KPI-JCI FT300DF Operation manual

86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax [phone]
24/7 Parts Number 888-474-0115
FT300DF
Plant Operation and Service Manual
and Parts Book
JCI Track Mounted Crushing Plant
XML Revision 0

Table of Contents
Introduction................................................................................................... 1
Operation and Service Manual .....................................................................................1
Address For Notices .....................................................................................................1
Track Plant Components ..............................................................................................2
Crusher Components ...............................................................................................3
Kodiak+ Series Crusher Theory of Operation ......................................................5
Crushing Parameters ...........................................................................................7
Safety............................................................................................................. 9
Safety Overview ............................................................................................................9
Hazard and Advisory Statements .................................................................................9
Hazard Warning Symbol ...........................................................................................9
Hazard Statements ...................................................................................................10
Advisory Statements .................................................................................................10
Arc Flash Safety ............................................................................................................10
Lockout/Tagout .............................................................................................................11
Who Must Use Lockout/Tagout? ..............................................................................11
What is Lockout/Tagout? ..........................................................................................11
When Must Lockout/Tagout Occur? .........................................................................11
When Can Lockout/Tagout Devices be Removed? ..................................................12
Lockout/Tagout Rules ...............................................................................................12
Additional Lockout/Tagout Requirements .................................................................12
Lockout/Tagout Devices ...........................................................................................13
Lockout/Tagout Kit ....................................................................................................14
Lockout/Tagout Procedure .......................................................................................15
Miscellaneous Safety Tips ............................................................................................18
Know Your Machinery ..............................................................................................18
Be Prepared for Emergencies ..................................................................................18
Wear Personal Protective Equipment (PPE) ............................................................18
Observe Personal Safety Precautions ......................................................................19
Help Prevent Accidents ............................................................................................19
Avoid Alcohol and Other Drugs ................................................................................20
Be Aware of Your Surroundings ...............................................................................20
Practice Good Housekeeping ...................................................................................20
Inspect And Maintain Machinery ..............................................................................20
Safety Decals ................................................................................................................21
Track Plant Safety Decal Locations ..........................................................................29
Crusher Safety Decal Locations ...............................................................................31
Emergency Stop (E-STOP) Locations ..........................................................................33
Omnex Screen (optional) ..........................................................................................34
Standard Screen .......................................................................................................34
Setup.............................................................................................................. 35
Hoisting and Handling Safety ........................................................................................35
General Precautions .................................................................................................35

Table of Contents
Wire Rope .................................................................................................................35
Connecting Or Clamping Wire Ropes .......................................................................35
Chains .......................................................................................................................36
Fiber Or Synthetic Slings ..........................................................................................36
Machinery Installation Safety ........................................................................................36
Foundations ..............................................................................................................36
Guarding ...................................................................................................................37
Customer Modifications ............................................................................................37
Electrical Connections ..............................................................................................37
Site Selection ................................................................................................................38
Plant Leveling ...........................................................................................................38
Track Plant Control Locations .......................................................................................39
Initial Startup Inspections ..............................................................................................40
Hopper and Crushing Chamber Inspection ...............................................................40
Hydraulic System Inspection .....................................................................................40
Lube Assembly Inspection ........................................................................................41
Crusher Inspection ....................................................................................................41
Under Crusher Inspection .........................................................................................42
The Importance of Record Keeping and Your Warranty ...........................................42
Startup and 30-day, 90-day Inspection Checklists ....................................................42
Conveyor Preparation ...................................................................................................43
Conveyor Safety .......................................................................................................43
General Conveyor Information ..................................................................................44
Conveyor Belt Training .............................................................................................45
Adjusting Belt Side Creep .........................................................................................47
Conveyor Loading .....................................................................................................49
Baghouse Operation .....................................................................................................50
Baghouse Programming LOGO! ...............................................................................51
Remote Operation .........................................................................................................55
Remote Operation Safety .........................................................................................55
Introduction ...........................................................................................................55
Preparing For Operation .......................................................................................55
Tethered Remote ......................................................................................................56
Kar-Tech Controller ...................................................................................................57
Hand-Held Remote Transmitter ............................................................................57
Remote Receiver ..................................................................................................58
Omnex Radio Remote Control (optional) ..................................................................59
Transporting Machinery .................................................................................................60
Moving the Plant .......................................................................................................61
Plant Travel Pre-Start Checks ...................................................................................61
Transporting the Crusher ......................................................................................62
Conveyor Shipping Bracket ..................................................................................63
Raising/Lowering the Feed Conveyor ...................................................................64
Baghouse Shipping Cover ....................................................................................65
Track Step ............................................................................................................65
Plant Travel Position .............................................................................................67
Moving Plant Using Tethered Remote ......................................................................68
Moving Plant Using Kar-Tech Remote ......................................................................74

