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Nordberg 4.25 Ft. Standard Cone Crusher Liner Replacement

Nordberg 4.25 Ft. Standard Cone Crusher Liner Replacement
Preparation Dismantle Crusher Dismantle and Re-build Bowl Disassemble and Rebuild the Mantle Pouring Backing Material Reassemble and Test Crusher
1. Preparation
Conduct Self Assessment Priority 2
Conduct Pre-Job meeting Priority 2
Review Safety Procedures Priority 2
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 Priority 2
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 Priority 2
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 Priority 2
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 Priority 2
Assign Jobs
Upper
Lower
Crane Operator
Loader Operator
Obtain tools, equipment, and materials Priority 2
Equipment Priority 2
Rigging Priority 2
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 Priority 2
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
Tools Priority 2
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 Priority 2
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 Priority 2
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 Priority 3
Crusher
Feed conveyor
Discharge conveyor
All oil systems including heaters
All neighboring circuits surrounding work area
Stage Crane in safe location Priority 3
Remove all conveyors, chutes and/or hoppers Priority 2
Pull oil drain plug Priority 2
Recycle oil
Cut distributor plate bolts Priority 2
Remove distributor plates Priority 2
Relieve pressure on locking post Priority 2
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 Priority 2
Wrap 1/2" X 30' wire rope cable around crusher bowl in a counter clockwise manner Priority 2
Attach the other end of the wire rope to the eye or hook on the loader bucket using an approved shackle Priority 2
Un-screw crusher bowl with the loader Priority 3
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) Priority 2
Lift basket out of the bowl (hydraulic crusher only) Priority 2
Place the basket on the ground Priority 2
Attach two way cable to the bowl cap ears Priority 2
Lift bowl out of the main frame in a slow manner Priority 2
Insure that all personnel are in a safe location during this step
Place bowl on the ground Priority 2
Remove bowl Priority 2
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 Priority 2
Attach the two way cable to the eye bolt with the correct shackle Priority 2
Ensure that the cable is perfectly vertical Priority 2
Hoist the shaft out of the main frame in a slow manner Priority 2
Ensure that all personnel are in a safe location during this step Priority 3
Ensure that the end of the shaft does not gouge socket liner
Place shaft on the ground Priority 2
Un-hook two way cable from shaft Priority 2
Place cover on the eccentric bushing Priority 2
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 Priority 2
Ensure that the eye bolts are properly secured
Attach the two way cable to the eye bolts with the proper shackle Priority 2
Lift socket sealing ring with slight pressure Priority 2
Check to ensure there is movement Priority 3
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 Priority 2
Remove the three locking dowel keys and set aside for reinstallation Priority 2
Place on clean surface
Disconnect the two way cable Priority 2
Raise cable out of the work area Priority 2
Remove O-Ring and/or valves and springs from the top of the socket Priority 2
Discard all and do not reuse
Inspect the root clearance, back lash, and condition of bronze eccentric bushing, socket liner and step washers Priority 2
Per manufactures specifications; order parts if required
Inspect main frame arms, main frame liners, and counter shaft liners for excessive wear Priority 2
Order parts if required
Inspect counter shaft box breathers Priority 2
Order parts if required
Cover crusher parts with a plastic tarp to prevent environmental damage Priority 2
3. Dismantle and Re-build Bowl
Attach ring end of two way cable to loader bucket Priority 2
Attach two way cable to bowl Priority 2
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 Priority 2
Wash U-bolt cover plates and/or U-bolts Priority 2
Transport bowl to rebuild area Priority 2
Disconnect two way cable from bowl Priority 2
Remove U-bolt covers with 1/2" impact and 3/4" socket Priority 2
Loosen and pry off U-bolt covers Priority 2
Clean, inspect, and replace as necessary Priority 2
Set aside for re-assembly
Remove U-bolt locking plates with pry bar Priority 2
Set aside for reassembly
Remove U-bolt nuts using 1" impact and appropriate impact socket Priority 2
Clean, inspect, and replace as necessary Priority 2
Set aside for reassembly
Pull off thin steel top plate, rubbers, and thick steel bottom plate from each of 6 U-bolts Priority 2
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 Priority 2
Pull U-bolts out of bowl assembly Priority 2
May need to dig out insulation to remove U-bolts
Set aside for cleaning & reassembly Priority 2
Attach ring on end of two-way cable to loader/crane Priority 2
Attach other ends of two-way cable to the bowl as before Priority 2
Raise bowl approximately 2" off ground Priority 2
From the outside, beat on U-bolt lugs using 3"x4' solid steel shaft Priority 2
