MSHA - Interactive Training - JTA Spiders - Nordberg 4.25 Ft. Standard Cone Crusher Liner Replacement

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	Nordberg 4.25 Ft. Standard Cone Crusher Liner Replacement
	Contact: Palmer.Melvin@dol.gov

Felt

Insulation

Silicone

Backing Material (Minimum of 10)

Grease ( 5 gallon can)

Never seize

Cleaning solvent

Review past successes and failures

Assign Jobs

Upper

Lower

Crane Operator

Loader Operator

Obtain tools, equipment, and materials

Equipment

Rigging

Gloves for rigger

Leather

Tag Line

Inspect wire rope for defects: frays, kinks, and broken wires

Inspect nylon straps for tears, oil, frays, cuts, and weather damage

Shackles, pins, and eyes

Proper size

condition

Service Truck

Cutting torch & Full Bottles

Inspect gauges, hoses, flash back arrestor, tips and torch head for defects

Hand tools

Inspect all tools for defects

Welder

Inspect leads, electrode holder, grounding clamp, all connections.

Insure that all connections are guarded.

Compressor

Check for fuel, hoses, gauges, pressure relief valve and oil. Drain the moisture from the air tank.

Loader

980 or larger

Crane

Use only certified personnel

Pre-Shift Inspection

Use company form

Tools

1" impact

Inspect all tools for defects

1/2" impact

Inspect all tools for defects

3/4" impact

Inspect all tools for defects

Appropriate sockets

Plant specific

Inspect all tools for defects

1" drive ratchet

Inspect all tools for defects

Side Grinders

Inspect all tools for defects

1/2" Drill

Inspect all tools for defects

Approved Extension Cord

Inspect all tools for defects

Cheater Bar

Inspect all tools for defects

Pry Bar

at least 3' long

Inspect all tools for defects

Sledge hammers (2)

Inspect all tools for defects

Nordberg Crusher Tools

Refer to Maintenance book

Inspect all tools for defects

Speciality Head Ball Tools

Plant specific

Inspect all tools for defects

Caulking Gun

Inspect all tools for defects

Bowl cable

1/2" X 30' wire rope with eyes on each end

Inspect all tools for defects

Slag hammer

Inspect all tools for defects

Materials

Rags

Welding Rod

Manganese or stainless

Air Arc Rods

Grinder wheels

Inspect for cracks, chips and oil on wheels

Wire Brushes

First Aid Kit

Check contents

WD40

Anti-Seize

Silicone

Backing Material

Grease

Welding Curtains

Ventilation Fan

1 gallon motor oil

Insulation

3 1/2" fiberglass bat

10'x10' tarp

Lid from 55 gallon grease barrel

Housekeeping

Crusher walkways

Liner Rebuild work areas

Crane staging area

2. Dismantle Crusher

Run Crusher

10-15 minutes for warm up

To prevent socket from sticking to shaft

Lock-out-Tag-Out per company policy

Crusher

Feed conveyor

Discharge conveyor

All oil systems including heaters

All neighboring circuits surrounding work area

Stage Crane in safe location

Remove all conveyors, chutes and/or hoppers

Pull oil drain plug

Recycle oil

Cut distributor plate bolts

Remove distributor plates

Relieve pressure on locking post

Hydraulic

Connect two way cable to cap

Lift cap with crane to relieve hydraulic pressure

Watch sight glass for fluid level

Disconnect hydraulic lines

Lower cap

Disconnect two way cable from the cap

Raise the two way cable out of the work area

Mechanical

Remove pin and lock link

Loosen the hold down bolts with socket and 1" ratchet

Back out bolts approximately 6 inches

Hook one end of the 1/2" X 30' wire rope onto the bowl ear

Wrap 1/2" X 30' wire rope cable around crusher bowl in a counter clockwise manner

Attach the other end of the wire rope to the eye or hook on the loader bucket using an approved shackle

