IDENTIFY THE SETUP PROCEDURES FOR A 150-TPH CRUSHER PLANT

SECTION III. PRESENTATION

A.

ELO 1: Action: Conditions:

Identify the Setup Procedures for a 150-TPH Crusher Plant Identify the setup procedures for a 150-TPH crusher plant. In a classroom, given job specifications, TM 5-332, TM 5-3820-255-14&P, TM 5-3820-256-14&P, TM 5-3820-257-14&P, TM 5-3820-258-14&P, TM 5-3820-259-14&P, TM 5-3820-260-14&P, TM 5-3820-262-14&P, TM 5-3820-263-14&P, paper, and a pencil Identify the procedures used to set up a 150-TPH crusher plant in accordance with (IAW) job specifications, TM 5-332, TM 5-3820-255-14&P, TM 5-3820-256-14&P, TM 5-3820-257-14&P, TM 5-3820-258-14&P, TM 5-3820-259-14&P, TM 5-3820-260-14&P, TM 5-3820-262-14&P, and TM 5-3820-263-14&P.

Standards:

Safety Requirements

None

Risk Assessment Level

Low

Environmental Considerations

None

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References Required

Number
TM 5-332 TM 5-3820-255-12&P TM 5-3820-256-14&P TM 5-3820-257-14&P TM 5-3820-258-14&P TM 5-3820-259-14&P TM 5-3820-260-14&P TM 5-3820-262-14&P TM 5-3820-263-14&P Pits and Quarries

Title
Operation, Model M150 Primary Crusher Unit, Model M3042 Portable Surge Bin Feeder, Model PSF-12 Secondary Crusher and Screening Unit, Model M1313 Tertiary Crusher Unit, Model MC45 Washing and Screening Unit, Model M1122 Product Conveyor, Model PC1245 Water Pump Unit, Model GB2060

Date
Dec 67 Jun 97 Jun 97 Jun 97 Jun 97 Jun 97 Jun 97 Jun 97 Jun 97

Additional Information

Equipment Required

Overhead projector and screen

Materials Required

Instructor Materials TM 5-332 TM 5-3820-255-12&P TM 5-3820-256-14&P TM 5-3820-257-14&P TM 5-3820-258-14&P TM 5-3820-259-14&P TM 5-3820-260-14&P TM 5-3820-262-14&P TM 5-3820-263-14&P C02 TSP VGTs

Student Materials TM 5-332 TM 5-3820-255-12&P TM 5-3820-256-14&P TM 5-3820-257-14&P TM 5-3820-258-14&P TM 5-3820-259-14&P TM 5-3820-260-14&P TM 5-3820-262-14&P TM 5-3820-263-14&P Student guides Pencils Paper

Instructional Guidance

Before presenting this lesson, a. Ensure classroom is available and ready for training. b. Ensure overhead projector, screen, and VGTs are on hand. c. Ensure all materials are on hand and in quantities needed. d. Read and understand C02 TSP prior to conducting training.

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Instructional Lead-In

Inform the students of the Enabling Learning Objective (ELO) requirements. State the complete action, conditions, standards, safety, risk assessment level, and environmental considerations. Explain the importance of being able to properly identify the setup procedures for a 150-TPH crusher plant. NOTE: Introduce the lesson topics to be discussed. a. Site Preparation b. Setup of Crusher Plant Components c. Setup and Installation Considerations

Learning Activity #1:

Explain the procedures for site preparation. AC RC CO 1:12 0.25 Student guide, VGTs

Method of instruction: Instructor-to-student ratio: Time of instruction: Media:

CO 1:12 0.25 Student guide, VGTs

1. Site Preparation NOTE: Show VGT #7 Have students refer to Chapter 2 in TM 5-3820-255-12&P. Only the equipment is shown in Figure 2-1. The required berms, headwalls, ponds, access roads to storage areas, and drilling sites are not shown.

NOTE: NOTE:

a. Size the site for the equipment. Ensure there is adequate room for trucks and loaders to move around the crusher equipment. b. Construct berms or headwalls. (1) Berms may be constructed for the loaders to access the primary crusher with blast rock. (2) Headwall construction is recommended for long term quarry sites. c. Establish a water intake site and settling pond for washing operations. (1) Whenever washing and screening operations are to be conducted, a good supply of water is needed. A pond may be constructed or a river site established as a water intake site for the washing unit.

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(2) A settling pond must be constructed to collect the runoff from the washing and screening plant. If the water from the washing plant is allowed the run directly into a river or waterway, the silt will affect the environmental condition of the waterway. d. Construct a material storage area Prepare an area large enough to store crushed rock used on projects. 2. Review Determine if students have learned the material presented by: (1) Soliciting student questions and explanations. (2) Asking questions and receiving answers from the students. (3) Correcting student misunderstandings.

Learning Activity #2:

Explain the procedures for the setup of crusher plant components. AC RC CO 1:12 1.5 Student guide, VGTs

Method of instruction: Instructor-to-student ratio: Time of instruction: Media:

CO 1:12 1.5 Student guide, VGTs

1. Setup of Crusher Plant Components NOTE: Show VGT #8

a. Primary crusher unit NOTE: NOTE: Refer students to Chapter 2 in TM 5-3820-256-12&P. Explain that a crane is needed at different points of the component setup.

