Mine Safety and Health Administration (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

Conduct Self Assessment

Conduct Pre-Job meeting

Obtain tools, equipment, and m...

2. Dismantle 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

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...

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...

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