+------------------------------------+---------------------------------+
| **Company Name:**                  | # **Equipment/Job Identificat   |
|                                    | ion: Jaw Maintenance** {#equipm |
|                                    | entjob-identification-jaw-maint |
|                                    | enance .MM-Topic-1 .unnumbered} |
|                                    |                                 |
|                                    | **Type of Equipment: Jaw        |
|                                    | Crusher**                       |
|                                    |                                 |
|                                    | **Make: Nordberg**              |
|                                    |                                 |
|                                    | **Model: C-125**                |
|                                    |                                 |
|                                    | **Year:**                       |
|                                    |                                 |
|                                    | **Use:**                        |
+------------------------------------+---------------------------------+
| **Mine Name:**                     |                                 |
+------------------------------------+---------------------------------+
| **Date of Analysis: 02/14 thru     |                                 |
| 2/16/2006**                        |                                 |
+------------------------------------+---------------------------------+

# 

# Pre-Assessment 

### 

All MSHA Part 46 requirements must be met including Task Training

Company policy requirements and SOPs

Task training records must be on file prior to operating any mobile
equipment

# 

# Duty 1: Prepare to Replace Jaw Dies

Learner will demonstrate how to safely and efficiently prepare to
replace jaw dies. The learner will also explain the job duties, why they
are conducted, any associated risk, and how to implement appropriate
controls. Preparing to replace the jaw dies includes the following
steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Conduct a self   | Mental or        | 2    |      |                 |
| assessment       | physical state   |      |      |                 |
|                  | will effect job  |      |      |                 |
|                  | efficiency and   |      |      |                 |
|                  | safety           |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Obtain Equipment |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Schedule     |                  | 1    |      |                 |
|     Crane with   |                  |      |      |                 |
|     proper       |                  |      |      |                 |
|     rigging      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Service      |                  | 1    |      |                 |
|     Truck        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Conduct      |                  |      |      |                 |
|     Pre-Op on    |                  |      |      |                 |
|     truck using  |                  |      |      |                 |
|     Cadman       |                  |      |      |                 |
|     Pre-Op check |                  |      |      |                 |
|     sheet        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Obtain Torch |                  |      |      |                 |
|     Kit with     |                  |      |      |                 |
|     adequate gas |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Ensure Fire  |                  |      |      |                 |
|                  |                  |      |      |                 |
|    Extinguishers |                  |      |      |                 |
|     are present  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Inspect Air  |                  |      |      | Fuel, Oil,      |
|     Compressor   |                  |      |      | Leaks and Gauge |
+------------------+------------------+------+------+-----------------+
| -   Inspect      |                  |      |      | Fuel, oil,      |
|     welder       |                  |      |      | welding leads   |
+------------------+------------------+------+------+-----------------+
| Obtain and       |                  |      |      |                 |
| inspect Tools    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Die lifting  | This is the only | 2    |      | Not to be used  |
|     apparatus    | device that can  |      |      | for any other   |
|                  | be used to       |      |      | purpose         |
|                  | remove dies not  |      |      |                 |
|                  | having this      |      |      |                 |
|                  | device could     |      |      |                 |
|                  | cause loss in    |      |      |                 |
|                  | production.      |      |      |                 |
|                  | Without          |      |      |                 |
|                  | conducting an    |      |      |                 |
|                  | inspection could |      |      |                 |
|                  | result in a      |      |      |                 |
|                  | lifting failure. |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Inspect the  |                  |      |      |                 |
|     pins         |                  |      |      |                 |
|     (Lifting     |                  |      |      |                 |
|     device)      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Inspect      |                  |      |      |                 |
|     condition of |                  |      |      |                 |
|     cables       |                  |      |      |                 |
|     (Lifting     |                  |      |      |                 |
|     device)      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Inspect the  |                  |      |      |                 |
|     condition of |                  |      |      |                 |
|     the D-Ring   |                  |      |      |                 |
|     (Lifting     |                  |      |      |                 |
|     device)      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -                | Failure to use   | 2    |      | Company         |
|    Wedge/working | this could       |      |      | designed and    |
|     platform     | result in sudden |      |      | fabricated      |
|                  | unexpected       |      |      | blocking /      |
|                  | movement causing |      |      | working         |
|                  | serious injury   |      |      | platform        |
+------------------+------------------+------+------+-----------------+
| -   Spline drive |                  | 1    |      |                 |
|     impact       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Socket       |                  | 1    |      | 28mm, 32mm &    |
|                  |                  |      |      | 50mm            |
+------------------+------------------+------+------+-----------------+
| -   3' Pry Bar   |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| -   6' Pry Bar   |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| -   8 pound      |                  | 1    |      |                 |
|     sledge       |                  |      |      |                 |
|     hammer       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   4 pound      |                  | 1    |      |                 |
|     sledge       |                  |      |      |                 |
|     hammer       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Wire brush   |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| -   4" Grinder   |                  | 1    |      |                 |
|     with disc &  |                  |      |      |                 |
|     wire wheel   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Specialty    |                  | 1    |      |                 |
|     Jaw Tool Kit |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Lifting hook |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Lug          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Eye bolt     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Shackle      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Tool box     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Open end     |                  |      |      |                 |
|     wrench       |                  |      |      |                 |
|     (55mm)       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Hex socket   |                  |      |      |                 |
|     head wrench  |                  |      |      |                 |
|     (25/31mm)    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Hit box      |                  |      |      |                 |
|     wrench       |                  |      |      |                 |
|     (32mm)       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   T-Bar        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Extension    |                  |      |      |                 |
|     rod          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Socket       |                  |      |      |                 |
|     wrench       |                  |      |      |                 |
|     (20mm)       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Grease gun   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Hose         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Mouth piece  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Ratchet      |                  |      |      |                 |
|     handle (3/4) |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Socket       |                  |      |      |                 |
|     Wrench       |                  |      |      |                 |
|     (80mm)       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Spacer       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Needle Gun   |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Extension    |                  | 1    |      |                 |
|     cord         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Putty knife  |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Straight     |                  | 1    |      |                 |
|     edge         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Tape measure |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Obtain Materials |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Two 12" x    |                  |      |      |                 |
|     12" x 3'     |                  |      |      |                 |
|     blocking     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Rags         |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Penetrating  |                  | 1    |      |                 |
|     oil          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Anti-Seize   |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Replacement  |                  | 1    |      |                 |
|     Dies         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Upper and    |                  | 1    |      |                 |
|     Lower Wedges |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Bolts, nuts, |                  | 1    |      |                 |
|     & washers    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   3/8" Rope X  |                  | 1    |      |                 |
|     30' long     |                  |      |      |                 |
|     (Tag Line)   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Conduct a crew   | Failure to       | 2    |      |                 |
| meeting          | discuss task     |      |      |                 |
|                  | could result in  |      |      |                 |
|                  | serious injury   |      |      |                 |
|                  | due to lack of   |      |      |                 |
|                  | awareness of the |      |      |                 |
|                  | potential        |      |      |                 |
|                  | hazards.         |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Discuss and  |                  |      |      |                 |
|     assign job   |                  |      |      |                 |
|     tasks (SLAM) |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Review the   |                  |      |      |                 |
|     maintenance  |                  |      |      |                 |
|     manual       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Review the   |                  |      |      | Requires        |
|     Cadman task  |                  |      |      | completion of   |
|     training     |                  |      |      | 5000-23 form    |
|     documents    |                  |      |      | for each miner  |
|     (STT)        |                  |      |      | working on the  |
|                  |                  |      |      | task            |
+------------------+------------------+------+------+-----------------+
| -   Ensure that  |                  |      |      |                 |
|     proper PPE   |                  |      |      |                 |
|     is available |                  |      |      |                 |
|     for use      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Full body    |                  |      |      | Each miner      |
|     harness with |                  |      |      | shall have      |
|     retractable  |                  |      |      | their own       |
|     lanyard      |                  |      |      | harness and     |
|                  |                  |      |      | lanyard         |
+------------------+------------------+------+------+-----------------+
| -   Safety       |                  |      |      |                 |
|     Glasses      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Face shield  |                  |      |      |                 |
|     or goggles   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Heavy        |                  |      |      |                 |
|     leather      |                  |      |      |                 |
|     gloves       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Cutting      |                  |      |      |                 |
|     goggles      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Coordinate with  |                  | 1    |      | Can't be        |
| the blasting     |                  |      |      | working in and  |
| crew             |                  |      |      | around jaw when |
|                  |                  |      |      | a shot is       |
|                  |                  |      |      | conducted       |
+------------------+------------------+------+------+-----------------+
| Barricade the    | Failure to       | 2    |      | To prevent      |
| feed hopper      | barricade could  |      |      | trucks from     |
|                  | allow haul truck |      |      | dumping in the  |
|                  | to inadvertently |      |      | hopper          |
|                  | dump shot rock   |      |      |                 |
|                  | into hopper      |      |      |                 |
|                  | resulting in     |      |      |                 |
|                  | serious injury.  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Lock and tag out | Failure to lock  | 3    |      | Follow company  |
| main power       | out and tag will |      |      | lock and tag    |
|                  | result in        |      |      | policy          |
|                  | serious injury   |      |      | (SOP:50115)     |
|                  | or death and is  |      |      | Failure to      |
|                  | a violation of   |      |      | follow this     |
|                  | company policy.  |      |      | procedure is    |
|                  |                  |      |      | grounds for     |
|                  |                  |      |      | discharge.      |
|                  |                  |      |      |                 |
|                  |                  |      |      | Main power      |
|                  |                  |      |      | includes:       |
|                  |                  |      |      | grizzly feeder, |
|                  |                  |      |      | under belt,     |
|                  |                  |      |      | hammer, jaw,    |
|                  |                  |      |      | and control     |
|                  |                  |      |      | tower           |
+------------------+------------------+------+------+-----------------+
| Conduct a "dry   | Failure to       | 2    |      | Ensure that the |
| run"; SLAM the   | discuss task     |      |      | contract crane  |
| tasks to be      | could result in  |      |      | operator and    |
| conducted;       | serious injury   |      |      | rigger is       |
| discuss who,     | due to lack of   |      |      | present at this |
| why, when,       | awareness of the |      |      | meeting         |
| where, and how   | potential        |      |      |                 |
|                  | hazards.         |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Stage the new    |                  | 1    |      |                 |
| dies and related |                  |      |      |                 |
| hardware         |                  |      |      |                 |
| (blocking if     |                  |      |      |                 |
| flipping dies)   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove paint     |                  | 1    |      | Make sure that  |
| from machined    |                  |      |      | the grinder and |
| surfaces with 4" |                  |      |      | cord is         |
| grinder with     |                  |      |      | inspected for   |
| wire wheel       |                  |      |      | defects. Ensure |
|                  |                  |      |      | that all proper |
|                  |                  |      |      | PPE is used     |
|                  |                  |      |      | while grinding. |
+------------------+------------------+------+------+-----------------+
| Stage and        |                  | 1    |      |                 |
| supervise crane  |                  |      |      |                 |
| operator         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Stage the        |                  | 1    |      |                 |
| service truck    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Ensure that  |                  |      |      |                 |
|     the wheels   |                  |      |      |                 |
|     are chocked  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+

