Sandvik Crusher QI440 Operators Manual – PDF DOWNLOAD

Sandvik Crusher QI440 Operators Manual – PDF DOWNLOAD

FILE DETAILS:

Sandvik Crusher QI440 Operators Manual – PDF DOWNLOAD

Language : English
Pages :340
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Sandvik Crusher QI440 Operators Manual – PDF DOWNLOAD

10 Safety Section – Introduction 11
11 The purpose of these instructions 12
12 Identification of the product 12
121 Product type and serial number 12
122 Product manufacturer 13
123 Manuals 13
124 How to identify the right manual for the product 14
125 Validity of the manuals 14
13 Copyright notice 14
14 Definitions 14
20 Safety Section – Safety and Environmental Instructions 17
21 Safety labels and signals 18
211 Signal words 18
212 General hazard symbol 18
213 Symbols for mandatory actions 19
214 Symbols for prohibited actions 20
215 Hazard symbols 20
216 Labels on the product 22
217 Visual and audible signals 28
22 User obligations 28
221 Managing work related hazards 29
222 Scheduled safety inspections and preventive maintenance 30
223 Personal protective equipment 31
23 Product limitations 32
231 Intended use 32
232 Foreseeable misuse 32
233 Prohibited use 32
234 32
235 Maximum inclination angles during tramming and parking 32
236 Maximum inclination angles during operation 33
237 Modifications 33
24 Hazard zones 34
241 Exclusion zone for QI440 34
25 Safeguarding 36
251 Guards 36
252 Protective Devices 40
26 Complementary protective measures 41
261 Use of Emergency stop function 41
262 Emergency exit 43
263 Safe access to machinery and three point support 43
264 Isolation and energy dissipation 44
265 Fire risk control measures 46
27 Protection against emission hazards 47
271 Noise 47
272 Vibration 48
273 Dust 48
28 Emergency procedures and methods for unblocking 49
29 Safety considerations for maintenance 50
210 Environment 53
2101 Decommissioning 53
2102 Dismantling 53
2103 Disposal 54
211 Potential product related hazards identified by the user 55
212 Incident reporting 56
30 Transport &Technical Data 57
31 Transport 58
311 Special Considerations For Transport Of The QI440 58
312 Machine Preparation for Transport 58
313 Folding the main conveyor and Positioning into Transport Position 59
314 Folding the Natural Fines Conveyor and removing the belt troughs 60
315 Folding the hopper sides 62
32 Additional Machine Preparation for Transport for Hanging Screen Options 64
321 Raising the Recirculation Jack Legs 64
322 Preparing the Midsize Transfer Conveyor 64
323 Preparing the Primary Screen Box 65
324 Preparing the secondary screen box 66
325 Preparing the Fines Conveyor 67
326 Preparing the Stock pile Conveyor 67
327 Positioning the Recirculation Conveyor into transport position 69
328 Preparing ladder 1 and ladder 2 for transport 72
329 Store the Loose Items 73
3210 Tracking the machine onto and off the transport vehicle 74
3211 QI440 Transport and Working Dimensions 75
3212 QI440 Hanging Screen Transport And Working Dimensions 77
33 Technical Information 80
34 Technical Data and General Information 80
341 Feed Hopper 80
342 Primary Feeder 80
343 Pre screen 80
344 Impactor 80
345 Main Conveyor 80
346 Natural Fines Conveyor 81
347 Power Unit 81
348 Tracks 81
349 Hanging Screen Option Data 81
3410 Recirculating Conveyor 81
3411 Fines Conveyor 81
3412 Stockpile Conveyor 81
3413 Transfer Conveyor (Oversize and Midsize) 82
3414 Underpan feeder 82
3415 Double Screen 82
35 General Technical Data 82
36 Options 84
361 Hopper extensions 84
362 Hopper Hardox liner plates back and sides 84
363 High impact Sandvik wear rubber back and sides 84
364 Central auto lube (crusher only) 84
365 Central auto lube 84
366 Remote Diesel pump 84
367 Water pump (Hyd) 84
368 Artic Packages 84
369 Tropical / High ambient package (may not be required) 84
3610 Wheeled Dolly (Open circuit only) 84
