Sandvik Mining QA441 Operators Manual – PDF DOWNLOAD
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Sandvik Mining QA441 Operators Manual – PDF DOWNLOAD
Language : English
Pages :254
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TABLE OF CONTENTS:
Sandvik Mining QA441 Operators Manual – PDF DOWNLOAD
1 Safety………………………………………………………………………………………………………………………………………………………………………………………………………. 9
1.1 Safety principles……………………………………………………………………………………………………………………………………………………………………………………….. 10
1.1.1 Signal words………………………………………………………………………………………………………………………………………………………………………………………. 10
1.1.2 General hazard symbol………………………………………………………………………………………………………………………………………………………………………………. 10
1.1.3 Essentials………………………………………………………………………………………………………………………………………………………………………………………… 11
1.1.4 Safety hazards pertaining to the equipment……………………………………………………………………………………………………………………………………………………………. 11
1.1.5 Colour coded safety signs…………………………………………………………………………………………………………………………………………………………………………… 12
1.1.6 Symbols for prohibited actions………………………………………………………………………………………………………………………………………………………………………. 12
1.1.7 Symbols for mandatory actions……………………………………………………………………………………………………………………………………………………………………….. 13
1.1.8 Symbols for hazards………………………………………………………………………………………………………………………………………………………………………………… 14
1.2 Features for operator safety……………………………………………………………………………………………………………………………………………………………………………… 15
1.3 Environmental safety…………………………………………………………………………………………………………………………………………………………………………………….. 16
1.3.1 Hazardous materials………………………………………………………………………………………………………………………………………………………………………………… 16
1.3.2 Battery disposal…………………………………………………………………………………………………………………………………………………………………………………… 17
1.3.3 Machine disposal…………………………………………………………………………………………………………………………………………………………………………………… 17
1.4 Personal protective equipment (PPE)……………………………………………………………………………………………………………………………………………………………………….. 18
1.5 Organisational safety measures……………………………………………………………………………………………………………………………………………………………………………. 19
1.5.1 Fire risk control measures………………………………………………………………………………………………………………………………………………………………………….. 19
1.6 Personnel qualifications, requirements and responsibilities………………………………………………………………………………………………………………………………………………….. 20
1.7 Safety advice regarding specific operational phases…………………………………………………………………………………………………………………………………………………………. 21
1.7.1 Standard Operation…………………………………………………………………………………………………………………………………………………………………………………. 21
1.7.2 Blockage or malfunction…………………………………………………………………………………………………………………………………………………………………………….. 21
1.7.3 Unguarded areas……………………………………………………………………………………………………………………………………………………………………………………. 21
1.7.4 Fire risk control measures………………………………………………………………………………………………………………………………………………………………………….. 22
1.8 Special work, including maintenance, parts disposal and hazardous materials……………………………………………………………………………………………………………………………………. 23
1.8.1 Securing equipment before performing maintenance………………………………………………………………………………………………………………………………………………………. 23
1.8.2 Maintenance site conditions…………………………………………………………………………………………………………………………………………………………………………. 24
1.8.3 Replacement & removal of components………………………………………………………………………………………………………………………………………………………………….. 24
1.8.4 Climbing and falling……………………………………………………………………………………………………………………………………………………………………………….. 24
1.8.5 Safety considerations during maintenance……………………………………………………………………………………………………………………………………………………………… 26
1.8.6 Safety considerations during cleaning………………………………………………………………………………………………………………………………………………………………… 26
1.8.7 Removal of safety devices, guards and decals………………………………………………………………………………………………………………………………………………………….. 26
1.8.8 Surrounding structures……………………………………………………………………………………………………………………………………………………………………………… 27
1.8.9 Safety when refuelling……………………………………………………………………………………………………………………………………………………………………………… 27
1.9 Specific hazards………………………………………………………………………………………………………………………………………………………………………………………… 28
1.9.1 Electrical energy………………………………………………………………………………………………………………………………………………………………………………….. 28
1.9.2 Automotive batteries……………………………………………………………………………………………………………………………………………………………………………….. 29
1.9.3 Gas, dust, steam, smoke and noise……………………………………………………………………………………………………………………………………………………………………. 29
1.9.4 Welding or Naked Flames…………………………………………………………………………………………………………………………………………………………………………….. 31
1.9.5 Hydraulic equipment………………………………………………………………………………………………………………………………………………………………………………… 31
1.9.6 Hazardous substances……………………………………………………………………………………………………………………………………………………………………………….. 32
1.10 Vibration levels……………………………………………………………………………………………………………………………………………………………………………………….. 33
1.11 Hazard exclusion zones………………………………………………………………………………………………………………………………………………………………………………….. 35
1.12 Measured noise levels…………………………………………………………………………………………………………………………………………………………………………………… 36
1.13 Safety decals – Locations……………………………………………………………………………………………………………………………………………………………………………….. 38
1.14 Emergency stop locations………………………………………………………………………………………………………………………………………………………………………………… 46
1.14.1 Operation of an emergency stop……………………………………………………………………………………………………………………………………………………………………… 47
1.14.2 To reset an emergency stop…………………………………………………………………………………………………………………………………………………………………………. 47
1.15 Machine guarding……………………………………………………………………………………………………………………………………………………………………………………….. 48
1.15.1 Outer guards……………………………………………………………………………………………………………………………………………………………………………………… 48
1.15.2 Inner guards – access guards removed………………………………………………………………………………………………………………………………………………………………… 49
2. Transport & technical data………………………………………………………………………………………………………………………………………………………………………………… 51
2.1 Special considerations for transport…………………………………………………………………………………………………………………………………………………………………… 52
2.1.1 Machine preparation for transport………………………………………………………………………………………………………………………………………………………………… 52
a. Make sure that all bolts and fixings are tight and that all safety devices operating correctly. Never start this machine without the safety devices operating correctly………………………………………… 53
b. Remove all tools and equipment from the transport area…………………………………………………………………………………………………………………………………………….. 53
c. Make sure all persons are away from the machine, drives, tracks and auxiliary equipment……………………………………………………………………………………………………………….. 53
d. Make sure that the pre-start checks outlined in the engine manufacturer’s instruction manual are completed………………………………………………………………………………………………. 53
e. Check the oil levels in the engine………………………………………………………………………………………………………………………………………………………………. 53
f. To remove a tag from the machine, refer to 4.7 Lockout and tag procedure…………………………………………………………………………………………………………………………….. 53
2.1.2 Moving the machine on or off transport vehicle…………………………………………………………………………………………………………………………………………………….. 54
