Controlled Document

MCC ENG SOP 106 2012

Number
TITLE: CRUSHER MAINTENANCE
REVISION No.: 03 Page 1 of 6
08th February 2012
DATE: 22nd June 2013
11th June 2015

AUTHOR: P Bagnall

Authorised by: PROJECT MANAGER

Designation
Signature
ENGINEERING MANAGER
Designation
Signature

Maintenance on a Mobile/Fixed crusher

1. OBJECTIVE

To provide a Standard Operating Procedure for safe maintenance on a mobile

and/fixed crusher

2. SCOPE

To eliminate or minimise the risk of fatalities, injuries, property damage and incidents
whilst doing maintenance on a crusher

3. RESPONSIBILITY

The Engineering Manager, Plant manager, Engineering Foremen, Supervisors,

Artisans and Sub Contractors involved with the maintenance on a Fixed or Mobile
Crusher.

4. REFERENCES

GEN SOP 53, ENG SOP 70, IBRA – 55

5. DEFINITIONS

Risk: means the likelihood that occupational injury or harm to persons will occur.

Project Manager Engineering Manager Employee Representative Safety Rep

 Controlled Document
MCC ENG SOP 106 2012
Number
TITLE: CRUSHER MAINTENANCE
REVISION No.: 03 Page 2 of 6
08th February 2012
DATE: 22nd June 2013
11th June 2015

AUTHOR: P Bagnall

Authorised by: PROJECT MANAGER

Designation
Signature
ENGINEERING MANAGER
Designation
Signature

Danger: means anything, which may cause injury or damage to persons or property.

Hazard: means a source of or exposure to danger.

6. ACTIVITIES

6.1 Change a conveyor belt

 Risk assessment must be completed

 Crusher must be locked out
 Conveyor belt must at state of rest
 Work area must be declared safe for work by Engineering Foreman
 Cut conveyor at tail pulley with a belt knife
 Hook conveyor at head pulley with mobile crane and pull conveyor out
 Load belt onto truck with mobile crane
 If a sub contractor is used, ensure that they comply with our safety standards
 The new conveyor belt must be placed on a stand in front and aligned with the
stringer/frame of the conveyor
 Pull the conveyor by means of a Tirfer. Hook the conveyor over the top of the idlers
underneath and through the crusher and then pull it into position
 Both ends must be prepared for splicing
 After splicing is completed, allow 4 hours for curing
 Tension conveyor to required specifications
 Make area safe and ensure all persons are standing away from the conveyor belt,
remove lock out
 Start conveyor and training/alignment
 Once conveyor has run into the required position, crusher is available for operation
Project Manager Engineering Manager Employee Representative Safety Rep
 Controlled Document
MCC ENG SOP 106 2012
Number
TITLE: CRUSHER MAINTENANCE
REVISION No.: 03 Page 3 of 6
08th February 2012
DATE: 22nd June 2013
11th June 2015

AUTHOR: P Bagnall

Authorised by: PROJECT MANAGER

Designation
Signature
ENGINEERING MANAGER
Designation
Signature

6.2 Changing jaw liners on Swing jaw/Fixed jaw

 Risk assessment must be completed

 Crusher must be locked out
 Work area must be declared safe for work by Engineering Foreman
 Loosen bolts of wedge plate from the back of the jaw
 Move wedge plate until one bolt is available to hook the lifting chain, then hook the
bolt and secure load
 Press the wedge out and remove wedge
 Hook lifting sling(supplied by OEM) and hook wedge plate
 Loosen liner bolts from the back, lift liner and guide liner out of jaw mouth
 Hook middle liner and remove liner from jaw mouth after loosened bolts
 Hook bottom liner and loosen bolts, then remove the liner and stag all liners on a
safe platform. (Some crusher models may differ with solid liners and amount of bolts)
 Clean back plate of crusher and inspect the toe plate
 Hook new bottom liner and install. Secure with bolts and ensure liner is in wedge
grooves. Fasten liner lightly
 Hook middle liner and install. Ensure liner is in wedge grooves. Fasten lightly
 Hook top liner and install. Ensure liner is in wedge grooves. Fasten lightly
 Hook wedge plate and install. Install all bolts and tighten them from the bottom
upwards.

