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Prepare to Replace Jaw Dies Conduct a self assessment 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 Inspect the pins (lifting device) Inspect condition of cables (lifting device) Inspect the condition of the D-Ring (lifting device) Wedge working platform 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 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 To prevent trucks from dumping in the hopper Lock and tag out main power 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 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 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 Insert the wedge/working platform 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 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 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 Insert the wedge/working platform 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 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 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 Jaw Prep and Cleaning Hose the inside of the jaw with water Attach lanyard to the body harness Install the wedge/working platform inside the jaw 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 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 Inspect both lower wedges for debris and wear 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 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 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 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 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 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 Climb into the jaw and onto the wedge Center the die Ensure that the die is seated properly on lower wedges Install the upper wedges into position 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 Remove the work platform Remove lanyard from the body harness Install the New Moveable Die Conduct a visual inspection of the lifting device Attach the lifting device to the moveable die Ensure that all persons are clear from the lifting area 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) Attach lanyard to body harness 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 Climb into the jaw and onto the wedge Center the die Ensure that the die is seated properly on lower wedges Install the upper wedges into position 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 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 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