a. Follow start up and tracking procedure, refer to 4.4 Moving machine on the tracks. The machine can be driven on or off the transport vehicle at the pre-set tracking speed……………………………………… 54
b. Before tracking machine off a transport vehicle make sure all temporary sealing and transport straps and chains are removed……………………………………………………………………………….. 54
c. After tracking machine onto transport vehicle make sure all temporary sealing, transport straps and chains are installed………………………………………………………………………………….. 54
2.1.3 Machine Transportation………………………………………………………………………………………………………………………………………………………………………….. 55
2.1.4 Vibrating grid…………………………………………………………………………………………………………………………………………………………………………………. 56
2. Lock out and tag the machine ->…………………………………………………………………………………………………………………………………………………………………. 56
3. Remove the bolts and the nuts with the washers from the positions shown……………………………………………………………………………………………………………………………… 57
4. Remove tag if safe to do so ->………………………………………………………………………………………………………………………………………………………………….. 57
5. Start the machine ->…………………………………………………………………………………………………………………………………………………………………………… 57
6. Move the lever to lift grid flares down………………………………………………………………………………………………………………………………………………………….. 57
7. Grid flares shown down…………………………………………………………………………………………………………………………………………………………………………. 57
2.1.5 Exhaust extension………………………………………………………………………………………………………………………………………………………………………………. 58
2. Loosen clip and rotate exhaust extension…………………………………………………………………………………………………………………………………………………………. 59
3. Remove tag if safe to do so ->………………………………………………………………………………………………………………………………………………………………….. 59
2.1.6 Jacking legs…………………………………………………………………………………………………………………………………………………………………………………… 60
2. Start the machine, refer to 4.3 Engine starting procedure………………………………………………………………………………………………………………………………………….. 60
3. Select auxiliary mode on control panel…………………………………………………………………………………………………………………………………………………………… 60
4. Move the lever to the right to raise the leg……………………………………………………………………………………………………………………………………………………… 60
5. Move the lever to the right to raise the leg……………………………………………………………………………………………………………………………………………………… 60
6. Turn the machine OFF ->………………………………………………………………………………………………………………………………………………………………………… 60
7. Lock out and tag the machine ->…………………………………………………………………………………………………………………………………………………………………. 61
8. Install the locating pins and clips……………………………………………………………………………………………………………………………………………………………… 61
2.1.7 Fines conveyor…………………………………………………………………………………………………………………………………………………………………………………. 62
2. Lockout machine ->…………………………………………………………………………………………………………………………………………………………………………….. 62
3. Remove the locating pins with the clips………………………………………………………………………………………………………………………………………………………….. 62
4. Remove the locating pins with the clips………………………………………………………………………………………………………………………………………………………….. 63
5. Remove lockout from the isolator and start the engine……………………………………………………………………………………………………………………………………………… 63
6. Set machine mode switch to auxiliary…………………………………………………………………………………………………………………………………………………………….. 63
7. Move the fines conveyor down/up lever to the transport position…………………………………………………………………………………………………………………………………….. 63
8. Stop the machine ->……………………………………………………………………………………………………………………………………………………………………………. 63
9. Lockout machine ->…………………………………………………………………………………………………………………………………………………………………………….. 63
10. Secure the locating pins and clips in the position shown………………………………………………………………………………………………………………………………………….. 63
2.1.8 Side conveyors…………………………………………………………………………………………………………………………………………………………………………………. 64
2. Lockout machine ->…………………………………………………………………………………………………………………………………………………………………………….. 64
3. Loosen nut to release side conveyor……………………………………………………………………………………………………………………………………………………………… 64
4. Remove lockout from the isolator and start the engine ->…………………………………………………………………………………………………………………………………………… 64
5. Set machine mode switch to auxiliary…………………………………………………………………………………………………………………………………………………………….. 65
6. Move the fines conveyor lever midway to the transport position……………………………………………………………………………………………………………………………………… 65
7. Release the support rod………………………………………………………………………………………………………………………………………………………………………… 65
8. Move the rollers and lock them in place with the locating pin………………………………………………………………………………………………………………………………………. 65
9. Remove the lower side flares. Put the flares into transport position, install the locating pins………………………………………………………………………………………………………… 66
10. Set machine mode switch to auxiliary……………………………………………………………………………………………………………………………………………………………. 66
11. Move the lever to put the side conveyor into transport position……………………………………………………………………………………………………………………………………. 66
12. Stop the machine ->…………………………………………………………………………………………………………………………………………………………………………… 66
13. Lockout machine ->……………………………………………………………………………………………………………………………………………………………………………. 66
14. Secure the side conveyor for transport………………………………………………………………………………………………………………………………………………………….. 66
2.1.9 Main conveyor and screenbox height……………………………………………………………………………………………………………………………………………………………….. 67
2. Remove the pins and clips that secure the screen box in position……………………………………………………………………………………………………………………………………. 68
3. Remove tag if safe to do so ->………………………………………………………………………………………………………………………………………………………………….. 68
4. Start the machine in operation mode ->…………………………………………………………………………………………………………………………………………………………… 68
5. Set machine mode switch to auxiliary…………………………………………………………………………………………………………………………………………………………….. 68
6. Move the levers to lift the tail/main conveyor and the screen box DOWN, to the transport position………………………………………………………………………………………………………. 68
2.1.10 Maintenance Platforms………………………………………………………………………………………………………………………………………………………………………….. 69
2. Start the machine in operation mode ->…………………………………………………………………………………………………………………………………………………………… 69
3. Set machine mode switch to auxiliary…………………………………………………………………………………………………………………………………………………………….. 70
4. Move the levers to lower the screen box, to the transport position………………………………………………………………………………………………………………………………….. 70
5. Stop the machine ->……………………………………………………………………………………………………………………………………………………………………………. 70
6. Lockout machine ->…………………………………………………………………………………………………………………………………………………………………………….. 70
7. Use suitable access platforms as defined by a site specific risk assessment, to the hand rail………………………………………………………………………………………………………….. 70
8. Remove the retaining bolts……………………………………………………………………………………………………………………………………………………………………… 70
9. Remove the locking pins and retaining bolts on both sides………………………………………………………………………………………………………………………………………….. 70
10. Remove the rear hand rail from the machine………………………………………………………………………………………………………………………………………………………. 70
11. Remove the locking pins……………………………………………………………………………………………………………………………………………………………………….. 71
12. Remove the retaining bolts on both sides………………………………………………………………………………………………………………………………………………………… 71