# 

**Duty 2: Remove the Jaw Dies**

Learner will demonstrate how to safely and efficiently remove jaw dies.
The learner will also explain the job duties, why they are conducted,
any associated risk, and how to implement appropriate controls. Removal
of the jaw dies includes the following steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Open the jaw as  |                  | 1    |      |                 |
| far as it will   |                  |      |      |                 |
| go               |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Clean toggle |                  |      |      |                 |
|     rod threads  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Loosen the   |                  |      |      |                 |
|     toggle       |                  |      |      |                 |
|     spring until |                  |      |      |                 |
|     all tension  |                  |      |      |                 |
|     is removed   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Back         |                  |      |      |                 |
|     adjusting    |                  |      |      |                 |
|     wedges out   |                  |      |      |                 |
|     to the end   |                  |      |      |                 |
|     of the       |                  |      |      |                 |
|     threads      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Put on harness   |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach the       | Failure to       | 2    |      |                 |
| lanyard to the   | attach lanyard   |      |      |                 |
| designated tie   | exposes the      |      |      |                 |
| off point on     | worker to        |      |      |                 |
| hammer frame     | falling hazards  |      |      |                 |
|                  | which could      |      |      |                 |
|                  | result in        |      |      |                 |
|                  | serious injury.  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert the wedge | Failure to use   | 2    |      |                 |
| / working        | this could       |      |      |                 |
| platform         | result in sudden |      |      |                 |
|                  | unexpected       |      |      |                 |
|                  | movement causing |      |      |                 |
|                  | serious injury   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clean the        |                  | 1    |      |                 |
| lifting holes    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach lifting   |                  | 1    |      |                 |
| tool to crane    |                  |      |      |                 |
| hook             |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Position the     |                  | 1    |      |                 |
| crane hook over  |                  |      |      |                 |
| the moveable die |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert lifting   |                  | 1    |      |                 |
| tool into the    |                  |      |      |                 |
| holes            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal crane     |                  | 1    |      |                 |
| operator to take |                  |      |      |                 |
| up the slack on  |                  |      |      |                 |
| the cables       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the nuts  |                  | 1    |      | The washers and |
| from the         |                  |      |      | nuts are        |
| moveable die     |                  |      |      | removed from    |
| retaining bolts  |                  |      |      | the back side   |
|                  |                  |      |      | of pitman. A    |
|                  |                  |      |      | torch may be    |
|                  |                  |      |      | needed to       |
|                  |                  |      |      | remove. Ensure  |
|                  |                  |      |      | that all proper |
|                  |                  |      |      | PPE is used     |
|                  |                  |      |      | during cutting  |
|                  |                  |      |      | operations.     |
|                  |                  |      |      | Make sure fire  |
|                  |                  |      |      | extinguisher is |
|                  |                  |      |      | immediately     |
|                  |                  |      |      | available.      |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| retaining bolts  |                  |      |      |                 |
| and wedges       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| wedge/working    |                  |      |      |                 |
| platform from    |                  |      |      |                 |
| the jaw          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clear all        | Failure to clear | 2    |      | Essential       |
| non-essential    | personnel could  |      |      | personnel are   |
| personnel from   | result in        |      |      | the signalman   |
| the area         | serious injury   |      |      | and one         |
|                  | from shifting    |      |      | mechanic to pry |
|                  | load or          |      |      | and guide the   |
|                  | unexpected       |      |      | die.            |
|                  | movement.        |      |      | Non-essential   |
|                  |                  |      |      | personnel       |
|                  |                  |      |      | should move to  |
|                  |                  |      |      | the service     |
|                  |                  |      |      | truck           |
+------------------+------------------+------+------+-----------------+
| Pry the moveable |                  | 1    |      |                 |
| die from the     |                  |      |      |                 |
| pitman with 6'   |                  |      |      |                 |
| pry bar          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  | Failure to       | 2    |      |                 |
| crane hook is    | center the crane |      |      |                 |
| centered over    | hook over the    |      |      |                 |
| the jaw die      | jaw die may      |      |      |                 |
|                  | result in the    |      |      |                 |
|                  | die swinging and |      |      |                 |
|                  | damaging front   |      |      |                 |
|                  | frame and is a   |      |      |                 |
|                  | serious hazard   |      |      |                 |
|                  | for all          |      |      |                 |
|                  | maintenance      |      |      |                 |
|                  | personnel        |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  |      |      |                 |
| moveable die     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      | If die does not |
|     crane        |                  |      |      | move freely,    |
|     operator to  |                  |      |      | release the     |
|     hoist        |                  |      |      | tension and     |
|     (slowly)     |                  |      |      | repeat the      |
|                  |                  |      |      | previous two    |
|                  |                  |      |      | steps           |
+------------------+------------------+------+------+-----------------+
| -   Guide the    |                  | 1    |      | Ensure that the |
|     die out of   |                  |      |      | die doesn't get |
|     the jaw by   |                  |      |      | hung up or      |
|     pushing or   |                  |      |      | snagged         |
|     pulling      |                  |      |      |                 |
|     hoist cables |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      |                 |
|     crane        |                  |      |      |                 |
|     operator to  |                  |      |      |                 |
|     stop the     |                  |      |      |                 |
|     hoist when   |                  |      |      |                 |
|     the die      |                  |      |      |                 |
|     clears the   |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Attach the   |                  | 1    |      | Ensure that you |
|     tag line to  |                  |      |      | are not         |
|     the bottom   |                  |      |      | standing under  |
|     of the die   |                  |      |      | the hoisted die |
|     when it      |                  |      |      |                 |
|     clears the   |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Drop the     |                  | 1    |      |                 |
|     other end of |                  |      |      |                 |
|     the tag line |                  |      |      |                 |
|     over the     |                  |      |      |                 |
|     edge of the  |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Unhook       |                  | 1    |      |                 |
|     lanyard from |                  |      |      |                 |
|     body harness |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Travel to    |                  | 1    |      |                 |
|     the ground   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Grab the end |                  | 1    |      | Ensure that you |
|     of the tag   |                  |      |      | are not         |
|     line         |                  |      |      | standing under  |
|                  |                  |      |      | the hoisted die |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      |                 |
|     crane        |                  |      |      |                 |
|     operator to  |                  |      |      |                 |
|     resume the   |                  |      |      |                 |
|     lift         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Set the die  |                  | 1    |      |                 |
|     on the       |                  |      |      |                 |
|     ground in a  |                  |      |      |                 |
|                  |                  |      |      |                 |
|    predetermined |                  |      |      |                 |
|     spot         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Disconnect   |                  | 1    |      |                 |
|     the lifting  |                  |      |      |                 |
|     device from  |                  |      |      |                 |
|     the die      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Return to jaw    |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Wash with water  |                  | 1    |      |                 |
| hose             |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Move retractable |                  | 1    |      |                 |
| lanyard to the   |                  |      |      |                 |
| stationary side  |                  |      |      |                 |
| (designated      |                  |      |      |                 |
| tie-off point)   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach lanyard   | Failure to       | 2    |      |                 |
| to the harness   | attach lanyard   |      |      |                 |
|                  | exposes the      |      |      |                 |
|                  | worker to        |      |      |                 |
|                  | falling hazards  |      |      |                 |
|                  | which could      |      |      |                 |
|                  | result in        |      |      |                 |
|                  | serious injury.  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert the wedge | Failure to use   | 2    |      |                 |
| / working        | this could       |      |      |                 |
| platform         | result in sudden |      |      |                 |
|                  | unexpected       |      |      |                 |
|                  | movement causing |      |      |                 |
|                  | serious injury   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clean stationary |                  | 1    |      |                 |
| die and gaps     |                  |      |      |                 |
| along the sides  |                  |      |      |                 |
| of the die       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Remove       |                  |      |      |                 |
|     compacted    |                  |      |      |                 |
|     material     |                  |      |      |                 |
|     with 3' bar  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Remove       |                  |      |      | Ensure that all |
|     remaining    |                  |      |      | proper PPE is   |
|     material     |                  |      |      | used while      |
|     with the     |                  |      |      | using the       |
|     needle gun   |                  |      |      | needle gun      |
+------------------+------------------+------+------+-----------------+
| Clean the        |                  | 1    |      | Ensure that all |
| lifting holes    |                  |      |      | proper PPE is   |
| with needle gun  |                  |      |      | used while      |
|                  |                  |      |      | using the       |
|                  |                  |      |      | needle gun      |
+------------------+------------------+------+------+-----------------+
| Position the     |                  | 1    |      |                 |
| crane hook over  |                  |      |      |                 |
| the stationary   |                  |      |      |                 |
| die              |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  |                  | 1    |      |                 |
| lifting device   |                  |      |      |                 |
| is correctly     |                  |      |      |                 |
| attached to the  |                  |      |      |                 |
| crane hook       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert lifting   |                  | 1    |      |                 |
| tool into the    |                  |      |      |                 |
| lifting holes    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal crane     |                  | 1    |      |                 |
| operator to take |                  |      |      |                 |
| up the slack on  |                  |      |      |                 |
| the cables       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the nuts  |                  | 1    |      | The washers and |
| and washers from |                  |      |      | nuts are        |
| the stationary   |                  |      |      | removed from    |
| die retaining    |                  |      |      | the back side   |
| bolts            |                  |      |      | of frame. A     |
|                  |                  |      |      | torch may be    |
|                  |                  |      |      | needed to       |
|                  |                  |      |      | remove. Ensure  |
|                  |                  |      |      | that all proper |
|                  |                  |      |      | PPE is used     |
|                  |                  |      |      | during cutting  |
|                  |                  |      |      | operations.     |
|                  |                  |      |      | Make sure Fire  |
|                  |                  |      |      | Extinguisher is |
|                  |                  |      |      | on immediately  |
|                  |                  |      |      | available.      |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| retaining bolts  |                  |      |      |                 |
| and wedges       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| wedge/working    |                  |      |      |                 |
| platform from    |                  |      |      |                 |
| the jaw          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clear all        | Failure to clear | 2    |      | Essential       |
| non-essential    | personnel could  |      |      | personnel are   |
| personnel from   | result in        |      |      | signalman and   |
| the area         | serious injury   |      |      | one mechanic to |
|                  | from shifting    |      |      | pry and guide   |
|                  | load or          |      |      | the die.        |
|                  | unexpected       |      |      | Non-essential   |
|                  | movement.        |      |      | personnel       |
|                  |                  |      |      | should move to  |
|                  |                  |      |      | the service     |
|                  |                  |      |      | truck           |
+------------------+------------------+------+------+-----------------+
| Pry the          |                  | 1    |      |                 |
| stationary die   |                  |      |      |                 |
| from the frame   |                  |      |      |                 |
| with 6' pry bar  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  | Failure to       | 2    |      |                 |
| crane hook is    | center the crane |      |      |                 |
| centered over    | hook over the    |      |      |                 |
| the jaw die      | jaw die may      |      |      |                 |
|                  | result in the    |      |      |                 |
|                  | die swinging and |      |      |                 |
|                  | damaging front   |      |      |                 |
|                  | frame and is a   |      |      |                 |
|                  | serious hazard   |      |      |                 |
|                  | for all          |      |      |                 |
|                  | maintenance      |      |      |                 |
|                  | personnel        |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  |      |      |                 |
| stationary die   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      | If die does not |
|     crane        |                  |      |      | move freely,    |
|     operator to  |                  |      |      | release the     |
|     hoist        |                  |      |      | tension and     |
|     (slowly)     |                  |      |      | repeat the      |
|                  |                  |      |      | previous two    |
|                  |                  |      |      | steps           |
+------------------+------------------+------+------+-----------------+
| -   Guide the    |                  | 1    |      | Ensure that the |
|     die out of   |                  |      |      | die doesn't get |
|     the jaw by   |                  |      |      | hung up or      |
|     pushing or   |                  |      |      | snagged         |
|     pulling      |                  |      |      |                 |
|     hoist cables |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      |                 |
|     crane        |                  |      |      |                 |
|     operator to  |                  |      |      |                 |
|     stop the     |                  |      |      |                 |
|     hoist when   |                  |      |      |                 |
|     the die      |                  |      |      |                 |
|     clears the   |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Attach the   |                  | 1    |      | Ensure that you |
|     tag line to  |                  |      |      | are not         |
|     the bottom   |                  |      |      | standing under  |
|     of the die   |                  |      |      | the hoisted die |
|     when it      |                  |      |      |                 |
|     clears the   |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Drop the     |                  | 1    |      |                 |
|     other end of |                  |      |      |                 |
|     the tag line |                  |      |      |                 |
|     over the     |                  |      |      |                 |
|     edge of the  |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Unhook       |                  | 1    |      |                 |
|     lanyard from |                  |      |      |                 |
|     the body     |                  |      |      |                 |
|     harness      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Travel to    |                  | 1    |      |                 |
|     the ground   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Grab the end |                  | 1    |      | Ensure that you |
|     of the tag   |                  |      |      | are not         |
|     line         |                  |      |      | standing under  |
|                  |                  |      |      | the hoisted die |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      |                 |
|     crane        |                  |      |      |                 |
|     operator to  |                  |      |      |                 |
|     resume the   |                  |      |      |                 |
|     lift         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Set the die  |                  | 1    |      |                 |
|     on the       |                  |      |      |                 |
|     ground in a  |                  |      |      |                 |
|                  |                  |      |      |                 |
|    predetermined |                  |      |      |                 |
|     spot         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Disconnect   |                  | 1    |      |                 |
|     the lifting  |                  |      |      |                 |
|     device from  |                  |      |      |                 |
|     the die      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+

