SET UP A 150-TPH CRUSHER PLANT

SEC VI: APPENDIXES

APPENDIX C: TEST AND TEST SOLUTIONS

051-62G1-C02

Set Up a 150-TPH Crusher Plant Evaluation (TE1)

Action: Conditions:

Calibrate a 150-TPH crusher plant. At a training site, given a 150-TPH crusher plant, job specifications, TM 5-3820-256-14&P, TM 5-3820-258-14&P, a general mechanic's tool kit, a drive set with sockets, an 18 pipe wrench, a 24 adjustable wrench, a 12 ruler, a grease gun, replacement screens, a cone and jaw adjustment pump, petroleum, oil, lubricants, penetrating oil, rags, appropriate maintenance forms, an equipment records folder, coveralls, safety boots, goggles, gloves, double hearing protection, a hard hat, paper, and a pencil Calibrate a 150-TPH crusher plant in accordance with (IAW) job specifications, TM 5-3820-256-14&P, and TM 5-3820-258-14&P, without damage to equipment or the environment and without injury to personnel

Standards:

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.

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References Required

Number
TM 5-3820-256-14&P TM 5-3820-258-14&P

Title
Primary Crusher Unit, Model M3042 Secondary Crusher and Screening Unit, Model M1313

Date
Jun 97 Jun 97

Additional Information

Instructional Guidance

Before conducting this evaluation, a. b. c. d. e. Inspect evaluation site for completeness. Ensure equipment is available and on site. Ensure reference materials are on hand. Ensure tool room is open. Ensure all student materials are on hand.

Learning Activity #1: Administer an Examination AC Method of instruction: Instructor-to-student ratio: Time of instruction: Media: TE1 1:4 6.0 Student guide RC TE1 1:4 6.0 Student guide

1. Introduction a. Introduction of the instructor b. Motivational statement c. State action, conditions, standards, safety, risk assessment level, and environmental considerations.

2. Test administration procedures a. Explain the importance of passing the performance evaluation. b. Tell students what tasks will be evaluated. (1) Setting discharge opening on the jaw crusher. (2) Adjusting the closed side setting on the cone crusher. (3) Removing and installing wire cloth.

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c.

Inform students of retest policy. (1) Students that fail will be counseled. (2) One retest may be given. (3) Students will receive additional training prior to retest. (4) Students will receive a retest only on tasks failed. (5) Allow students questions.

3. Performance Evaluation Test Provide the following information at the test site. (1) Read the action, conditions, standards, safety, risk assessment level, and environmental considerations statements. (2) Inform students that a GO on all performance measures are required to receive a GO for the action. (3) Allow students to ask questions.

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SEC VI: APPENDIXES

APPENDIX C: TEST AND TEST SOLUTIONS

TLO

Calibrate a 150-TPH Crusher Plant

NAME UNIT RESULTS

CLASS NO. ATTEMPT NO.

PERFORMANCE MEASURES OR TEST

1. Set discharge opening a. Ensures crusher chamber is completely empty, stops the jaw crusher drive, and locks out the power source. b. Loosens the four toggle seat wedge bolts. c. Loosens tension spring nuts so that shims can be added or removed

GO

NO GO

_______ _______ _______ _______ _______ _______

_______ _______ _______ _______ _______ _______

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

g. Holds the wood spacer so it is centered in the crusher chamber and it extends below the bottom of the jaw. If increasing the jaw opening, pushes the movable jaw forward and remove the shims before inserting wood spacer. h. Operates the hydraulic pump and pushes the movable jaw forward until it contact the spacer. i. Installs an equal number of shims on each side to hold toggle seat into position.

_______ _______ _______

_______ _______ _______

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PERFORMANCE MEASURES OR TEST

GO

NO GO

j. k. 2.

Tightens the four toggle seat wedge bolts. Tightens tension spring nuts to restore holding force on toggle. Adjust closed side setting (CSS)

_______ _______

_______ _______

a. Checks the toggle switch on the adjusting pump to be sure it is in the OFF position. Plugs in the pump to an appropriate electrical outlet. b. Connects line B to the adjusting jack manifold. Connects line A to the relief valve threaded into the flange of the bonnet support. Be sure the fitting snaps fully into place. 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. f. Uses the 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. (2) Checks to ensure everyone is clear and moves the adjusting pump valve to the A position. (3) Replaces the shims that were removed from the lower shim stack into the upper shim stack.

_______ _______

_______ _______

_______

_______

_______ _______

_______ _______

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PERFORMANCE MEASURES OR TEST

j. Adjusts to a wider CSS. (1) Moves the control valve on the adjusting pump to the A position. Determines the proper shim to remove. (2) After removing the desired shims, moves the control valve on the adjusting pump back to the B position. (3) 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 lines of pressure. (8) Uses the small pry bar to raise any one adjusting jack to a height of approximately 2. 3. Remove wire cloth a. Removes the tail gates as needed. b. Removes 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.

GO

NO GO

_______ _______ _______

_______ _______ _______

_______

_______

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_______ _______

_______ _______

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PERFORMANCE MEASURES OR TEST

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

GO

NO GO

_______ _______ _______ _______

_______ _______ _______ _______

d. Positions the draw plates and bolts. Ensures the ends of the draw plates do not catch on adjacent plates.

Evaluators Overall Rating:

_______

_______

Evaluators Comments:

Evaluator's Signature: Date:

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