Table of Contents
Moving Plant Using Omnex Remote ........................................................................81
Operation....................................................................................................... 89
Crusher Safety ..............................................................................................................89
Pre-Start Checks ...........................................................................................................91
Plant Pre-Start Checks .............................................................................................91
Conveyor Pre-Start Checks ......................................................................................91
Crusher Pre-Start Checks ........................................................................................92
Plant Startup, Operation, and Shutdown ......................................................................93
Plant Startup .............................................................................................................93
Plant Operation .........................................................................................................97
Plant Shutdown ........................................................................................................99
Plant Startup Using Omnex Remote ........................................................................101
Plant Operation Using Omnex Remote ....................................................................106
Plant Shutdown Using Omnex Remote ....................................................................108
Emergency Stop (ESTOP) Re-Start Procedure ........................................................110
Digsy Screen Navigation ...............................................................................................111
Digsy Icons ...............................................................................................................113
Main Screen ..................................................................................................................115
Setup Configuration ......................................................................................................118
Password Entry ........................................................................................................120
Hopper Level Sensor ................................................................................................122
Hopper Level Sensor Initial Configuration ............................................................124
Hopper Sensor Calibration Procedure .................................................................127
Local Mode Screen .......................................................................................................129
Engine Screen ..............................................................................................................130
Engine RPM Adjustment ..........................................................................................131
Performance Screen .....................................................................................................132
Crusher Screen .............................................................................................................133
Closed Side Setting (CSS) .......................................................................................133
The Crushing Zone ...................................................................................................134
Maximum Bowl Position ...........................................................................................135
Bowl Float .................................................................................................................136
Bowl Rotation and CSS Adjustment .........................................................................137
Zeroing Out Bowl Position Counter ......................................................................138
Crusher Clear Procedure ..........................................................................................140
Adjusting Conveyor Speed ...........................................................................................142
Operating the Plant in Extreme Weather Conditions ....................................................143
Crusher Lubrication Heater ......................................................................................143
Ambient Temperature ...............................................................................................143
Humidity ....................................................................................................................143
Automatic Error Guiding ................................................................................................144
Warning Screens ..........................................................................................................145
Diagnostics ...................................................................................................................154
Fault Condition Warning ...........................................................................................156
Engine Diagnostics ...................................................................................................156
Clutch Diagnostics ....................................................................................................157

