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Crusher Operator

Crusher Operator
1. Pre-shift/Start-up 2. Production 7. Unusual Conditions/Emergency Situations/Non-Routine 6. Shift Change 5. Rebuild C110 4. Rebuild 44 crusher 3. Maintenance
1. 1. Pre-shift/Start-up
Open main gate
Keep all travel ways and working surfaces free of slip, trip and fall hazards Priority 2
Open maintenance shop
Obtain/wear PPE Priority 2
Wear hard hat Priority 2
Company policy
Wear safety shoes Priority 2
Company policy
Wear ear plugs where appropriate Priority 2
Company policy
Wear safety glasses Priority 2
Company policy
Wear fall protection (when necessary) Priority 3
Company policy
Review check-sheet from previous shift Priority 2
Conduct safety check on site truck Priority 2
Company policy
Take truck out of service if safety defects are found
Check oil Priority 2
Check water Priority 2
Check lights Priority 2
Check back-up alarm Priority 2
Check seat belts Priority 3
Check horn Priority 2
Check brakes Priority 3
Complete inspection report and turn in to foreman Priority 2
Always check blind spots prior to engaging
Drive truck to screen house
Conduct safety check on screen/screen house Priority 2
Travel to fourth floor (steps/ladder)
Face ladders when ascending/descending
Maintain 3-point contact
Check oil level at gear housing Priority 2
Check oil in screen on third floor Priority 2
Check screen on third floor
Check for holes which don't make spec
4 inch
3 inch
modified
require screen changes
2RC
3 inch modified
2A modified
Check guard on motor Priority 2
Travel to second floor
Check crusher
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
in place
no holes
Check oil in lube pump
Travel to first floor
Conduct visual exam of tail pulleys
look for rocks
Check guards
in place
Check belts for wear, tears, clips missing
Lock out oversize belt, crusher, and modified stacker at the panel Priority 2
Check under crusher for debris Priority 2
metal
large rocks
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
Remove cover
Check for blockage
If blocked, remove blockage with bar
bar stays on the catwalk
Replace cover
Report any immediate dangers to life/health immediately
Report any defects found verbally
Electrical
Other
Ensure all defects are corrected before starting up screen and crusher Priority 2
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
Check for wear
Complete daily maintenance checklist for each plant
2. 2. Production
Notify/signal driver when it is okay to dump Priority 2
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
6 X 16 screen
44 crusher
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 Priority 2
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 Priority 3
go upstairs and roll away the chute
get into the 3 chute and get a hold of the plate and flip it by hand Priority 2
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 Priority 3
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 Priority 2
lock and tag out Priority 3
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
stop feeding
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 Priority 3
Releasing stored energy (belt hang ups)
lock and tag out belt Priority 3
use crane with big hooks connected to the counterweight to release tension from the belt Priority 3
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) Priority 2
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 Priority 2
5. 5. Rebuild C110
Lock and tag out the C110 Priority 3
Lock and tag out C1B Priority 3
Open jaw
release pressure on hydraulics
Lock and tag out hydraulics at the panel Priority 3
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 Priority 2
Caution employee to wear PPE (helmet and gloves)
lift the stationary plate with a crane Priority 2
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 Priority 2
Caution employee to wear PPE (helmet and gloves)
Inspect rigging for wear, etc.
lift with the crane and place on ground Priority 2
weld eyes to all the cheek plates Priority 2
Caution employee to wear PPE (helmet and gloves)
loosen the bolts
add rigging to each cheek plate, lift out and place on ground Priority 2
Inspect rigging for wear, etc.
get inside of crusher with face mask, shield and electric wire wheel
clean inside of crusher with wire wheel Priority 2
Wear PPE
weld eyes on new cheek plates and new jaw dies Priority 2
Caution employee to wear PPE (helmet and gloves)
lift in the cheek plates and place bolts, tighten down Priority 2
attach rigging to swing jaw and place into crusher with crane Priority 2
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 Priority 2
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 Priority 3
Obtain tools/equipment
ratchet
sockets
wrenches
slings
clevises
forklift
hammer
pry bar
torch
welder/rods
Remove chute
attach sling with clevises Priority 2
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 Priority 2
Wear PPE Priority 2
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 Priority 2
Wear PPE Priority 2
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 Priority 2
Caution employee on use of PPE (mask, shield, gloves)
cut off the four ears of the concave Priority 2
Caution employee on use of PPE (mask, shield, gloves)
knock the concave out of the frame
clean concave up using grinder with wire wheel Priority 2
Caution employee on use of PPE (mask, shield, gloves)
level out concave Priority 2
place level across top of concave
caulk bottom lip of concave Priority 2
oil inside of frame using rag Priority 2
take frame and set it down on top of concave
hammer wedges underneath ears of concave and weld fast to frame and ears Priority 2
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 Priority 2
Caution employee on use of PPE (helmet, gloves)
oil and caulk cone before placing mantle Priority 2
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 Priority 2
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 Priority 3
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 Priority 3
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
pull the new belt on
attach clamps and come-a-longs
pull the belt tight
square it off
cut the belt
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 board
remove clamps and come-a-longs
add tension to the tail
remove lock and tag
grease tail to take up tension
run and train Priority 2
make final adjustments
change screens (when necessary)
obtain necessary tools
hammer
pry bar
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 Priority 2
dig out grizzly chute
obtain tools
hammer
pry bar
lift door up by hand to remove
use hammer and pry bar to bar down dirt
obtain torch/welding equipment
chipping hammer
rods
wire brush
grinder
grinding shield
tape measure
Wear personal protective equipment Priority 2
welding gloves
welding helmet
welding mask
cut out old steps
weld in new steps
remove old material
replace door
training the existing belt
determined by belt type
by grease
grease tail pulley
by wrench
wrenching on tail pulley
by hammer
hammering on trough rollers or return rollers