged, 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
(8 pcs, M20).

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.

Remove the slide circle (57 kg (117 lbs)) and

the old dust seal (6 kg (13 lbs)).
Figure 9.3.1 Replace dust seal if gap between
Clean the new seal and the housing and place
seal and slip ring is more than 1.5 mm (1/16").
the seal. Add grease 1,3 kg (2.9 lbs).
Remove the main shaft. Screw the ringbolt
M48, which belongs to the accessory box, in Lift the slide circle on the seal. Install the slide
the hole on top of the main shaft and carefully circle with bolts (6 pcs). Do not forget the
lift the main shaft (2600 kg (5700 lbs)) away washers. Make sure that the seal can freely
from the crusher. If you lift too fast, the move in the housing (figure 9.3.3). Shims may
intermediate plate of the thrust bearing may be used between the slide circle and head if
follow the upper bearing and fall back down necessary.
thus damaging the eccentric bushing.

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
use a piece of rubber as a protection in between
(figure 9.3.2).

Figure 9.3.3 Inspect seal movement in housing

2/03 140564 9-3

GP11F/GP11M Other maintenance

9.4 THRUST BEARING Slide the intermediate plate (steel) on the

bearing plate (bronze) to the eccentric side, to
The condition of the thrust bearing must be allow the thrust bearing to settle as well as
inspected every year. The most convenient possible.
time to check them is when replacing the
liners.

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 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 9.4.1 Thrust bearings
Remove the locking washer of the mounting
bolt at the end of the main shaft and unscrew To check that the intermediate plate (B) is on
the bolt (M16). Remove the thrust bearing (16 right position it is possible to measure the
kg). distance "k" between the seal ring (D) and the
slip ring (E) when the main shaft is at the
Clean the new bearing, the seating surfaces bottom.
and install the bearing. Note the locking pin.
Secure the mounting bolt with the locking The value of "k" should be 22 +1 mm
washer. -5
+0.04"
7
( /8" - 0.2" ).
Drain the oil from the crusher to replace the
intermediate plate and the lower bronze
bearing.

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

the lower bearing plate and carefully remove
the bearing and intermediate plates together
(total weight 37 kg (82 lbs)). The diameter of
bearing plates is about 1.5 mm (1/16") less the
diameter of the eccentric bushing.

Clean the lower bearing housing and place a

new bearing plate and the intermediate plate Figure 9.4.2 Check dimension "k" for the
separately. Lubricate the bearing surfaces intermediate plate positioning
before installing. Ensure, that the locking pin
If it is more it means that the intermediate plate
of the bearing plate goes into the hole and the
is not on right position. Lift up the main shaft
bearing is properly seated.
and reposition the plate.

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 Other maintenance GP11F/GP11M

9.5 CHANGING THE STROKE Unscrew the mounting bolt (M10) B (figure
9.5.2) of the eccentric bushing. The bolt is
General secured with locking compund, which can be
softened by heating.
There are three strokes available for the
crusher: 20, 25 and 30 mm (3/4, 1 and 11/8"). Remove the eccentric bushing (65 kg (143
The stroke can be changed by changing the lbs)) with the special tool A (figure 9.5.2). The
eccentric bushing. The stroke is generated by key comes out with the bushing. Place the
the eccentricity of the eccentric bushing. To bushing away.
change the stroke, the upper 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 from the lower 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
the hole on the top of the main shaft and
carefully lift the main shaft (2600 kg (5730
lbs)) from the crusher.

Put the shaft on the stand supported under the Figure 9.5.2 Remove the eccentric bushing
head - NOT THE DUST SEAL - or turn it on with the special tool
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 Check the thrust bearings (one mounted below
use a piece of rubber as a protection in between the main shaft and the other on the adjusting
(figure 9.5.1). 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
intermediate plate (steel) must also be
checked, and replaced as necessary. See
chapter 9.4.

Figure 9.5.1 Remove the main shaft

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GP11F/GP11M Other maintenance

Mounting After tightening

Check the condition of the new eccentric After 25 operating hours, tighten the
bushing, key and eccentric shaft. Clean as mounting bolts between the lower and upper
necessary. frame (10 pcs) M48, tightening torque see
chapter 9.10.2.
Place the key in the groove of the new
eccentric bushing and lower the bushing in its
place. The bushing must slide in, do not hit it.

Secure the eccentric bushing with the screw

(M10) B (figure 9.5.2). Lock the bolt with
locking compound, e.g. Loctite 270. Note !
The head of the screw must be fully inside the
eccentric bushing.

Make sure, that the intermediate plate of the

thrust bearing has not moved from its location,
when removing the main shaft out of the
crusher.

Before installing the main shaft, slide the

intermediate plate (steel) on the bearing plate Figure 9.5.3 Be careful not to damage the dust
(bronze) to the eccentric side, to allow the seal ring, when it slides around the slip ring
thrust bearing to settle as well as possible.

Lubricate the main shaft and new eccentric

bushing well with the oil used in the crusher.

Lift the main shaft (2600 kg (5730 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 9.5.3).