#  

# Duty 3: Jaw Prep and Cleaning

Learner will demonstrate how to safely and efficiently prep and clean
the jaw. The learner will also explain the job duties, why they are
conducted, any associated risk, and how to implement appropriate
controls. Safe and efficient performance of prepping and cleaning of the
jaw includes the following steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Hose the inside  |                  | 1    |      |                 |
| of the jaw with  |                  |      |      |                 |
| water            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach lanyard   | Failure to       | 2    |      |                 |
| to the body      | attach lanyard   |      |      |                 |
| harness          | exposes the      |      |      |                 |
|                  | worker to        |      |      |                 |
|                  | falling hazards  |      |      |                 |
|                  | which could      |      |      |                 |
|                  | result in        |      |      |                 |
|                  | serious injury.  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      | Failure to use   | 2    |      |                 |
| wedge/working    | this could       |      |      |                 |
| platform inside  | result in sudden |      |      |                 |
| the jaw          | unexpected       |      |      |                 |
|                  | movement causing |      |      |                 |
|                  | serious injury   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Climb inside jaw |                  | 1    |      |                 |
| and on the       |                  |      |      |                 |
| wedge/working    |                  |      |      |                 |
| platform         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clean machined   |                  | 1    |      | Ensure that a   |
| surfaces with    |                  |      |      | face shield is  |
| wire wheel       |                  |      |      | used during     |
|                  |                  |      |      | this step       |
+------------------+------------------+------+------+-----------------+
| Check the        | Failure may      | 2    |      |                 |
| machined         | reduce the       |      |      |                 |
| surfaces with a  | operational life |      |      |                 |
| straight edge    | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Grind the high   |                  | 1    |      | Ensure that a   |
| spots off with   |                  |      |      | face shield is  |
| grinder if       |                  |      |      | used during     |
| needed           |                  |      |      | this step       |
+------------------+------------------+------+------+-----------------+
| Repeat the       |                  | 1    |      |                 |
| previous two     |                  |      |      |                 |
| steps until the  |                  |      |      |                 |
| surface is       |                  |      |      |                 |
| properly         |                  |      |      |                 |
| prepared         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Get out of the   |                  | 1    |      |                 |
| jaw              |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Disconnect the   |                  | 1    |      |                 |
| lanyard from the |                  |      |      |                 |
| body harness     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Go to the under  |                  | 1    |      |                 |
| jaw belt         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Slide down the   |                  | 1    |      |                 |
| belt to the      |                  |      |      |                 |
| bottom of the    |                  |      |      |                 |
| jaw              |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  | Failure may      | 2    |      |                 |
| lower wedge      | reduce the       |      |      |                 |
| bolts for both   | operational life |      |      |                 |
| sides are tight  | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Inspect both     | Failure may      | 2    |      | Replace if      |
| lower wedge for  | reduce the       |      |      | necessary       |
| debris and wear  | operational life |      |      |                 |
|                  | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Slide out from   |                  | 1    |      |                 |
| under the jaw    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Replace lower    |                  |      |      |                 |
| wedges           |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Obtain tools |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| -   28mm socket  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Splined      |                  |      |      |                 |
|     drive impact |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   28mm end     |                  |      |      |                 |
|     wrench       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   3' pry bar   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Hammer       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Remove the   |                  | 1    |      | The washers and |
|     nuts and     |                  |      |      | nuts are        |
|     washers from |                  |      |      | removed from    |
|     the wedges   |                  |      |      | the back side   |
|                  |                  |      |      | of frame and    |
|                  |                  |      |      | the pitman. A   |
|                  |                  |      |      | torch may be    |
|                  |                  |      |      | needed to       |
|                  |                  |      |      | remove. Ensure  |
|                  |                  |      |      | that all proper |
|                  |                  |      |      | PPE is used     |
|                  |                  |      |      | during cutting  |
|                  |                  |      |      | operations.     |
|                  |                  |      |      | Make sure a     |
|                  |                  |      |      | fire            |
|                  |                  |      |      | extinguisher is |
|                  |                  |      |      | immediately     |
|                  |                  |      |      | available.      |
+------------------+------------------+------+------+-----------------+
| -   Remove the   |                  | 1    |      |                 |
|     bolts from   |                  |      |      |                 |
|     the wedges   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Pry the      |                  | 1    |      |                 |
|     wedge out    |                  |      |      |                 |
|     with the 3'  |                  |      |      |                 |
|     pry bar      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Clean seat   |                  | 1    |      |                 |
|     with the     |                  |      |      |                 |
|     wire brush   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Check seat   | Failure may      | 2    |      |                 |
|                  | reduce the       |      |      |                 |
|                  | operational life |      |      |                 |
|                  | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Clean the    |                  | 1    |      |                 |
|     wedge with   |                  |      |      |                 |
|     the wire     |                  |      |      |                 |
|     brush        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Install new  |                  | 1    |      | Install with    |
|     wedge into   |                  |      |      | the lip up      |
|     the seat     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Brush        |                  | 1    |      |                 |
|     anti-seize   |                  |      |      |                 |
|     on the bolts |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Insert bolts |                  | 1    |      |                 |
|     through      |                  |      |      |                 |
|     wedge and    |                  |      |      |                 |
|     through      |                  |      |      |                 |
|     frame        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Put the nuts |                  | 1    |      |                 |
|     and washers  |                  |      |      |                 |
|     on           |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Tighten nuts |                  | 1    |      |                 |
|     with spline  |                  |      |      |                 |
|     drive        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+