Un-screw crusher bowl with the loader

Raise the loader bucket to protect the loader operator while un-screwing bowl

Ensure that all co-workers are in a safe location in case of cable failure

Only one person is used for designated hand signals

Back the loader up carefully until the end of the cable is reached watching the hand signals of the designated person

Repeat this process until the end of threads are visible

Do not over-unscrew

Disconnect wire rope from loader and bowl

Store in a safe location for use during re-assembly

Attach two way cable to basket (hydraulic crusher only)

Lift basket out of the bowl (hydraulic crusher only)

Place the basket on the ground

Attach two way cable to the bowl cap ears

Lift bowl out of the main frame in a slow manner

Insure that all personnel are in a safe location during this step

Place bowl on the ground

Remove bowl

Hydraulic

Disconnect hold down rams by removing cotter pins, keepers, and washers

Lift the cap with the crane and inspect the hydraulic ram shaft and place it to the side

Disconnect the two way cable from the cap

Mechanical

Remove the hold down bolts

Set aside for cleaning

Remove cap with crane and set it aside

Disconnect the two way cable from the cap

Clean main frame threads with water hose or scraper

Place eye bolt in the head of the shaft ensuring that the eye bolt is properly secured

Attach the two way cable to the eye bolt with the correct shackle

Ensure that the cable is perfectly vertical

Hoist the shaft out of the main frame in a slow manner

Ensure that all personnel are in a safe location during this step

Ensure that the end of the shaft does not gouge socket liner

Place shaft on the ground

Un-hook two way cable from shaft

Place cover on the eccentric bushing

Must be able to support weight of persons working in the area (55 gallon barrel metal lid); prevents contaminants

Install eye bolts in the socket sealing ring

Ensure that the eye bolts are properly secured

Attach the two way cable to the eye bolts with the proper shackle

Lift socket sealing ring with slight pressure

Check to ensure there is movement

If no movement, use penetrating oil and/or foot pressure to help it break the ring free

Lift the socket sealing ring out of main frame

Remove the three locking dowel keys and set aside for reinstallation

Place on clean surface

Disconnect the two way cable

Raise cable out of the work area

Remove O-Ring and/or valves and springs from the top of the socket

Discard all and do not reuse

Inspect the root clearance, back lash, and condition of bronze eccentric bushing, socket liner and step washers

Per manufactures specifications; order parts if required

Inspect main frame arms, main frame liners, and counter shaft liners for excessive wear

Order parts if required

Inspect counter shaft box breathers

Order parts if required

Cover crusher parts with a plastic tarp to prevent environmental damage

3. Dismantle and Re-build Bowl

Attach ring end of two way cable to loader bucket

Attach two way cable to bowl

Hydraulic

Place shackles in locking post holes

Mechanical

Using 2-1 1/2" bolts from the lock down cap, screw back into the bowl opposite each other

Place cables over the bolts and under the ears of the bowl

Screw the bolts down to lock the cables in place (not tight)

Transport bowl to wash area using loader

Wash outside threads

Wash U-bolt cover plates and/or U-bolts

Transport bowl to rebuild area

Disconnect two way cable from bowl

Remove U-bolt covers with 1/2" impact and 3/4" socket

Loosen and pry off U-bolt covers

Clean, inspect, and replace as necessary

Set aside for re-assembly

Remove U-bolt locking plates with pry bar

Set aside for reassembly

Remove U-bolt nuts using 1" impact and appropriate impact socket

Clean, inspect, and replace as necessary

Set aside for reassembly

Pull off thin steel top plate, rubbers, and thick steel bottom plate from each of 6 U-bolts

Note position of narrow side and wide side of steel & rubber plates to ensure upright position of U-bolts upon re-assembly

Stack accordingly for reassembly in a safe place

Pull U-bolts out of bowl assembly

May need to dig out insulation to remove U-bolts

Set aside for cleaning & reassembly

Attach ring on end of two-way cable to loader/crane

Attach other ends of two-way cable to the bowl as before

Raise bowl approximately 2" off ground

From the outside, beat on U-bolt lugs using 3"x4' solid steel shaft

Make sure you are wearing proper PPE

Be careful of flying metal chips and liner falling from bowl

Lift bowl assembly after liner separates

Place bowl assembly to the side

Reposition cables on the bowl from its previous points to a side by side position