Table of Contents
Crusher Diagnostics ..................................................................................................158
System Diagnostics ..................................................................................................158
Automatic Crusher Shutdown ........................................................................................160
Circuit Breakers .............................................................................................................161
Crusher Operational Troubleshooting ...........................................................................162
Maintenance ................................................................................................. 165
Maintenance and Repair Safety ....................................................................................165
General Precautions .................................................................................................165
Electrical Systems .....................................................................................................165
Pressurized Systems ................................................................................................166
Welding On Machinery ..............................................................................................166
Clearing Jammed Material ........................................................................................167
Hazardous Materials .................................................................................................168
Disposal Of Excess Fuels, Lubricants And Liquids ...................................................168
System Controls ............................................................................................................169
Maintenance Screen .....................................................................................................169
Disconnecting Digsy Control Components ....................................................................170
Depressurize Plant Hydraulic System Procedure .........................................................174
Depressurize Crusher Hydraulic System Procedure .....................................................174
Track Plant Maintenance Procedures ...........................................................................176
Track Plant Daily Inspection Checklists ....................................................................176
Before Plant Startup .............................................................................................176
After Plant Startup ................................................................................................177
During Plant Operation .........................................................................................177
Restriction Indicator ..............................................................................................178
Engine Air Cleaner ................................................................................................178
Engine Coolant Level ............................................................................................179
Engine Drive Belts ................................................................................................180
Engine Fuel Level .................................................................................................181
Engine Oil Level ....................................................................................................182
Fuel Water Separator ...........................................................................................184
Hydraulic Cooler ...................................................................................................185
Hydraulic Hoses and Connections ........................................................................185
Hydraulic Oil Level ................................................................................................186
Hydraulic Restriction Indicator ..............................................................................187
Drive Cog Sheave Alignment and Belt Tension ....................................................187
Baghouse Filter Change .......................................................................................203
Track Plant Maintenance Schedules ........................................................................208
Weekly or Every 50 Hours of Operation ...............................................................208
Monthly or Every 200 Hours of Operation ............................................................209
Every 500 Hours of Operation ..............................................................................209
Every 1,000 Hours of Operation ...........................................................................209
Yearly or Every 2,000 Hours of Operation ............................................................209
Every 5,000 Hours of Operation ...........................................................................209
Batteries ................................................................................................................210
Feed Conveyor Gear Reducer ..............................................................................211

Table of Contents
Plant Grease Points .............................................................................................212
Radiator and Cooler Care ....................................................................................213
Track Checks .......................................................................................................213
Track Drive Gearbox Oil .......................................................................................213
Lube Oil Sample Procedure .................................................................................214
Lube and Hydraulic Reservoir Air Breather Change Procedure ...........................216
Oil Filter Restriction Indicator ...............................................................................218
Lube Oil Filter Change Procedure ........................................................................218
Lube Oil Reservoir Fill Procedure ........................................................................220
Lube Oil Change Procedure .................................................................................221
Hydraulic Filter Change Procedure ......................................................................222
Hydraulic Oil Change Procedure ..........................................................................225
Hydraulic Accumulator Removal Procedure .........................................................225
Hydraulic Accumulator Refill Procedure ...............................................................227
Hydraulic Accumulator Installation Procedure ......................................................230
Conveyor Maintenance .................................................................................................232
Conveyor Daily Inspection Checklist ........................................................................232
Weekly or Every 50 Hours of Operation ...................................................................232
Repairing a Broken Conveyor Belt ...........................................................................234
Measuring a Conveyor Belt Procedure ................................................................234
Squaring the Ends of the Conveyor Belt ..............................................................235
How to Drill and Skive the Conveyor Belt .............................................................238
Attaching the Belt Ends ........................................................................................242
Using the Flexco 840 Belt Cutter ..........................................................................247
Crusher Maintenance ....................................................................................................250
Crusher Hydraulic Safety Precautions ......................................................................250
Crusher Daily Inspection Checklist ...........................................................................251
Crusher Maintenance Schedules .............................................................................252
After First 200 Hours of Operation .......................................................................252
Every 500 Hours of Operation ..............................................................................253
Annually or 4,000 Hours .......................................................................................253
At Every Liner Change .........................................................................................253
Before Recommissioning the Crusher ..................................................................254
Under Crusher Access Door .....................................................................................255
Bowl Rotation Gear Box Lubrication Procedure .......................................................256
Bowl Rotation Gear Box Oil Change Procedure .......................................................258
Removing the Hopper Extension ..............................................................................259
Installing the Hopper Extension ................................................................................260
Hopper Assembly Removal Procedure ....................................................................262
Hopper Assembly Installation Procedure .................................................................263
Upper Assembly Removal Procedure ......................................................................265
Upper Assembly Installation Procedure ...................................................................269
Bowl Removal Procedure .........................................................................................275
Bowl Installation Procedure ......................................................................................278
Manganese Liner Changes ......................................................................................281
Bowl Liner Change Procedure .............................................................................281
Mantle Liner Change Procedure ..........................................................................293
System Relief Valve Testing and Setting Procedure ................................................304