# Duty 4: Install the Stationary Die

Learner will demonstrate how to safely and efficiently install the
stationary die. The learner will also explain the job duties, why they
are conducted, any associated risk, and how to implement appropriate
controls. Safe and efficient performance of installing the stationary
die includes the following steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Position the     |                  | 1    |      | The stationary  |
| crane hook over  |                  |      |      | and moveable    |
| the stationary   |                  |      |      | dies are        |
| die              |                  |      |      | different;      |
|                  |                  |      |      | check the part  |
|                  |                  |      |      | numbers for the |
|                  |                  |      |      | correct die     |
+------------------+------------------+------+------+-----------------+
| Conduct a visual | This is the only | 2    |      |                 |
| inspection of    | device that can  |      |      |                 |
| the lifting      | be used to       |      |      |                 |
| device           | remove dies not  |      |      |                 |
|                  | having this      |      |      |                 |
|                  | device could     |      |      |                 |
|                  | cause loss in    |      |      |                 |
|                  | production.      |      |      |                 |
|                  | Without          |      |      |                 |
|                  | conducting an    |      |      |                 |
|                  | inspection could |      |      |                 |
|                  | result in a      |      |      |                 |
|                  | lifting failure. |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach the       |                  | 1    |      |                 |
| lifting device   |                  |      |      |                 |
| to the           |                  |      |      |                 |
| stationary die   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach the tag   |                  | 1    |      |                 |
| line to the      |                  |      |      |                 |
| bottom of the    |                  |      |      |                 |
| stationary die   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that all  | Failure to clear | 2    |      |                 |
| persons are      | personnel could  |      |      |                 |
| clear from the   | result in        |      |      |                 |
| lifting area     | serious injury   |      |      |                 |
|                  | from shifting    |      |      |                 |
|                  | load or          |      |      |                 |
|                  | unexpected       |      |      |                 |
|                  | movement.        |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal the crane |                  | 1    |      |                 |
| operator to      |                  |      |      |                 |
| hoist the die    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Hoist die        |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Center the die   |                  | 1    |      |                 |
| over the jaw     |                  |      |      |                 |
| opening          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal the crane |                  | 1    |      |                 |
| operator to stop |                  |      |      |                 |
| hoisting         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach lanyard   | Failure to       | 2    |      |                 |
| to the hammer    | attach lanyard   |      |      |                 |
| frame            | exposes the      |      |      |                 |
|                  | worker to        |      |      |                 |
|                  | falling hazards  |      |      |                 |
|                  | which could      |      |      |                 |
|                  | result in        |      |      |                 |
|                  | serious injury.  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Climb on top of  |                  | 1    |      |                 |
| the pitman       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the tag   |                  | 1    |      | Ensure that     |
| line from the    |                  |      |      | persons are not |
| die              |                  |      |      | exposed to the  |
|                  |                  |      |      | suspended load  |
+------------------+------------------+------+------+-----------------+
| Lower the die    |                  | 1    |      |                 |
| into the jaw     |                  |      |      |                 |
| while guiding    |                  |      |      |                 |
| into position    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      | Failure to use   | 2    |      |                 |
| wedge / work     | this could       |      |      |                 |
| platform into    | result in sudden |      |      |                 |
| the jaw          | unexpected       |      |      |                 |
|                  | movement causing |      |      |                 |
|                  | serious injury   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Climb into the   |                  | 1    |      |                 |
| jaw and onto the |                  |      |      |                 |
| wedge            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Center the die   | Failure may      | 2    |      |                 |
|                  | reduce the       |      |      |                 |
|                  | operational life |      |      |                 |
|                  | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  | Failure may      | 2    |      |                 |
| die is seated    | reduce the       |      |      |                 |
| properly on      | operational life |      |      |                 |
| lower wedges     | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      | Failure may      | 2    |      | Install with    |
| upper wedges     | reduce the       |      |      | the chisel side |
| into position    | operational life |      |      | toward the die; |
|                  | of the equipment |      |      | this must be    |
|                  | because the die  |      |      | installed       |
|                  | may come loose   |      |      | correctly       |
+------------------+------------------+------+------+-----------------+
| Brush anti-seize |                  | 1    |      |                 |
| on the bolts     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert the bolts |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      |                  | 1    |      | Washers and     |
| washers and nuts |                  |      |      | nuts are        |
|                  |                  |      |      | installed from  |
|                  |                  |      |      | the back side   |
|                  |                  |      |      | of frame        |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| lifting device   |                  |      |      |                 |
| from the die     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Reposition the   |                  | 1    |      |                 |
| crane hook over  |                  |      |      |                 |
| the moveable die |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Tighten the nuts | Failure may      | 2    |      |                 |
| with spline      | reduce the       |      |      |                 |
| drive impact     | operational life |      |      |                 |
|                  | of the equipment |      |      |                 |
|                  | because the die  |      |      |                 |
|                  | may come loose   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the work  |                  | 1    |      |                 |
| platform         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove lanyard   |                  | 1    |      |                 |
| from the body    |                  |      |      |                 |
| harness          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+

# Duty 5: Install the Moveable Die

Learner will demonstrate how to safely and efficiently install the
moveable die. The learner will also explain the job duties, why they are
conducted, any associated risk, and how to implement appropriate
controls. Safe and efficient performance of installing the moveable die
includes the following steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Conduct a visual | This is the only | 2    |      |                 |
| inspection of    | device that can  |      |      |                 |
| the lifting      | be used to       |      |      |                 |
| device           | remove dies not  |      |      |                 |
|                  | having this      |      |      |                 |
|                  | device could     |      |      |                 |
|                  | cause loss in    |      |      |                 |
|                  | production.      |      |      |                 |
|                  | Without          |      |      |                 |
|                  | conducting an    |      |      |                 |
|                  | inspection could |      |      |                 |
|                  | result in a      |      |      |                 |
|                  | lifting failure. |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach the       |                  | 1    |      |                 |
| lifting device   |                  |      |      |                 |
| to the moveable  |                  |      |      |                 |
| die              |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that all  | Failure to clear | 2    |      |                 |
| persons are      | personnel could  |      |      |                 |
| clear from the   | result in        |      |      |                 |
| lifting area     | serious injury   |      |      |                 |
|                  | from shifting    |      |      |                 |
|                  | load or          |      |      |                 |
|                  | unexpected       |      |      |                 |
|                  | movement.        |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal the crane |                  | 1    |      | Only the pre    |
| operator to      |                  |      |      | assigned person |
| hoist the die    |                  |      |      | will give       |
|                  |                  |      |      | signals to      |
|                  |                  |      |      | crane operator  |
+------------------+------------------+------+------+-----------------+
| Hoist die        |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Center the die   |                  | 1    |      |                 |
| over the jaw     |                  |      |      |                 |
| opening          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal crane     |                  | 1    |      |                 |
| operator to stop |                  |      |      |                 |
| hoist            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Move retractable |                  | 2    |      |                 |
| lanyard to the   |                  |      |      |                 |
| stationary side  |                  |      |      |                 |
| (designated      |                  |      |      |                 |
| tie-off point)   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach lanyard   | Failure to       | 2    |      |                 |
| to body harness  | attach lanyard   |      |      |                 |
|                  | exposes the      |      |      |                 |
|                  | worker to        |      |      |                 |
|                  | falling hazards  |      |      |                 |
|                  | which could      |      |      |                 |
|                  | result in        |      |      |                 |
|                  | serious injury.  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Proceed to the   |                  | 1    |      |                 |
| stationary side  |                  |      |      |                 |
| of the jaw       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the tag   |                  | 1    |      | Ensure that     |
| line from the    |                  |      |      | persons are not |
| die              |                  |      |      | exposed to the  |
|                  |                  |      |      | suspended load  |
+------------------+------------------+------+------+-----------------+
| Lower the die    |                  | 1    |      |                 |
| into the jaw     |                  |      |      |                 |
| while guiding    |                  |      |      |                 |
| into position    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      | Failure to use   | 2    |      |                 |
| wedge / work     | this could       |      |      |                 |
| platform into    | result in sudden |      |      |                 |
| the jaw          | unexpected       |      |      |                 |
|                  | movement causing |      |      |                 |
|                  | serious injury   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Climb into the   |                  | 1    |      |                 |
| jaw and onto the |                  |      |      |                 |
| wedge            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Center the die   | Failure may      | 2    |      |                 |
|                  | reduce the       |      |      |                 |
|                  | operational life |      |      |                 |
|                  | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  | Failure may      | 2    |      |                 |
| die is seated    | reduce the       |      |      |                 |
| properly on      | operational life |      |      |                 |
| lower wedges     | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      | Failure may      | 2    |      | Install with    |
| upper wedges     | reduce the       |      |      | the chisel side |
| into position    | operational life |      |      | toward the die; |
|                  | of the equipment |      |      | this must be    |
|                  | because the die  |      |      | installed       |
|                  | may come loose   |      |      | correctly       |
+------------------+------------------+------+------+-----------------+
| Brush on         |                  | 1    |      |                 |
| anti-seize onto  |                  |      |      |                 |
| the bolts        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert the bolts |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      |                  | 1    |      | Washers and     |
| washer and nuts  |                  |      |      | nuts are        |
|                  |                  |      |      | installed from  |
|                  |                  |      |      | the back side   |
|                  |                  |      |      | of pitman       |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| lifting device   |                  |      |      |                 |
| from the die     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Reposition the   |                  | 1    |      |                 |
| crane hook away  |                  |      |      |                 |
| from the working |                  |      |      |                 |
| area             |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Tighten the nuts | Failure may      | 2    |      |                 |
| with splined     | reduce the       |      |      |                 |
| drive impact     | operational life |      |      |                 |
|                  | of the equipment |      |      |                 |
|                  | because the die  |      |      |                 |
|                  | may come loose   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Climb out of the |                  | 1    |      |                 |
| jaw              |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the work  |                  | 1    |      |                 |
| platform         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Lower lifting    |                  | 1    |      |                 |
| device to ground |                  |      |      |                 |
| level            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the die   |                  | 1    |      |                 |
| lifting device   |                  |      |      |                 |
| from crane hook  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Inspect lifting  | This is the only | 2    |      | Inspect for     |
| device           | device that can  |      |      | Cuts, nicks,    |
|                  | be used to       |      |      | gouges, cracks, |
|                  | remove dies not  |      |      | excessive       |
|                  | having this      |      |      | corrosion, heat |
|                  | device could     |      |      | discoloration,  |
|                  | cause loss in    |      |      | bent or any     |
|                  | production.      |      |      | other defects.  |
|                  | Without          |      |      |                 |
|                  | conducting an    |      |      |                 |
|                  | inspection could |      |      |                 |
|                  | result in a      |      |      |                 |
|                  | lifting failure. |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Store lifting    |                  | 1    |      |                 |
| device in proper |                  |      |      |                 |
| place            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Communicate with |                  | 1    |      | Ensure that     |
| crane operator   |                  |      |      | Crane operator  |
| that the crane   |                  |      |      | fills out       |
| is done          |                  |      |      | vendor daily    |
|                  |                  |      |      | report form     |
+------------------+------------------+------+------+-----------------+