13. Fold the front floor section…………………………………………………………………………………………………………………………………………………………………… 71
14. Remove the infill plate retaining bolts on both sides…………………………………………………………………………………………………………………………………………….. 71
15. Fold the infill plate into the transport position and secure………………………………………………………………………………………………………………………………………. 72
16. Fold ladder into the transport position…………………………………………………………………………………………………………………………………………………………. 72
17. Remove all the securing pins with the R- clips…………………………………………………………………………………………………………………………………………………… 72
18. Remove tag if safe to do so ->…………………………………………………………………………………………………………………………………………………………………. 72
19. Start the machine in operation mode ->………………………………………………………………………………………………………………………………………………………….. 72
20. Set the mode control to auxiliary………………………………………………………………………………………………………………………………………………………………. 72
21. Move the lever to fold the right hand maintenance platform DOWN……………………………………………………………………………………………………………………………………. 72
22. Move the lever to fold the left hand maintenance platform DOWN…………………………………………………………………………………………………………………………………….. 73
23. Turn the machine OFF ->……………………………………………………………………………………………………………………………………………………………………….. 73
24. Remove all the R-clips and the locating pins so the rail is able to fold……………………………………………………………………………………………………………………………. 73
25. Secure the access gate………………………………………………………………………………………………………………………………………………………………………… 73
26. Close gate on non access side………………………………………………………………………………………………………………………………………………………………….. 73
27. Fold UP the rail and install all the locating pins and clips………………………………………………………………………………………………………………………………………. 74
28. Make sure the maintenance platform locating pins are removed………………………………………………………………………………………………………………………………………. 74
29. Hook the ladder on the maintenance platform and secure……………………………………………………………………………………………………………………………………………. 74
30. Hook the rear hand rail on the maintenance platform and secure…………………………………………………………………………………………………………………………………….. 74
31. Remove tag if safe to do so ->…………………………………………………………………………………………………………………………………………………………………. 74
32. Start the machine in operation mode ->………………………………………………………………………………………………………………………………………………………….. 74
33. Set the mode control to auxiliary………………………………………………………………………………………………………………………………………………………………. 74
34. Lower the end fines conveyor…………………………………………………………………………………………………………………………………………………………………… 75
35. Fold the end fines conveyor up…………………………………………………………………………………………………………………………………………………………………. 75
36. Raise the end fines conveyor and secure it………………………………………………………………………………………………………………………………………………………. 75
2.1.11 Reject grid…………………………………………………………………………………………………………………………………………………………………………………… 76
2. Select auxiliary mode on control panel…………………………………………………………………………………………………………………………………………………………… 76
3. Move the grid lever and adjust the angle reject grid UP……………………………………………………………………………………………………………………………………………. 77
4. Turn the machine OFF ->………………………………………………………………………………………………………………………………………………………………………… 77
5. Lockout machine ->…………………………………………………………………………………………………………………………………………………………………………….. 77
6. Remove the clips and securing pins then lower the support leg as necessary, and secure with the clips and securing pins…………………………………………………………………………………… 77
7. Move the grid lever and lower the reject grid DOWN………………………………………………………………………………………………………………………………………………… 77
2.1.12 Ladder……………………………………………………………………………………………………………………………………………………………………………………….. 78
2. Secure the retaining clips and pins……………………………………………………………………………………………………………………………………………………………… 78
2.2 Machine data………………………………………………………………………………………………………………………………………………………………………………………… 79
2.3 Transport dimensions…………………………………………………………………………………………………………………………………………………………………………………. 82
2.3.1 Option – 4m (13ft) Tipping grid and inlet chute……………………………………………………………………………………………………………………………………………………. 82
2.3.2 Option – 4.5m (15ft) Tipping grid………………………………………………………………………………………………………………………………………………………………… 83
2.3.3 Option – Vibrating grid and inlet chute…………………………………………………………………………………………………………………………………………………………… 84
3. Product Overview…………………………………………………………………………………………………………………………………………………………………………………………. 85
3.1 Machine layout indicating main components………………………………………………………………………………………………………………………………………………………………. 86
3.1.1 General information…………………………………………………………………………………………………………………………………………………………………………….. 86
3.1.2 Main components – overview………………………………………………………………………………………………………………………………………………………………………. 86
A. Reject grid…………………………………………………………………………………………………………………………………………………………………………………… 86
B. Hopper and feed conveyor……………………………………………………………………………………………………………………………………………………………………….. 86
C. Power pack……………………………………………………………………………………………………………………………………………………………………………………. 86
D. Screen box x2…………………………………………………………………………………………………………………………………………………………………………………. 86
E. Fines conveyor………………………………………………………………………………………………………………………………………………………………………………… 86
F. Control levers………………………………………………………………………………………………………………………………………………………………………………… 86
G. Main conveyor…………………………………………………………………………………………………………………………………………………………………………………. 86
H. Control levers (on opposite side)……………………………………………………………………………………………………………………………………………………………….. 86
I. Tracks……………………………………………………………………………………………………………………………………………………………………………………….. 86
J. Maintenance platform…………………………………………………………………………………………………………………………………………………………………………… 86
K. Side conveyors………………………………………………………………………………………………………………………………………………………………………………… 86
3.2 Applications………………………………………………………………………………………………………………………………………………………………………………………… 87
3.2.1 Common applications…………………………………………………………………………………………………………………………………………………………………………….. 87
3.2.2 Machine application and limitations………………………………………………………………………………………………………………………………………………………………. 87
3.3 Screening machine……………………………………………………………………………………………………………………………………………………………………………………. 88
3.3.1 Machine description…………………………………………………………………………………………………………………………………………………………………………….. 88
3.3.2 Operation description…………………………………………………………………………………………………………………………………………………………………………… 88
3.4 Main control devices…………………………………………………………………………………………………………………………………………………………………………………. 89
3.4.1 Electrical controls…………………………………………………………………………………………………………………………………………………………………………….. 89
3.4.2 Hydraulic controls……………………………………………………………………………………………………………………………………………………………………………… 89
3.5 Operational controls…………………………………………………………………………………………………………………………………………………………………………………. 91
A. Information and extra operations display…………………………………………………………………………………………………………………………………………………………….. 91
B. Selection buttons for information and operation display……………………………………………………………………………………………………………………………………………….. 91
C. Machine mode switch: auxiliary, operation, track……………………………………………………………………………………………………………………………………………………… 91