Table of Contents
Individual TIR Cylinder Relief Valve Testing and Setting Procedure ........................308
Bowl Thread Lubrication Procedure ..........................................................................313
Mantle Bolt Thread Maintenance ..............................................................................316
Service .......................................................................................................... 319
Track Plant Service .......................................................................................................319
Remote Control System ID Code Procedure ............................................................319
Crusher Service .............................................................................................................323
Offset Cone Lifting Eye Safety ..................................................................................323
Cone Lifting Eye and Cone Lifting Eye Assembly .....................................................324
Cone Lifting Eye (one-piece) ................................................................................324
Cone Lifting Eye Assembly (two-piece) ................................................................326
Cone Lifting Eye Assembly Installation Procedure ...............................................326
Cone Removal Procedure .........................................................................................328
Cone Installation Procedure ......................................................................................330
TIR Relief Cylinder Removal Procedure ...................................................................333
TIR Relief Cylinder Installation Procedure ................................................................336
Replacing V-Seat Liners ...........................................................................................340
Method 1: ..............................................................................................................340
Method 2: ..............................................................................................................340
Method 3: ..............................................................................................................340
Setup: ...................................................................................................................340
Preheat considerations: ........................................................................................340
V-Seat Liner Removal Procedure .............................................................................341
V-Seat Liner Installation Procedure ..........................................................................343
Pinion Assembly Removal Procedure .......................................................................344
Pinion Assembly Installation Procedure ....................................................................348
Backlash Setting Procedure ......................................................................................350
Setting Gap Between Thrustplate and Wedgeplate Procedure ................................356
Pin Clutch Removal Procedure .................................................................................357
Pin Clutch Installation Procedure ..............................................................................360
Drive Ring Seal Installation Procedure .....................................................................364
Bowl Support Thread Removal Procedure ................................................................366
Bowl Support Thread Installation Procedure .............................................................368
Bowl Clamp Thread Removal Procedure ..................................................................375
Bowl Clamp Thread Installation Procedure ...............................................................377
Bowl Clamp Piston Seal Removal Procedure ...........................................................383
Bowl Clamp Piston Seal Installation Procedure ........................................................386
Hydraulic Motor Removal Procedure ........................................................................392
Gear Box Removal Procedure ..................................................................................393
Hydraulic Motor and Gear Box Installation Procedure ..............................................395
Hydraulic Manifold Relief Valve Removal Procedure ................................................406
Hydraulic Manifold Relief Valve Installation Procedure .............................................407
Hydraulic Pressure Transducer Removal Procedure ................................................408
Hydraulic Pressure Transducer Installation Procedure .............................................409
Low Lubrication Oil Level Shutoff Switch Removal Procedure .................................410
Low Lubrication Oil Level Shutoff Switch Installation Procedure ..............................412

