Sandvik Crusher QI240 Operators Manual – PDF DOWNLOAD
FILE DETAILS:
Sandvik Crusher QI240 Operators Manual – PDF DOWNLOAD
Language : English
Pages :268
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Sandvik Crusher QI240 Operators Manual – 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…………………………………………………………………… 26
2.2 User obligations…………………………………………………………………………………. 26
2.2.1 Managing work related hazards………………………………………………………………… 27
2.2.2 Scheduled safety inspections and preventive maintenance…………………………………………. 28
2.2.3 Personal protective equipment………………………………………………………………… 29
2.3 Product limitations………………………………………………………………………………. 30
2.3.1 Intended use……………………………………………………………………………….. 30
2.3.2 Foreseeable misuse………………………………………………………………………….. 30
2.3.3 Prohibited use……………………………………………………………………………… 30
2.3.4…………………………………………………………………………………………… 30
2.3.5 Maximum inclination angles during tramming and parking………………………………………….. 30
2.3.6 Maximum inclination angles during operation……………………………………………………. 31
2.3.7 Modifications………………………………………………………………………………. 31
2.4 Hazard zones…………………………………………………………………………………….. 32
2.5 Safeguarding…………………………………………………………………………………….. 33
2.5.1 Guards…………………………………………………………………………………….. 33
2.5.2 Protective Devices………………………………………………………………………….. 36
2.6 Complementary protective measures………………………………………………………………….. 37
2.6.1 Use of Emergency stop function……………………………………………………………….. 37
2.6.2 Emergency exit……………………………………………………………………………… 39
2.6.3 Safe access to machinery and three point support……………………………………………….. 39
2.6.4 Isolation and energy dissipation……………………………………………………………… 40
2.6.5 Fire risk control measures…………………………………………………………………… 42
2.7 Protection against emission hazards………………………………………………………………… 43
2.7.1 Noise……………………………………………………………………………………… 43
2.7.2 Vibration………………………………………………………………………………….. 44
2.7.3 Dust………………………………………………………………………………………. 44
2.8 Emergency procedures and methods for unblocking……………………………………………………… 45
2.9 Safety considerations for maintenance………………………………………………………………. 46
2.10 Environment…………………………………………………………………………………….. 49
2.10.1 Decommissioning……………………………………………………………………………. 49
2.10.2 Dismantling……………………………………………………………………………….. 49
2.10.3 Disposal………………………………………………………………………………….. 50
2.11 Potential product related hazards identified by the user…………………………………………….. 51
2.12 Incident reporting………………………………………………………………………………. 52
3.0 Transport &Technical Data…………………………………………………………………………….. 53
3.1 Transport……………………………………………………………………………………….. 54
3.1.1 Special Considerations For Transport Of The QI240………………………………………………. 54
3.1.2 Machine Preparation for Transport…………………………………………………………….. 54
3.1.3 Folding the main conveyor and Positioning into Transport Position………………………………… 57
3.1.4 Removing the belt troughs and Fold the Side Conveyor……………………………………………. 59
3.1.5 Unfolding the hopper sides…………………………………………………………………… 60
3.1.6 Fold ladder 1 and ladder 2…………………………………………………………………… 62
3.1.7 Tracking the machine onto and off the transport vehicle…………………………………………. 64
3.1.8 Transport and Working Dimensions……………………………………………………………… 65
3.2 Technical Information…………………………………………………………………………….. 67
3.2.1 Standard Features…………………………………………………………………………… 67
3.2.2 Options……………………………………………………………………………………. 67
3.3 Identification of Main Units………………………………………………………………………. 67
3.4 Technical Data and General Information……………………………………………………………… 68
3.4.1 Hopper…………………………………………………………………………………….. 68
3.4.2 Feeder…………………………………………………………………………………….. 68
3.4.3 Pre Screen…………………………………………………………………………………. 68
3.4.4 4 Hammer Impact Crusher type Sandvik CI411…………………………………………………….. 68
3.4.5 Main Conveyor………………………………………………………………………………. 68
3.4.6 Pan Feeder…………………………………………………………………………………. 69