D. Component operation numbers and colour key…………………………………………………………………………………………………………………………………………………………… 91
E. Key operated Power, Heater coils, Start engine, Engine run…………………………………………………………………………………………………………………………………………….. 91
F. Component start and stop sequence buttons 1 to 5……………………………………………………………………………………………………………………………………………………… 91
G. Automatic start and stop sequence button 5…………………………………………………………………………………………………………………………………………………………… 91
H. Engine speed control………………………………………………………………………………………………………………………………………………………………………………. 91
I. Battery isolator switch and lockout…………………………………………………………………………………………………………………………………………………………………. 91
3.6 Machine mode switch………………………………………………………………………………………………………………………………………………………………………………….. 92
A. Auxiliary mode for setting up machine and preparing it for transport……………………………………………………………………………………………………………………………………. 92
B. Operation for screening and position for starting the engine…………………………………………………………………………………………………………………………………………… 92
C. Track for moving the machine on the tracks…………………………………………………………………………………………………………………………………………………………… 92
3.7 Display screen………………………………………………………………………………………………………………………………………………………………………………………. 93
A. Screen display……………………………………………………………………………………………………………………………………………………………………………………. 93
B. Four buttons to navigate between display pages and operate functions……………………………………………………………………………………………………………………………………. 93
C. 4-way screen control………………………………………………………………………………………………………………………………………………………………………………. 93
D. OK button [Not used]………………………………………………………………………………………………………………………………………………………………………………. 93
3.7.1 Auxiliary mode home screen………………………………………………………………………………………………………………………………………………………………………. 93
3.7.2 Operation mode home screen………………………………………………………………………………………………………………………………………………………………………. 94
3.7.3 Track mode home screen………………………………………………………………………………………………………………………………………………………………………….. 94
3.7.4 Engine information……………………………………………………………………………………………………………………………………………………………………………… 95
3.7.5 Machine diagnostics…………………………………………………………………………………………………………………………………………………………………………….. 96
3.7.6 Service mode……………………………………………………………………………………………………………………………………………………………………………………103
3.7.7 Active error display screen………………………………………………………………………………………………………………………………………………………………………103
3.8 Reject grid radio control……………………………………………………………………………………………………………………………………………………………………………..104
3.9 Track controls……………………………………………………………………………………………………………………………………………………………………………………….105
3.10 Machine working dimensions……………………………………………………………………………………………………………………………………………………………………………106
3.10.1 Option – 4m (13ft) Tipping grid and inlet chute……………………………………………………………………………………………………………………………………………………106
3.10.2 Option – 4.5m (15ft) Tipping grid………………………………………………………………………………………………………………………………………………………………..107
3.10.3 Option – Vibrating grid and inlet chute…………………………………………………………………………………………………………………………………………………………..108
4. Commissioning & Shut Down………………………………………………………………………………………………………………………………………………………………………………….109
4.1 General Safety……………………………………………………………………………………………………………………………………………………………………………………….110
4.2 Pre-commissioning instructions…………………………………………………………………………………………………………………………………………………………………………111
4.2.1 Pre-start instructions…………………………………………………………………………………………………………………………………………………………………………..111
4.3 Engine starting procedure……………………………………………………………………………………………………………………………………………………………………………..113
4.3.1 Before starting engine…………………………………………………………………………………………………………………………………………………………………………..113
4.3.2 Engine start……………………………………………………………………………………………………………………………………………………………………………………114
2. Before starting the engine, check that the dummy plug is fitted. It is located at the hopper end of the machine. It must be plugged in for all operations except if the umbilical track control is to be used……….114
3. The alternative plug with umbilical track control can be plugged in if it is to be used………………………………………………………………………………………………………………..114
4.3.3 Engine controls…………………………………………………………………………………………………………………………………………………………………………………115
2. Turn battery isolation switch to the ON position…………………………………………………………………………………………………………………………………………………..115
3. Set the engine speed control down to the slowest position…………………………………………………………………………………………………………………………………………..115
4. Set mode control switch to screening operation position…………………………………………………………………………………………………………………………………………….115
5. Insert the ignition key into the ignition switch and turn it clockwise to the first power ON position indicated…………………………………………………………………………………………..115
6. Turn the key clockwise to the heater position and hold if the engine pre-heat is required………………………………………………………………………………………………………………115
7. Turn the key clockwise to the crank position and hold until the pre-start warning time count down is complete and the engine starts, then release the key……………………………………………………..116
8. The key should return to the power ON position…………………………………………………………………………………………………………………………………………………….116
4.4 Moving machine on the tracks…………………………………………………………………………………………………………………………………………………………………………..117
4.4.1 Before moving the machine………………………………………………………………………………………………………………………………………………………………………..117
4.4.2 Radio remote control…………………………………………………………………………………………………………………………………………………………………………….118
4.4.3 Wired umbilical control………………………………………………………………………………………………………………………………………………………………………….119
4.4.4 Track control mode………………………………………………………………………………………………………………………………………………………………………………120
4.4.5 Operating track control………………………………………………………………………………………………………………………………………………………………………….120
4.5 Preparing for screening operation………………………………………………………………………………………………………………………………………………………………………123
4.5.1 Vibrating grid………………………………………………………………………………………………………………………………………………………………………………….124
4.5.2 Exhaust extension……………………………………………………………………………………………………………………………………………………………………………….126
2. Loosen clip and rotate exhaust extension………………………………………………………………………………………………………………………………………………………….127
3. Remove tag if safe to do so ->…………………………………………………………………………………………………………………………………………………………………..127
4.5.3 Jacking legs……………………………………………………………………………………………………………………………………………………………………………………128
4.5.4 Fines conveyor………………………………………………………………………………………………………………………………………………………………………………….130
4.5.5 Side conveyors………………………………………………………………………………………………………………………………………………………………………………….133
4.5.6 Set up the main conveyor and screen-box height……………………………………………………………………………………………………………………………………………………..136
4.5.7 Maintenance Platforms……………………………………………………………………………………………………………………………………………………………………………138
2. Lock out and tag the machine ->………………………………………………………………………………………………………………………………………………………………….139
3. Remove rear hand rail from the maintenance platform………………………………………………………………………………………………………………………………………………..139
4. Remove tag if safe to do so ->…………………………………………………………………………………………………………………………………………………………………..139
