Sandvik QH331 Operators Manual_1884BG – PDF DOWNLOAD

Sandvik QH331 Operators Manual_1884BG - PDF DOWNLOAD

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Sandvik QH331 Operators Manual_1884BG - PDF DOWNLOAD

Language : English
Pages :256
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Sandvik QH331 Operators Manual_1884BG - PDF DOWNLOAD

1.0 Safety Section - Introduction............................................................................... 11
1.1 The purpose of these instructions....................................................................... 12
1.2 Identification of the product........................................................................... 12
1.2.1 Product type and serial number.................................................................... 12
1.2.2 Product manufacturer.............................................................................. 13
1.2.3 Manuals........................................................................................... 13
1.2.4 How to identify the right manual for the product.................................................. 14
1.2.5 Validity of the manuals........................................................................... 14
1.3 Copyright notice........................................................................................ 14
1.4 Definitions............................................................................................. 14
2.0 Safety Section - Safety and Environmental Instructions...................................................... 17
2.1 Safety labels and signals............................................................................... 18
2.1.1 Signal words...................................................................................... 18
2.1.2 General hazard symbol............................................................................. 18
2.1.3 Symbols for mandatory actions..................................................................... 19
2.1.4 Symbols for prohibited actions.................................................................... 20
2.1.5 Hazard symbols.................................................................................... 20
2.1.6 Labels on the product............................................................................. 22
2.1.7 Visual and audible signals........................................................................ 25
2.2 User obligations........................................................................................ 25
2.2.1 Managing work related hazards..................................................................... 26
2.2.2 Scheduled safety inspections and preventive maintenance........................................... 27
2.2.3 Personal protective equipment..................................................................... 28
2.3 Product limitations..................................................................................... 29
2.3.1 Intended use...................................................................................... 29
2.3.2 Foreseeable misuse................................................................................ 29
2.3.3 Prohibited use.................................................................................... 29
2.3.4................................................................................................... 29
2.3.5 Maximum inclination angles during tramming and parking............................................ 29
2.3.6 Maximum inclination angles during operation....................................................... 30
2.3.7 Modifications..................................................................................... 30
2.4 Hazard zones............................................................................................ 31
2.5 Safeguarding............................................................................................ 32
2.5.1 Guards............................................................................................ 32
2.5.2 Protective devices................................................................................ 34
2.6 Complementary protective measures....................................................................... 35
2.6.1 Use of Emergency stop function.................................................................... 35
2.6.2 Emergency exit.................................................................................... 37
2.6.3 Safe access to machinery and three point support.................................................. 37
2.6.4 Isolation and energy dissipation.................................................................. 38
2.6.5 Fire risk control measures........................................................................ 40
2.7 Protection against emission hazards..................................................................... 41
2.7.1 Noise............................................................................................. 41
2.7.2 Vibration......................................................................................... 42
2.7.3 Dust.............................................................................................. 42
2.8 Emergency procedures and methods for unblocking......................................................... 43
2.9 Safety considerations for maintenance................................................................... 44
2.10 Environment............................................................................................ 47
2.10.1 Decommissioning.................................................................................. 47
2.10.2 Dismantling...................................................................................... 47
2.10.3 Disposal......................................................................................... 48
2.11 Potential product related hazards identified by the user............................................... 49
2.12 Incident reporting..................................................................................... 50
3.0 Technical and Transport..................................................................................... 51
3.1 Transport............................................................................................... 52
3.1.1 Special Considerations For Transport Of The QH331................................................. 52
3.1.2 Machine Preparation for Transport................................................................. 52
3.1.3 Preparing the Feed Conveyor....................................................................... 54
3.1.4 Preparing the feed Conveyor maintenance platform.................................................. 55
3.1.5 Preparing the ladders............................................................................. 56
3.1.6 Tracking the machine onto and off the transport vehicle........................................... 58
3.2 Technical Information................................................................................... 59
3.2.1 Standard Features................................................................................. 59
3.2.2 Options........................................................................................... 59
3.2.3 Transport and Working Dimensions.................................................................. 61
3.3 Identification of Main Units............................................................................ 63
3.4 Specification of Main Units............................................................................. 64
3.4.1 Feeder Hopper..................................................................................... 64
3.4.2 Feed Conveyor..................................................................................... 64
3.4.3 Crusher........................................................................................... 64
3.4.4 Main Conveyor..................................................................................... 64
3.4.5 Tracks............................................................................................ 64
3.4.6 Power Unit........................................................................................ 64
4.1 Product Overview........................................................................................ 66
4.1.1 Major Components.................................................................................. 66
4.1.2 Identification and Operation of the QH331 Controls................................................ 67