(1) Unpack the crusher unit NOTE: Refer students to paragraph 2-4, TM 5-3820-256-12&P and explain the steps for assembly.

NOTE: Show VGT #9 (2) Assemble and install the feeder module. NOTE: Show VGT #10

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CAUTION: Failure to remove braces prior to operating the feeder unit could damage the shipping braces or drive components of the VGF.

WARNING: With braces installed the springs are under slight tension. Injury could result from careless removal (3) Setting up on site (a) When setting up an assembled portable plant, place the crusher frame on substantial blocking or cribbing so the weight is off the wheels. If the tires are in contact with the ground, the vibration of the equipment running may damage the wheel bearings and/or axle assembly. The weight of the crusher, plus the live moving load of rock, must be supported. (b) The jaw crusher must be perfectly level in both axis to maintain even load on all the bearings and proper distribution of grease in the bearings. (4) Crib and stabilize the trailer. CAUTION: To prevent damage to the trailer suspension and wheel bearings, raise all plant weight off the rear suspension while operating. (a) Ensure the jack landing pads rest on a firm surface of the proper height to match related equipment, such as pivoting conveyors. You may need timbers under the jack pads to increase the bearing surface on soft ground. (b) Place the landing pads and screwjacks under the middle plant legs. Place landing pads under the 4 hydraulic leveling jacks. (c) Extend the jacks to support the trailer. Remove the tractor from under the kingpin NOTE: NOTE: Refer students to paragraph 2-8 and explain the steps for leveling the plant

Show VGT #11 (5) Level the plant

NOTE:

Refer students to paragraph 2-9 and explain the steps to install the engine intake and exhaust stacks

(6) Engine intake and exhaust stacks NOTE: Refer students to paragraph 2-12 and explain the steps to perform electrical hookup.

(7) Electrical hookup WARNING: Dangerous voltage is used in the operation of this equipment. Ensure all power is off and lockout/tagout all switches and power sources before handling any electrical components or cables.

NOTE:

Show VGTs #12, #13, and #14

b. Surge bin feeder

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NOTE:

Refer students to Chapter 2 of TM 5-3820-257-14&P.

(1) Site selection will depend on final plant configuration. The surge bin is capable of being loaded from the primary crusher or a loader. NOTE: Refer students to paragraph 2-6 through 2-9 and explain the steps for setup and installation.

(2) Setup and installation WARNING: CAUTION: CAUTION: WARNING: Do not enter the area under the suspended conveyor while supported by the crane alone. A dropped conveyor could kill Maintain contact between the surge bin support legs and the screw jacks at all times to prevent warping the surge bin frame If the tires are in contact with the ground the vibration of the equipment running may damage the wheel bearings and/or axle assembly Dangerous voltage is used in the operation of this equipment. Ensure that all power is off and lockout/tagout all switches and power sources before handling any electrical components or cables.

c. NOTE:

Secondary crusher unit Show VGTs #15 and #16 Refer students to Chapter 2 in TM 5-3820-258-14&P. Refer students to paragraph 2-7 and explain the steps for assembly.

NOTE: NOTE:

(1) Setting up on site (a) When setting up an assembled portable plant, place the crusher frame on substantial blocking or cribbing so the weight is off the wheels. If the tires are in contact with the ground, the vibration of the equipment running may damage the wheel bearings and/or axle assembly. The weight of the crusher, plus the live moving load of rock, must be supported. (b) The cone crusher must be perfectly level in both axis to maintain even load on all the bearings and proper distribution of grease in the bearings. (2) Crib and stabilize the trailer CAUTION: To prevent damage to the trailer suspension and wheel bearings, raise all plant weight off the rear suspension while operating. (a) During operation, all plant weight must be off the rear suspension. The support legs for the trailer frame and conveyor must be installed and used effectively.
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(b) Ensure the jack landing pads rest on a firm surface of the proper height to match related equipment, such as pivoting conveyors. You may need timbers under the jack pads to increase the bearing surface on soft ground. (c) Place the landing pads and screwjacks under the middle plant legs. Place landing pads under the 4 hydraulic leveling jacks. (d) Extend the jacks to support the trailer and remove the tractor from under the kingpin NOTE: NOTE: Refer students to paragraph 2-9 and explain the steps for leveling the plant.

Show VGT #17 (3) Level the plant

NOTE:

Refer students to paragraph 2-10 and explain the steps to install the engine intake and exhaust stacks.

(4) Engine intake and exhaust stacks NOTE: Refer students to paragraph 2-11 and explain the steps to perform electrical hookup.

(5) Electrical hookup WARNING: Dangerous voltage is used in the operation of this equipment. Ensure all power is off and lockout/tagout all switches and power sources before handling any electrical components or cables. Refer students to paragraph 2-12 and explain the precautions and suggestions for the cone crusher.

NOTE:

(6) Cone crusher precautions and suggestions NOTE: Refer students to paragraph 2-13 and explain the precautions and suggestions for the vibrating screen feeder.