5. Start the machine in operation mode ->……………………………………………………………………………………………………………………………………………………………139
6. Set the mode control to auxiliary………………………………………………………………………………………………………………………………………………………………..139
24. Fold the infill plate down into working position………………………………………………………………………………………………………………………………………………….142
25. Secure the infill plate retaining bolts both sides………………………………………………………………………………………………………………………………………………..142
26. Remove the locking pins………………………………………………………………………………………………………………………………………………………………………..142
27. Fold the front floor section into working position………………………………………………………………………………………………………………………………………………..142
28. Secure the locking pins………………………………………………………………………………………………………………………………………………………………………..142
29. Secure the retaining bolts both sides……………………………………………………………………………………………………………………………………………………………142
30. Put the handrail into working position…………………………………………………………………………………………………………………………………………………………..143
31. Secure the retaining bolts……………………………………………………………………………………………………………………………………………………………………..143
32. Secure the locking pins both sides………………………………………………………………………………………………………………………………………………………………143
33. Secure the retaining bolts both sides……………………………………………………………………………………………………………………………………………………………143
4.5.8 Reject grid…………………………………………………………………………………………………………………………………………………………………………………….144
2. Select auxiliary mode on control panel……………………………………………………………………………………………………………………………………………………………144
3. Move the grid lever and adjust the angle reject grid UP…………………………………………………………………………………………………………………………………………….144
4. Remove the clips and securing pins then adjust the support leg as necessary…………………………………………………………………………………………………………………………..145
5. With the support legs in the required position, install the securing pins and clips……………………………………………………………………………………………………………………145
6. Move the grid lever and adjust the angle reject grid DOWN on to the legs……………………………………………………………………………………………………………………………..145
4.5.9 Ladder…………………………………………………………………………………………………………………………………………………………………………………………146
4.5.10 Screen-box angle……………………………………………………………………………………………………………………………………………………………………………….146
4.6 Shut down the machine…………………………………………………………………………………………………………………………………………………………………………………148
4.6.1 Automatic shut down……………………………………………………………………………………………………………………………………………………………………………..149
4.6.2 Manual shut down………………………………………………………………………………………………………………………………………………………………………………..150
4.7 Lockout and tag procedure……………………………………………………………………………………………………………………………………………………………………………..152
4.7.1 How to fit a single tag………………………………………………………………………………………………………………………………………………………………………….152
4.7.2 To remove a single tag…………………………………………………………………………………………………………………………………………………………………………..152
4.7.3 How to fit a gang tag……………………………………………………………………………………………………………………………………………………………………………153
4.7.4 To remove a gang tag…………………………………………………………………………………………………………………………………………………………………………….153
5. Operations……………………………………………………………………………………………………………………………………………………………………………………………….155
5.1 Operations – minimum safety requirements………………………………………………………………………………………………………………………………………………………………..156
5.2 Screening operation…………………………………………………………………………………………………………………………………………………………………………………..157
5.2.1 Preparation…………………………………………………………………………………………………………………………………………………………………………………….157
2. Start the engine >……………………………………………………………………………………………………………………………………………………………………………..157
3. This screen will be displayed……………………………………………………………………………………………………………………………………………………………………158
4. Set engine speed control up to the fastest position………………………………………………………………………………………………………………………………………………..158
5. Start the machine, in automatic or manual sequence…………………………………………………………………………………………………………………………………………………158
5.2.2 Machine starting sequence – Automatic……………………………………………………………………………………………………………………………………………………………..159
2. When all the red lights are ON and the feeder is operating the sequence is complete……………………………………………………………………………………………………………………159
5.2.3 Machine starting sequence – Manual………………………………………………………………………………………………………………………………………………………………..160
2. Press button 2 and wait until the flashing green/red button changes to a continuous red light indicating the system is operating normally……………………………………………………………………161
3. Follow the sequence of starting each system by pressing button 3…………………………………………………………………………………………………………………………………….161
4. Wait while the button 3 light button changes to a continuous red light, then press 4…………………………………………………………………………………………………………………..161
5. Wait while the button 4 light button changes to a continuous red light, then press 5…………………………………………………………………………………………………………………..161
6. When all the red lights are ON and the feeder is operating the sequence is complete……………………………………………………………………………………………………………………161
5.2.4 Operation Preparation……………………………………………………………………………………………………………………………………………………………………………162
5.2.5 Operation and shut down………………………………………………………………………………………………………………………………………………………………………….163
5.2.6 Machine blockage………………………………………………………………………………………………………………………………………………………………………………..164
5.2.7 Loading material into machine…………………………………………………………………………………………………………………………………………………………………….166
5.3 Set up the conveyor speeds…………………………………………………………………………………………………………………………………………………………………………….168
5.3.1 Side conveyor speed adjustment……………………………………………………………………………………………………………………………………………………………………168
2. Turn the flow controller as necessary to change to speed……………………………………………………………………………………………………………………………………………168
5.3.2 Main conveyor speed adjustment……………………………………………………………………………………………………………………………………………………………………168
2. Turn the flow controller as necessary to change to speed……………………………………………………………………………………………………………………………………………168
5.3.3 Hopper feeder conveyor speed adjustment……………………………………………………………………………………………………………………………………………………………169
2. Turn the flow controller as necessary to change to speed……………………………………………………………………………………………………………………………………………169
5.4 Installation and removal of the optional vibrating grid mesh………………………………………………………………………………………………………………………………………………170
2. Make sure that the mesh clamp has moved enough and releases the mesh…………………………………………………………………………………………………………………………………….170
3. Remove the mesh from the mesh clamp DOWN then OUT……………………………………………………………………………………………………………………………………………………..170
4. When fitting the mesh, install the mesh into the mesh clamp IN and UP……………………………………………………………………………………………………………………………………170
5. Make sure that the mesh is installed correctly in the mesh clamp………………………………………………………………………………………………………………………………………..170
6. Tighten the tension bolts against the tension blocks, until the mesh is correctly tightened………………………………………………………………………………………………………………..170
5.5 Radio remote grid operation……………………………………………………………………………………………………………………………………………………………………………171
5.6 Switching off operation……………………………………………………………………………………………………………………………………………………………………………….173