3.4.7 Tracks…………………………………………………………………………………….. 69
3.4.8 Optional CAT C9…………………………………………………………………………….. 69
3.4.9 Optional Magnetic Separator Type Eriez CP 20/100-SC2……………………………………………. 69
3.4.10 Side Conveyor……………………………………………………………………………… 69
3.5 General Technical Data:…………………………………………………………………………… 70
3.6 Options…………………………………………………………………………………………. 70
3.6.1 Wheel Dolly System………………………………………………………………………….. 70
3.6.2 Neodynium Magnetic Separator…………………………………………………………………. 70
3.6.3 Arctic Packages…………………………………………………………………………….. 70
3.6.4 Tropical/High ambient package………………………………………………………………… 70
3.6.5 Hardox Wear Plates for hopper walls…………………………………………………………… 70
3.6.6 Dust Suppression canvas covers……………………………………………………………….. 70
3.6.7 Central Auto Lube (crusher)………………………………………………………………….. 70
3.6.8 Central Auto Lube (conveyors)………………………………………………………………… 70
3.6.9 Remote Diesel Pump………………………………………………………………………….. 70
3.6.10 Water Pump………………………………………………………………………………… 70
3.6.11 Double deck recirculation system (final spec TBC)……………………………………………… 70
3.6.12 No Magnet Fitted…………………………………………………………………………… 70
3.6.13 No Side Conveyor Fitted…………………………………………………………………….. 70
4.1 Product Overview…………………………………………………………………………………. 72
4.2 Major Components…………………………………………………………………………………. 72
4.2.1 Identification and Operation of the QI240 Controls……………………………………………… 74
4.2.2 Main Control Panel………………………………………………………………………….. 74
4.2.3 Hydraulic Control Banks……………………………………………………………………… 76
4.2.4 Radio Remote Control Unit……………………………………………………………………. 78
4.2.5 Umbilical Remote Control Unit………………………………………………………………… 79
5.0 Commissioning and Shut Down…………………………………………………………………………… 81
5.1 Commissioning & Shutdown Safety……………………………………………………………………. 82
5.1.1 Who is at Risk……………………………………………………………………………… 82
5.1.2 Managing Work related Hazards with a Risk Assessment……………………………………………. 82
5.1.3 When carrying out maintenance or adjustment……………………………………………………. 82
5.2 Commissioning……………………………………………………………………………………. 83
5.2.1 Preparation for Machine STARTUP………………………………………………………………. 83
5.2.2 Engine Start-up Sequence…………………………………………………………………….. 84
5.2.3 Setting Language of Control Panel Display……………………………………………………… 85
5.2.4 Setting the date/time……………………………………………………………………….. 85
5.2.5 Sequence For Tracking Machine………………………………………………………………… 87
5.3 Initial Setup and Operation……………………………………………………………………….. 90
5.3.1 Remove the Loose Items – Located in the Feeder…………………………………………………. 90
5.3.2 Set Up ladder 1 and ladder 2…………………………………………………………………. 91
5.3.3 Restarting the engine to activate Auxillary Controls……………………………………………. 92
5.3.4 Folding the hopper sides…………………………………………………………………….. 93
5.3.5 Unfold the Side Conveyor and fitting the belt troughs…………………………………………… 94
5.3.6 Unfolding the main conveyor and Positioning into Working Position………………………………… 96
5.3.7 Belt Tension Check during Commissioning………………………………………………………..100
5.3.8 Diverter Chute………………………………………………………………………………103
5.4 Machine operation…………………………………………………………………………………104
5.5 Machine Shut Down…………………………………………………………………………………104
5.5.1 Auto Stop Sequence…………………………………………………………………………..104
5.5.2 Preparing the machine for transport or for the machine to be moved to another location………………105
5.5.3 Emergency Stop………………………………………………………………………………106
5.6 Location Of Emergency Stops On QI240………………………………………………………………..107
6.1 Operation Safety………………………………………………………………………………….110
6.1.1 Who is at Risk………………………………………………………………………………110
6.1.2 Managing Work related Hazards with a Risk Assessment…………………………………………….110
6.1.3 When carrying out maintenance or adjustment…………………………………………………….110
6.2 Loading the feeder………………………………………………………………………………..111
6.2.1 Avoid damage to equipment…………………………………………………………………….111
6.3 Common Applications……………………………………………………………………………….114