Table of Contents
Lube Cooler Bypass Valve Removal Procedure ......................................................413
Lube Cooler Bypass Valve Install Procedure ...........................................................416
Lube Flow Encoder Removal Procedure ..................................................................418
Lube Flow Encoder Installation Procedure ...............................................................421
Reference Information ................................................................................. 423
Plant Information ...........................................................................................................423
Specifications ...........................................................................................................423
Capacities .............................................................................................................423
Conveyor Widths ..................................................................................................423
Engine ..................................................................................................................423
Batteries ...............................................................................................................423
Track Plant Oil Recommendations ...........................................................................424
Grease Recommendations ...................................................................................424
Hydraulic Oil Recommendations ..........................................................................424
Standard Gear Oil Recommendations .................................................................424
Track Oil Recommendations ................................................................................425
Engine Oil Recommendations ..............................................................................425
Omnex Receiver Unit ...............................................................................................425
Kar-Tech Controller Troubleshooting .......................................................................427
Crusher Information ......................................................................................................429
Available Liner Configurations ..................................................................................429
K300+ Coarse Chamber ......................................................................................429
K300+ Medium Coarse Chamber .........................................................................430
K300+ Medium Chamber .....................................................................................431
K300+ Medium Chamber with Feed Slots ............................................................432
K300+ Medium Fine Chamber .............................................................................433
K300+ Fine Chamber ...........................................................................................434
K300+ Product Capacities ........................................................................................435
Kodiak Plus Gradation Chart ....................................................................................436
K300+ CSS Chart .....................................................................................................438
Crushing Application Guidelines ...............................................................................439
Pinion Speed ........................................................................................................443
Choke Feeding .....................................................................................................444
Rock Characteristics ............................................................................................444
Fine Crushing .......................................................................................................446
Causes of Bowl Float ...........................................................................................446
Feed Related Problems ........................................................................................447
Product Specification Troubleshooting .....................................................................449
Crusher Lubrication Oil Specifications ......................................................................450
Recommended Oil Type .......................................................................................450
Synthetic Oil .........................................................................................................450
Lubrication System Oil Flow .................................................................................451
Lube Oil Analysis ..................................................................................................452
Hydraulic System ......................................................................................... 455

Table of Contents
Hydraulic Pressures ......................................................................................................455
Conveyor and Track Pressure ..................................................................................455
Crusher System Pressure .........................................................................................457
Feeder Lift Pressure .................................................................................................457
Lube Flow Pressure ..................................................................................................458
Crusher Hydraulic Manifold Assembly ..........................................................................459
Crusher System Relief Pressure ...............................................................................460
Bowl Clamp ...................................................................................................................461
Bowl Clamp Circuit ....................................................................................................463
Bowl Rotation Motor ......................................................................................................464
Bowl Rotation Circuit .................................................................................................465
Tramp Iron Relief (TIR) System ....................................................................................466
Tramp Iron Relief (TIR) Circuit ..................................................................................468
TIR Relief Valve Pressure .........................................................................................469
Clear Circuit ..............................................................................................................470

INTRODUCTION
OPERATION AND SERVICE MANUAL
1
Introduction
Operation and Service Manual
This manual provides the information for an experienced operator to successfully and safely operate your
equipment. Please review this manual carefully to ensure you receive the most benefit from your machine.
Make sure that all personnel are aware of, and use, proper safety precautions when working with and/or
around the plant and related equipment. For information on service, contact your dealer or the manufacturer
service department. Please refer to your parts book for further manufacturer contact information.
Address For Notices
Any and all inquiries and/or warranty claims should be submitted in writing to JCI at the following address:
Johnson Crushers International, Inc.
86470 Franklin Blvd.
Eugene, Oregon 97405
Office: 541-736-1400 / Fax: [phone]
Toll Free: 800-314-4656
Service Department: [phone]
Parts Sales Department: [phone]

INTRODUCTION
TRACK PLANT COMPONENTS
2
Track Plant Components
The FT Direct Feed plant is a remote-controlled, track-mounted crushing plant system. The plant consists of
a feed conveyor, a discharge conveyor, and a Kodiak+ series crusher. The conveyors and tracks are hydrau-
lically driven and are operated by a bank of control valves mounted in an enclosure on the left-hand side of
the plant. The feed conveyor folds down to lower the height of the plant for travel.
The plant has a diesel engine that powers the hydraulic and electrical systems.
There are several radio remote control options. These controllers allow you to move the plant forward and in
reverse, turn the plant, and stop the engine.
1 Feed Conveyor
2 Hydraulic Control Panel Enclosure
3 Engine Compartment
4 Right-Hand Side Emergency Stop Location
5 Baghouse (optional)
6 Discharge Conveyor
7 Left-Hand Side Emergency Stop Location
8 Kodiak+ Crusher
9 Folding Hopper

