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Jaw Maintenance (1)

Jaw Maintenance (1)
Prepare to Replace Jaw Dies Remove the Jaw Dies Jaw Prep and Cleaning Install the New Stationary Die Install the New Moveable Die
1. Prepare to Replace Jaw Dies
Conduct a self assessment Priority 2
Obtain Equipment
Schedule Crane with proper rigging
Service Truck
Conduct Pre-Op on truck using Cadman Pre-Op check sheet
Obtain Torch Kit with adequate gas
Ensure Fire Extinguishers are present
Inspect Air Compressor
Fuel
Oil
Leaks
Gauge
Inspect welder
Fuel
Oil
Welding leads
Obtain and inspect Tools
Die lifting apparatus Priority 2
Inspect the pins (lifting device)
Inspect condition of cables (lifting device)
Inspect the condition of the D-Ring (lifting device)
Wedge working platform Priority 2
Company designed and fabricated blocking/working platform
Spline drive impact
Sockets
28mm, 32mm & 50mm
3' Pry Bar
6' Pry Bar
8 pound sledge hammer
4 pound sledge hammer
Wire brush
4" Grinder with disc & wire wheel
Specialty Jaw tool kit
Lifting hook
Lug
Eye bolt
Shackle
Tool box
Open end wrench (55mm)
Hex socket head wrench (25/31mm)
Hit box wrench (32)
T-Bar
Extension Rod
Socket wrench (20mm)
Grease gun
Hose
Mouth Piece
Ratchet Handle (3/4)
Socket Wrench (80mm)
Spacer
Needle Gun
Extension cord
Putty knife
Straight edge
Tape measure
Obtain Materials
Two 12"X12"X3' blocking
Rags
Penetrating oil
Anti-Seize
Replacement Dies
Upper and lower wedges
Bolts, nuts,& washers
3/8" Rope X 30' long (Tag Line)
Conduct a crew meeting Priority 2
Discuss and assign job tasks (SLAM)
Review the maintenance manual
Review the Cadman task training documents (STT)
Requires completion of 5000-23 for each miner working on the task
Ensure that the proper PPE is available for use
Full body harness with retractable lanyard
Safety Glasses
Face shield or goggles
Heavy leather gloves
Cutting goggles
Coordinate with the blasting crew
Can't be working in and around jaw when a shot is conducted
Barricade the feed hopper Priority 2
To prevent trucks from dumping in the hopper
Lock and tag out main power Priority 3
Follow company lock and tag policy (SOP:5011S) Failure to follow this procedure is grounds for discharge
Main power includes: grizzly feeder, under belt, hammer, jaw, and control tower
Conduct a "dry run"; SLAM the tasks to be conducted; discuss who, why, when, where, and how Priority 2
Ensure that the contract crane operator and rigger are present at this meeting
Stage the new dies and related hardware
Remove paint from machined surfaces with 4" grinder with wire wheel
Make sure that the grinder and cord is inspected for defects
Ensure that all proper PPE is used while grinding
Stage and supervise crane operator
Stage the service truck
Ensure that the wheels are chocked
2. Remove the Jaw Dies
Open the jaw as far as it will go
Clean toggle rod threads
Loosen the toggle spring until all tension is removed
Back adjusting wedges out to the end of the threads
Put on harness
Attach the lanyard to the designated tie off point on hammer frame Priority 2
Insert the wedge/working platform Priority 2
Clean the lifting holes
Attach the lifting tool to the crane hook
Position the crane hook over the moveable die
Insert lifting tool into the holes
Signal crane operator to take up the slack on the cables
Remove the nuts from the moveable die retaining bolts
The washers and nuts are removed from the back side of pitman
A torch may be needed to remove. Ensure that all proper PPE is used during cutting operations. Make sure fire extinguisher is immediately available
Remove the retaining bolts and wedges
Remove the wedge/working platform from the jaw
Clear all non-essential personnel from the area Priority 2
Essential personnel are the signalman and one mechanic to pry and guide the die
Non-essential personnel should move to the service truck
Pry the moveable die from the pitman with the 6' pry bar
Ensure that the crane hook is centered over the jaw die Priority 2
Remove the moveable die
Signal the crane operator to hoist (slowly)
If die does not move freely, release the tension and repeat the previous two steps
Guide the die out of the jaw by pushing or pulling hoist cables
Ensure that the die doesn't get hung up or snagged
Signal the crane operator to stop the hoist when the die clears the hopper
Attach a tag line to the bottom of the die when it clears the hopper
Ensure that you are not standing under the hoisted die
Drop the other end of the tag line over the edge of the hopper
Unhook lanyard from body harness
Travel to the ground
Grab the end of the tag line
Ensure that you are not standing under the hoisted die
Signal the crane operator to resume the lift
Set the die on the ground in a predetermined spot
Disconnect the lifting device from the die
Return to jaw
Wash with water hose
Move retractable lanyard to the stationary side (designated tie-off point)
Attach the lanyard to the harness Priority 2
Insert the wedge/working platform Priority 2
Clean stationary die and gaps along the sides of the die
Remove compacted material with 3' bar
Remove remaining material with the needle gun
Ensure that all proper PPE is used while using the needle gun
Clean the lifting holes with needle gun
Ensure that all proper PPE is used while using the needle gun
Position the crane hook over the stationary die
Ensure that the lifting device is correctly attached to the crane hook
Insert lifting tool into the lifting holes
Signal crane operator to take up the slack on the cables
Remove the nuts and washers from the stationary die retaining bolts
The washers and nuts are removed from the back side of frame. A torch may be needed to remove. Ensure that all proper PPE is used during cutting operations. Make sure fire extinguisher is immediately available
Remove the retaining bolts and wedges
Remove the wedge/working platform from the jaw