6.3.1 Construction, Demolition and recycling…………………………………………………………114
6.3.2 Minerals and Quarrying……………………………………………………………………….114
6.3.3 Maximum Feed size for Crusher…………………………………………………………………114
6.4 Feed and Jams…………………………………………………………………………………….115
6.5 Operating the QI240……………………………………………………………………………….116
6.5.1 Start-up Sequence For Running the Crusher………………………………………………………116
6.6 Automatic Run Mode………………………………………………………………………………..118
6.6.1 MMPRO S menu Flow chart in automatic Run mode…………………………………………………..120
6.7 Manual Operating Mode……………………………………………………………………………..121
6.7.1 Feeder Load Control………………………………………………………………………….122
6.7.2 Machine Adjustment…………………………………………………………………………..123
6.7.3 Tail Level adjustment………………………………………………………………………..124
6.7.4 Diverter Chute………………………………………………………………………………125
6.7.5 Fault Logs………………………………………………………………………………….126
6.8 Clearing Crusher Chamber Jam’s……………………………………………………………………..127
6.8.1 Managing Work Related Hazards with a Risk Assessment…………………………………………….127
6.0 Operation……………………………………………………………………………………………109
7.0 Maintenance………………………………………………………………………………………….129
7.1 Maintenance Safety………………………………………………………………………………..130
7.1.1 Who is at Risk………………………………………………………………………………130
7.1.2 Managing Work related Hazards with a Risk Assessment…………………………………………….130
7.1.3 When carrying out maintenance or adjustment…………………………………………………….130
7.2 Maintenance Schedule………………………………………………………………………………131
7.2.1 Testing the Emergency stop function and Battery Isolator…………………………………………134
7.2.2 Belt Tension………………………………………………………………………………..135
7.2.3 Maintenace to the CI411 Impactor using DC Maintenance Motor………………………………………138
7.2.4 Engine Maintenance…………………………………………………………………………..140
7.2.5 Radio Remote Control battery Charging………………………………………………………….140
7.2.6 Working at height hazard……………………………………………………………………..141
7.2.7 Air Cleaner Inspection, Daily Inspection Required……………………………………………….141
7.2.8 Air Cleaner Maintenance………………………………………………………………………142
7.2.9 Battery Maintenance………………………………………………………………………….143
7.2.10 Checking Fuel Level, Adding Fuel and Draining fuel tank…………………………………………144
7.2.11 Emptying the Fuel Filter Water Trap…………………………………………………………..145
7.2.12 Special Considerations For Maintenance Or Repair with Welding……………………………………146
7.3 Hydraulic System………………………………………………………………………………….147
7.3.1 Hydraulic Oil daily check…………………………………………………………………….148
7.3.2 Hydraulic Oil is added as follows……………………………………………………………..149
7.3.3 Changing The Return Line Filter……………………………………………………………….150
7.3.4 Changing The Suction Filters and the Hydraulic Oil………………………………………………151
7.3.5 HPTO Clutch Hydraulic Oil daily check………………………………………………………….153
7.3.6 HPTO Clutch adding hydraulic oil………………………………………………………………153
7.3.7 HPTO CLutch Lubrication tank Suction Filter change………………………………………………153
7.3.8 HPTO Oil filter Replacement…………………………………………………………………..154
7.4 Track Maintenance…………………………………………………………………………………155
7.4.1 Checking the Track Tension……………………………………………………………………155
7.4.2 Tighten the Tracks…………………………………………………………………………..156
7.4.3 Loosen the Tracks……………………………………………………………………………156
7.4.4 Track Drive Units……………………………………………………………………………157
7.5 Tensioning the Side Conveyor Belt…………………………………………………………………..158
7.5.1 Tensioning The Main Conveyor belt……………………………………………………………..159
7.5.2 Tracking the Conveyor Belts…………………………………………………………………..160
7.5.3 Hydraulic Oil Requirements for QI240 Machines…………………………………………………..162
7.5.4 Hydraulic Oil Requirements for HPTO Clutch……………………………………………………..163
7.5.5 Lubricants and Fluids………………………………………………………………………..163
7.5.6 Greasing Schedule……………………………………………………………………………164
7.5.7 Care of chrome………………………………………………………………………………166
8.1 Trouble Shooting Safety……………………………………………………………………………168
