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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 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 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 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 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 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 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 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