Lift bowl and lower so that it is laying on it's side

Chip excess backing material from bowl assembly using slag hammer

Buff seat area on bowl assembly with wire wheel

Inspect seat area looking for cracks, excess wear per manufacturers specifications

Apply oil or grease from above the seat area to the top of the bowl

Lift bowl assembly and set upright

Reposition the two way cables opposite each other on the bowl assembly

Buff paint from the seat area of the new bowl liner using the wire wheel or gator pads

Apply two beads of silicone on seat of new bowl liner

Cut 6-6"x6" squares of insulation

Slice a hole in the center of each square of insulation big enough to fit over the lugs on the bowl liner

Place insulation squares over the lugs on the new liner

Lift the bowl assembly and place it over the lugs on the new bowl liner

Pry with bar to center lugs in the holes

Disconnect two-way cables from bowl

Move crane/loader out of the way

Pack insulation firmly around lugs using small pry bar or large screwdriver

To prevent backing from leaking into the U-bolt chambers

Pack insulation to the point where you can still firmly install the U-bolts under the lugs

Clean U-bolts with a wire wheel, wire brush, and/or thread chase, with lots of WD40. Replace as needed

Install U-bolts under lugs

Pack insulation firmly around U-bolts using small pry bar or large screwdriver until the U-bolt chambers are full and tight

Install thick steel bottom plate, rubbers, and thin steel top plate over U-bolt threads (6 total installations)

Make sure to position steel and rubber plates so that U-bolts are upright when re-assembled

Apply never seize to U-bolt threads

Install all nuts on U-bolts, hand tight

Partially tighten nuts using 1" impact and proper socket utilizing cross pattern sequence

Make sure that the liner stays centered and level with the bowl

This will take several rounds to bring liner up to bowl level making sure that both seating surfaces are aligned to manufacturer's specifications and nuts are properly tightened

Re-install U-bolt locking plates on all 6 U-bolts

Place a square of insulation over U-bolt ends and nuts

Re-install U-bolt covers

Pour backing material in conjunction with or at the same time when pouring backing material with the mantle

4. Disassemble and Rebuild the Mantle

Attach the ring of the two-way cable to the loader using an approved shackle

Attach the other ends of the two-way cable to the lifting eye on the stem

Lift the shaft off the ground just high enough so as the shaft does not make contact with the ground

Transport shaft to the work area

Lower shaft into the assembly hole and rest on the floor

Remove two-way cable from shaft

Remove lifting eye

Cut the torch ring using the torch with a scarfing tip. Cut the torch ring horizontally in the center, all the way around and all the way through

Place Nordberg splined wrench into the splined nut on top of the shaft

Pound Nordberg wrench in a counter clockwise direction using a sledge hammer to loosen the splined nut

Remove the Nordberg wrench from the splined nut

Install eye bolts into the distributor plate holes on the splined nut

Remove the two-way cable from the loader bucket

Attach the ring on the two-way cable to the crane hook

Attach the two-way cable to the eye bolts on the splined nut using approved shackles

Take up the tension on the cable

Continue to remove nut by grasping cable and eye bolts and turning counter clockwise

