MSHA - Interactive Training - JTA Spiders - Crusher Operator Table of Contents

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	Crusher Operator
	Contact: Palmer.Melvin@dol.gov

1. 1. Pre-shift/Start-up

Keep all travel ways and working surfaces free of slip, trip and fall hazards

Open maintenance shop

Obtain/wear PPE

Wear safety shoes

Wear ear plugs where appropriate

Wear safety glasses

Wear fall protection (when necessary)

Review check-sheet from previous shift

Conduct safety check on site truck

Take truck out of service if safety defects are found

Check back-up alarm

Check seat belts

Complete inspection report and turn in to foreman

Always check blind spots prior to engaging

Drive truck to screen house

Conduct safety check on screen/screen house

Travel to fourth floor (steps/ladder)

Face ladders when ascending/descending

Maintain 3-point contact

Check oil level at gear housing

Check oil in screen on third floor

Check screen on third floor

Check for holes which don't make spec

require screen changes

2RC

3 inch modified

Check guard on motor

Travel to second floor

Check adjustment on 44 crusher, if necessary

look at oversize, if over 4 inches, adjust manually (aprx. 20-30 clicks)

Check chute going into cone crusher for blockage

If blocked, open cone cover at 2nd floor panel

Take bar with you to knock debris down

Pass bar to each other - don't climb ladder with bar

Stand on crusher box

Determine if fall protection is necessary

Remove debris with bar

Close cone cover

Check guard on crusher

Check oil in lube pump

Travel to first floor

Conduct visual exam of tail pulleys

Check belts for wear, tears, clips missing

Lock out oversize belt, crusher, and modified stacker at the panel

Check under crusher for debris

Check skirt boards

Check oil in crusher

Report any immediate dangers to life/health immediately

Travel to modified stacker

Clean underneath tail by removing spillage with shovel

climb ladder above modified stacker to catwalk

Check for blockage

If blocked, remove blockage with bar

bar stays on the catwalk

Report any immediate dangers to life/health immediately

Report any defects found verbally

Ensure all defects are corrected before starting up screen and crusher

Travel back to panel room

Start up the screen and crusher

Push the button for the hydraulic pump for the crusher

Pull the button for the horn to blow

After horn blows, everything starts up automatically

Travel by truck to jaw

pull up on ramp of hopper

Look into hopper at grizzly bars and side plates

can be visually checked from top

Proceed across catwalk to crusher shack

Change numbers in the belt scale

Zero out the scale

Make jaw adjustment prior to starting up

turn pump on for primary crusher

Start up primary crusher in order to grease the bearings

Warning horn should sound before start up

Check the 48" belt

Check return rollers

Check troughing rollers

Check the box for the 42" belt for blockage

Check metal magnet for debris

Go upstairs to crusher shack and turn on 48" belt

Warning horn should sound before start up

Throw breaker for the feeder

Check oil in the hammer

Conduct visual exam of the hammer

Check for pins coming out

Report any immediate dangers to life/health immediately

Conduct visual exam of belts

Check for tears

Check for clips missing

Complete daily maintenance checklist for each plant

2. 2. Production

Notify/signal driver when it is okay to dump

Repeat for each load

Dump material into the feeder

Start up the feeder

Regulate power setting as necessary with dial

Dial is normally set between 7-8

keep the primary choked with material

make visual check for oversized (shot rock) materials

Break oversized (shot rock) materials with hammer

adjust the dial as material drops into jaw crusher

Lower the dial as load goes down

Turn water on to entire plant for production

flip toggle switches when starting feeder (simultaneously)

Run the material into primary crusher (C110) and onto 48" belt

Check to ensure materials are flowing into box onto 42" belt

Check belt scale in the crusher shack for tonnage per hour

Should not run more than 800 ton per hour up the belt

If rate exceeds 800 ton per hour, adjust power dial down as necessary

Prevent overflow

Check cameras to make sure you have flow of materials

Check to make sure you have flow of materials throughout (belts/stackers)

3", 4" and modified go onto piles

Screen oversize goes into 44 crusher and out to stockpile

Move stackers when needed (pile location and elevation)

3 on plant C and 1 at top (modified stacker)

Plant operator will conduct visual from shack or loader operators will notify operator if stackers need to be moved