2. Wait for all material to fully discharge from hopper, screen box and all conveyors………………………………………………………………………………………………………………………..173
3. The machine has two stopping sequences, automatic or manual mode………………………………………………………………………………………………………………………………………..173
5.6.1 Automatic………………………………………………………………………………………………………………………………………………………………………………………173
5.6.2 Manual…………………………………………………………………………………………………………………………………………………………………………………………173
5.6.3 Isolate and lockout……………………………………………………………………………………………………………………………………………………………………………..173
6. Maintenance………………………………………………………………………………………………………………………………………………………………………………………………175
6.1 Introduction – machine maintenance……………………………………………………………………………………………………………………………………………………………………..176
6.2 Reference information…………………………………………………………………………………………………………………………………………………………………………………179
6.3 Maintenance schedules – power module maintenance…………………………………………………………………………………………………………………………………………………………180
6.3.1 Daily (8 hour) maintenance schedule……………………………………………………………………………………………………………………………………………………………….180
6.3.2 Weekly (40 hour) maintenance schedule……………………………………………………………………………………………………………………………………………………………..180
6.3.3 Every 250 hour maintenance schedule……………………………………………………………………………………………………………………………………………………………….181
6.3.4 Every 500 hour maintenance schedule……………………………………………………………………………………………………………………………………………………………….181
6.3.5 Every 1000 hour maintenance schedule………………………………………………………………………………………………………………………………………………………………182
6.3.6 Every 2000 hour maintenance schedule………………………………………………………………………………………………………………………………………………………………182
6.4 Maintenance schedules…………………………………………………………………………………………………………………………………………………………………………………183
6.4.1 Daily maintenance schedule……………………………………………………………………………………………………………………………………………………………………….183
6.4.2 Weekly maintenance schedule………………………………………………………………………………………………………………………………………………………………………185
6.4.3 Every 250 hour maintenance schedule……………………………………………………………………………………………………………………………………………………………….186
6.4.4 Every 500 hour maintenance schedule……………………………………………………………………………………………………………………………………………………………….187
6.4.5 Every 1000 hour maintenance schedule………………………………………………………………………………………………………………………………………………………………188
6.5 Engine oil…………………………………………………………………………………………………………………………………………………………………………………………..189
2. Drainage Point…………………………………………………………………………………………………………………………………………………………………………………….190
3. Refill if necessary………………………………………………………………………………………………………………………………………………………………………………..190
4. For engine oil specification.->……………………………………………………………………………………………………………………………………………………………………..190
6.6 Diesel fuel………………………………………………………………………………………………………………………………………………………………………………………….191
2. If necessary refill diesel tank……………………………………………………………………………………………………………………………………………………………………..192
3. Clean around the filler cap before opening……………………………………………………………………………………………………………………………………………………………192
4. Make sure when the diesel tank is refilled, a hose or funnel is used to avoid spillage…………………………………………………………………………………………………………………….192
5. Drain water from the diesel water trap……………………………………………………………………………………………………………………………………………………………….192
6.7 Hydraulic fluid………………………………………………………………………………………………………………………………………………………………………………………193
2. Clean around the filler cap before opening……………………………………………………………………………………………………………………………………………………………193
3. Fill if necessary………………………………………………………………………………………………………………………………………………………………………………….193
6.8 Engine coolant……………………………………………………………………………………………………………………………………………………………………………………….194
2. Check engine coolant level and refill if necessary…………………………………………………………………………………………………………………………………………………….194
3. Install the cover plate into position and tighten the bolts…………………………………………………………………………………………………………………………………………….194
6.9 Air cleaner servicing…………………………………………………………………………………………………………………………………………………………………………………195
2. If the air filter icon is red then renew the filter……………………………………………………………………………………………………………………………………………………195
3. Regardless of condition of service indicator, remove outer element from air cleaner as shown and use a vacuum suction cleaner. Make sure the filter is cleaned away from the filter housing. Never clean inner element…..195
4. After 5 cleaning services, replace both the inner and outer elements…………………………………………………………………………………………………………………………………….195
5. If air cleaner indicator shows on the control panel whilst machine running, change the filters……………………………………………………………………………………………………………..195
6. Press the reset button on the air cleaner if the indicator switch has operated……………………………………………………………………………………………………………………………195
7. Open the clips…………………………………………………………………………………………………………………………………………………………………………………….196
8. Remove the cover…………………………………………………………………………………………………………………………………………………………………………………..196
9. Remove the primary air cleaner………………………………………………………………………………………………………………………………………………………………………196
10. Only remove and replace the secondary air cleaner after five services…………………………………………………………………………………………………………………………………..196
11. Clean the inside with a dry cloth. Install the filters………………………………………………………………………………………………………………………………………………..196
12. Install the cover and close the clips……………………………………………………………………………………………………………………………………………………………….197
6.10 Inspect the hydraulic return filter indicator…………………………………………………………………………………………………………………………………………………………..198
2. Check the filter condition indicator on top of the filter housing. If the service indicator is red, replace the hydraulic return filter, refer to 6.13 Hydraulic tank filters……………………………………….198
6.11 Grease the bearings………………………………………………………………………………………………………………………………………………………………………………….199
A. Conveyor grease points……………………………………………………………………………………………………………………………………………………………………………..199
B. Screen box bearings………………………………………………………………………………………………………………………………………………………………………………..201
6.12 Fuel filters………………………………………………………………………………………………………………………………………………………………………………………..202
6.13 Hydraulic tank filters……………………………………………………………………………………………………………………………………………………………………………….203
2. Filter condition indicator on the return filter housing. If the service indicator is red, replace the hydraulic return filter………………………………………………………………………………….204
3. Remove the filter housing cover and filter……………………………………………………………………………………………………………………………………………………………204
4. Install the new filter and cover. Make sure the o-rings are in position. Install and tighten the bolts………………………………………………………………………………………………………204
5. Changing the hydraulic tank suction filter, when tank is drained for fluid renewal and cover removed………………………………………………………………………………………………………..204
6. Check the hydraulic tank vent and filler cap………………………………………………………………………………………………………………………………………………………….204
6.14 Conveyors…………………………………………………………………………………………………………………………………………………………………………………………..205
