SET UP A 150-TPH CRUSHER PLANT

SEC VI: APPENDIXES

APPENDIX B. PRACTICAL EXERCISES AND SOLUTIONS

ELO 1: Identify the Setup Procedures for a 150-TPH Crusher Plant (Practical Exercise #1)

Safety Requirements

None

Risk Assessment Level

Low

Environmental Considerations

None

Special Instructions

1. Explain to the students: a. Each student will work individually. b. Practical exercise will consist of completing three scenarios. c. At the end of each scenario, the instructor will review the solutions and answer and clarify questions. 2. Ensure the students have all applicable references.

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SET UP A 150-TPH CRUSHER PLANT

SEC VI: APPENDIXES

APPENDIX B:
ELO 1:

PRACTICAL EXERCISES AND SOLUTIONS

Identify the Setup Procedures for a 150-TPH Crusher Plant (Practical Exercise #1) (continued)

Scenario 1:

You have been given the task of setting up a 150-TPH crusher plant. All components are available. The crusher site has not been prepared for placement of equipment. List the four steps that must be taken to prepare the crusher site for equipment placement.

Scenario 2:

You have been given the task of setting up a 150-TPH crusher plant. All components are available. The crusher site has been prepared for placement of equipment. Support equipment and personnel are available for plant setup. 1. List the order of equipment placement when all components are used. 2. When leveling crusher equipment, what two things must you ensure? 3. List the steps necessary to install a product conveyor. 4. Where should the water pump be positioned? 5. Where should the generator set be located?

Scenario 3:

You have been given a mission to produce a clean graded aggregate from a river bed. Per job specifications, size reduction is not required for this rock material. The rock does not need to be washed. You have support equipment and personnel available. 1. List the equipment needed for this task. 2. List the order in which the equipment should be arranged.

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SET UP A 150-TPH CRUSHER PLANT

SEC VI: APPENDIXES

APPENDIX B:
ELO 1:

PRACTICAL EXERCISES AND SOLUTIONS

Identify the Setup Procedures for a 150-TPH Crusher Plant (Practical Exercise #1 Solutions)

Scenario 1:

You have been given the task of setting up a 150-TPH crusher plant. All components are available. The crusher site has not been prepared for the placement of equipment. List the four steps that must be taken to prepare the crusher site for equipment placement. Size the site for the equipment Construct a berm or headwall Establish a water intake site and settling pond Construct a material storage area

Scenario 2:

You have been given the task of setting up a 150-TPH crusher plant. All components are available. The crusher site has been prepared for placement of equipment. Support equipment and personnel are available for plant setup. 1. List the order of equipment placement when all components are used: Primary Crusher Unit Surge Bin Feeder Secondary Crusher Unit Product Conveyor Washing and Screening Unit Tertiary Crushing Unit Water Pump Generator Set 2. When leveling crusher equipment, what two things must you ensure? Both axis are perfectly level. Blocking or cribbing is used to ensure that the weight of the crusher is off the wheels. 3. List the steps necessary to install a product conveyor. Position the conveyor at the required discharge point. Elevate the conveyor. Plug in the power cable.

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SET UP A 150-TPH CRUSHER PLANT

SEC VI: APPENDIXES

APPENDIX B:
ELO 1:

PRACTICAL EXERCISES AND SOLUTIONS

Identify the Setup Procedures for a 150-TPH Crusher Plant (Practical Exercise #1 Solutions) (continued)

4. Where should the water pump be positioned? Near the water source 5. Where should the generator set be located? As close to the unit it will power without creating interference with traffic patterns, and upwind from the CSWP

Scenario 3:

You have been given a mission to produce a clean graded aggregate from a river bed. Because of the job specification, size reduction is not required for this rock material. The rock does not need to be washed. You have support equipment and personnel available. 1. List the equipment needed for this task. Surge bin Product conveyors Washing and screening unit 2. List the order in which the equipment should be configured. Surge bin feeds a product conveyor Product conveyor feeds the screening unit Screening unit feeds product conveyor to stockpile