Inspect the top bearing seal and replace as

necessary. See the chapter 9.2.

Install the upper frame according to the chapter

8.5.

Test operate the crusher for few hours without

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

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 Other maintenance GP11F/GP11M

9.6 REPLACING THE TOP BEARING Fill the top bearing housing with grease (figure
9.6.1) and grease the bearing. See the
The top bearing must be replaced, if it is lubricating instructions in chapter 6.2.
damaged or worn.
Check the condition of the cover and repair or
Replace the top bearing when the upper and replace as necessary. Lift the cover on its place
intermediate frames are removed, e.g. when and install with bolts (2 pcs) M20, tightening
replacing the liners. torque see chapter 9.10.2.

Remove the bolts of the cover of top bearing Test operate the crusher for few hours without
housing, 2 bolts M20, and lift the cover (105 load to check, that the crusher is running
kg 201 lbs)) away. properly.

Remove the grease from upper part of the top

bearing housing (figure 9.6.1).

Figure 9.6.1 Remove the grease from upper

part of the top bearing housing

Remove the top bearing by using the special

tool (figure 9.6.2).

The protective sleeve of the main shaft has to

be replaced, if damaged. See the instructions
in the chapter 9.7.
Figure 9.6.2 Remove the top bearing by using
Install the new top bearing. Heat the housing the special tool
to ease the mounting. Install the top bearing
bolts (4 pcs) M20/keyhole 30 mm, tightening
torque 382 Nm (39 kpm).

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GP11F/GP11M Other maintenance

9.7 REPLACING THE PROTECTIVE

SLEEVE OF THE MAIN SHAFT

The protective sleeve (figure 9.7.1) of the

main shaft must be replaced when damaged or
worn. To replace the sleeve, the upper frame
must be removed.

Figure 9.7.1 Main shaft protection sleeve

Cut the sleeve carefully with grinding

machine. Be careful not to damage the shaft.

Carefully clean the shaft and the new

protective sleeve.

Heat the new sleeve to a temperature of 160°C

(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 holes, place the sleeve at once. If the

mounting fails, cut the sleeve away and try
again with a new sleeve.

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 Other maintenance GP11F/GP11M

9.8 SETTING OF BEVEL GEARING

GENERAL

The Zyklo-Palloid bevel gears are used for

transmitting the operating force from the drive
shaft to the eccentric shaft. During the
manufacturing stage the gears are finished in
pairs, so that if one of the gears is damaged or
worn out, both gears have to be changed.

To ensure proper function of the gear, the tooth

contact must be correct. It is not important
whether the ends of the gears match together
in the length of the teeth direction or not. The
tooth contact is correct when the contact
pattern is in the middle of the driving side (v)
of the tooth (in an unloaded condition) and on
the adjacent opposite side (r) somewhat on the
heel of the tooth (figure 9.8.1). The higher the
load, the more will the contact area move to
the toe of the tooth. Figure 9.8.1 The tooth contact

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GP11F/GP11M Other maintenance

SETTING Check the tooth contact by applying thinly

contact colour on the crown wheel teeth (3 or
For setting the tooth contact and the clearance, 4 adjacent teeth). Rotate the smaller gear by
the larger gear (crown wheel) can be lifted up the belt pulley to spread out the colour also to
or lowered down by adding or removing shims the smaller gear. The tooth contact can be
(A) between the bearing (B) and the adjusting adjusted with the help of the contact marks
cylinder (C) (figure 9.8.2.). according to figure 9.8.4.

The backlash must be correct. It is approx. 0.7

mm (0.028"). To check the backlash turn the
eccentric shaft to a position where the
minimum setting of the crusher is
perpendicularly against the countershaft. The
backlash can now be measured as the free
movement of the V-belt pulley, where by the
backlash of 0.7 mm (0.028") is equivalent to
a free movement of 1.65-1.95 mm
(0.065-0.077") on a pulley diameter of 530
mm (207/8"), 1.4-1.7 mm (0.055-0.067") on a
pulley diameter of 450 mm (1723/32") or
1.2-1.5 mm (0.047-0.059") on a pulley
diameter of 400 mm (153/4") (figure 9.8.5).

Figure 9.8.2 The tooth contact can be adjusted

by adding and removing shims (A) between the
bearing (B) and the adjusting cylinder (C)

The basic setting for the shims has made at the

factory and normally it is not necessary to
decrease or increase the thickness of the shims.
If it is necessary to decrease or increase the
thickness of the shims the adjusting cylinder
must be disassembled and the assembled. The
weight of the adjusting cylinder is approx.
1050 kg (2320 lbs).

