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Nordberg 4.25 Ft. Standard Cone Crusher Liner Replacement
Contact:
Palmer.Melvin@dol.gov
Home
1. Preparation
Conduct Self Assessment
Conduct Pre-Job meeting
Obtain tools, equipment, and m...
Housekeeping
2. Dismantle Crusher
Run Crusher
Lock-out-Tag-Out per company p...
Stage Crane in safe location
Remove all conveyors, chutes a...
Pull oil drain plug
Cut distributor plate bolts
Remove distributor plates
Relieve pressure on locking po...
Hook one end of the 1/2" X 30'...
Wrap 1/2" X 30' wire rope cabl...
Attach the other end of the wi...
Un-screw crusher bowl with the...
Disconnect wire rope from load...
Attach two way cable to basket...
Lift basket out of the bowl (h...
Place the basket on the ground
Attach two way cable to the bo...
Lift bowl out of the main fram...
Place bowl on the ground
Remove bowl
Clean main frame threads with ...
Place eye bolt in the head of ...
Attach the two way cable to th...
Ensure that the cable is perfe...
Hoist the shaft out of the mai...
Place shaft on the ground
Un-hook two way cable from sha...
Place cover on the eccentric b...
Install eye bolts in the socke...
Attach the two way cable to th...
Lift socket sealing ring with ...
Check to ensure there is movem...
Lift the socket sealing ring o...
Remove the three locking dowel...
Place on clean surface
Disconnect the two way cable
Raise cable out of the work ar...
Remove O-Ring and/or valves an...
Inspect the root clearance, ba...
Inspect main frame arms, main ...
Inspect counter shaft box brea...
Cover crusher parts with a pla...
3. Dismantle and Re-build Bowl
Attach ring end of two way cab...
Attach two way cable to bowl
Transport bowl to wash area us...
Wash outside threads
Wash U-bolt cover plates and/o...
Transport bowl to rebuild area
Disconnect two way cable from ...
Remove U-bolt covers with 1/2"...
Loosen and pry off U-bolt cove...
Clean, inspect, and replace as...
Set aside for re-assembly
Remove U-bolt locking plates w...
Set aside for reassembly
Remove U-bolt nuts using 1" im...
Clean, inspect, and replace as...
Set aside for reassembly
Pull off thin steel top plate,...
Stack accordingly for reassemb...
Pull U-bolts out of bowl assem...
Set aside for cleaning & reass...
Attach ring on end of two-way ...
Attach other ends of two-way c...
Raise bowl approximately 2" of...
From the outside, beat on U-bo...
Lift bowl assembly after liner...
Place bowl assembly to the sid...
Reposition cables on the bowl ...
Lift bowl and lower so that it...
Chip excess backing material f...
Buff seat area on bowl assembl...
Inspect seat area looking for ...
Apply oil or grease from above...
Lift bowl assembly and set upr...
Reposition the two way cables ...
Buff paint from the seat area ...
Apply two beads of silicone on...
Cut 6-6"x6" squares of insulat...
Slice a hole in the center of ...
Place insulation squares over ...
Lift the bowl assembly and pla...
Disconnect two-way cables from...
Move crane/loader out of the w...
Pack insulation firmly around ...
Pack insulation to the point w...
Clean U-bolts with a wire whee...
Install U-bolts under lugs
Pack insulation firmly around ...
Install thick steel bottom pla...
Apply never seize to U-bolt th...
Install all nuts on U-bolts, h...
Partially tighten nuts using 1...
Re-install U-bolt locking plat...
Place a square of insulation o...
Re-install U-bolt covers
Pour backing material in conju...
4. Disassemble and Rebuild the Ma...
Attach the ring of the two-way...
Attach the other ends of the t...
Lift the shaft off the ground ...
Transport shaft to the work ar...
Lower shaft into the assembly ...
Remove two-way cable from shaf...
Remove lifting eye
Cut the torch ring using the t...