3611 Conveyor pull cords 84
3612 Grizzly 84
3613 Pre screen top deck punch plate 84
3614 Pre screen top deck mesh (ashalt / secondary applications) 84
3615 Pre screen open bottom rubber to feed natural fines conveyor (high fine / sticky applications) 84
3616 No overband magnet 84
3617 No natural fines conveyor 84
41 Product Overview 86
42 Major Components QI440 86
421 Hanging Screen [ QI440 HS ] Option 87
43 Identification and Operation of the QI440 Controls 88
431 Main Control Panel 88
432 Hydraulic Control Banks 90
433 Hydraulic Control Banks with Hanging Screen [ QI440 HS ] Option Fitted 91
434 Flow Control Valves with Hanging Screen [ QI440 HS ] Option Fitted 92
435 Radio Remote Control Unit 93
436 Umbilical Remote Control Unit 94
50 Commissioning and Shut Down 95
51 Commissioning & Shutdown Safety 96
511 Who is at Risk 96
512 Managing Work related Hazards with a Risk Assessment 96
513 When carrying out maintenance or adjustment 96
52 Commissioning 97
521 Preparation for Machine STARTUP 97
522 Engine Start-up Sequence 98
523 Setting Language of Control Panel Display 99
524 Setting the date/time100
525 Sequence For Tracking Machine101
53 Initial Setup and Operation104
531 Remove the Loose Items104
532 Set Up ladder 1 and ladder 2105
533 Procedure to engage Auxiliary Controls106
534 Folding the hopper sides107
535 Unfold the Natural Fines Conveyor and fitting the belt troughs109
536 Unfolding the main conveyor and Positioning into Working Position111
54 Additional Initial Setup and Operation for Hanging Screen Options112
541 Setting Up the Recirculation Conveyor112
542 Preparing the Stock pile Conveyor114
543 Unfolding the main conveyor and Positioning into Working Position116
544 Preparing the Fines Conveyor117
545 Preparing the secondary screen box117
546 Preparing the primary Screen Box119
547 Preparing the Midsize transfer conveyor120
548 Preparing the Recirculation Jack Legs120
549 Belt Tension121
55 Machine operation124
56 Machine Shut Down124
561 Auto Stop Sequence125
562 Preparing the machine for transport or for the machine to be moved to another location126
563 Emergency Stop127
57 Location Of Emergency Stops On QI440128
61 Operation Safety132
611 Who is at Risk132
612 Managing Work related Hazards with a Risk Assessment132
613 When carrying out maintenance or adjustment132
62 Loading the feeder133
621 Avoid damage to equipment133
63 Common Applications135
631 Construction, Demolition and recycling135
632 Minerals and Quarrying135
633 Maximum Feed size for Crusher135
64 Feed and Jams136
65 Operating the QI440137
651 Start-up Sequence For Running the Crusher137
652 Auto Run Mode139
653 Automatic Mode – Recirculation System141
654 MMPRO S menu Flow chart in automatic Run mode142
655 Manual Run Mode143
656 Feeder Load Control144
657 Machine Adjustment145
658 Tail Level adjustment146
659 Are Precautions Adequate?147
6510 Diverter Chute148
6511 Primary Screen Box Working Angles149
6512 Fault Logs150
66 Clearing Crusher Chamber Jam’s151
661 Managing Work Related Hazards with a Risk Assessment151
60 Operation131
70 Maintenance153
71 Maintenance Safety154
711 Who is at Risk154
712 Managing Work related Hazards with a Risk Assessment154
713 When carrying out maintenance or adjustment154
72 Maintenance Schedule155
721 Testing the Emergency stop function and Battery Isolator159
722 Belt Tension160
723 Maintenace to the CI322 Impactor using DC Maintenance Motor163
724 Engine Maintenance165
725 Radio Remote Control battery Charging165
726 Working at height hazard166
727 Air Cleaner Inspection, Daily Inspection Required166
728 Air Cleaner Maintenance167
729 Battery Maintenance168
7210 Checking Fuel Level, Adding Fuel and Draining fuel tank169
7211 Emptying the Fuel Filter Water Trap170
7212 Special Considerations For Maintenance Or Repair with Welding171
73 Hydraulic System172
731 Hydraulic Oil daily check172