(7) Vibrating screen feeder precautions and suggestions NOTE: Show VGTs #18, #19, and #20

d. Washing and screening unit NOTE: NOTE: Refer students to Chapter 2 in TM 5-3820-260-14&P Refer students to paragraph 2-3 and explain the steps to unpack the washing and screening unit.

(1) Unpacking

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NOTE:

Refer students to paragraph 2-4 through 2-7 and explain the steps for setup and installation.

(2) Setup and installation NOTE: Refer students to paragraph 2-8 and explain the precautions and suggestions for the vibrating screen.

(3) Vibrating screen precautions and suggestions NOTE: Refer students to paragraph 2-9 and explain the precautions and suggestions for the washing/dewatering screw.

(4) Washing/dewatering screw precautions and suggestions NOTE: Show VGT #21

e. Tertiary crushing unit NOTE: NOTE: Refer students to Chapter 2 in TM 5-3820-259-14&P. Refer students to paragraph 2-3 through 2-6 and explain the steps to unpack and assemble the tertiary crusher unit.

(1) Unpack and assemble the tertiary crusher unit. NOTE: Refer students to paragraph 2-8 through 2-12 and explain the steps for setup and installation of the tertiary crusher unit.

(2) Setup and installation NOTE: f. Show VGT #22 Water pump Refer students to Chapter 2 in TM 5-3820-263-14&P. Refer students to paragraph 2-5 and 2-6 and explain the steps for setup and installation of the water pump

NOTE: NOTE:

Setup and installation NOTE: Show VGT #23, and #24

g. Product conveyor NOTE: Refer students to Chapter 2 in TM 5-3820-262-14&P.

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NOTE: Refer students to paragraph 2-14 through 2-17 and explain the steps for setup and installation of the product conveyor.

Setup and installation NOTE: Explain that positioning the conveyor is the most efficient means of establishing equipment locations. Place the conveyor based on the infeed of material and position the next unit to the conveyor drop point. The conveyor must be pinned at the desired elevation with the pressure released from the elevating cylinder to prevent hydraulic system damage during operation.

NOTE: NOTE:

Show VGT #25

h. Generator set NOTE: NOTE: Refer students to chapter 2 in TM 5-3820-264-14&P. Refer students to paragraph 2-5 and 2-6 and explain the steps for setup and installation of the generator set.

Setup and installation NOTE: The generator should be placed as close to the unit it will power without creating interference with traffic patterns. In addition, the generator should be upwind of the CSWP to reduce problems associated with stone and traffic dust. Generator must be grounded to prevent electrical shock. Connect to the CSWP unit MAIN circuit breaker before connecting the generator end of the cable. Connecting an unterminated cable to the generator could lead to electrocution. Do not remove the cover from the generator breaker while the generator is operating. Do not remove the breaker panel cover while the generator is operating. Dangerous voltage is generated by this equipment. Lockout and tagout all switched and controls before connecting to generator terminals.

WARNING: WARNING:

WARNING: WARNING: WARNING:

2. Review Determine if students have learned the material presented by: (1) Soliciting student questions and explanations. (2) Asking questions and receiving answers from the students. (3) Correcting student misunderstandings.

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Learning Activity #3:

Explain setup and installation considerations. AC RC CO 1:12 0.25 Student guide, VGTs

Method of instruction: Instructor-to-student ratio: Time of instruction: Media:

CO 1:12 0.25 Student guide, VGTs

NOTE:

Show VGTs #26 and #27 Refer students to Chapter 2, Section III of TM 5-3820-255-14&P. Refer students to paragraph 2-13 through 2-15 and explain the setup and installation considerations for the CSWP.

NOTE: NOTE

1. Setup and Installation Considerations WARNING: Inattentiveness can cause injury or death around an operating CSWP. All personnel must be alert for themselves and others while in the CSWP area. Failure to understand and heed the instructions in paragraph 2-14 and 2-15 could lead to personnel injury 2. Review Determine if students have learned the material presented by: (1) Soliciting student questions and explanations. (2) Asking questions and receiving answers from the students. (3) Correcting student misunderstandings.

Learning Activity #4:

Conduct a practical exercise on identifying the setup procedures for a 150-TPH crusher plant. AC RC PE2 1.12 2.0 Student guide

Method of instruction: Instructor-to-student ratio: Time of instruction: Media:

PE2 1:12 2.0 Student guide

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1. Practical Exercise Instructions a. Give detailed instructions on what is expected during each practical exercise IAW Appendix B. b. Ensure students have required materials and references IAW Appendix B. c. Clarify students questions.

d. Conduct the practical exercise IAW Appendix B. e. Check on students progress and provide assistance as necessary throughout the exercise. f. Ensure students complete the practical exercise within the allotted time.

g. Provide solutions to the practical exercise. 2. Review Determine if students have learned the material presented by: (1) Soliciting student questions and explanations. (2) Asking questions and receiving answers from the students. (3) Correcting student misunderstandings.

Instructor Guidance

Refer to Appendix C for test administration procedures.

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