Apply Nordberg wrench to loosen until free if the nut is too tight

Keep tension on the cable using the crane

Place the splined nut on the ground in a safe place

Disconnect the two-way cable from the splined nut

Clean and inspect the nut

Set aside for reassembly

Remove the remainder of the torch ring from the shaft and discard

Remove silicone from eye bolt holes in the shaft sleeve

Install the eye bolts into the shaft sleeve

Attach the two-way cable to the shaft sleeve

Lift and remove the shaft sleeve using the crane

Clean and inspect the shaft sleeve

Set aside for reassembly

Un-hook the two-way cable from the shaft sleeve

Weld two pad eyes on the mantle liner opposite of each other

Must use manganese or stainless welding rod

Attach the two-way cable to the pad eyes on the mantle liner

Lift mantle liner off of the shaft and place on ground to discard

Disconnect two-way cable from mantle liner

Lift cables from the working area

Clean the old backing material from the shaft

Proper cleaning may require wire wheel, brush or chipping hammer

Clean the seat area on the shaft

Clean using a wire brush, gator pad, or a wire wheel

Oil the shaft where the backing is to be installed

Clean and inspect the threads at the top of the shaft where the splined nut goes

Clean using a wire brush

Apply two beads of silicone to seat area on the shaft

Weld two pad eyes approximately 3" below the notches on the new mantle liner

Must use manganese or stainless welding rod

Work in a well ventilated area and wear an appropriate respirator

Enlarge the backing pour notches on mantle liner

Using the torch at a 45 degree angle enlarge the notches approximately 3" in width

Work in a well ventilated area and wear an appropriate respirator

Cut off the three casted lifting lugs at the bottom of mantle liner

Work in a well ventilated area and wear an appropriate respirator

Attach the two-way cable to one pad eye on the new mantle liner

Lift the mantle liner and turn the mantle liner over so the seat side is up

Watch for un-expected movement

Inspect and clean the seat

Clean using a wire brush, gator pad, or a wire wheel

Lift the mantle liner and turn the mantle liner over so the seat side is down

Re-attach both cables to pad eyes

Lift the new mantle liner up

Center the new mantle liner on the shaft and lower

Disconnect two-way cable from mantle liner

Attach two-way cable to the shaft sleeve

Lift and place sleeve over shaft and lower into position on top of new mantle liner

Remove the two-way cable and eye bolt from the shaft sleeve

Fill eye bolt holes in shaft sleeve with silicone

Attach the two-way cable to the splined nut

Install new torch ring by hand

Apply never seize to the shaft threads

Lift the splined nut onto the shaft threads

Start splined nut onto thread of shaft using cables and eye bolts to turn while lowering with crane until snug

Ensure that the torch ring is centered on the sleeve while turning the nut into place

Remove the two-way cable and eye bolts from the splined nut

Tighten the splined nut using the Nordberg splined wrench

Refer to the Nordberg manual

Remove the Nordberg wrench after proper tightening

Construct a pour trough/birds nest around the pour holes in the mantle liner

Pour backing material in conjunction with or at the same time when pouring backing material with the bowl

5. Pouring Backing Material

Ensure that the proper tools, equipment, MSDS, and PPE are at the pour site per the preparation meeting

Ensure that the backing material is warmed to a proper temperature for easy pouring

Place inside or in the sun if needed

Never warm material with an open flame

Ensure that the mantle and the bowl are on a level surface prior to pouring

Install the ventilation fans into place

Don proper PPE

Remove the lids from the backing material

Place the mixing paddle into the drill

Mix the epoxy to ensure a consistent blend

Ensure that the sides and bottom is mixed

Remove the lid from the hardener

Add, slowly, the hardener to the epoxy while mixing with drill and paddle

Ensure that the material is mixed to a consistent color

Refer to the manufacturers mixing procedure

Pour mixed backing material into the cavities of the mantle and bowl liners

As pouring continues, new batches of material is being mixed

Repeat as necessary until filled

Refer to the manufactures specifications on the proper quantity

Ensure proper backing levels

Mantle

Backing material will be poured to the bottom of the pour holes

Bowl

Backing material will be poured to the top of the bowl liner

Leave the mantle and bowl stand until backing is completely cured

Refer to the manufacturers recommendations

6. Reassemble and Test Crusher

Conduct a Pre-shift inspection on all mobile equipment

Follow company policy

Inspect Backing

Check for hardness and leakage

Cut pad eyes off of mantle

Remove the tarp carefully insuring that no debris fall into the stem hole

Clean off socket assembly

Remove excess oil, dirt, and grease from the socket assembly using rags, and minimum solvent

Clean the surface of the O-ring, valves and springs, with a scraper and/or grease rag including spring holes

