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)
production
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
Open jaw
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
remove wedges
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
Wear PPE
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 ladder
remove lock and tag from hydraulics
adjust crusher to proper crush dimension
remove lock and tag from primary crusher (C110) and from the C1B
clean up tools
6. 4. Rebuild 44 crusher
Lock and tag out
Obtain tools/equipment
ratchet
sockets
wrenches
slings
clevises
forklift
hammer
pry bar
torch
welder/rods
Remove chute
attach sling with clevises
Inspect rigging for wear, etc.
hook to the crane
remove bolts and lift
place on floor
remove hopper
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
remove the cap
torch the torch ring off of the mantle
Wear PPE
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
Wear PPE
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
Remove rigging
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
Clean up tools
7. 3. Maintenance
Lock and tag out all equipment prior to performing maintenance and repairs
Company policy
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
chutes
replace if necessary
Check bolts and feeder plates daily
replace if necessary
wrench
Inspect rollers and belts weekly (Saturday)
replace rollers (if necessary)
Lock and tag out belts prior to replacing rollers
Company policy
Obtain necessary tools
come-a-long
hammer
pry bar
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)
Obtain tools
bucket of clips
hole punch/cutter
drill
extension cord
tightener
seam tape
template for punching holes
2 clamps and 2 come-a-longs
utility knife
pen
square
tape measure
hammer
backer board
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 board
remove belt clamps
re-adjust belt tension by adding grease
remove lock and tag and start belt to make final adjustments
change belts
Obtain tools/equipment
bucket of clips
hole punch/cutter
drill
extension cord
tightener
seam tape
template for punching holes
2 clamps and 2 come-a-longs
utility knife
pen
square
tape measure
hammer
backer board
belt material
slings
clevises
bar
chains
tag line
rope
clamp
crane
vehicle
remove grease from tail pulley when doing full splice
