Sandvik Mining QI440 Operator’s Manual SN 1884BG – PDF DOWNLOAD
FILE DETAILS:
Sandvik Mining QI440 Operator’s Manual SN 1884BG – PDF DOWNLOAD
Language : English
Pages : 340
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Sandvik Mining QI440 Operator’s Manual SN 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 28
2 2 User obligations 28
2 2 1 Managing work related hazards 29
2 2 2 Scheduled safety inspections and preventive maintenance 30
2 2 3 Personal protective equipment 31
2 3 Product limitations 32
2 3 1 Intended use 32
2 3 2 Foreseeable misuse 32
2 3 3 Prohibited use 32
2 3 4 32
2 3 5 Maximum inclination angles during tramming and parking 32
2 3 6 Maximum inclination angles during operation 33
2 3 7 Modifications 33
2 4 Hazard zones 34
2 4 1 Exclusion zone for QI440 34
2 5 Safeguarding 36
2 5 1 Guards 36
2 5 2 Protective Devices 40
2 6 Complementary protective measures 41
2 6 1 Use of Emergency stop function 41
2 6 2 Emergency exit 43
2 6 3 Safe access to machinery and three point support 43
2 6 4 Isolation and energy dissipation 44
2 6 5 Fire risk control measures 46
2 7 Protection against emission hazards 47
2 7 1 Noise 47
2 7 2 Vibration 48
2 7 3 Dust 48
2 8 Emergency procedures and methods for unblocking 49
2 9 Safety considerations for maintenance 50
2 10 Environment 53
2 10 1 Decommissioning 53
2 10 2 Dismantling 53
2 10 3 Disposal 54
2 11 Potential product related hazards identified by the user 55
2 12 Incident reporting 56
3 0 Transport &Technical Data 57
3 1 Transport 58
3 1 1 Special Considerations For Transport Of The QI440 58
3 1 2 Machine Preparation for Transport 58
3 1 3 Folding the main conveyor and Positioning into Transport Position 59
3 1 4 Folding the Natural Fines Conveyor and removing the belt troughs 60
3 1 5 Folding the hopper sides 62
3 2 Additional Machine Preparation for Transport for Hanging Screen Options 64
3 2 1 Raising the Recirculation Jack Legs 64
3 2 2 Preparing the Midsize Transfer Conveyor 64
3 2 3 Preparing the Primary Screen Box 65
3 2 4 Preparing the secondary screen box 66
3 2 5 Preparing the Fines Conveyor 67
3 2 6 Preparing the Stock pile Conveyor 67
3 2 7 Positioning the Recirculation Conveyor into transport position 69
3 2 8 Preparing ladder 1 and ladder 2 for transport 72
3 2 9 Store the Loose Items 73
3 2 10 Tracking the machine onto and off the transport vehicle 74
3 2 11 QI440 Transport and Working Dimensions 75
3 2 12 QI440 Hanging Screen Transport And Working Dimensions 77
3 3 Technical Information 80
3 4 Technical Data and General Information 80
3 4 1 Feed Hopper 80
3 4 2 Primary Feeder 80
3 4 3 Pre screen 80
3 4 4 Impactor 80
3 4 5 Main Conveyor 80
3 4 6 Natural Fines Conveyor 81
3 4 7 Power Unit 81
3 4 8 Tracks 81
3 4 9 Hanging Screen Option Data 81
3 4 10 Recirculating Conveyor 81
3 4 11 Fines Conveyor 81
3 4 12 Stockpile Conveyor 81
3 4 13 Transfer Conveyor (Oversize and Midsize) 82
3 4 14 Underpan feeder 82
3 4 15 Double Screen 82
3 5 General Technical Data 82
3 6 Options 84
3 6 1 Hopper extensions 84
3 6 2 Hopper Hardox liner plates back and sides 84
3 6 3 High impact Sandvik wear rubber back and sides 84
3 6 4 Central auto lube (crusher only) 84
3 6 5 Central auto lube 84
3 6 6 Remote Diesel pump 84
3 6 7 Water pump (Hyd) 84
3 6 8 Artic Packages 84
3 6 9 Tropical / High ambient package (may not be required) 84
3 6 10 Wheeled Dolly (Open circuit only) 84
3 6 11 Conveyor pull cords 84
3 6 12 Grizzly 84
3 6 13 Pre screen top deck punch plate 84
3 6 14 Pre screen top deck mesh (ashalt / secondary applications) 84
3 6 15 Pre screen open bottom rubber to feed natural fines conveyor (high fine / sticky applications) 84
3 6 16 No overband magnet 84
3 6 17 No natural fines conveyor 84
4 1 Product Overview 86
4 2 Major Components QI440 86
4 2 1 Hanging Screen [ QI440 HS ] Option 87
4 3 Identification and Operation of the QI440 Controls 88
4 3 1 Main Control Panel 88
4 3 2 Hydraulic Control Banks 90
4 3 3 Hydraulic Control Banks with Hanging Screen [ QI440 HS ] Option Fitted 91
4 3 4 Flow Control Valves with Hanging Screen [ QI440 HS ] Option Fitted 92
4 3 5 Radio Remote Control Unit 93
4 3 6 Umbilical Remote Control Unit 94
5 0 Commissioning and Shut Down 95
5 1 Commissioning & Shutdown Safety 96
5 1 1 Who is at Risk 96
5 1 2 Managing Work related Hazards with a Risk Assessment 96
5 1 3 When carrying out maintenance or adjustment 96
5 2 Commissioning 97
5 2 1 Preparation for Machine STARTUP 97
5 2 2 Engine Start-up Sequence 98
5 2 3 Setting Language of Control Panel Display 99