Clear all non-essential personnel from the area Priority 2
Essential personnel are the signalman and one mechanic to pry and guide the die
Non-essential personnel should move to the service truck
Pry the stationary die from the frame with the 6' pry bar
Ensure that the crane hook is centered over the jaw die Priority 2
Remove the stationary die
Signal the crane operator to hoist (slowly)
If die does not move freely, release the tension and repeat the previous two steps
Guide the die out of the jaw by pushing or pulling hoist cables
Ensure that the die doesn't get hung up or snagged
Signal the crane operator to stop the hoist when the die clears the hopper
Attach a tag line to the bottom of the die when it clears the hopper
Ensure that you are not standing under the hoisted die
Drop the other end of the tag line over the edge of the hopper
Unhook lanyard from the body harness
Travel to the ground
Grab the end of the tag line
Ensure that you are not standing under the hoisted die
Signal the crane operator to resume the lift
Set the die on the ground in a predetermined spot
Disconnect the lifting device from the die
3. Jaw Prep and Cleaning
Hose the inside of the jaw with water
Attach lanyard to the body harness Priority 2
Install the wedge/working platform inside the jaw Priority 2
Climb inside jaw and on to the wedge/working platform
Clean the machined surfaces with the wire wheel
Ensure that a face shield is used during this step
Check the machined surfaces with a straight edge Priority 2
Grind the high spots off with grinder if needed
Ensure that a face shield is used during this step
Repeat the previous two steps until the surface is properly prepared
Get out of the jaw
Disconnect the lanyard from the body harness
Go to the under jaw belt
Slide down the belt to the bottom of the jaw
Ensure that the lower wedge bolts for both sides are tight Priority 2
Inspect both lower wedges for debris and wear Priority 2
Replace if necessary
Slide out from under the jaw
Replace lower wedges
Obtain tools
28mm socket
splined drive impact
28mm end wrench
3' Pry bar
Hammer
Remove the nuts and washers from the wedges
The washers and nuts are removed from the back side of frame and the pitman
A torch may be needed to remove. Ensure that all proper PPE is used during cutting operations. Make sure a fire extinguisher is immediately available
Remove the bolts from the wedges
Pry the wedge out with the 3' pry bar
Clean seat with the wire brush
Check seat Priority 2
Clean the wedge with the wire brush
Install new wedge into the seat
Install with the lip up
Brush anti-seize on the bolts
Insert bolts through wedge and through frame
Put the nuts and washers on
Tighten nuts with spline drive
4. Install the New Stationary Die
Position the crane hook over the stationary die
The stationary and the moveable dies are different; check the part numbers for the correct die
Conduct a visual inspection of the lifting device Priority 2
Attach the lifting device to the stationary die
Attach the tag line to the bottom of the stationary die
Ensure that all persons are clear from the lifting area Priority 2
Signal the crane operator to hoist the die
Hoist the die
Center the die over the jaw opening
Signal the crane operator to stop hoisting
Attach lanyard to the hammer frame Priority 2
Climb on top of the pitman
Remove the tag line from the die
Lower the die into the jaw while guiding into position
Install the wedge/work platform into the jaw Priority 2
Climb into the jaw and onto the wedge
Center the die Priority 2
Ensure that the die is seated properly on lower wedges Priority 2
Install the upper wedges into position Priority 2
Install with the chisel side toward the die; this must be installed correctly
Brush on anti-seize onto the bolts
Insert the bolts
Install the washers and nuts
Washers and nuts are installed from the back side of frame
Remove the lifting device from the die
Reposition the crane hook over the moveable die
Tighten the nuts with spline drive impact Priority 2
Remove the work platform
Remove lanyard from the body harness
5. Install the New Moveable Die
Conduct a visual inspection of the lifting device Priority 2
Attach the lifting device to the moveable die
Ensure that all persons are clear from the lifting area Priority 2
Signal the crane operator to hoist the die
Only the pre assigned person will give signals to crane operator
Hoist the die
Center the die over the jaw opening
Signal the crane operator to stop hoist
Attach retractable lanyard to the stationary side (designated tie-off point) Priority 2
Attach lanyard to body harness Priority 2
Proceed to the stationary side of the jaw
Remove the tag line from the die
Ensure that persons are not exposed to the suspended load
Lower the die into the jaw while guiding into position
Install the wedge/work platform into the jaw Priority 2
Climb into the jaw and onto the wedge
Center the die Priority 2
Ensure that the die is seated properly on lower wedges Priority 2
Install the upper wedges into position Priority 2
Install with the chisel side toward the die; this must be installed correctly
Brush on anti-seize onto the bolts
Insert the bolts
Install the washers and nuts
Washers and nuts are installed from the back side of the pitman
Remove the lifting device from the die
Reposition the crane hook away from the working area
Tighten the nuts with spline drive impact Priority 2
Climb out of the jaw
remove the wedge/work platform
Lower lifting device to ground level
Remove the die lifting device from crane hook
Inspect lifting device Priority 2
Inspect for cuts, nicks, gouges, cracks, excessive corrosion, heat discoloration, bent or any other defects
Store lifting device in proper place
Communicate with crane operator that the crane is done
Ensure that crane operator fills out vendor daily report form