732 Hydraulic Oil is added as follows173
733 Changing The Return Line Filter174
734 Changing the suction Filters and Hydraulic Oil175
735 HPTO Clutch Hydraulic Oil daily check177
736 HPTO Clutch adding hydraulic oil177
737 HPTO CLutch Lubrication tank Suction Filter change177
738 HPTO Oil filter Replacement178
74 Track Maintenance179
741 Checking the Track Tension179
742 Tighten the Tracks180
743 Loosen the Tracks180
744 Track Drive Units181
75 Tensioning Conveyor Belts on the Standard QI440182
751 Tensioning the Natural Fines Conveyor Belt182
752 Tensioning The Main Conveyor belt183
76 Tensioning Conveyor Belts on the QI440 with Hanging Screen184
761 Tensioning the Fines Conveyor Belt184
762 Tensioning the Recirculating Conveyor and Stockpile Conveyor Belts185
763 Tensioning the Oversize and Midsize Transfer Conveyor Belts186
764 Tracking the Conveyor Belts187
765 Removing and Installing Screen Media190
766 Maintenance Data192
767 Hydraulic Oil Requirements for QI440 Machines192
768 Hydraulic Oil Requirements for HPTO Clutch194
769 Lubricants and Fluids194
7610 Greasing Schedule195
7611 Care of chrome200
81 Trouble Shooting Safety202
811 Who is at Risk202
812 Managing Work related Hazards with a Risk Assessment202
813 When carrying out maintenance or adjustment202
82 Machine Faults203
821 Engine Faults (Engine Control Unit)203
822 Engine Diagnostic Codes204
83 Using the Proportional Spool Valve System (PSVS) controls to Diagnose Hydraulic or Electrical Faults206
831 Service Engineer Selection for PSVS Diagnosis206
832 PSVS Diagnosis for Hydraulic or Electrical Faults206
84 Commissioning and Engine Warranty208
841 Commissioning and Warranty Registration208
85 CAT Register Instructions209
851 CAT C Series Warranty Statement210
80 Trouble Shooting and Engine Warranty201
90 Spare Parts213
91 Spare Parts214
911 Spare Parts illustrations214
912 Ordering Procedure:214
913 Managing Work related Hazards with a Risk Assessment215
914 When carrying out maintenance or adjustment215
92 Machine Assemblies216
93 Top Level216
94 Hydraulic Water Pump217
95 Vbelt Guard218
96 Pre Screen220
97 Chassis Complete222
971 Chassis Tower224
972 crusher Drive Tensioning226
973 Jack Leg228
98 Maintenance Platform229
99 Impactor Assemly Complete230
991 Crusher Inlet Chute232
992 diverter Chute233
993 Impactor Chute234
910 Hydraulic Control Box235
911 Natural Fines Conveyor236
912 Powerunit238
9121 Powerpack240
9122 Clutch Lube Tank244
9123 Diesel tank245
9124 Hydraulic tank246
913 Eriez Magnet247
914 Hopper Wing Plate248
915 Main Conveyor250
9151 Main Conveyor Lower Section252
9152 Main Conveyor Upper Section254
9153 Main Conveyor Extension256
916 Primary Feeder258
9161 Feeder260
917 Pan Feeeder264
918 HS System – Recirculating Oversize [ Option where Fitted ]266
9181 Recirculation conveyor268
9182 HS System – Mounting Frame recirculating oversize273
9183 Recirculation Fines conveyor274
9184 Recirculation Screen278
919 Stock Pile Conveyor284
920 Transfer Conveyor 1440-35-00286
921 Transfer Conveyor 1442-35-00288
9211 HS System – Recirculating Mid & Oversize [ Option where fitted ]290
9212 Transfer Conveyor – Recirculating Over & Midsize292
9213 Engine Filter Kits – CAT C13 TIER 3A)294
9214 Engine Filter Kits – CAT C13 TIER 3B296
100 Electrical and Hydraulic299
101 Electrical Schematics300
102 Hydraulics322
1021 Hydraulic Circuit Diagrams322
103 Hydraulic Hose Kits323
111 OEM Appendices340
1111 CI322 Impactor Crusher Operation340
1112 CI322 Impactor Crusher Maintenance Manual340
1113 CI322 Impactor Crusher Spare Parts340
1114 CI322 Impactor Crusher Wear Parts340
1115 Eriez Magnetic Separator340
1116 Roxon Vibrating Feeder340
1117 Crawler Tracks Operation Manual340
1118 M-PROS Control System Spare Parts340
1119 Optional Extra’s340
110 OEM Section339

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