# Duty 6: Flip Jaw Dies

Learner will demonstrate how to safely and efficiently flip the jaw
dies. The learner will also explain the job duties, why they are
conducted, any associated risk, and how to implement appropriate
controls. A safe and efficient flipping of the jaw dies includes the
following steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Open the jaw as  |                  | 1    |      |                 |
| far as it will   |                  |      |      |                 |
| go               |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Clean toggle |                  |      |      |                 |
|     rod threads  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Loosen the   |                  |      |      |                 |
|     toggle       |                  |      |      |                 |
|     spring until |                  |      |      |                 |
|     all tension  |                  |      |      |                 |
|     is removed   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Back         |                  |      |      |                 |
|     adjusting    |                  |      |      |                 |
|     wedges out   |                  |      |      |                 |
|     to the end   |                  |      |      |                 |
|     of the       |                  |      |      |                 |
|     threads      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Put on harness   |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach the       | Failure to       | 2    |      |                 |
| lanyard to the   | attach lanyard   |      |      |                 |
| designated tie   | exposes the      |      |      |                 |
| off point on     | worker to        |      |      |                 |
| hammer frame     | falling hazards  |      |      |                 |
|                  | which could      |      |      |                 |
|                  | result in        |      |      |                 |
|                  | serious injury.  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert the wedge | Failure to use   | 2    |      |                 |
| / working        | this could       |      |      |                 |
| platform         | result in sudden |      |      |                 |
|                  | unexpected       |      |      |                 |
|                  | movement causing |      |      |                 |
|                  | serious injury   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clean the        |                  | 1    |      |                 |
| lifting holes    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach lifting   |                  | 1    |      |                 |
| tool to crane    |                  |      |      |                 |
| hook             |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Position the     |                  | 1    |      |                 |
| crane hook over  |                  |      |      |                 |
| the moveable die |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert lifting   |                  | 1    |      |                 |
| tool into the    |                  |      |      |                 |
| holes            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal crane     |                  | 1    |      |                 |
| operator to take |                  |      |      |                 |
| up the slack on  |                  |      |      |                 |
| the cables       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the nuts  |                  | 1    |      | The washers and |
| from the         |                  |      |      | nuts are        |
| moveable die     |                  |      |      | removed from    |
| retaining bolts  |                  |      |      | the back side   |
|                  |                  |      |      | of pitman a     |
|                  |                  |      |      | Torch may be    |
|                  |                  |      |      | needed to       |
|                  |                  |      |      | remove. Ensure  |
|                  |                  |      |      | that all proper |
|                  |                  |      |      | PPE is used     |
|                  |                  |      |      | during cutting  |
|                  |                  |      |      | operations.     |
|                  |                  |      |      | Make sure Fire  |
|                  |                  |      |      | Extinguisher is |
|                  |                  |      |      | on immediately  |
|                  |                  |      |      | available.      |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| retaining bolts  |                  |      |      |                 |
| and wedges       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| wedge/working    |                  |      |      |                 |
| platform from    |                  |      |      |                 |
| the jaw          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clear all        | Failure to clear | 2    |      | Essential       |
| non-essential    | personnel could  |      |      | personnel are   |
| personnel from   | result in        |      |      | signalman and   |
| the area         | serious injury   |      |      | one mechanic to |
|                  | from shifting    |      |      | pry and guide   |
|                  | load or          |      |      | the die.        |
|                  | unexpected       |      |      | Non-essential   |
|                  | movement.        |      |      | personnel       |
|                  |                  |      |      | should move to  |
|                  |                  |      |      | the service     |
|                  |                  |      |      | truck           |
+------------------+------------------+------+------+-----------------+
| Pry the moveable |                  | 1    |      |                 |
| die from the     |                  |      |      |                 |
| pitman with 6'   |                  |      |      |                 |
| pry bar          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  | Failure to       | 2    |      |                 |
| crane hook is    | center the crane |      |      |                 |
| centered over    | hook over the    |      |      |                 |
| the jaw die      | jaw die may      |      |      |                 |
|                  | result in the    |      |      |                 |
|                  | die swinging and |      |      |                 |
|                  | damaging front   |      |      |                 |
|                  | frame and is a   |      |      |                 |
|                  | serious hazard   |      |      |                 |
|                  | for all          |      |      |                 |
|                  | maintenance      |      |      |                 |
|                  | personnel        |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  |      |      |                 |
| moveable die     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      | If die does not |
|     crane        |                  |      |      | move freely,    |
|     operator to  |                  |      |      | release the     |
|     hoist        |                  |      |      | tension and     |
|     (slowly)     |                  |      |      | repeat the      |
|                  |                  |      |      | previous two    |
|                  |                  |      |      | steps           |
+------------------+------------------+------+------+-----------------+
| -   Guide the    |                  | 1    |      | Ensure that the |
|     die out of   |                  |      |      | die doesn't get |
|     the jaw by   |                  |      |      | hung up or      |
|     pushing or   |                  |      |      | snagged         |
|     pulling      |                  |      |      |                 |
|     hoist cables |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      |                 |
|     crane        |                  |      |      |                 |
|     operator to  |                  |      |      |                 |
|     stop the     |                  |      |      |                 |
|     hoist when   |                  |      |      |                 |
|     the die      |                  |      |      |                 |
|     clears the   |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Attach the   |                  | 1    |      | Ensure that you |
|     tag line to  |                  |      |      | are not         |
|     the bottom   |                  |      |      | standing under  |
|     of the die   |                  |      |      | the hoisted die |
|     when it      |                  |      |      |                 |
|     clears the   |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Drop the     |                  | 1    |      |                 |
|     other end of |                  |      |      |                 |
|     the tag line |                  |      |      |                 |
|     over the     |                  |      |      |                 |
|     edge of the  |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Unhook       |                  | 1    |      |                 |
|     lanyard from |                  |      |      |                 |
|     body harness |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Travel to    |                  | 1    |      |                 |
|     the ground   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Grab the end |                  | 1    |      | Ensure that you |
|     of the tag   |                  |      |      | are not         |
|     line         |                  |      |      | standing under  |
|                  |                  |      |      | the hoisted die |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      |                 |
|     crane        |                  |      |      |                 |
|     operator to  |                  |      |      |                 |
|     resume the   |                  |      |      |                 |
|     lift         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Set the die  |                  | 1    |      |                 |
|     face down on |                  |      |      |                 |
|     the blocking |                  |      |      |                 |
|     in a         |                  |      |      |                 |
|                  |                  |      |      |                 |
|    predetermined |                  |      |      |                 |
|     spot         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Disconnect   |                  | 1    |      |                 |
|     the lifting  |                  |      |      |                 |
|     device from  |                  |      |      |                 |
|     the die      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Return to jaw    |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Wash with water  |                  | 1    |      |                 |
| hose             |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Move retractable |                  | 1    |      |                 |
| lanyard to the   |                  |      |      |                 |
| stationary side  |                  |      |      |                 |
| (designated      |                  |      |      |                 |
| tie-off point)   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach lanyard   | Failure to       | 2    |      |                 |
| to the harness   | attach lanyard   |      |      |                 |
|                  | exposes the      |      |      |                 |
|                  | worker to        |      |      |                 |
|                  | falling hazards  |      |      |                 |
|                  | which could      |      |      |                 |
|                  | result in        |      |      |                 |
|                  | serious injury.  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert the wedge | Failure to use   | 2    |      |                 |
| / working        | this could       |      |      |                 |
| platform         | result in sudden |      |      |                 |
|                  | unexpected       |      |      |                 |
|                  | movement causing |      |      |                 |
|                  | serious injury   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clean stationary |                  | 1    |      |                 |
| die and gaps     |                  |      |      |                 |
| along the sides  |                  |      |      |                 |
| of the die       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Remove       |                  |      |      |                 |
|     compacted    |                  |      |      |                 |
|     material     |                  |      |      |                 |
|     with 3' bar  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Remove       |                  |      |      | Ensure that all |
|     remaining    |                  |      |      | proper PPE is   |
|     material     |                  |      |      | used while      |
|     with the     |                  |      |      | using the       |
|     needle gun   |                  |      |      | needle gun      |
+------------------+------------------+------+------+-----------------+
| Clean the        |                  | 1    |      | Ensure that all |
| lifting holes    |                  |      |      | proper PPE is   |
| with needle gun  |                  |      |      | used while      |
|                  |                  |      |      | using the       |
|                  |                  |      |      | needle gun      |
+------------------+------------------+------+------+-----------------+
| Position the     |                  | 1    |      |                 |
| crane hook over  |                  |      |      |                 |
| the stationary   |                  |      |      |                 |
| die              |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  |                  | 1    |      |                 |
| lifting device   |                  |      |      |                 |
| is correctly     |                  |      |      |                 |
| attached to the  |                  |      |      |                 |
| crane hook       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert lifting   |                  | 1    |      |                 |
| tool into the    |                  |      |      |                 |
| lifting holes    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal crane     |                  | 1    |      |                 |
| operator to take |                  |      |      |                 |
| up the slack on  |                  |      |      |                 |
| the cables       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the nuts  |                  | 1    |      | The washers and |
| and washers from |                  |      |      | nuts are        |
| the stationary   |                  |      |      | removed from    |
| die retaining    |                  |      |      | the back side   |
| bolts            |                  |      |      | of frame. A     |
|                  |                  |      |      | torch may be    |
|                  |                  |      |      | needed to       |
|                  |                  |      |      | remove. Ensure  |
|                  |                  |      |      | that all proper |
|                  |                  |      |      | PPE is used     |
|                  |                  |      |      | during cutting  |
|                  |                  |      |      | operations.     |
|                  |                  |      |      | Make sure Fire  |
|                  |                  |      |      | Extinguisher is |
|                  |                  |      |      | immediately     |
|                  |                  |      |      | available.      |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| retaining bolts  |                  |      |      |                 |
| and wedges       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| wedge/working    |                  |      |      |                 |
| platform from    |                  |      |      |                 |
| the jaw          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clear all        | Failure to clear | 2    |      | Essential       |
| non-essential    | personnel could  |      |      | personnel are   |
| personnel from   | result in        |      |      | signalman and   |
| the area         | serious injury   |      |      | one mechanic to |
|                  | from shifting    |      |      | pry and guide   |
|                  | load or          |      |      | the die.        |
|                  | unexpected       |      |      | Non-essential   |
|                  | movement.        |      |      | personnel       |
|                  |                  |      |      | should move to  |
|                  |                  |      |      | the service     |
|                  |                  |      |      | truck           |
+------------------+------------------+------+------+-----------------+
| Pry the          |                  | 1    |      |                 |
| stationary die   |                  |      |      |                 |
| from the frame   |                  |      |      |                 |
| with 6' pry bar  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  | Failure to       | 2    |      |                 |
| crane hook is    | center the crane |      |      |                 |
| centered over    | hook over the    |      |      |                 |
| the jaw die      | jaw die may      |      |      |                 |
|                  | result in the    |      |      |                 |
|                  | die swinging and |      |      |                 |
|                  | damaging front   |      |      |                 |
|                  | frame and is a   |      |      |                 |
|                  | serious hazard   |      |      |                 |
|                  | for all          |      |      |                 |
|                  | maintenance      |      |      |                 |
|                  | personnel        |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  |      |      |                 |
| stationary die   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      | If die does not |
|     crane        |                  |      |      | move freely,    |
|     operator to  |                  |      |      | release the     |
|     hoist        |                  |      |      | tension and     |
|     (slowly)     |                  |      |      | repeat the      |
|                  |                  |      |      | previous two    |
|                  |                  |      |      | steps           |
+------------------+------------------+------+------+-----------------+
| -   Guide the    |                  | 1    |      | Ensure that the |
|     die out of   |                  |      |      | die doesn't get |
|     the jaw by   |                  |      |      | hung up or      |
|     pushing or   |                  |      |      | snagged         |
|     pulling      |                  |      |      |                 |
|     hoist cables |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      |                 |
|     crane        |                  |      |      |                 |
|     operator to  |                  |      |      |                 |
|     stop the     |                  |      |      |                 |
|     hoist when   |                  |      |      |                 |
|     the die      |                  |      |      |                 |
|     clears the   |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Attach the   |                  | 1    |      | Ensure that you |
|     tag line to  |                  |      |      | are not         |
|     the bottom   |                  |      |      | standing under  |
|     of the die   |                  |      |      | the hoisted die |
|     when it      |                  |      |      |                 |
|     clears the   |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Drop the     |                  | 1    |      |                 |
|     other end of |                  |      |      |                 |
|     the tag line |                  |      |      |                 |
|     over the     |                  |      |      |                 |
|     edge of the  |                  |      |      |                 |
|     hopper       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Unhook       |                  | 1    |      |                 |
|     lanyard from |                  |      |      |                 |
|     the body     |                  |      |      |                 |
|     harness      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Travel to    |                  | 1    |      |                 |
|     the ground   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Grab the end |                  | 1    |      | Ensure that you |
|     of the tag   |                  |      |      | are not         |
|     line         |                  |      |      | standing under  |
|                  |                  |      |      | the hoisted die |
+------------------+------------------+------+------+-----------------+
| -   Signal the   |                  | 1    |      |                 |
|     crane        |                  |      |      |                 |
|     operator to  |                  |      |      |                 |
|     resume the   |                  |      |      |                 |
|     lift         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Set the die  |                  | 1    |      |                 |
|     on the       |                  |      |      |                 |
|     blocking in  |                  |      |      |                 |
|     a            |                  |      |      |                 |
|                  |                  |      |      |                 |
|    predetermined |                  |      |      |                 |
|     spot         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Disconnect   |                  | 1    |      |                 |
|     the lifting  |                  |      |      |                 |
|     device from  |                  |      |      |                 |
|     the die      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+