Clean bronze with rags only

Remove the lid from the hole

Ensure that no debris are inside the hole

Install the oil drain plug

Reinstall the cover over the hole

Lubricate valves and springs with oil

This step done if valves and springs are used

Install the O-ring and/or valves and springs

Hook the two-way cable to the crane

Install eye bolts into the socket sealing ring

Attach the two-way cable to the eye bolts attached to the socket sealing ring

Pick up socket sealing ring approximately waist high with the crane

Clean out cavity with scraper and gloved hand

Be careful of sharp edges and slippery surfaces because of grease

Wipe top surface down with solvent and rags

Follow company HazCom policy when working with chemicals

Raise socket sealing ring up approximately chin high

Remove the old felt with a screw driver and/or scraper

Do not work under a suspended load

Discard the old felt

Dunk new felt in oil

Install the new felt into the groove by pushing firmly until seated

Cut off any excess felt with a utility knife

Lower socket sealing ring approximately waist high

Do not work under a suspended load

Pack grease cavity by gloved hand with grease ensuring that no air pockets exist

Follow company HazCom policy when working with chemicals

Be careful of sharp surfaces

Ensure that dowel key ways are clear of grease

Ensure that the dowel keys, inside the crusher main frame, are in the proper vertical position in socket

Refer to the Nordberg manual

Lower, slowly, the socket sealing ring while aligning the locking keys with the keyways until seated ensuring that the socket sealing ring has movement and is not binding

Disconnect two-way cable from socket sealing ring

Remove the eye bolts from the socket sealing ring

Attach the ring of the two-way cable on the loader bucket if transporting mantle by loader

Install the eye bolts into the top of the mantle shaft

Attach two-way cable to eye bolt on the top of the mantle shaft

Raise the mantle shaft up out of the hole

Lower mantle shaft on cribbing ensuring that the shaft is approximately 1" above the ground. If cribbing is not available, lower shaft onto its side on a soft clean surface

Ensure that the main shaft is clean by using a rag (if necessary)

Clear oil passage with water or compressed air by inserting air or water into the hole located at the bottom of the shaft

Raise the shaft off of the cribbing or clean surface keeping shaft clean

Transport mantle to the crusher

Lower mantle onto cribbing or clean surface

Disconnect two way cable ring from the loader

Connect the two way cable ring to the crane hook

Carefully raise the mantle ensuring cleanliness

Remove the lid from the socket

Inspect socket area for cleanliness(visually)

Douse the bronze with 5 gallons of oil ensuring that all bronze surfaces are coated

Position the shaft over the main frame

Ensure that all personnel are at a safe location

Slowly lower the mantle all the way down until it sits on the socket leaving slight tension on the cable

Position someone on the outside of the main frame to watch and guide the lowering process, to ensure that the end of the shaft does not contact the bronze socket liner

Pull the lockout tagout on the crusher and any interlocked systems that will allow the crusher to be started with oil pressure

Removal of lockout tagouts will be site specific

Remove all tools, materials, and non-essential personnel from immediate area of the crusher

Energize the motor just enough to bump the crusher ensuring that the mantle is seated in the socket liner

Refer to manufacturer's manual

Lower the crane to remove tension on the two way cable

Energize the motor approximately 15 seconds ensuring that the mantle is seated in the socket liner

Refer to manufacturer's manual

Lockout tagout all crusher systems previously energized for the seating of the mantle

Remove the two way cables from the mantle

Remove eye bolt from the shaft

Stuff the splined nut with rags up to the top

Remove the two way cable from the crane hook and attach to the loader

Attach two way cable to the eye bolts on the bowl

Clean the hold down bolts and threads in the hold down bolt holes in the crusher bowl using wire wheel and tap as necessary

For mechanical crusher only

Lift bowl approximately waist high

Apply ample amounts of grease to outside threads of bowl with gloved hands

Be careful of sharp edges

Transport bowl to crusher main frame area

Lower bowl to clean surface

Detach two way cable ring from loader

Attach two way cable ring to crane hook

Detach the two way cable from the bowl

Remove the two hold down bolts from the bowl that were used to transport it and set aside