Place Nordberg splined wrench ...
Pound Nordberg wrench in a cou...
Remove the Nordberg wrench fro...
Install eye bolts into the dis...
Remove the two-way cable from ...
Attach the ring on the two-way...
Attach the two-way cable to th...
Take up the tension on the cab...
Continue to remove nut by gras...
Apply Nordberg wrench to loose...
Place the splined nut on the g...
Disconnect the two-way cable f...
Clean and inspect the nut
Set aside for reassembly
Remove the remainder of the to...
Remove silicone from eye bolt ...
Install the eye bolts into the...
Attach the two-way cable to th...
Lift and remove the shaft slee...
Clean and inspect the shaft sl...
Set aside for reassembly
Un-hook the two-way cable from...
Weld two pad eyes on the mantl...
Attach the two-way cable to th...
Lift mantle liner off of the s...
Disconnect two-way cable from ...
Lift cables from the working a...
Clean the old backing material...
Clean the seat area on the sha...
Oil the shaft where the backin...
Clean and inspect the threads ...
Apply two beads of silicone to...
Weld two pad eyes approximatel...
Enlarge the backing pour notch...
Cut off the three casted lifti...
Attach the two-way cable to on...
Lift the mantle liner and turn...
Inspect and clean the seat
Lift the mantle liner and turn...
Re-attach both cables to pad e...
Lift the new mantle liner up
Center the new mantle liner on...
Disconnect two-way cable from ...
Attach two-way cable to the sh...
Lift and place sleeve over sha...
Remove the two-way cable and e...
Fill eye bolt holes in shaft s...
Attach the two-way cable to th...
Install new torch ring by hand
Apply never seize to the shaft...
Lift the splined nut onto the ...
Start splined nut onto thread ...
Ensure that the torch ring is ...
Remove the two-way cable and e...
Tighten the splined nut using ...
Remove the Nordberg wrench aft...
Construct a pour trough/birds ...
Pour backing material in conju...
5. Pouring Backing Material
Ensure that the proper tools, ...
Ensure that the backing materi...
Ensure that the mantle and the...
Install the ventilation fans i...
Don proper PPE
Remove the lids from the backi...
Place the mixing paddle into t...
Mix the epoxy to ensure a cons...
Remove the lid from the harden...
Add, slowly, the hardener to t...
Ensure that the material is mi...
Pour mixed backing material in...
Repeat as necessary until fill...
Ensure proper backing levels
Leave the mantle and bowl stan...
6. Reassemble and Test Crusher
Conduct a Pre-shift inspection...
Inspect Backing
Cut pad eyes off of mantle
Remove the tarp carefully insu...
Clean off socket assembly
Remove excess oil, dirt, and g...
Clean the surface of the O-rin...
Clean bronze with rags only
Remove the lid from the hole
Ensure that no debris are insi...
Install the oil drain plug
Reinstall the cover over the h...
Lubricate valves and springs w...
Install the O-ring and/or valv...
Hook the two-way cable to the ...
Install eye bolts into the soc...
Attach the two-way cable to th...
Pick up socket sealing ring ap...
Clean out cavity with scraper ...
Wipe top surface down with sol...
Raise socket sealing ring up a...
Remove the old felt with a scr...
Discard the old felt
Dunk new felt in oil
Install the new felt into the ...
Cut off any excess felt with a...
Lower socket sealing ring appr...
Pack grease cavity by gloved h...
Ensure that dowel key ways are...
Ensure that the dowel keys, in...
Lower, slowly, the socket seal...
Disconnect two-way cable from ...
Remove the eye bolts from the ...
Attach the ring of the two-way...
Install the eye bolts into the...
Attach two-way cable to eye bo...
Raise the mantle shaft up out ...
Lower mantle shaft on cribbing...
Ensure that the main shaft is ...
Clear oil passage with water o...
Raise the shaft off of the cri...
Transport mantle to the crushe...