6.14.1 Conveyor precautions……………………………………………………………………………………………………………………………………………………………………………205
6.14.2 Feed conveyor belt……………………………………………………………………………………………………………………………………………………………………………..206
2. Raise the each side and end access doors………………………………………………………………………………………………………………………………………………………….206
3. Remove bolts and conveyor drum guards at each side…………………………………………………………………………………………………………………………………………………207
4. Loosen the two bearing clamp bolts on both sides of the machine……………………………………………………………………………………………………………………………………..207
5. Adjust the belt tension as necessary by turning the adjuster equally…………………………………………………………………………………………………………………………………207
6. Make sure that both sides are adjusted equally and the conveyor is aligned correctly…………………………………………………………………………………………………………………..207
7. Make sure that the conveyor belt is in the centre of the drum……………………………………………………………………………………………………………………………………….207
8. Tighten the bearing clamp bolts when the belt is central and the tension is correct……………………………………………………………………………………………………………………207
9. Install all guards and secure with bolts and washers……………………………………………………………………………………………………………………………………………….207
10. Close the side and end access doors and secure with bolts and washers……………………………………………………………………………………………………………………………….207
6.14.3 Main conveyor belt……………………………………………………………………………………………………………………………………………………………………………..208
2. Loosen the two bearing clamp bolts on both sides of the machine……………………………………………………………………………………………………………………………………..209
3. Release lock nut and adjust the belt tension as necessary by turning the adjusters…………………………………………………………………………………………………………………….209
4. Make sure that both sides are adjusted equally and the conveyor is aligned correctly…………………………………………………………………………………………………………………..209
5. Make sure that the conveyor belt is in the centre of the drum……………………………………………………………………………………………………………………………………….209
6. Tighten the bearing clamp bolts when the belt is central and the tension is correct……………………………………………………………………………………………………………………209
7. If necessary repeat the procedure………………………………………………………………………………………………………………………………………………………………..209
8. Install all guards and secure with bolts and washers……………………………………………………………………………………………………………………………………………….209
6.14.4 Side conveyor belts…………………………………………………………………………………………………………………………………………………………………………….210
2. Loosen the two bearing clamp bolts on both sides of the machine……………………………………………………………………………………………………………………………………..211
3. Adjust the belt tension as necessary by turning the adjusters……………………………………………………………………………………………………………………………………….211
4. Make sure that both sides are adjusted equally and the conveyor is aligned correctly…………………………………………………………………………………………………………………..211
5. Make sure that the conveyor belt is in the centre of the drum……………………………………………………………………………………………………………………………………….211
6. Tighten the bearing clamp bolts when the belt is central and the tension is correct……………………………………………………………………………………………………………………211
7. If necessary repeat the procedure………………………………………………………………………………………………………………………………………………………………..211
8. Install all guards and secure with bolts and washers……………………………………………………………………………………………………………………………………………….211
6.14.5 Tail conveyor belt……………………………………………………………………………………………………………………………………………………………………………..212
2. Loosen the two bearing clamp bolts on both sides of the machine……………………………………………………………………………………………………………………………………..213
3. Adjust the belt tension as necessary by turning the adjusters……………………………………………………………………………………………………………………………………….213
4. Make sure that both sides are adjusted equally and the conveyor is aligned correctly…………………………………………………………………………………………………………………..213
5. Make sure that the conveyor belt is in the centre of the drum……………………………………………………………………………………………………………………………………….213
6. Tighten the bearing clamp bolts when the belt is central and the tension is correct……………………………………………………………………………………………………………………213
7. If necessary repeat the procedure………………………………………………………………………………………………………………………………………………………………..213
8. Install all guards and secure with bolts and washers……………………………………………………………………………………………………………………………………………….213
6.14.6 Belt scrapers………………………………………………………………………………………………………………………………………………………………………………….214
2. Put a spanner on the adjuster hold it, loosen and remove the clamp bolt………………………………………………………………………………………………………………………………214
3. Rotate the adjuster with the spanner to the next slot and install and tighten the clamp bolt……………………………………………………………………………………………………………214
4. Tighten the pivot bolt………………………………………………………………………………………………………………………………………………………………………….214
5. Loosen the bolts and move the flexible scraper UP as necessary. Tighten the bolts to secure…………………………………………………………………………………………………………….214
6.14.7 Inspecting / adjusting belt sealing rubbers……………………………………………………………………………………………………………………………………………………….215
2. Main conveyor………………………………………………………………………………………………………………………………………………………………………………….215
3. Tail conveyor………………………………………………………………………………………………………………………………………………………………………………….215
4. Side conveyor………………………………………………………………………………………………………………………………………………………………………………….215
5. Loosen the bolts……………………………………………………………………………………………………………………………………………………………………………….215
6. Move the sealing strip as necessary. Make sure there is no clearance between the conveyor belt and the strip……………………………………………………………………………………………..215
7. Tighten the bolts………………………………………………………………………………………………………………………………………………………………………………215
6.14.8 Optional magnetic conveyor………………………………………………………………………………………………………………………………………………………………………216
6.15 Installation and removal of the screenbox mesh………………………………………………………………………………………………………………………………………………………….217
6.15.1 Set up access to the screenbox…………………………………………………………………………………………………………………………………………………………………..218
2. Set machine mode switch to auxiliary……………………………………………………………………………………………………………………………………………………………..218
3. Raise the main conveyor fully ->…………………………………………………………………………………………………………………………………………………………………218
4. Lower the fines conveyor fully ->………………………………………………………………………………………………………………………………………………………………..218
5. Install the fines conveyor locating pins and the clips……………………………………………………………………………………………………………………………………………..219
6. Install the main conveyor locating pins or the hooks correctly………………………………………………………………………………………………………………………………………219
7. Install the locating pins……………………………………………………………………………………………………………………………………………………………………….219
6.15.2 Removal of the screenbox mesh……………………………………………………………………………………………………………………………………………………………………220
2. Position the ratchet latch then move the levers to loosen the mesh tension……………………………………………………………………………………………………………………………221
3. Make sure the mesh is unhooked from the tension spring bar………………………………………………………………………………………………………………………………………….221
4. Move the mesh to the side as shown and up…………………………………………………………………………………………………………………………………………………………221