For mechanical crusher only

Attach two way cable to the lugs on the adjustment cap

Raise the adjustment cap

Move, position, and lower the adjustment cap onto the bowl

For the mechanical crusher, make sure the holes on the adjustment cap line up with the threaded holes on the bowl

For the hydraulic crusher, lower the adjustment cap just enough so that the slotted keeper ends of the cylinders clear the lock post holes

Attach adjustment cap to the bowl

For mechanical crusher, add two to three washers to bolts and screw in at least 6" making sure that all bolts are equal in height

For hydraulic crusher, reinstall the beveled washers (2 for each shaft) over the cylinder shafts and install the keepers through the slots on the cylinder shafts. Reinstall cotter pins (2 for each keeper) through holes in the keepers. Total of 6 cylinder shafts.

Raise bowl

Mechanical, ensure that the bowl remains level. If not, set down and readjust bolt heights

Ensure that all unnecessary personnel are in a safe place

Position over the crusher main frame

Lower the bowl until 6-12" above the main frame

Locate the starter threads on the bowl and main frame

Align starter threads on bowl and main frame

Lower bowl and spin simultaneously into threads on main frame using as many people as necessary

The crane keeps the threads in a neutral position for threading into the main frame

If hand threading becomes too difficult, refer to disassembly procedures in reverse using cable. Refer to manufacturer's manual

Thread in to desired closed side opening

see manufacturer's manual

Lower adjustment cap

Attach lock link to the closest hole and pin it

for mechanical only

Disconnect two way cable from adjustment cap

Tighten cap bolts in a crossing pattern using 1" ratchet, appropriate socket and 3-5' cheater bar

for mechanical only

Go around at least 3 times to ensure tightness refer to manufacturer's manual

Attach quick disconnect hydraulic hose to rams and pull clamp down lever

for hydraulic only

Attach two way cable to basket

for hydraulic only

Lower basket into place

for hydraulic only

Disconnect two way cable from basket

for hydraulic only

Attach two way cable to eye bolts on distributor plate

for hydraulic only

Lift and position over shaft nut

Lower distributor plate into place

Disconnect two way cables from eye bolts

Raise cable and remove crane from work area

Remove eye bolts from distributor plate

Align bolt holes in the distributor plate with the holes in the shaft nut

Install 4 new bolting hardware sets using appropriate amounts of lock washers

Bolts in from the bottom, nuts on top

Tighten and secure all bolts with 3/4" impact gun and appropriate socket and wrench

Weld or double nut hardware

Reinstall chutes, belts, conveyors, hoppers as per site requirements in reverse order of disassembly procedure

Remove the lockout tagout on the crusher and any interlocked systems that will allow the crusher to be started with oil pressure

Removal of lockout tagouts will be site specific

Start the crusher

Verify 2500 PSI clamping pressure on the hydraulic rams

For hydraulic only

Check oil pressure and for leaks

Should be 7-12 PSI, or in accordance with the manufacturer's specifications

Ensure that there is proper oil return back to the tank

Inspect and listen for any unusual noises and conditions

Check head spin and ensure that it's spinning in accordance with manufacturer's specifications

visual check

Turn off crusher and check coast down time

In accordance with manufacturer's specifications

Lockout tagout all crusher systems previously energized

Recheck the crusher adjustment/tolerance by observing the gap on the closed side

Remove all lockout tagout equipment

Start the crusher

Take an amp reading

No load amp reading

Start the plant including all related feed belts and discharge belts (Plant Operator)

Plant operator will make all through-put adjustments

Take a full load amp reading

Wait for the crusher to fill up with material

Proper amp readings are crusher motor specific

Gather all tools, equipment, and materials and ensure that the area is clean

Store cables and rigging equipment in its proper place. Equipment and tools replaced to its proper storage areas

Release to production

Title

Nordberg 4.25 Ft. Standard Cone Crusher Liner Replacement

Subject

Company

Author

Version

165

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