Lower mantle onto cribbing or ...
Disconnect two way cable ring ...
Connect the two way cable ring...
Carefully raise the mantle ens...
Remove the lid from the socket
Inspect socket area for cleanl...
Douse the bronze with 5 gallon...
Position the shaft over the ma...
Slowly lower the mantle all th...
Pull the lockout tagout on the...
Remove all tools, materials, a...
Energize the motor just enough...
Lower the crane to remove tens...
Energize the motor approximate...
Lockout tagout all crusher sys...
Remove the two way cables from...
Remove eye bolt from the shaft
Stuff the splined nut with rag...
Remove the two way cable from ...
Attach two way cable to the ey...
Clean the hold down bolts and ...
Lift bowl approximately waist ...
Apply ample amounts of grease ...
Transport bowl to crusher main...
Lower bowl to clean surface
Detach two way cable ring from...
Attach two way cable ring to c...
Detach the two way cable from ...
Remove the two hold down bolts...
Attach two way cable to the lu...
Raise the adjustment cap
Move, position, and lower the ...
Attach adjustment cap to the b...
Raise bowl
Ensure that all unnecessary pe...
Position over the crusher main...
Lower the bowl until 6-12" abo...
Locate the starter threads on ...
Align starter threads on bowl ...
Lower bowl and spin simultaneo...
Thread in to desired closed si...
Lower adjustment cap
Attach lock link to the closes...
Disconnect two way cable from ...
Tighten cap bolts in a crossin...
Attach quick disconnect hydrau...
Attach two way cable to basket
Lower basket into place
Disconnect two way cable from ...
Attach two way cable to eye bo...
Lift and position over shaft n...
Lower distributor plate into p...
Disconnect two way cables from...
Raise cable and remove crane f...
Remove eye bolts from distribu...
Align bolt holes in the distri...
Install 4 new bolting hardware...
Tighten and secure all bolts w...
Weld or double nut hardware
Reinstall chutes, belts, conve...
Remove the lockout tagout on t...
Start the crusher
Verify 2500 PSI clamping press...
Check oil pressure and for lea...
Ensure that there is proper oi...
Inspect and listen for any unu...
Check head spin and ensure tha...
Turn off crusher and check coa...
Lockout tagout all crusher sys...
Recheck the crusher adjustment...
Remove all lockout tagout equi...
Start the crusher
Take an amp reading
Start the plant including all ...
Take a full load amp reading
Gather all tools, equipment, a...
Release to production
Nordberg 4.25 Ft. Standard Cone Crusher Liner Replacement
1.
Preparation
Conduct Self Assessment
Conduct Pre-Job meeting
Review Safety Procedures
Crane hand signals
Lock-Out-Tag Out Procedures
Review cutting/Grinding safety
Overhead load safety
Ventilation
Discuss weather conditions
Review emergency response procedures
Review Manufacturers Manual
Ensure that all recommended parts, equipment, tools are available
Check component weights of crusher to ensure that safe picks are made; refer to crane load charts
Review Equipment Needs
Cranes
Use only certified crane personnel
Rigging
Tag Line
Ensure that someone inspects the rigging for defects
Gloves for rigger
Loader
980 or larger
Service Truck
Cutting torch & Full Bottles
Hand tools
Welder
Compressor
Obtain job specific PPE
Face shield
Cutting Goggles
Leathers
Welding Hood
Welding Gloves
Respirator
Fall Protection
Long Sleeve shirts
Safety Glasses
As per Company Policy
Hearing Protection
Hard Hats
As per Company Policy
Safety Shoes
As per Company Policy
Ensure that the proper parts are on site and available
Mantle Liners
Bowl Liners
Torch Ring
O-Rings
Springs & Guide Kit
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.
Pre-Shift Inspection
Use company form
Loader
Pre-Shift Inspection
Use company form
Must be task trained
980 or larger
Crane
Use only certified personnel
Pre-Shift Inspection
Use company form