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1. Pre-shift/Start-up Open main gate Keep all travel ways and working surfaces free of slip, trip and fall hazards Open maintenance shop Obtain/wear PPE Wear hard hat Company policy Wear safety shoes Company policy Wear ear plugs where appropriate Company policy Wear safety glasses Company policy Wear fall protection (when necessary) Company policy Review check-sheet from previous shift Conduct safety check on site truck Company policy Take truck out of service if safety defects are found Check oil Check water Check lights Check back-up alarm Check seat belts Check horn Check brakes 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 4 inch 3 inch modified require screen changes 2RC 3 inch modified 2A modified Check guard on motor 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 Check under crusher for debris 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 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. 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 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 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 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) 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 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. 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 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 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 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 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 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 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