6.15.3 Installation of the screenbox mesh……………………………………………………………………………………………………………………………………………………………….222
2. Make sure the mesh is hooked in position on the tension spring bar and in the mesh hook………………………………………………………………………………………………………………..223
3. Position the ratchet latch then move the levers to tighten the mesh………………………………………………………………………………………………………………………………….223
6.15.4 Screen mesh tension and adjustments………………………………………………………………………………………………………………………………………………………………224
2. Top and bottom mesh, tighten the ratchets…………………………………………………………………………………………………………………………………………………………224
6.16 Tracks……………………………………………………………………………………………………………………………………………………………………………………………..225
6.16.1 Inspection of the tracks………………………………………………………………………………………………………………………………………………………………………..225
2. Check the track surface of the track rollers, idler wheels, track shoes and drive sprockets for wear and loose mounting bolts………………………………………………………………………………225
3. Listen for abnormal noises when the machine is moving slowly………………………………………………………………………………………………………………………………………..225
4. To adjust the track tension ->…………………………………………………………………………………………………………………………………………………………………..225
6.16.2 Track adjustment……………………………………………………………………………………………………………………………………………………………………………….226
2. When the cylinder is filled with grease it extends and pushes the spring tension and the idler, forward………………………………………………………………………………………………….226
3. The grease is filled through the track adjuster grease valve………………………………………………………………………………………………………………………………………..226
6.16.3 Track tension check…………………………………………………………………………………………………………………………………………………………………………….227
2. Sag ‘A’ should not exceed 30mm (1.2in)……………………………………………………………………………………………………………………………………………………………227
6.16.4 Increasing the track tension…………………………………………………………………………………………………………………………………………………………………….228
2. Make sure track adjuster valve is tight…………………………………………………………………………………………………………………………………………………………..228
3. Attach special grease gun connector to a grease gun and fit it onto the track adjuster valve……………………………………………………………………………………………………………228
4. Pump grease into adjuster valve until droop of the track is correct, Refer to 6.19 Lubricants and fluids…………………………………………………………………………………………………228
5. Recheck the track tension, refer to 6.16.3 Track tension check………………………………………………………………………………………………………………………………………228
6. Clean off any excess grease and install the inspection cover………………………………………………………………………………………………………………………………………..228
6.16.5 Releasing the track tension……………………………………………………………………………………………………………………………………………………………………..228
2. Check droop of track, refer to 6.16.3 Track tension check…………………………………………………………………………………………………………………………………………..228
3. Loosen track adjuster valve, by turning it ONLY A HALF turn anti-clockwise……………………………………………………………………………………………………………………………228
4. Grease should slowly escape from track tensioning cylinder and the track slacken………………………………………………………………………………………………………………………228
5. When satisfactorily tensioned, tighten track adjuster valve…………………………………………………………………………………………………………………………………………228
6. Install inspection cover………………………………………………………………………………………………………………………………………………………………………..228
6.17 Track gearbox……………………………………………………………………………………………………………………………………………………………………………………….229
6.17.1 Check and fill gearbox………………………………………………………………………………………………………………………………………………………………………….230
2. Remove the upper plugs, check and top up level with threaded hole with suitable oil, refer to 6.19 Lubricants and fluids…………………………………………………………………………………..230
3. Install and tighten plugs……………………………………………………………………………………………………………………………………………………………………….230
6.17.2 Drain gearbox oil………………………………………………………………………………………………………………………………………………………………………………230
2. Remove the upper plugs then the drain plug………………………………………………………………………………………………………………………………………………………..230
3. Allow oil to thoroughly drain into a suitable container. Refer to 6.19 Lubricants and fluids for quantity………………………………………………………………………………………………..230
4. Install drain plug and fill, refer to Make sure that the gearbox oil is filled correctly to avoid contamination as this will damage the equipment…………………………………………………………….230
6.18 Vibrating grid in hopper [option]……………………………………………………………………………………………………………………………………………………………………..231
2. These bolts and all other fasteners should be checked periodically and any that become loose tightened also………………………………………………………………………………………………….231
6.18.1 General torque reference chart…………………………………………………………………………………………………………………………………………………………………..231
6.19 Lubricants and fluids………………………………………………………………………………………………………………………………………………………………………………..232
6.20 Machine error messages and fault codes…………………………………………………………………………………………………………………………………………………………………233
7. Trouble Shooting………………………………………………………………………………………………………………………………………………………………………………………….237
7.1 Fault finding tables………………………………………………………………………………………………………………………………………………………………………………….238
7.1.1 Starting and running…………………………………………………………………………………………………………………………………………………………………………….239
7.1.2 Moving the machine on the tracks………………………………………………………………………………………………………………………………………………………………….240
7.1.3 Conveyors – maintenance platforms – legs…………………………………………………………………………………………………………………………………………………………..241
7.1.4 Loading and operating……………………………………………………………………………………………………………………………………………………………………………243
7.1.5 Screen box……………………………………………………………………………………………………………………………………………………………………………………..244
7.1.6 Electrical, radio, umbilical controls……………………………………………………………………………………………………………………………………………………………..245
7.2 Problems not listed…………………………………………………………………………………………………………………………………………………………………………………..246
8. Engine…………………………………………………………………………………………………………………………………………………………………………………………………..247
8.1 Engine in power pack………………………………………………………………………………………………………………………………………………………………………………….248
8.1.1 Engine manual…………………………………………………………………………………………………………………………………………………………………………………..248
8.1.2 Engine alternatives……………………………………………………………………………………………………………………………………………………………………………..248
9. Electrical and Hydraulic information………………………………………………………………………………………………………………………………………………………………………..249
9.1 Schematic diagrams……………………………………………………………………………………………………………………………………………………………………………………250
9.1.1 Electrical schematic diagram……………………………………………………………………………………………………………………………………………………………………..250
9.1.2 Hydraulic schematic diagram………………………………………………………………………………………………………………………………………………………………………250
10. Information and Data sheets……………………………………………………………………………………………………………………………………………………………………………….251
10.1 Original equipment manufacturer information…………………………………………………………………………………………………………………………………………………………….252
10.2 Hazardous substances…………………………………………………………………………………………………………………………………………………………………………………253
10.3 Variations and options (if applicable)…………………………………………………………………………………………………………………………………………………………………254
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