INTRODUCTION
TRACK PLANT COMPONENTS
3
Crusher Components

INTRODUCTION
TRACK PLANT COMPONENTS
4
1 Tramp Iron Relief (TIR) Cylinder
2 Hydraulic Bowl Clamp
3 Bowl Assembly
4 Hopper
5 Bowl Liner Retention System
6 Drive Ring
7 Hydraulic Bowl Rotation Motor
8 Bowl Support
9 Crusher Base Frame Assembly
10 Wedgeplate
11 Pin Clutch Assembly
12 Cone Assembly
13 Pinion Assembly
14 Driven Sheave
15 Mantle

INTRODUCTION
TRACK PLANT COMPONENTS
5
Kodiak+ Series Crusher Theory of Operation
The Kodiak+ remote adjust crusher crushes rock by feeding it through the hopper and bowl opening into the
crushing chamber. As the cone gyrates inside the chamber, the crushing action is achieved when rock falls
into the open side and is crushed as the gap between the mantle and liner closes up.
The “closed side setting” (CSS) is the area in the chamber where the mantle and liner is the closest, and the
widest area between the mantle and liner iscalled the “open side.” The “stroke” is the difference between the
open and closed side distances, measured at the bottom of the parallel zone. The location of the CSS rotates
within the bowl as the cone gyrates. As the gap reopens, the crushed rock falls down lower in the chamber
or out of the chamber and onto the discharge conveyor.
The gyratory motion of the cone in a Kodiak+ crusher is created by the rotation of the wedgeplate around the
baseframe spindle. The cone is mounted on the upper half of the wedgeplate. The center axis of the upper
half of the wedgeplate is offset from the lower half and inclined at an angle. The wedgeplate is driven by a
right angle spiral bevel gear powered by the pinion shaft, which is housed in the baseframe. The wedgeplate
and cone assemblies are supported by large radial and thrust roller bearings. Although the cone gyrates
about the main center axis of the chamber, it does not spin about its own center axis in the wedgeplate. The
cone is allowed to rotate slowly about its center axis in a clockwise direction during crushing, but is prevented
from rotating in an counterclockwise direction by an anti-spin cone brake. Prevention of spinning improves
liner wear life and improves the balance of the machine when running empty.
1 Open Side
2 Bowl Liner
3Mantle
4 Closed Side
NOTICE: Damage to the crusher bearings could result from bringing a spinning cone head to an abrupt halt. In
addition, manganese steel does not hold up well under sliding abrasion so its life would be greatly reduced.

INTRODUCTION
TRACK PLANT COMPONENTS
6
Crusher Upper Assembly
1 Bowl Rotation Assembly
2 Bowl Position Proximity Sensor
3 Driven Gear
4 Drive Ring
5 Upper Dust Seal Assembly
6 Bowl Clamp
7Bowl
8 Liner Retention Components
9 Manganese Bowl Liner
10 Lower Dust Seal Assembly
11 Bowl Support
12 Bowl Clamp Hydraulic Oil Supply Hose

INTRODUCTION
TRACK PLANT COMPONENTS
7
The upper assembly includes the bowl and liner and is threaded into the bowl support. The upper assembly
is held into place by the bowl clamp, which is a hydraulically controlled lock nut. As hydraulic pressure is
increased, the bowl clamp piston removes all end play in the threads, which in turn secures the bowl
assembly. The threaded connection allows the bowl to be rotated up or down to adjust the closed side setting
(CSS) using the remotely operated control panel. The bowl is turned by a bowl rotator assembly mounted on
the bowl support. A proximity sensor detects the number of turns the drive ring makes. An electronic counter
displays the CSS on the control panel. Since the position indicator does not consider changes in the CSS due
to liner wear, the bowl position indicator should be reset often.
Crushing Parameters
The life of your crusher depends on adherence to these instructions.
Material
• Material with a compressive strength greater than 40,000 pounds per square inch should be reviewed
and approved in advance by JCI.
• No more than 10% of the total volume of feed materialis sizedless than the crusher closed side setting.
• The crusher feed material conforms to the recommended feed size on at least two sides.
• Moisture content of material is below 5%.
• Feed gradation remains uniform.
• Clay or wood material in crusher feed is limited to prevent the formation of compacted material or
“pancakes” being created.
Mechanical
• Crusher operates at factory recommended tramp iron relief pressures without bowl float.
• Crusher support structure is level and evenly supported across all four corners. In addition, the support
structure provides adequate strength to resist static and dynamic loads. (See the installation drawing.)
• Crusher is operated only when all electrical, lubrication and hydraulic systems are correctly adjusted
and functioning properly.
• Lubrication low flow warning system functions correctly.
• Lubrication oil filter functions properly and shows adequate filtering capacity on its indicator.
• Crusher drive belts are in good condition and tensioned to factory specifications.
• Crusher lubrication reservoir is full of lubricant that meets factory required specifications.
• Any welding on the crusher or support structure is grounded directly at the weld location.
• Crusher input shaft rotates in the correct direction.
• Manganese wear liners are replaced before coming loose or developing cracks.
• Crusher cone head is properly blocked prior to transport.
• Only authorized OEM parts or factory approved wear parts are used.