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SET UP A 150-TPH CRUSHER PLANT

SEC VI: APPENDIXES

APPENDIX B:
ELO 2:

PRACTICAL EXERCISES AND SOLUTIONS

Calibrate a 150-TPH Crusher Plant (Practical Exercise #2)

Safety Requirements

Hard hats must be worn at all times. Hearing protection must be worn while equipment is running. Eye protection, gloves, and proper foot protection must be worn when operating equipment. Use three points of contact when mounting or dismounting equipment. Remove all jewelry. Use caution around moving parts.

Risk Assessment Level

Low

Environmental Considerations

Avoid unnecessary stripping and damage to vegetation and waterways. Control dust conditions and limit water erosion by dressing area at the end of each day. Avoid unnecessary equipment usage and follow established procedures for cleanup of fluid leaks. Restore site and surrounding areas as close as possible to the original ecological condition.

Special Instructions

1. Explain to the students: a. If more than one student is assigned to the same piece of equipment, students will rotate, performing all practical exercise steps. b. The practical exercise will consist of continuous practice. c. Allotted time will be equally shared between both operators. d. All steps will be practiced in sequence. 2. Ensure the students have TM 5-3820-256-14&P, TM 5-3820-258-14&P and student guides.

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SET UP A 150-TPH CRUSHER PLANT

SEC VI: APPENDIXES

APPENDIX B:
ELO 2:

PRACTICAL EXERCISES AND SOLUTIONS

Calibrate a 150-TPH Crusher Plant (Practical Exercise #2) (continued)

Requirements: 1. Sets the Discharge Opening a. Stops the jaw crusher drive and locks out the power source when the crusher chamber is completely empty. b. Loosens the four toggle seat wedge bolts. c. Loosens the tension spring nuts so the shims can be added or removed.

d. Installs the hydraulic rams and pump the unit as needed. e. Places a wooden spacer which is the exact thickness of the desired discharge opening. f. Rotates the flywheel so the jaws close as much as possible and hold it in this position.

g. Holds the wood spacer so it is centered in the crusher chamber and extends below the bottom of the jaw. If increasing the jaw opening, pushes the movable jaw forward and removes the shims before inserting the wood spacer. h. Operates the hydraulic pump by pushing the movable jaw forward until it contacts the spacer. i. j. k. Installs an equal number of shims on each side to hold the toggle seat into position. Tightens the four toggle seat wedge bolts. Tightens the tension spring nuts to restore the holding force on the toggle.

2. Adjusts the Closed Side Setting (CSS) CAUTION: When connecting the electric hydraulic pump hose to the quick couplers, be certain to clean the hose tip and check the quick coupler for dirt or other obstructions. Ensure threads are clean and in good condition. Before starting the pump, ensure the threaded fittings at the coupler are threaded fully and couplers are tight.

a. Checks the toggle switch on the adjusting pump to ensure it is in the off position. Plugs in the pump to an appropriate electrical outlet.

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SET UP A 150-TPH CRUSHER PLANT

SEC VI: APPENDIXES

APPENDIX B:
ELO 2:

PRACTICAL EXERCISES AND SOLUTIONS

Calibrate a 150-TPH Crusher Plant (Practical Exercise #2) (continued)

b. Connects line B (the bottom hose) to the adjusting jack manifold. Connects line A (the top hose) to the relief valve threaded into the flange of the bonnet support. Ensures the fitting snaps fully into place. CAUTION: Overtightening ruins the relief valve. Use only gentle force. c. Uses a wrench to gently close the relief valve at the bottom of the small (one gallon) accumulator.

d. Lowers the shim guard. e. Places the valve on the adjusting pump to position B (toward the hoses). f. Uses a wrench to slowly open the clamp cylinder manifold valve.

g. Places the toggle switch on the adjusting pump to the run position until the clamp cylinders are completely collapsed. Uses the jog position on the switch to prevent unnecessarily high pressure buildup. h. Stops the pump motor. i. Adjusts to a narrower CSS. (1) Removes the desired shims from the lower shim stacks. Places these shims close by for use in Step 3. Determines the proper shims to remove, IAW Table 3-7, page 3-19, TM 5-3820-258-14&P. WARNING: The next step will lower the upper assembly onto the shim stack. Be sure all personnel are clear.