4.1.3 Main Control Panel................................................................................ 67
4.1.4 Hydraulic Controls................................................................................ 69
4.1.5 Radio Remote Control Unit......................................................................... 70
4.1.6 Umbilical Remote Control Unit..................................................................... 71
4.0 Product Overview............................................................................................ 65
5.0 Commissioning and Shut Down................................................................................. 73
5.1 Commissioning & Shutdown Safety......................................................................... 74
5.1.1 Who is at Risk.................................................................................... 74
5.1.2 Managing Work related Hazards with a Risk Assessment.............................................. 74
5.1.3 When carrying out maintenance or adjustment....................................................... 74
5.2 Commissioning........................................................................................... 75
5.2.1 Preparation for Machine STARTUP................................................................... 75
5.2.2 Engine Start-up Sequence.......................................................................... 76
5.2.3 Setting Language of Control Panel Display......................................................... 77
5.2.4 Setting the date/time............................................................................. 78
5.2.5 Sequence For Tracking Machine..................................................................... 79
5.2.6 Initial Setup and Operation....................................................................... 82
5.2.7 Set Up ladder 1 and ladder 2...................................................................... 83
5.2.8 Preparing the feed Conveyor maintenance platform.................................................. 85
5.2.9 Restarting the Engine to activate Auxillary Controls.............................................. 86
5.2.10 Preparing the Feed Conveyor...................................................................... 86
5.2.11 Belt Tension Check during Commissioning.......................................................... 89
5.3 Machine operation....................................................................................... 92
5.4 Machine Shut Down....................................................................................... 92
5.4.1 Auto Stop Sequence................................................................................ 92
5.4.2 Preparing the machine for transport or for the machine to be moved to another location............ 93
5.4.3 Emergency Stop.................................................................................... 93
5.5 Location Of Emergency Stops On qh331.................................................................... 94
5.5.1 Preparing the machine for transport or for the machine to be moved to another location............ 95
6.1 Operation Safety........................................................................................100
6.1.1 Who is at Risk....................................................................................100
6.1.2 Managing Work related Hazards with a Risk Assessment..............................................100
6.1.3 When carrying out maintenance or adjustment.......................................................100
6.2 Loading the feeder......................................................................................101
6.2.1 Avoid damage to equipment.........................................................................101
6.3 Common Applications.....................................................................................103
6.3.1 Construction, Demolition and recycling............................................................103
6.3.2 Minerals and Quarrying............................................................................103
6.3.3 Maximum Feed size for Crusher.....................................................................103
6.4 Feed and Jams...........................................................................................104
6.5 Operating the QH331.....................................................................................105
6.5.1 Start-up Sequence For Running the Crusher.........................................................105
6.5.2 Auto Run Mode.....................................................................................107
6.5.3 Auto Start Up Sequence............................................................................108
6.5.4 Auto Stop Sequence................................................................................109
6.5.5 Manual Run Mode...................................................................................110
6.5.6 Manual Start Up...................................................................................111
6.5.7 Feed Conveyor Adjustment..........................................................................113
6.5.8 Hopper Level Adjustment...........................................................................114
6.5.9 Tail Conveyor Level Sensor........................................................................115
6.6 Machine Shut Down.......................................................................................116
6.6.1 Manual Stop Sequence..............................................................................116
6.7 Clearing Crusher Chamber Jam’s..........................................................................117
6.7.1 Managing Work Related Hazards with a Risk Assessment..............................................117
6.7.2 Auto Run Closed Side Setting (CSS) Adjustment.....................................................118
6.7.3 Main Operations Menu..............................................................................119
6.0 Operation................................................................................................... 99
7.0 Maintenance.................................................................................................121
7.1 Maintenance Safety......................................................................................122
7.1.1 Who is at Risk....................................................................................122
7.1.2 Managing Work related Hazards with a Risk Assessment..............................................122
7.1.3 When carrying out maintenance or adjustment.......................................................122
7.2 Maintenance Schedule....................................................................................123
7.2.1 Power Unit Engine and Hydraulic...................................................................123
7.2.2 Crusher & Feeder..................................................................................124
7.2.3 Testing the Emergency stop function and Battery Isolator..........................................126
7.2.4 Conveyors and General.............................................................................128
7.2.5 Belt Tension......................................................................................129
7.2.6 Engine Maintenance................................................................................132
7.2.7 Radio Remote Control battery Charging.............................................................132
7.2.8 Air Cleaner Maintenance...........................................................................133
7.2.9 Battery Maintenance...............................................................................134
7.2.10 Check / Adding Fuel..............................................................................134
7.2.11 Emptying the Fuel Filter Water Trap..............................................................135
7.2.12 Special Considerations For Maintenance Or Repair with Welding....................................136
7.3 Hydraulic System........................................................................................137
7.3.1 Hydraulic Oil.....................................................................................137
7.3.2 Hydraulic oil is added as follows:................................................................138
7.3.3 Changing The Return Line Filter...................................................................139
7.3.4 Changing The Suction Filters and the Hydraulic Oil................................................140