INTRODUCTION
TRACK PLANT COMPONENTS
8
Application
• Reduction ratio limited to 6 to 1 below 1" closed side setting and 8 to 1 above 1" closed side setting,
provided no bowl float occurs.
• Manganese chamber configuration conforms to the factory recommended application guidelines.
• Crusher is operated at the factory recommended RPM for the application.
• Crusher feed is consistent, providing an even flow of material, centered in the feed opening, and
covering the mantle nut at all times.
• Crusher input horsepower does not exceed factory specifications.
• Crusher discharge chamber is kept clear of material buildup.
• If the crusher cannot be totally isolated from metal in the feed material, a magnet should be used over
the crusher feed belt.

SAFETY
SAFETY OVERVIEW
9
Safety
Safety Overview
It is the responsibility of the quarry management team to develop a comprehensive safety awareness
program, and to ensure that all quarry workers and support personnel receive appropriate safety training as
approved by federal, state, and local regulations. Safety is basically common sense. There are standard
safetyrules,buteachsituationhasitsownpeculiarities,whichcannotalwaysbecoveredbyrules.Therefore,
quarry personnel must continually watch for possible safety hazards and be prepared to take prompt correc-
tive action when necessary. Failure toobserve the precautions contained in this chapter can result in serious
personal injury and even loss of life. As with most industrial work environments, a careful operator is the best
insurance against an accident. The complete observance of one simple rule would prevent many unneces-
sary injuries and deaths each year.
The rule is:
“Never attempt to clean, lubricate, repair or adjust any machinery unless it is stopped and properly locked
out.”
Please note that this chapter is only intended as a brief review of basic quarry precautions and procedures.
The general guidelines included in the following paragraphs should not be considered in lieu of a quarry’s
official safety procedures, insurance company requirements, or applicable federal, state, and local regula-
tions.
Hazard and Advisory Statements
Hazard Warning Symbol
Hazard and advisory statements are emphasized throughout this manual.
The following safety alert symbol is used to bring attention to the specific advisory:
Whenyouseethesymbol, payparticularattentiontothe advisory thatfollowsas yoursafetyandthat ofothers
is involved.

SAFETY
ARC FLASH SAFETY
10
Hazard Statements
The Caution, Warning and Danger statements are hazard statements used to alert workers of unsafe prac-
ticesandpotentiallyharmful or life-threatening situations.Each of these statementsis preceded by the Safety
Alert Symbol.
• CAUTION indicates a potentially hazardous condition that, if not avoided, MAY result in minor personal
injury.
• WARNING indicates a potentially hazardous condition that, if not avoided, COULD result in serious
personal injury or death.
• DANGERindicatesapotentially hazardous conditionthat,ifnotavoided,WILLresult in severe personal
injury or death.
Advisory Statements
The Note statements are advisory statements that relate to equipment operation, maintenance and service
procedures. They are used to draw attention to proper procedures and practices.
• NOTICE is used to draw attention to a procedure that must be observed to prevent machine damage or
malfunction.
• NOTE is a basic informational statement or helpful suggestion.
Arc Flash Safety