The smaller gear can be adjusted horizontally

by adding and removing shims (A) between
the lower frame (B) and the countershaft
housing (C) (figure. 9.8.3.). Also here the shim Figure 9.8.3 The smaller gear can be adjusted
piles must be of equal thickness. horizontally by adding and removing shims(A)
between the lower frame and the countershaft
housing

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 Other maintenance GP11F/GP11M

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

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GP11F/GP11M Other maintenance

9.9 PROTECTION PLATES 9.10 BOLT TORQUE VALUES

The plates protect the crusher frame against 9.10.1 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 that are not surface treated. The table applies
supporting arms of the upper frame, in the to bolts with property class 5.6.
cavity and above the supporting arms of the
lower frame.
Torque
Check the condition of the guards regularly. Bolt
Worn out guards must be replaced with new Nm ft lbs
ones, which will be welded according to the
M30 579 426
instructions in chapter 4.11.

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 Other maintenance GP11F/GP11M

9.10.2 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.

Torque Width across the flats

Bolt
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

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 Trouble shooting GP11F/GP11M

10. TROUBLE SHOOTING

Equipment malfunction may occur for a For trouble shooting see also Instruction
number of reasons: incorrect operation of the Manual for Lubricating and Adjusting
equipment (from overloading, carelessness, or Equipment.
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
operating.
Remove the reason for overload (uncrushable
particle, too small setting) and switch on the
adjusting pump to reset setting.

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GP11F/GP11M Trouble shooting

THE CRUSHER HALTS AND THE SIGNAL LIGHT "OVERLOAD / MOTOR HOT"
IS ILLUMINATED.

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

Empty the crusher cavity, remove the reason for overload and restart the crusher after the motor
has cooled down. 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 lon g and /or thin supply cables,
insufficient overall power etc.
Inspect cables and/or supply and replace as
necessary.

The crusher has been operated with too small

a setting causing a considerably higher power
need.
Increase the setting or replace the motor with
a more efficient one (max 160 kW (250 hp)).

Uncrushable material, i.e. excavator tooth

etc. has entered the cavity.
Inspect the operation of the magnetic
separator (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
necessary

Inspect that the liners are not worn as a "bag

shape". Replace liners as necessary.

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 Trouble shooting GP11F/GP11M

THE CRUSHER HALTS AND SIGNAL LIGHT "HIGH OIL TEMPERATURE" IS

ILLUMINATED.

The temperature of the oil returning from the crusher has exceeded +65°C (+149°F), thus
activating the return oil thermostat to halt the crusher. The lubricating pumps are still running.
Empty the crushing cavity and remove the reason for overheating. The crusher cannot be restarted
before the return 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
overloaded 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
necessary.

Inspect that the liners are not worn as a "bag

shape". Replace liners as necessary.

Insufficient cooling of the lubricating oil.

Check the function and the setting of cooler
thermostat.

Check the function of the cooler fan.

Clean the cooler from outside and also from

inside as necessary.

Insufficient oil flow.

Check output of the lubricating oil pumps
and function of the float switch.

Crusher bearing is getting damaged.

Check if an unusual amount of metal exists
in the return oil sump or in the magnetic
plugs. Check the condition of the bearings.

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GP11F/GP11M Trouble shooting

THE CRUSHER HALTS AND THE SIGNAL LIGHT "NO OIL PRESSURE" IS ILLU-
MINATED.

There is a fault in the lubricating oil supply and the pressostat has stopped the crusher. Empty
the crushing cavity, trace and repair the fault.

If the lubricating pumps are running and the

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

If the lubricating pumps are running and the

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

If the pumps are running, the manometer

indicates pressure and the hoses are
undamaged, the pressostat may be defective.
Inspect the function of the 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 GP11F/GP11M

THE CRUSHER HALTS AND THE SIGNAL LIGHT "NO OIL FLOW" IS ILLU-
MINATED.

The float switch in the return oil sump has been activated stopping the motor. The lubricating
pumps are still running. Stop the pumps immediately. Empty the crushing cavity trace the fault
and repair it.

No oil return flow due to a damaged, loosened

or clogged return oil hose.
Repair or replace the return oil hose.

Insufficient oil return flow.

Measure the capacity of the oil pumps and
check the operation of the float switch.

THE CRUSHER HALTS AND THE SIGNAL LIGHTS "NO OIL PRESSURE" AND "NO
OIL FLOW" ARE ILLUMINATED.

There is a fault in the lubrication oil supply and the pressostat has stopped the crusher. The return
oil flow has ended before the signal light has been checked. (The flow continues for a while even
though the pumps have been stopped). Empty the crushing cavity, trace and repair the fault.

If the lubricating pumps are running and the

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

If the pumps are running, the manometer

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

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GP11F/GP11M Trouble shooting

THE CRUSHER HALTS, NO FAULT IN LUBRICATION SYSTEM.

The V-belts are slipping.

Tighten the belts or replace as necessary.

The V-belts are broken.

Empty the crushing cavity, trace the reason
for breakage and replace the belts.

THE OIL FILTERS ARE CLOGGING VERY RAPIDLY.

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

Wear of the main shaft dust seal.

Check the seal condition and replace as
necessary.

Latches of lubricating equipment are open.

See that the latches are always carefully
closed.

Lubricating oil is dirty and/or contains an

excessive amount of water.
Replace the oil.

UNUSUAL SOUND IS HEARD FROM THE CRUSHER.

If an unusual sound is heard from the 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.

10-6 140564 12/02