7.4 Lubrication System......................................................................................142
7.4.1 Lubrication Oil...................................................................................143
7.4.2 Changing the Lubrication Oil......................................................................144
7.4.3 Track Maintenance.................................................................................145
7.4.4 Checking the Track Tension........................................................................146
7.4.5 Tighten the Tracks................................................................................147
7.4.6 Loosen the Tracks.................................................................................147
7.4.7 Track Drive Units.................................................................................148
7.5 Conveyor Belt Maintenance...............................................................................149
7.5.1 Tensioning the Feed Conveyor Belt.................................................................149
7.5.2 Tensioning The Main Conveyor belt.................................................................150
7.5.3 Tracking the Belts................................................................................152
7.5.4 Maintenance Data..................................................................................154
7.5.5 Hydraulic Oil Requirements for QH331 Machines.....................................................154
7.6 Lubricants and Fluids...................................................................................157
7.6.1 Greasing Schedule.................................................................................158
7.6.2 Care of chrome....................................................................................160
8.1 Trouble Shooting Safety.................................................................................162
8.1.1 Who is at Risk....................................................................................162
8.1.2 Managing Work related Hazards with a Risk Assessment..............................................162
8.1.3 When carrying out maintenance or adjustment.......................................................162
8.1.4 Diagnostic Screen.................................................................................163
8.1.5 Engine Status.....................................................................................164
8.2 Service Log and Faults..................................................................................165
8.3 Machine Shutdown Faults.................................................................................170
8.3.1 FC 101Emergency Stop Alarm........................................................................170
8.4 Using the Proportional Spool Valve System (PSVS) controls to Diagnose Hydraulic or Electrical Faults....171
8.4.1 Service Engineer Selection for PSVS Diagnosis.....................................................171
8.4.2 PSVS Diagnosis for Hydraulic or Electrical Faults.................................................171
8.5 Commissioning and Engine Warranty.......................................................................173
8.5.1 Commissioning and Warranty Registration...........................................................173
8.6 CAT Register Instructions...............................................................................174
8.6.1 CAT C Series Warranty Statement...................................................................175
8.0 Trouble Shooting and Warranty...............................................................................161
9.0 Spare Parts.................................................................................................177
9.1 Spare Parts.............................................................................................178
9.1.1 Spare Parts illustrations.........................................................................178
9.1.2 Ordering Procedure:...............................................................................178
9.1.3 Managing Work related Hazards with a Risk Assessment..............................................179
9.1.4 When carrying out maintenance or adjustment.......................................................179
9.2 Machine Assemblies......................................................................................180
9.2.1 Top Level.........................................................................................180
9.2.2 QH331 Chassis assembly............................................................................182
9.2.3 Mid Section Walkway...............................................................................184
9.2.4 R.H.S. Maintenance Platform.......................................................................186
9.2.5 Rear Maintenance Platform.........................................................................188
9.2.6 Lubrication Tank..................................................................................189
9.2.7 Clutch Lubrication Tank...........................................................................190
9.2.8 Cone Assembly.....................................................................................192
9.2.9 Cone Discharge Chute..............................................................................194
9.2.10 Chassis Tower....................................................................................196
9.2.11 Hydraulic Tank...................................................................................198
9.2.12 Diesel Tank......................................................................................200
9.2.13 Feed Conveyor....................................................................................202
9.2.14 Feeder Support Frame.............................................................................205
9.2.15 Main Conveyor....................................................................................206
9.2.16 Main Conveyor lower section......................................................................208
9.2.17 Control Cabinet..................................................................................210
9.2.18 Power Unit.......................................................................................212
9.2.19 Flywheel guard...................................................................................217
9.2.20 Tensioning Device................................................................................218
9.2.21 Tensioning Pulley................................................................................219
9.2.22 Active Turnbuckle Assembly.......................................................................220
9.2.23 Engine Filter Kits - CAT C9 3A...................................................................221
9.2.24 Engine Filter Kits - CAT C9.3 3B.................................................................222
10.1 Electrical Schematics..................................................................................224
10.2 Hydraulic..............................................................................................246
10.2.1 Hydraulic circuit................................................................................246
10.2.2 Hydraulic hose kits..............................................................................247
10.0 Electrical and Hydraulic...................................................................................223
11.1 OEM Appendices.........................................................................................254
11.1.1 CH430 CONE Crusher Operation.....................................................................254
11.1.2 CH430 CONE Crusher maintenance Manual............................................................254
11.1.3 CH430 CONE Crusher Spare Parts...................................................................254
11.1.4 CH430 CONE Crusher Wear Parts....................................................................254
11.1.5 Crawler Tracks Operation Manual..................................................................254
11.1.6 M-PROS Control System Spare Parts................................................................254
11.1.7 Optional Extra’s.................................................................................254
11.0 OEM Section................................................................................................253

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