Have loader operator move 3" and 4" materials to stockpiles

Observe for spillage

Shut down and lock out belt if spillage needs to be cleaned up

Major clean up only during 1st shift; routine/minor clean up done by 2nd shift

Flip plate from 2a to 3a

lock out and tag out screen

go upstairs and roll away the chute

get into the 3 chute and get a hold of the plate and flip it by hand

Caution employees to have enough personnel available to do the job (at least 2 persons, maybe 3)

shut the chute and roll back

remove lock and tag

Change to rip-rap

lock and tag out screen and 44 crusher

obtain slings and clevises

Inspect rigging material for wear, etc. prior to using

attach to crane and chute of 44 crusher

unbolt chute and lift with crane and place chute on floor

get into chute of the oversize and dig around the plates that need to be removed (3 plates)

Once uncovered, unbolt and lift out by hand and place on floor

attach rigging to cover plate and using crane, place plate on hole where chute was and bolt plate to the wall

remove rigging and move crane

remove lock and tag to screen

leave 44 crusher locked and tagged out

Crusher is already by-passed

clean up work area

correct belt slippage

lock and tag out

shovel off belt

remove lock and tag

start up belt and spray belt dressing at the same time

stand back from belt when spraying belt dressing

stand on catwalk and spray through the guard

Start end-of-shift shutdown

allow material to run through entire system

Turn water off once belts are empty

press all the off switches

3 in shack (primary crusher, 48 and feeder)

2 (pump to 44 and off switch)

3. 7. Unusual Conditions/Emergency Situations/Non-Routine

Observe SLAM (Stop, Look, Analyze and Manage) twice

Releasing stored energy (belt hang ups)

lock and tag out belt

use crane with big hooks connected to the counterweight to release tension from the belt

shovel build up/debris

repair gear reducer

reverse process to reassemble

4. 6. Shift Change

Crusher operator will give incoming operator a daily report (verbal and written check-sheet)

report on feed size of rock

deficiencies in equipment

current overrides

outgoing operator will complete daily check sheet and turn in to plant manager

incoming plant operator will receive maximum production and additional instruction from plant supervisor

Extension shift plant operator will report problems to 2nd shift supervisor who will repair and/or report to plant manager

5. 5. Rebuild C110

Lock and tag out the C110

Lock and tag out C1B

release pressure on hydraulics

Lock and tag out hydraulics at the panel

loosen nuts on wedges

place ladder inside crusher

Have one person stands inside crusher on ladder and another person goes outside crusher and beats the bolts inward loosening the wedges on the stationary

push the wedges to the inside of crusher

weld the eye onto the die to attach rigging

Caution employee to wear PPE (helmet and gloves)

lift the stationary plate with a crane

Inspect rigging for wear, etc.

Have one person outside of the crusher loosen the bolts

Have one person stand inside crusher on ladder and another person goes outside crusher and beats the bolts inward loosening the wedges on the swing jaw

weld the eye to the swing jaw and hook rigging

Caution employee to wear PPE (helmet and gloves)

Inspect rigging for wear, etc.

lift with the crane and place on ground

weld eyes to all the cheek plates

Caution employee to wear PPE (helmet and gloves)

loosen the bolts

add rigging to each cheek plate, lift out and place on ground

Inspect rigging for wear, etc.

get inside of crusher with face mask, shield and electric wire wheel

clean inside of crusher with wire wheel

weld eyes on new cheek plates and new jaw dies

Caution employee to wear PPE (helmet and gloves)

lift in the cheek plates and place bolts, tighten down

attach rigging to swing jaw and place into crusher with crane

Inspect rigging for wear, etc.

place wedges and bolts into proper position

Outside man will insert spacers and tighten nuts

attach rigging up to stationary and lift with crane into crusher

Inspect rigging for wear, etc.

place wedges and bolts in proper position

Outside man will insert spacers and tighten nuts

remove lock and tag from hydraulics

adjust crusher to proper crush dimension

remove lock and tag from primary crusher (C110) and from the C1B

6. 4. Rebuild 44 crusher

Lock and tag out

Obtain tools/equipment

attach sling with clevises

Inspect rigging for wear, etc.