(2) Ensures everyone is clear. Moves the adjusting pump valve to the A position (away from hoses). (3) Replaces the shims that were removed from the lower shim stack into the upper shim stack. j. Adjusts to a wider CSS. (1) Moves the control valve on the adjusting pump to the A position. Determines the proper shims to remove IAW Table 3-7, page 3-19, in TM 5-820-258-14&P.

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SET UP A 150-TPH CRUSHER PLANT

SEC VI: APPENDIXES

APPENDIX B:
ELO 2:

PRACTICAL EXERCISES AND SOLUTIONS

Calibrate a 150-TPH Crusher Plant (Practical Exercise #2) (continued)

(2) After removing the desired shims, moves the control valve on the adjusting pump back to the B position. WARNING: The next step will lower the upper assembly. Ensure everyone is clear.

(3) Ensures everyone is clear. Moves the control valve on the adjusting pump back to position A to lower the upper assembly. (4) With the adjusting pump valve in the A position, starts the pump and pressures the system to 1000 psi. Stops the pump at 1000 psi. (5) Opens the relief valve on the one gallon accumulator. If the system pressure drops, continues to pressurize with the pump until the system pressure stabilizes at 1600 psi. Stops the pump. (6) Closes the clamp cylinder relief valve. (7) Moves the control valve on the adjusting pump to the B position to clean the lines of pressure. (8) Uses the small pry bar to raise any one adjusting jack to a height of approximately 2. (9) Removes both hoses. Secures the pump. Raises and secures the shim guard. 3. Removes Wire Cloth a. Removes the tail gates as needed. b. To remove the top decks wire cloth on the signal crown deck, removes all the draw bolts and draw plates. Lifts the wire cloth out from the top. c. To remove the wire cloth from the middle and bottom decks, removes the draw blots and draw plates. Pulls all cloth out from either end of the screen.

4. Installs Wire Cloth a. Ensures all the rubber channels are in position and in good condition. Replaces the channels if they are worn to help preserve wire cloth and screen decks.

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SET UP A 150-TPH CRUSHER PLANT

SEC VI: APPENDIXES

APPENDIX B:
ELO 2:

PRACTICAL EXERCISES AND SOLUTIONS

Calibrate a 150-TPH Crusher Plant (Practical Exercise #2) (continued)

b. Centers the subscreen cloth (if used) on the screen deck. c. Centers the sizing wire cloth on the screen deck.

d. Positions the draw plates and bolts. Ensures the ends of the draw plates do not catch on adjacent plates. CAUTION: Too much torque on the draw bolts can damage the wire cloth draw plates or draw bolts.

e. Tightens the draw bolts evenly. With one person working on each side of the screen basket, tightens the first pair of draw bolts directly across from each other. f. Repeats the tightening procedure to ensure a tight fit.

g. Retighten the draw bolts after the screen has run for a few hours. h. After installing the new wire cloth, ensures it is tight and secure.

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SET UP A 150-TPH CRUSHER PLANT

SEC VI: APPENDIXES

APPENDIX B:
ELO 2:

PRACTICAL EXERCISES AND SOLUTIONS

Calibrate a 150-TPH Crusher Plant (Practical Exercise #2 Solutions)

NOTE:

There are no correct solutions for this practical exercise. The sole purpose of this period of instruction is to provide the students with time to practice plant calibration.

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