8.1.1 Who is at Risk………………………………………………………………………………168
8.1.2 Managing Work related Hazards with a Risk Assessment…………………………………………….168
8.1.3 When carrying out maintenance or adjustment…………………………………………………….168
8.1.4 Using the Proportional Spool Valve System (PSVS) controls to Diagnose Hydraulic or Electrical Faults….169
8.1.5 Service Engineer Selection for PSVS Diagnosis…………………………………………………..169
8.1.6 PSVS Diagnosis for Hydraulic or Electrical Faults……………………………………………….169
8.1.7 Engine Diagnostic Codes………………………………………………………………………171
8.2 Commissioning and Engine Warranty…………………………………………………………………..173
8.2.1 Commissioning and Warranty Registration………………………………………………………..173
8.3 CAT Register Instructions………………………………………………………………………….174
8.3.1 CAT C Series Warranty Statement……………………………………………………………….175
8.0 Trouble Shooting and Engine Warranty……………………………………………………………………167
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 Top Level………………………………………………………………………………………..180
9.2.1 Hydraulic Water Pump Option…………………………………………………………………..181
9.3 Hopper Wing Plates………………………………………………………………………………..182
9.4 Chassis Complete………………………………………………………………………………….184
9.4.1 Chassis Tower……………………………………………………………………………….186
9.4.2 Oil Cooler Mount…………………………………………………………………………….187
9.4.3 Tension Pulley Mount…………………………………………………………………………188
9.4.4 Pulley Mounting Complete……………………………………………………………………..189
9.4.5 Tension Pulley Frame Complete…………………………………………………………………190
9.5 Walkway………………………………………………………………………………………….191
9.6 Control Box………………………………………………………………………………………192
9.7 Feeder…………………………………………………………………………………………..194
9.8 Pan Feeder……………………………………………………………………………………….198
9.9 Main conveyor…………………………………………………………………………………….199
9.9.1 Main conveyor Lower Section…………………………………………………………………..200
9.9.2 Main Conveyor Upper section…………………………………………………………………..202
9.9.3 Main conveyor Head Section……………………………………………………………………204
9.10 Side Conveyor……………………………………………………………………………………206
9.10.1 Side Conveyor Lower Section………………………………………………………………….208
9.10.2 Side Conveyor Mid Section……………………………………………………………………210
9.11 Pre Screen………………………………………………………………………………………212
9.12 Diverter Chute…………………………………………………………………………………..214
9.13 Belt Guard………………………………………………………………………………………215
9.14 Drive Pulley…………………………………………………………………………………….216
9.15 CI411 Impactor…………………………………………………………………………………..218
9.16 QI240 Powerpack………………………………………………………………………………….220
9.16.1 Diesel tank………………………………………………………………………………..226
9.16.2 Hydraulic Oil Tank………………………………………………………………………….227
9.16.3 Clutch Lube Tank……………………………………………………………………………228
9.17 Magnet Spares……………………………………………………………………………………229
9.17.1 CAT Engine Spare Parts………………………………………………………………………230
9.17.2 Engine Filter Kits – CAT…………………………………………………………………….231
10.1 Electrical Schematics…………………………………………………………………………….238
10.2 Hydraulics………………………………………………………………………………………260
10.2.1 Hydraulic Circuit Diagrams…………………………………………………………………..260
10.2.2 Hydraulic Hose Kits…………………………………………………………………………261
10.0 Electrical and Hydraulic……………………………………………………………………………..237
11.1 OEM Appendices…………………………………………………………………………………..268
11.1.1 CI411 Impact Crusher Operation and Maintenance Manual…………………………………………..268
11.1.2 CI411 Impact Crusher Spare Parts……………………………………………………………..268
11.1.3 CI411 Interlock Manual………………………………………………………………………268
11.1.4 CI411 Daily log…………………………………………………………………………….268
11.1.5 Eriez Magnetic Separator…………………………………………………………………….268
11.1.6 HPTO clutch Manual………………………………………………………………………….268
11.1.7 Crawler Tracks Operation Manual………………………………………………………………268
11.1.8 M-PROS Control System Spare Parts…………………………………………………………….268
11.1.9 Optional Extra’s……………………………………………………………………………268
11.0 OEM Section…………………………………………………………………………………………267
IMAGES PREVIEW OF THE MANUAL:
S.M 5/24