#  

# 

# Duty 7: Jaw Prep and Cleaning

Learner will demonstrate how to safely and efficiently perform jaw prep
and cleaning. The learner will also explain the job duties, why they are
conducted, any associated risk, and how to implement appropriate
controls. Safe and efficient performance of the jaw prep and cleaning
includes the following steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Hose the inside  |                  | 1    |      |                 |
| of the jaw with  |                  |      |      |                 |
| water            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach lanyard   | Failure to       | 2    |      |                 |
| to the body      | attach lanyard   |      |      |                 |
| harness          | exposes the      |      |      |                 |
|                  | worker to        |      |      |                 |
|                  | falling hazards  |      |      |                 |
|                  | which could      |      |      |                 |
|                  | result in        |      |      |                 |
|                  | serious injury.  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      | Failure to use   | 2    |      |                 |
| working platform | this could       |      |      |                 |
| inside the jaw   | result in sudden |      |      |                 |
|                  | unexpected       |      |      |                 |
|                  | movement causing |      |      |                 |
|                  | serious injury   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clean machined   |                  | 1    |      | Ensure that a   |
| surfaces with    |                  |      |      | face shield is  |
| wire wheel       |                  |      |      | used during     |
|                  |                  |      |      | this step       |
+------------------+------------------+------+------+-----------------+
| Check the        | Failure may      | 2    |      |                 |
| machined         | reduce the       |      |      |                 |
| surfaces with a  | operational life |      |      |                 |
| straight edge    | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Grind the high   |                  | 1    |      | Ensure that a   |
| spots off with   |                  |      |      | face shield is  |
| grinder if       |                  |      |      | used during     |
| needed           |                  |      |      | this step       |
+------------------+------------------+------+------+-----------------+
| Repeat the       |                  | 1    |      |                 |
| previous two     |                  |      |      |                 |
| steps until the  |                  |      |      |                 |
| surface is       |                  |      |      |                 |
| properly         |                  |      |      |                 |
| prepared         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Get out of the   |                  | 1    |      |                 |
| jaw              |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Disconnect the   |                  | 1    |      |                 |
| lanyard from the |                  |      |      |                 |
| body harness     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Go to the under  |                  | 1    |      |                 |
| jaw belt         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Slide down the   |                  | 1    |      |                 |
| belt to the      |                  |      |      |                 |
| bottom of the    |                  |      |      |                 |
| jaw              |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  | Failure may      | 2    |      |                 |
| lower wedge      | reduce the       |      |      |                 |
| bolts for both   | operational life |      |      |                 |
| sides are tight  | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Inspect both     | Failure may      | 2    |      | Replace if      |
| lower wedge for  | reduce the       |      |      | necessary       |
| debris and wear  | operational life |      |      |                 |
|                  | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Slide out from   |                  | 1    |      |                 |
| under the jaw    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Replace lower    |                  |      |      |                 |
| wedges           |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Obtain tools |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| -   28mm socket  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Splined      |                  |      |      |                 |
|     drive impact |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   28mm end     |                  |      |      |                 |
|     wrench       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   3' pry bar   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Hammer       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Remove the   |                  | 1    |      | The washers and |
|     nuts and     |                  |      |      | nuts are        |
|     washers from |                  |      |      | removed from    |
|     the wedges   |                  |      |      | the back side   |
|                  |                  |      |      | of frame and    |
|                  |                  |      |      | the pitman. A   |
|                  |                  |      |      | torch may be    |
|                  |                  |      |      | needed to       |
|                  |                  |      |      | remove. Ensure  |
|                  |                  |      |      | that all proper |
|                  |                  |      |      | PPE is used     |
|                  |                  |      |      | during cutting  |
|                  |                  |      |      | operations.     |
|                  |                  |      |      | Make sure a     |
|                  |                  |      |      | fire            |
|                  |                  |      |      | extinguisher is |
|                  |                  |      |      | immediately     |
|                  |                  |      |      | available.      |
+------------------+------------------+------+------+-----------------+
| -   Remove the   |                  | 1    |      |                 |
|     bolts from   |                  |      |      |                 |
|     the wedges   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Pry the      |                  | 1    |      |                 |
|     wedge out    |                  |      |      |                 |
|     with the 3'  |                  |      |      |                 |
|     pry bar      |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Clean seat   |                  | 1    |      |                 |
|     with the     |                  |      |      |                 |
|     wire brush   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Check seat   | Failure may      | 2    |      |                 |
|                  | reduce the       |      |      |                 |
|                  | operational life |      |      |                 |
|                  | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Clean the    |                  | 1    |      |                 |
|     wedge with   |                  |      |      |                 |
|     the wire     |                  |      |      |                 |
|     brush        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Install new  |                  | 1    |      | Install with    |
|     wedge into   |                  |      |      | the lip up      |
|     the seat     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Brush        |                  | 1    |      |                 |
|     anti-seize   |                  |      |      |                 |
|     on the bolts |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Insert bolts |                  | 1    |      |                 |
|     through      |                  |      |      |                 |
|     wedge and    |                  |      |      |                 |
|     through      |                  |      |      |                 |
|     frame        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Put the nuts |                  | 1    |      |                 |
|     and washers  |                  |      |      |                 |
|     on           |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Tighten nuts |                  | 1    |      |                 |
|     with spline  |                  |      |      |                 |
|     drive        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+