Make sure you are wearing proper PPE
Be careful of flying metal chips and liner falling from bowl
Lift bowl assembly after liner separates Priority 2
Place bowl assembly to the side Priority 2
Reposition cables on the bowl from its previous points to a side by side position Priority 2
Lift bowl and lower so that it is laying on it's side Priority 2
Chip excess backing material from bowl assembly using slag hammer Priority 2
Buff seat area on bowl assembly with wire wheel Priority 2
Inspect seat area looking for cracks, excess wear per manufacturers specifications Priority 2
Apply oil or grease from above the seat area to the top of the bowl Priority 2
Lift bowl assembly and set upright Priority 2
Reposition the two way cables opposite each other on the bowl assembly Priority 2
Buff paint from the seat area of the new bowl liner using the wire wheel or gator pads Priority 2
Apply two beads of silicone on seat of new bowl liner Priority 2
Cut 6-6"x6" squares of insulation Priority 2
Slice a hole in the center of each square of insulation big enough to fit over the lugs on the bowl liner Priority 2
Place insulation squares over the lugs on the new liner Priority 2
Lift the bowl assembly and place it over the lugs on the new bowl liner Priority 2
Pry with bar to center lugs in the holes
Disconnect two-way cables from bowl Priority 2
Move crane/loader out of the way Priority 2
Pack insulation firmly around lugs using small pry bar or large screwdriver Priority 2
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 Priority 2
Clean U-bolts with a wire wheel, wire brush, and/or thread chase, with lots of WD40. Replace as needed Priority 2
Install U-bolts under lugs Priority 2
Pack insulation firmly around U-bolts using small pry bar or large screwdriver until the U-bolt chambers are full and tight Priority 2
Install thick steel bottom plate, rubbers, and thin steel top plate over U-bolt threads (6 total installations) Priority 2
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 Priority 2
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 Priority 2
Attach the other ends of the two-way cable to the lifting eye on the stem Priority 2
Lift the shaft off the ground just high enough so as the shaft does not make contact with the ground Priority 2
Transport shaft to the work area Priority 2
Lower shaft into the assembly hole and rest on the floor Priority 2
Remove two-way cable from shaft Priority 2
Remove lifting eye Priority 2
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 Priority 2
Place Nordberg splined wrench into the splined nut on top of the shaft Priority 2
Pound Nordberg wrench in a counter clockwise direction using a sledge hammer to loosen the splined nut Priority 2
Remove the Nordberg wrench from the splined nut Priority 2
Install eye bolts into the distributor plate holes on the splined nut Priority 2
Remove the two-way cable from the loader bucket Priority 2
Attach the ring on the two-way cable to the crane hook Priority 2
Attach the two-way cable to the eye bolts on the splined nut using approved shackles Priority 2
Take up the tension on the cable Priority 2
Continue to remove nut by grasping cable and eye bolts and turning counter clockwise Priority 2
Apply Nordberg wrench to loosen until free if the nut is too tight Priority 2
Keep tension on the cable using the crane
Place the splined nut on the ground in a safe place Priority 2
Disconnect the two-way cable from the splined nut Priority 2
Clean and inspect the nut Priority 2
Set aside for reassembly Priority 2
Remove the remainder of the torch ring from the shaft and discard Priority 2
Remove silicone from eye bolt holes in the shaft sleeve Priority 2
Install the eye bolts into the shaft sleeve Priority 2
Attach the two-way cable to the shaft sleeve Priority 2
Lift and remove the shaft sleeve using the crane Priority 2
Clean and inspect the shaft sleeve Priority 2
Set aside for reassembly Priority 2
Un-hook the two-way cable from the shaft sleeve Priority 2
Weld two pad eyes on the mantle liner opposite of each other Priority 2
Must use manganese or stainless welding rod
Attach the two-way cable to the pad eyes on the mantle liner Priority 2
Lift mantle liner off of the shaft and place on ground to discard Priority 2
Disconnect two-way cable from mantle liner Priority 2
Lift cables from the working area Priority 2
Clean the old backing material from the shaft Priority 2
Proper cleaning may require wire wheel, brush or chipping hammer
Clean the seat area on the shaft Priority 2
Clean using a wire brush, gator pad, or a wire wheel
Oil the shaft where the backing is to be installed Priority 2
Clean and inspect the threads at the top of the shaft where the splined nut goes Priority 2
Clean using a wire brush
Apply two beads of silicone to seat area on the shaft Priority 2
Weld two pad eyes approximately 3" below the notches on the new mantle liner Priority 2
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 Priority 2
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 Priority 2
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 Priority 2
Lift the mantle liner and turn the mantle liner over so the seat side is up Priority 2
Watch for un-expected movement
Inspect and clean the seat Priority 2