6.3 Change tail pulley

 Risk assessment must be completed

Project Manager Engineering Manager Employee Representative Safety Rep
 Controlled Document
MCC ENG SOP 106 2012
Number
TITLE: CRUSHER MAINTENANCE
REVISION No.: 03 Page 4 of 6
08th February 2012
DATE: 22nd June 2013
11th June 2015

AUTHOR: P Bagnall

Authorised by: PROJECT MANAGER

Designation
Signature
ENGINEERING MANAGER
Designation
Signature

 Crusher must be locked out

 Work area must be declared safe for work by Engineering Foreman
 Release tension of the conveyor by adjusting bolts at head/tail pulley
 Hook pulley with chain block/coffin hoist
 Loosen clamping bars/slides and lower the pulley to ground level
 Twist pulley sideways to be removed between the conveyor
 Hook the conveyor side to an anchor point and remove the conveyor with a chain
block until there is enough clearance to remove the pulley
 To install the new pulley, press the pulley in sideways between the conveyor and
secure pulley into position
 Remove chain block and hook from conveyor and set conveyor in place
 Hook pulley and lift into position
 Install clamping bars/slides and secure with bolts
 Ensure pulley is lined up and then tension the conveyor by adjusting bolts
 Remove all tools and lifting equipment and clear the area
 Ensure all persons are not in close proximity to the conveyor belt then remove lock
out and start the conveyor for testing
 Train/align the conveyor into the required position
 Crusher is now available for operation
Note

This SOP can be used to change bearings, plumber blocks and pillar block bearings
on tail and head pulleys

6.4 Change idlers, rollers, impact idlers and frames

 Risk assessment must be completed

 Crusher must be locked out
Project Manager Engineering Manager Employee Representative Safety Rep
 Controlled Document
MCC ENG SOP 106 2012
Number
TITLE: CRUSHER MAINTENANCE
REVISION No.: 03 Page 5 of 6
08th February 2012
DATE: 22nd June 2013
11th June 2015

AUTHOR: P Bagnall

Authorised by: PROJECT MANAGER

Designation
Signature
ENGINEERING MANAGER
Designation
Signature

 Work area must be declared safe for work by Engineering Foreman

 Install chain block where component needs to be replaced
 Install a clamping bar on conveyor and clamp
 Hook chain to lifting lug and pull conveyor up/down until here is enough
clearance to change the component
 Remove the component and install a new one
 Lower chain block and remove hook
 Remove clamping bar and all lifting equipment and tools
 Remove lock out and start when area is declared safe to do so

6.5 Change side skirts and liners

 Risk assessment must be completed

 Crusher must be locked out
 Work area must be declared safe for work by Engineering Foreman
 Remove damaged liner/skirts on conveyor
 Cut new liner/skirt and punch a 14mm hole in the liner/skirt
 Install the new liner/skirt and fasten with 12mm bolts
 Remove lock out and start

6.6 Change electrical motor on drive

 Risk assessment must be completed

 Crusher must be locked out
 Work area must be declared safe for work by Engineering Foreman
 Disconnect power supply to the motor
 Hook lifting equipment to motor and crane
Project Manager Engineering Manager Employee Representative Safety Rep
 Controlled Document
MCC ENG SOP 106 2012
Number
TITLE: CRUSHER MAINTENANCE
REVISION No.: 03 Page 6 of 6
08th February 2012
DATE: 22nd June 2013
11th June 2015

AUTHOR: P Bagnall

Authorised by: PROJECT MANAGER

Designation
Signature
ENGINEERING MANAGER
Designation
Signature

 Loosen all bolts on guards and remove guards with mobile crane
 Loosen motor base bolts and remove V-belts
 Loosen bolts on base plate completely and lift motor
 Lower motor to ground level
 Remove V- pulley studs, pulley, and taper lock
 Bolt V-pulley on new motor shaft
 Lift motor into position and install bolts on motor base
 Fit V-belts and tension motor until V-belt setting is correct
 Fasten motor base plate
 Install guards
 Connect power supply to motor and remove lifting equipment
 Stop/start motor to determine direction
 Make area safe and remove lock out
 Crusher is now ready for operation

6.5 PROTECTIVE EQUIPMENT

PERSONAL PROTECTIVE EQUIPMENT

Delete the ticks under the PPE when it is not applicable to this SOP
Overall Hard Safety Safety Safety Ear Dust Reflective Safety Respirator Rescue -
hat boots Gloves Goggles / Glasses / Protection Mask Vest Harness pack and
Shield Cap lamp

Project Manager Engineering Manager Employee Representative Safety Rep

 Controlled Document
MCC ENG SOP 106 2012
Number
TITLE: CRUSHER MAINTENANCE
REVISION No.: 03 Page 7 of 6
08th February 2012
DATE: 22nd June 2013
11th June 2015

AUTHOR: P Bagnall

Authorised by: PROJECT MANAGER

Designation
Signature
ENGINEERING MANAGER
Designation
Signature

        

OTHER

6.6 HAZARDS IDENTIFIED

 Unqualified personnel
 Falling from heights
 Caught between
 Struck by
 Confined space
 Electrocution
 Nip points
 Slip and fall

7. MONITORING AND MEASUREMENT

7.1 This procedure will be reviewed every two years or as required.

Project Manager Engineering Manager Employee Representative Safety Rep