#  

# 

# Duty 8: Flip the Stationary Die

Learner will demonstrate how to safely and efficiently flip the
stationary die. The learner will also explain the job duties, why they
are conducted, any associated risk, and how to implement appropriate
controls. Safe and efficient performance of flipping the stationary die
includes the following steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Position the     |                  | 1    |      | The stationary  |
| crane hook over  |                  |      |      | and moveable    |
| the stationary   |                  |      |      | dies are        |
| die              |                  |      |      | different;      |
|                  |                  |      |      | check the part  |
|                  |                  |      |      | numbers for the |
|                  |                  |      |      | correct die     |
+------------------+------------------+------+------+-----------------+
| Conduct a visual | This is the only | 2    |      |                 |
| inspection of    | device that can  |      |      |                 |
| the lifting      | be used to       |      |      |                 |
| device           | remove dies not  |      |      |                 |
|                  | having this      |      |      |                 |
|                  | device could     |      |      |                 |
|                  | cause loss in    |      |      |                 |
|                  | production.      |      |      |                 |
|                  | Without          |      |      |                 |
|                  | conducting an    |      |      |                 |
|                  | inspection could |      |      |                 |
|                  | result in a      |      |      |                 |
|                  | lifting failure. |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clean die        |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Check die        | Bent dies can    | 3    |      | If old die is   |
| machine surface  | cause severe     |      |      | bent replace    |
| with straight    | damage to        |      |      | with new die    |
| edge             | crusher which    |      |      | refer die       |
|                  | would cause      |      |      | replacement     |
|                  | stopping of      |      |      | duty.           |
|                  | production.      |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Trim edge of die | Failure to trim  | 2    |      | Wear proper PPE |
| with torch if    | the edge will    |      |      |                 |
| necessary to     | result in delay  |      |      |                 |
| original         | of task.         |      |      |                 |
| dimension.       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach the       |                  | 1    |      | Worn end up     |
| lifting device   |                  |      |      |                 |
| to the opposite  |                  |      |      |                 |
| end of the       |                  |      |      |                 |
| stationary die   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach the tag   |                  | 1    |      |                 |
| line to the      |                  |      |      |                 |
| bottom of the    |                  |      |      |                 |
| stationary die   |                  |      |      |                 |
| (Opposite of     |                  |      |      |                 |
| lifting device)  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that all  | Failure to clear | 2    |      |                 |
| persons are      | personnel could  |      |      |                 |
| clear from the   | result in        |      |      |                 |
| lifting area     | serious injury   |      |      |                 |
|                  | from shifting    |      |      |                 |
|                  | load or          |      |      |                 |
|                  | unexpected       |      |      |                 |
|                  | movement.        |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal the crane |                  | 1    |      |                 |
| operator to      |                  |      |      |                 |
| hoist the die    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Hoist die        |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Center the die   |                  | 1    |      |                 |
| over the jaw     |                  |      |      |                 |
| opening          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal the crane |                  | 1    |      |                 |
| operator to stop |                  |      |      |                 |
| hoisting         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach lanyard   | Failure to       | 2    |      |                 |
| to the hammer    | attach lanyard   |      |      |                 |
| frame            | exposes the      |      |      |                 |
|                  | worker to        |      |      |                 |
|                  | falling hazards  |      |      |                 |
|                  | which could      |      |      |                 |
|                  | result in        |      |      |                 |
|                  | serious injury.  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Climb on top of  |                  | 1    |      |                 |
| the pitman       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the tag   |                  | 1    |      | Ensure that     |
| line from the    |                  |      |      | persons are not |
| die              |                  |      |      | exposed to the  |
|                  |                  |      |      | suspended load  |
+------------------+------------------+------+------+-----------------+
| Lower the die    |                  | 1    |      |                 |
| into the jaw     |                  |      |      |                 |
| while guiding    |                  |      |      |                 |
| into position    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      | Failure to use   | 2    |      |                 |
| wedge / work     | this could       |      |      |                 |
| platform into    | result in sudden |      |      |                 |
| the jaw          | unexpected       |      |      |                 |
|                  | movement causing |      |      |                 |
|                  | serious injury   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Climb into the   |                  | 1    |      |                 |
| jaw and onto the |                  |      |      |                 |
| wedge            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Center the die   | Failure may      | 2    |      |                 |
|                  | reduce the       |      |      |                 |
|                  | operational life |      |      |                 |
|                  | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  | Failure may      | 2    |      |                 |
| die is seated    | reduce the       |      |      |                 |
| properly on      | operational life |      |      |                 |
| lower wedges     | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      | Failure may      | 2    |      | Install with    |
| upper wedges     | reduce the       |      |      | the chisel side |
| into position    | operational life |      |      | toward the die; |
|                  | of the equipment |      |      | this must be    |
|                  | because the die  |      |      | installed       |
|                  | may come loose   |      |      | correctly       |
+------------------+------------------+------+------+-----------------+
| Brush anti-seize |                  | 1    |      |                 |
| on the bolts     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert the bolts |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      |                  | 1    |      | Washers and     |
| washers and nuts |                  |      |      | nuts are        |
|                  |                  |      |      | installed from  |
|                  |                  |      |      | the back side   |
|                  |                  |      |      | of frame        |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| lifting device   |                  |      |      |                 |
| from the die     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Reposition the   |                  | 1    |      |                 |
| crane hook over  |                  |      |      |                 |
| the moveable die |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Tighten the nuts | Failure may      | 2    |      |                 |
| with spline      | reduce the       |      |      |                 |
| drive impact     | operational life |      |      |                 |
|                  | of the equipment |      |      |                 |
|                  | because the die  |      |      |                 |
|                  | may come loose   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the work  |                  | 1    |      |                 |
| platform         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove lanyard   |                  | 1    |      |                 |
| from the body    |                  |      |      |                 |
| harness          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+

#  

# 

# Duty 9: Flip Moveable Die

Learner will demonstrate how to safely and efficiently flip the moveable
die. The learner will also explain the job duties, why they are
conducted, any associated risk, and how to implement appropriate
controls. Safe and efficient performance of flipping a moveable die
includes the following steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Conduct a visual | This is the only | 2    |      |                 |
| inspection of    | device that can  |      |      |                 |
| the lifting      | be used to       |      |      |                 |
| device           | remove dies not  |      |      |                 |
|                  | having this      |      |      |                 |
|                  | device could     |      |      |                 |
|                  | cause loss in    |      |      |                 |
|                  | production.      |      |      |                 |
|                  | Without          |      |      |                 |
|                  | conducting an    |      |      |                 |
|                  | inspection could |      |      |                 |
|                  | result in a      |      |      |                 |
|                  | lifting failure. |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Clean die        |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Check die        | Bent dies can    | 3    |      | If old die is   |
| machine surface  | cause severe     |      |      | bent replace    |
| with straight    | damage to        |      |      | with new die    |
| edge             | crusher which    |      |      | refer to the    |
|                  | would cause      |      |      | die replacement |
|                  | stopping of      |      |      | duty.           |
|                  | production.      |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Trim edge of die | Failure to trim  | 2    |      | Wear proper PPE |
| with torch if    | the edge will    |      |      |                 |
| necessary to     | result in delay  |      |      |                 |
| original         | of task.         |      |      |                 |
| dimension.       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach the       |                  | 1    |      | Worn end up     |
| lifting device   |                  |      |      |                 |
| to the opposite  |                  |      |      |                 |
| end of the       |                  |      |      |                 |
| moveable die     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach the tag   |                  | 1    |      |                 |
| line to the      |                  |      |      |                 |
| bottom of the    |                  |      |      |                 |
| moveable die     |                  |      |      |                 |
| (Opposite of     |                  |      |      |                 |
| lifting device)  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that all  | Failure to clear | 2    |      |                 |
| persons are      | personnel could  |      |      |                 |
| clear from the   | result in        |      |      |                 |
| lifting area     | serious injury   |      |      |                 |
|                  | from shifting    |      |      |                 |
|                  | load or          |      |      |                 |
|                  | unexpected       |      |      |                 |
|                  | movement.        |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal the crane |                  | 1    |      | Only the pre    |
| operator to      |                  |      |      | assigned person |
| hoist the die    |                  |      |      | will give       |
|                  |                  |      |      | signals to      |
|                  |                  |      |      | crane operator  |
+------------------+------------------+------+------+-----------------+
| Hoist die        |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Center the die   |                  | 1    |      |                 |
| over the jaw     |                  |      |      |                 |
| opening          |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Signal crane     |                  | 1    |      |                 |
| operator to stop |                  |      |      |                 |
| hoist            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Move retractable |                  | 2    |      |                 |
| lanyard to the   |                  |      |      |                 |
| stationary side  |                  |      |      |                 |
| (designated      |                  |      |      |                 |
| tie-off point)   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Attach lanyard   | Failure to       | 2    |      |                 |
| to body harness  | attach lanyard   |      |      |                 |
|                  | exposes the      |      |      |                 |
|                  | worker to        |      |      |                 |
|                  | falling hazards  |      |      |                 |
|                  | which could      |      |      |                 |
|                  | result in        |      |      |                 |
|                  | serious injury.  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Proceed to the   |                  | 1    |      |                 |
| stationary side  |                  |      |      |                 |
| of the jaw       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the tag   |                  | 1    |      | Ensure that     |
| line from the    |                  |      |      | persons are not |
| die              |                  |      |      | exposed to the  |
|                  |                  |      |      | suspended load  |
+------------------+------------------+------+------+-----------------+
| Lower the die    |                  | 1    |      |                 |
| into the jaw     |                  |      |      |                 |
| while guiding    |                  |      |      |                 |
| into position    |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      | Failure to use   | 2    |      |                 |
| wedge / work     | this could       |      |      |                 |
| platform into    | result in sudden |      |      |                 |
| the jaw          | unexpected       |      |      |                 |
|                  | movement causing |      |      |                 |
|                  | serious injury   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Climb into the   |                  | 1    |      |                 |
| jaw and onto the |                  |      |      |                 |
| wedge            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Center the die   | Failure may      | 2    |      |                 |
|                  | reduce the       |      |      |                 |
|                  | operational life |      |      |                 |
|                  | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Ensure that the  | Failure may      | 2    |      |                 |
| die is seated    | reduce the       |      |      |                 |
| properly on      | operational life |      |      |                 |
| lower wedges     | of the jaw dies  |      |      |                 |
|                  | because the dies |      |      |                 |
|                  | would not fit    |      |      |                 |
|                  | properly;        |      |      |                 |
|                  | premature wear   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      | Failure may      | 2    |      | Install with    |
| upper wedges     | reduce the       |      |      | the chisel side |
| into position    | operational life |      |      | toward the die; |
|                  | of the equipment |      |      | this must be    |
|                  | because the die  |      |      | installed       |
|                  | may come loose   |      |      | correctly       |
+------------------+------------------+------+------+-----------------+
| Brush on         |                  | 1    |      |                 |
| anti-seize onto  |                  |      |      |                 |
| the bolts        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Insert the bolts |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Install the      |                  | 1    |      | Washers and     |
| washer and nuts  |                  |      |      | nuts are        |
|                  |                  |      |      | installed from  |
|                  |                  |      |      | the back side   |
|                  |                  |      |      | of pitman       |
+------------------+------------------+------+------+-----------------+
| Remove the       |                  | 1    |      |                 |
| lifting device   |                  |      |      |                 |
| from the die     |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Reposition the   |                  | 1    |      |                 |
| crane hook away  |                  |      |      |                 |
| from the working |                  |      |      |                 |
| area             |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Tighten the nuts | Failure may      | 2    |      |                 |
| with splined     | reduce the       |      |      |                 |
| drive impact     | operational life |      |      |                 |
|                  | of the equipment |      |      |                 |
|                  | because the die  |      |      |                 |
|                  | may come loose   |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Climb out of the |                  | 1    |      |                 |
| jaw              |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the work  |                  | 1    |      |                 |
| platform         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Lower lifting    |                  | 1    |      |                 |
| device to ground |                  |      |      |                 |
| level            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove the die   |                  | 1    |      |                 |
| lifting device   |                  |      |      |                 |
| from crane hook  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Inspect lifting  | This is the only | 2    |      | Inspect for     |
| device           | device that can  |      |      | Cuts, nicks,    |
|                  | be used to       |      |      | gouges, cracks, |
|                  | remove dies not  |      |      | excessive       |
|                  | having this      |      |      | corrosion, heat |
|                  | device could     |      |      | discoloration,  |
|                  | cause loss in    |      |      | bent or any     |
|                  | production.      |      |      | other defects.  |
|                  | Without          |      |      |                 |
|                  | conducting an    |      |      |                 |
|                  | inspection could |      |      |                 |
|                  | result in a      |      |      |                 |
|                  | lifting failure. |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Store lifting    |                  | 1    |      |                 |
| device in proper |                  |      |      |                 |
| place            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Communicate with |                  | 1    |      | Ensure that     |
| crane operator   |                  |      |      | Crane operator  |
| that the crane   |                  |      |      | fills out       |
| is done          |                  |      |      | vendor daily    |
|                  |                  |      |      | report form     |
+------------------+------------------+------+------+-----------------+