hook to the crane

remove bolts and lift

attach to crane with slings

lift out and place on ground

Attach bolt extensions to upper frame of crusher

turn hydraulic pump on and wind it out

hook upper frame of crusher with concave to crane with eye bolts and lift out

cut the cap off of the mantle by torching off the bolts

torch the torch ring off of the mantle

Requires shield, mask and burning gloves

wind the nut off

use crane with sling to lift nut out and place on floor

weld two lugs on mantle

Requires helmet and burning gloves

use two slings and two clevises to connect to the lugs and lift mantle to outside

clean mantle piece using grinder with wire wheel

Caution employee on use of PPE (mask, shield, gloves)

cut off the four ears of the concave

Caution employee on use of PPE (mask, shield, gloves)

knock the concave out of the frame

clean concave up using grinder with wire wheel

Caution employee on use of PPE (mask, shield, gloves)

level out concave

place level across top of concave

caulk bottom lip of concave

oil inside of frame using rag

take frame and set it down on top of concave

hammer wedges underneath ears of concave and weld fast to frame and ears

Caution employee on use of PPE (helmet, gloves)

pour Nordbak (backing material) into void area between concave and frame

review/discuss MSDS

Discuss proper mix of backing material

weld ears on to mantle

Caution employee on use of PPE (helmet, gloves)

oil and caulk cone before placing mantle

place mantle using crane, clevises and slings

place torch ring on mantle

use the crane to bring nut down to you and then spin on by hand

Use tee wrench/plate to tap and ensure tightness

weld torch ring to the mantle and the nut

Caution employee on use of PPE (helmet, gloves)

place cap on and bolt down

pour Nordbak (backing material) between mantle and main shaft

review/discuss MSDS

Discuss proper mix of backing material

Attach four slings to hoist upper frame up with crane

Inspect rigging for wear, etc.

Set upper frame down in main frame

Turn hydraulic pump on

Spin it down into main frame until you reach proper crush dimension

Remove three extensions

Attach two slings, two clevises and two eye bolts to hopper and lift it up into upper frame

Inspect rigging for wear, etc.

Bolt to upper frame

Attach two slings and two clevises to the chute and lift up onto the main oversize chute

Inspect rigging for wear, etc.

Bolt chute to main oversize chute

Release rigging from chute

7. 3. Maintenance

Lock and tag out all equipment prior to performing maintenance and repairs

Lubricate equipment

Conduct Weekly (Saturday)

Grease four grease fittings on 44 crusher

Check and fill lube tank on 44 crusher

Check and fill hydraulic tank on 44 crusher

Check and fill oil in feeder

Check and fill hydraulic tank on hammer

Check and fill lube tank on C110 crusher

Grease head and tail pulleys

Check wear plates daily

several in feeder

replace if necessary

Check bolts and feeder plates daily

replace if necessary

Inspect rollers and belts weekly (Saturday)

replace rollers (if necessary)

Lock and tag out belts prior to replacing rollers

Obtain necessary tools

attach come-a-long to frame of conveyor to take the tension off the belt/roller

Depends on belt (gravity take-ups)

take pry bar and hammer and pry/hammer until it comes out of the frame

Must wear eye protection

take roller and pop it right in the frame

clip belts (if necessary)

bucket of clips

hole punch/cutter

template for punching holes

2 clamps and 2 come-a-longs

pen

remove grease from tail pulley when doing full splice

attach come-a-long to belt to relieve tension

make splice/repairs to belt

release come-a-longs

remove belt clamps

re-adjust belt tension by adding grease

remove lock and tag and start belt to make final adjustments

Obtain tools/equipment

bucket of clips

hole punch/cutter

template for punching holes

2 clamps and 2 come-a-longs

pen

bar

rope

remove grease from tail pulley when doing full splice

pull the new belt on

attach clamps and come-a-longs

pull the belt tight

use template to drill holes through the belt

remove template and put clips in

run the tape through

tighten the clips down

break off the ends of clips with bar

remove clamps and come-a-longs

add tension to the tail

remove lock and tag

grease tail to take up tension

make final adjustments

change screens (when necessary)

obtain necessary tools

come-a-long for the 4 inch screens

lubrication (WD40)

obtain help (takes at least two people)

Caution employees on physical strain

open roll away chute

crawl inside to screens

use pry bar and hammer to remove the screens

Use come-a-long to remove the 4" screens

lubricate screens and channels

Tap screens in with hammer to full stop

Tap in dowel pins for 4" screens

Manually raise and lower screens from catwalk

replace steps in grizzly chute

dig out grizzly chute

lift door up by hand to remove

use hammer and pry bar to bar down dirt

obtain torch/welding equipment

chipping hammer

rods

grinding shield

Wear personal protective equipment

cut out old steps

weld in new steps

remove old material

training the existing belt

determined by belt type

grease tail pulley

wrenching on tail pulley

hammering on trough rollers or return rollers

Title

Crusher Operator

Subject

-

Company

-

Author

D. Combs

Version

76

Comments

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