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 Priority 2
Re-attach both cables to pad eyes Priority 2
Lift the new mantle liner up Priority 2
Center the new mantle liner on the shaft and lower Priority 2
Disconnect two-way cable from mantle liner Priority 2
Attach two-way cable to the shaft sleeve Priority 2
Lift and place sleeve over shaft and lower into position on top of new mantle liner Priority 2
Remove the two-way cable and eye bolt from the shaft sleeve Priority 2
Fill eye bolt holes in shaft sleeve with silicone
Attach the two-way cable to the splined nut Priority 2
Install new torch ring by hand Priority 2
Apply never seize to the shaft threads
Lift the splined nut onto the shaft threads Priority 2
Start splined nut onto thread of shaft using cables and eye bolts to turn while lowering with crane until snug Priority 2
Ensure that the torch ring is centered on the sleeve while turning the nut into place Priority 2
Remove the two-way cable and eye bolts from the splined nut Priority 2
Tighten the splined nut using the Nordberg splined wrench Priority 2
Refer to the Nordberg manual
Remove the Nordberg wrench after proper tightening Priority 2
Construct a pour trough/birds nest around the pour holes in the mantle liner Priority 2
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 Priority 3
Remove the lids from the backing material Priority 2
Place the mixing paddle into the drill Priority 2
Mix the epoxy to ensure a consistent blend Priority 2
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 Priority 3
Ensure that the material is mixed to a consistent color Priority 2
Refer to the manufacturers mixing procedure
Pour mixed backing material into the cavities of the mantle and bowl liners Priority 2
As pouring continues, new batches of material is being mixed
Repeat as necessary until filled Priority 2
Refer to the manufactures specifications on the proper quantity
Ensure proper backing levels Priority 2
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 Priority 2
Refer to the manufacturers recommendations
6. Reassemble and Test Crusher
Conduct a Pre-shift inspection on all mobile equipment Priority 2
Follow company policy
Inspect Backing Priority 2
Check for hardness and leakage
Cut pad eyes off of mantle Priority 2
Remove the tarp carefully insuring that no debris fall into the stem hole
Clean off socket assembly Priority 2
Remove excess oil, dirt, and grease from the socket assembly using rags, and minimum solvent Priority 2
Clean the surface of the O-ring, valves and springs, with a scraper and/or grease rag including spring holes Priority 2
Clean bronze with rags only Priority 2
Remove the lid from the hole
Ensure that no debris are inside the hole Priority 2
Install the oil drain plug Priority 2
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 Priority 2
Hook the two-way cable to the crane Priority 2
Install eye bolts into the socket sealing ring Priority 2
Attach the two-way cable to the eye bolts attached to the socket sealing ring Priority 2
Pick up socket sealing ring approximately waist high with the crane Priority 2
Clean out cavity with scraper and gloved hand Priority 2
Be careful of sharp edges and slippery surfaces because of grease
Wipe top surface down with solvent and rags Priority 2
Follow company HazCom policy when working with chemicals
Raise socket sealing ring up approximately chin high Priority 2
Remove the old felt with a screw driver and/or scraper Priority 2
Do not work under a suspended load
Discard the old felt
Dunk new felt in oil Priority 2
Install the new felt into the groove by pushing firmly until seated Priority 2
Cut off any excess felt with a utility knife Priority 2
Lower socket sealing ring approximately waist high Priority 2
Do not work under a suspended load
Pack grease cavity by gloved hand with grease ensuring that no air pockets exist Priority 2
Follow company HazCom policy when working with chemicals
Be careful of sharp surfaces
Ensure that dowel key ways are clear of grease Priority 2
Ensure that the dowel keys, inside the crusher main frame, are in the proper vertical position in socket Priority 2
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 Priority 2
Disconnect two-way cable from socket sealing ring Priority 2
Remove the eye bolts from the socket sealing ring Priority 2
Attach the ring of the two-way cable on the loader bucket if transporting mantle by loader Priority 2
Install the eye bolts into the top of the mantle shaft Priority 2
Attach two-way cable to eye bolt on the top of the mantle shaft Priority 2
Raise the mantle shaft up out of the hole Priority 2
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 Priority 2
Ensure that the main shaft is clean by using a rag (if necessary) Priority 2
Clear oil passage with water or compressed air by inserting air or water into the hole located at the bottom of the shaft Priority 2
Raise the shaft off of the cribbing or clean surface keeping shaft clean Priority 2
Transport mantle to the crusher Priority 2
Lower mantle onto cribbing or clean surface Priority 2
Disconnect two way cable ring from the loader Priority 2
Connect the two way cable ring to the crane hook Priority 2