#  

# 

# 

# Duty 10: Adjusting closed side setting (CSS)

Learner will demonstrate how to safely and efficiently adjust the closed
side setting of the jaw (CSS). The learner will also explain the job
duties, why they are conducted, any associated risk, and how to
implement appropriate controls. Safe and efficient performance adjusting
the closed side setting includes the following steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Slide under the  |                  | 1    |      |                 |
| jaw on the belt  |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Measure the      | Failure to       | 2    |      | Measure from    |
| current opening  | measure the      |      |      | die ridge to    |
| between the      | opening may      |      |      | ridge, Target   |
| stationary and   | result in        |      |      | measurement for |
| moveable jaw     | excessive stress |      |      | the open        |
| dies             | on bearing which |      |      | setting is 6"   |
|                  | would reduce the |      |      |                 |
|                  | operational life |      |      |                 |
|                  | of the           |      |      |                 |
|                  | equipment, and   |      |      |                 |
|                  | damage to down   |      |      |                 |
|                  | stream belts and |      |      |                 |
|                  | crushers.        |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Tighten the      | Failure to       | 2    |      | Count the       |
| adjustment       | properly adjust  |      |      | rotations (one  |
| wedges as needed | the opening may  |      |      | rotation is     |
| to obtain the 6" | result in        |      |      | equal to 1/16   |
| OSS setting      | excessive stress |      |      | of a inch) to   |
|                  | on bearing which |      |      | adjust the      |
|                  | would reduce the |      |      | wedges equally  |
|                  | operational life |      |      |                 |
|                  | of the           |      |      |                 |
|                  | equipment, and   |      |      |                 |
|                  | damage to down   |      |      |                 |
|                  | stream belts and |      |      |                 |
|                  | crushers.        |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Inspect the      | Failure to       | 3    |      |                 |
| toggle rod and   | conduct could    |      |      |                 |
| springs          | result in        |      |      |                 |
|                  | equipment damage |      |      |                 |
|                  | to the Jaw,      |      |      |                 |
|                  | which would      |      |      |                 |
|                  | severely reduce  |      |      |                 |
|                  | the operational  |      |      |                 |
|                  | life of the      |      |      |                 |
|                  | equipment, belt  |      |      |                 |
|                  | damage,          |      |      |                 |
|                  | secondary        |      |      |                 |
|                  | crusher and      |      |      |                 |
|                  | production would |      |      |                 |
|                  | be stopped.      |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Look for     |                  |      |      | Replace         |
|     cracks       |                  |      |      | immediately if  |
|                  |                  |      |      | cracks are      |
|                  |                  |      |      | found           |
+------------------+------------------+------+------+-----------------+
| -   Look for     |                  |      |      | Schedule        |
|     visible wear |                  |      |      | replacement     |
|     on the rod   |                  |      |      | with site       |
|                  |                  |      |      | supervisor      |
+------------------+------------------+------+------+-----------------+
| Tighten the      | Toggle rod could | 2    |      |                 |
| toggle rod nuts  | come loose which |      |      |                 |
| until knocking   | would result in  |      |      |                 |
| stops to obtain  | equipment damage |      |      |                 |
| (16 ¾" overall   | which would      |      |      |                 |
| spring length)   | severely reduce  |      |      |                 |
|                  | the operational  |      |      |                 |
|                  | life of the      |      |      |                 |
|                  | equipment.       |      |      |                 |
+------------------+------------------+------+------+-----------------+

# 

# 

# Duty 11: Work area cleanup

Learner will demonstrate how to safely and efficiently perform work area
cleanup. The learner will also explain the job duties, why they are
conducted, any associated risk, and how to implement appropriate
controls. Safe and efficient performance of work area cleanup includes
the following steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Gather and       |                  | 1    |      |                 |
| account for all  |                  |      |      |                 |
| tools            |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Put all special  | Failure to       | 2    |      |                 |
| jaw tools back   | replace tools    |      |      |                 |
| into the tool    | could result in  |      |      |                 |
| kit              | delays on next   |      |      |                 |
|                  | job.             |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Wrap all hoses   |                  | 1    |      |                 |
| up and put into  |                  |      |      |                 |
| the proper       |                  |      |      |                 |
| places           |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Scrap out old    |                  | 1    |      |                 |
| jaw dies with    |                  |      |      |                 |
| the loader       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Conduct general  |                  | 1    |      |                 |
| housekeeping     |                  |      |      |                 |
| cleanup duties   |                  |      |      |                 |
| around the jaw   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+

# Duty 12: Jaw Start up

Learner will demonstrate how to safely and efficiently perform the Jaw
start up. The learner will also explain the job duties, why they are
conducted, any associated risk, and how to implement appropriate
controls. Safe and efficient performance of the Jaw start up includes
the following steps:

+------------------+------------------+------+------+-----------------+
| **Job Steps**    | **Importance     | **Im | **Sa | **              |
|                  | Narrative**      | port | tisf | Procedures/Risk |
|                  |                  | ance | acto | Resolution/**   |
|                  | **(Consider      | R    | ry** |                 |
|                  | Safety,          | anki |      | **N             |
|                  | Production,      | ng** | **   | otes/Comments** |
|                  | Maintenance)**   |      | or** |                 |
|                  |                  | *    |      |                 |
|                  |                  | *1=I | **N  |                 |
|                  |                  | mpor | eeds |                 |
|                  |                  | tant | Wo   |                 |
|                  |                  | 2=   | rk** |                 |
|                  |                  | Very |      |                 |
|                  |                  | I    |      |                 |
|                  |                  | mpor |      |                 |
|                  |                  | tant |      |                 |
|                  |                  | 3=Cr |      |                 |
|                  |                  | itic |      |                 |
|                  |                  | al** |      |                 |
+==================+==================+======+======+=================+
| Assemble all     |                  | 1    |      |                 |
| team members at  |                  |      |      |                 |
| the main power   |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove lock and  |                  | 1    |      | Follow proper   |
| tags             |                  |      |      | company policy  |
+------------------+------------------+------+------+-----------------+
| Take a head      | Failure to       | 3    |      |                 |
| count            | conduct head     |      |      |                 |
|                  | count may result |      |      |                 |
|                  | in a high        |      |      |                 |
|                  | probability of   |      |      |                 |
|                  | injury or death  |      |      |                 |
|                  | to workers       |      |      |                 |
|                  | because of       |      |      |                 |
|                  | sudden           |      |      |                 |
|                  | energizing of    |      |      |                 |
|                  | equipment.       |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Turn main power  |                  | 1    |      | Stand to the    |
| on               |                  |      |      | side and turn   |
|                  |                  |      |      | face away from  |
|                  |                  |      |      | the switch      |
+------------------+------------------+------+------+-----------------+
| Push the start   |                  | 1    |      |                 |
| button           |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Listen for       | Failure to       | 2    |      | Knocking noises |
| unusual noises   | listen for noise |      |      | may indicate a  |
|                  | may result in    |      |      | loose toggle    |
|                  | not identifying  |      |      | plate           |
|                  | possible damage  |      |      |                 |
|                  | to the toggle    |      |      |                 |
|                  | plate reducing   |      |      |                 |
|                  | production.      |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Tighten the      | Failure to       | 2    |      | This step       |
| toggle spring if | tighten toggle   |      |      | requires proper |
| a knocking noise | spring may       |      |      | lock and tag    |
| is heard         | result in        |      |      | out procedure;  |
|                  | possible damage  |      |      | follow company  |
|                  | to the toggle    |      |      | policy          |
|                  | plate reducing   |      |      |                 |
|                  | production.      |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Remove barricade |                  | 1    |      |                 |
+------------------+------------------+------+------+-----------------+
| Release the jaw  |                  | 1    |      |                 |
| crusher to the   |                  |      |      |                 |
| operator         |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Order new Jaw    |                  | 1    |      |                 |
| dies             |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Notify the drill |                  | 1    |      |                 |
| and blast        |                  |      |      |                 |
| personnel when   |                  |      |      |                 |
| job is completed |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| Conduct follow   | Failure to       | 2    |      |                 |
| up during the    | conduct follow   |      |      |                 |
| next shift       | up could result  |      |      |                 |
|                  | in equipment     |      |      |                 |
|                  | damage from      |      |      |                 |
|                  | loose bolts.     |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Check die    |                  |      |      |                 |
|     bolt to      |                  |      |      |                 |
|     ensure that  |                  |      |      |                 |
|     they are     |                  |      |      |                 |
|     tight        |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+
| -   Listen for   |                  |      |      |                 |
|     knocking     |                  |      |      |                 |
|     noises       |                  |      |      |                 |
+------------------+------------------+------+------+-----------------+

#