Carefully raise the mantle ensuring cleanliness Priority 2
Remove the lid from the socket Priority 2
Inspect socket area for cleanliness(visually) Priority 2
Douse the bronze with 5 gallons of oil ensuring that all bronze surfaces are coated Priority 2
Position the shaft over the main frame Priority 2
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 Priority 2
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 Priority 2
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 Priority 2
Refer to manufacturer's manual
Lower the crane to remove tension on the two way cable Priority 2
Energize the motor approximately 15 seconds ensuring that the mantle is seated in the socket liner Priority 2
Refer to manufacturer's manual
Lockout tagout all crusher systems previously energized for the seating of the mantle Priority 3
Remove the two way cables from the mantle Priority 2
Remove eye bolt from the shaft Priority 2
Stuff the splined nut with rags up to the top Priority 2
Remove the two way cable from the crane hook and attach to the loader Priority 2
Attach two way cable to the eye bolts on the bowl Priority 2
Clean the hold down bolts and threads in the hold down bolt holes in the crusher bowl using wire wheel and tap as necessary Priority 2
For mechanical crusher only
Lift bowl approximately waist high Priority 2
Apply ample amounts of grease to outside threads of bowl with gloved hands Priority 2
Be careful of sharp edges
Transport bowl to crusher main frame area Priority 2
Lower bowl to clean surface Priority 2
Detach two way cable ring from loader Priority 2
Attach two way cable ring to crane hook Priority 2
Detach the two way cable from the bowl Priority 2
Remove the two hold down bolts from the bowl that were used to transport it and set aside Priority 2
For mechanical crusher only
Attach two way cable to the lugs on the adjustment cap Priority 2
Raise the adjustment cap Priority 2
Move, position, and lower the adjustment cap onto the bowl Priority 2
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 Priority 2
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 Priority 2
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 Priority 3
Position over the crusher main frame Priority 2
Lower the bowl until 6-12" above the main frame Priority 2
Locate the starter threads on the bowl and main frame Priority 2
Align starter threads on bowl and main frame Priority 2
Lower bowl and spin simultaneously into threads on main frame using as many people as necessary Priority 2
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 Priority 2
see manufacturer's manual
Lower adjustment cap Priority 2
Attach lock link to the closest hole and pin it Priority 2
for mechanical only
Disconnect two way cable from adjustment cap Priority 2
Tighten cap bolts in a crossing pattern using 1" ratchet, appropriate socket and 3-5' cheater bar Priority 2
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 Priority 2
for hydraulic only
Attach two way cable to basket Priority 2
for hydraulic only
Lower basket into place Priority 2
for hydraulic only
Disconnect two way cable from basket Priority 2
for hydraulic only
Attach two way cable to eye bolts on distributor plate Priority 2
for hydraulic only
Lift and position over shaft nut Priority 2
Lower distributor plate into place Priority 2
Disconnect two way cables from eye bolts Priority 2
Raise cable and remove crane from work area Priority 2
Remove eye bolts from distributor plate Priority 2
Align bolt holes in the distributor plate with the holes in the shaft nut Priority 2
Install 4 new bolting hardware sets using appropriate amounts of lock washers Priority 2
Bolts in from the bottom, nuts on top
Tighten and secure all bolts with 3/4" impact gun and appropriate socket and wrench Priority 2
Weld or double nut hardware
Weld or double nut hardware
Reinstall chutes, belts, conveyors, hoppers as per site requirements in reverse order of disassembly procedure Priority 2
Remove the lockout tagout on the crusher and any interlocked systems that will allow the crusher to be started with oil pressure Priority 2
Removal of lockout tagouts will be site specific
Start the crusher Priority 2
Verify 2500 PSI clamping pressure on the hydraulic rams Priority 2
For hydraulic only
Check oil pressure and for leaks Priority 2
Should be 7-12 PSI, or in accordance with the manufacturer's specifications
Ensure that there is proper oil return back to the tank Priority 2
Inspect and listen for any unusual noises and conditions Priority 2
Check head spin and ensure that it's spinning in accordance with manufacturer's specifications Priority 2
visual check
Turn off crusher and check coast down time Priority 2
In accordance with manufacturer's specifications
Lockout tagout all crusher systems previously energized Priority 3
Recheck the crusher adjustment/tolerance by observing the gap on the closed side Priority 2
Remove all lockout tagout equipment Priority 2
Start the crusher
Take an amp reading Priority 2
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 Priority 2
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 Priority 2
Store cables and rigging equipment in its proper place. Equipment and tools replaced to its proper storage areas
Release to production