5 2 4 Setting the date/time 100
5 2 5 Sequence For Tracking Machine 101
5 3 Initial Setup and Operation 104
5 3 1 Remove the Loose Items 104
5 3 2 Set Up ladder 1 and ladder 2 105
5 3 3 Procedure to engage Auxiliary Controls 106
5 3 4 Folding the hopper sides 107
5 3 5 Unfold the Natural Fines Conveyor and fitting the belt troughs 109
5 3 6 Unfolding the main conveyor and Positioning into Working Position 111
5 4 Additional Initial Setup and Operation for Hanging Screen Options 112
5 4 1 Setting Up the Recirculation Conveyor 112
5 4 2 Preparing the Stock pile Conveyor 114
5 4 3 Unfolding the main conveyor and Positioning into Working Position 116
5 4 4 Preparing the Fines Conveyor 117
5 4 5 Preparing the secondary screen box 117
5 4 6 Preparing the primary Screen Box 119
5 4 7 Preparing the Midsize transfer conveyor 120
5 4 8 Preparing the Recirculation Jack Legs 120
5 4 9 Belt Tension 121
5 5 Machine operation 124
5 6 Machine Shut Down 124
5 6 1 Auto Stop Sequence 125
5 6 2 Preparing the machine for transport or for the machine to be moved to another location 126
5 6 3 Emergency Stop 127
5 7 Location Of Emergency Stops On QI440 128
6 1 Operation Safety 132
6 1 1 Who is at Risk 132
6 1 2 Managing Work related Hazards with a Risk Assessment 132
6 1 3 When carrying out maintenance or adjustment 132
6 2 Loading the feeder 133
6 2 1 Avoid damage to equipment 133
6 3 Common Applications 135
6 3 1 Construction, Demolition and recycling 135
6 3 2 Minerals and Quarrying 135
6 3 3 Maximum Feed size for Crusher 135
6 4 Feed and Jams 136
6 5 Operating the QI440 137
6 5 1 Start-up Sequence For Running the Crusher 137
6 5 2 Auto Run Mode 139
6 5 3 Automatic Mode – Recirculation System 141
6 5 4 MMPRO S menu Flow chart in automatic Run mode 142
6 5 5 Manual Run Mode 143
6 5 6 Feeder Load Control 144
6 5 7 Machine Adjustment 145
6 5 8 Tail Level adjustment 146
6 5 9 Are Precautions Adequate? 147
6 5 10 Diverter Chute 148
6 5 11 Primary Screen Box Working Angles 149
6 5 12 Fault Logs 150
6 6 Clearing Crusher Chamber Jam’s 151
6 6 1 Managing Work Related Hazards with a Risk Assessment 151
6 0 Operation 131
7 0 Maintenance 153
7 1 Maintenance Safety 154
7 1 1 Who is at Risk 154
7 1 2 Managing Work related Hazards with a Risk Assessment 154
7 1 3 When carrying out maintenance or adjustment 154
7 2 Maintenance Schedule 155
7 2 1 Testing the Emergency stop function and Battery Isolator 159
7 2 2 Belt Tension 160
7 2 3 Maintenace to the CI322 Impactor using DC Maintenance Motor 163
7 2 4 Engine Maintenance 165
7 2 5 Radio Remote Control battery Charging 165
7 2 6 Working at height hazard 166
7 2 7 Air Cleaner Inspection, Daily Inspection Required 166
7 2 8 Air Cleaner Maintenance 167
7 2 9 Battery Maintenance 168
7 2 10 Checking Fuel Level, Adding Fuel and Draining fuel tank 169
7 2 11 Emptying the Fuel Filter Water Trap 170
7 2 12 Special Considerations For Maintenance Or Repair with Welding 171
7 3 Hydraulic System 172
7 3 1 Hydraulic Oil daily check 172
7 3 2 Hydraulic Oil is added as follows 173
7 3 3 Changing The Return Line Filter 174
7 3 4 Changing the suction Filters and Hydraulic Oil 175
7 3 5 HPTO Clutch Hydraulic Oil daily check 177
7 3 6 HPTO Clutch adding hydraulic oil 177
7 3 7 HPTO CLutch Lubrication tank Suction Filter change 177
7 3 8 HPTO Oil filter Replacement 178
7 4 Track Maintenance 179
7 4 1 Checking the Track Tension 179
7 4 2 Tighten the Tracks 180
7 4 3 Loosen the Tracks 180
7 4 4 Track Drive Units 181
7 5 Tensioning Conveyor Belts on the Standard QI440 182
7 5 1 Tensioning the Natural Fines Conveyor Belt 182
7 5 2 Tensioning The Main Conveyor belt 183
7 6 Tensioning Conveyor Belts on the QI440 with Hanging Screen 184
7 6 1 Tensioning the Fines Conveyor Belt 184
7 6 2 Tensioning the Recirculating Conveyor and Stockpile Conveyor Belts 185
7 6 3 Tensioning the Oversize and Midsize Transfer Conveyor Belts 186
7 6 4 Tracking the Conveyor Belts 187
7 6 5 Removing and Installing Screen Media 190
7 6 6 Maintenance Data 192
7 6 7 Hydraulic Oil Requirements for QI440 Machines 192
7 6 8 Hydraulic Oil Requirements for HPTO Clutch 194
7 6 9 Lubricants and Fluids 194
7 6 10 Greasing Schedule 195
7 6 11 Care of chrome 200
8 1 Trouble Shooting Safety 202
8 1 1 Who is at Risk 202
8 1 2 Managing Work related Hazards with a Risk Assessment 202
8 1 3 When carrying out maintenance or adjustment 202
8 2 Machine Faults 203
8 2 1 Engine Faults (Engine Control Unit) 203
8 2 2 Engine Diagnostic Codes 204
8 3 Using the Proportional Spool Valve System (PSVS) controls to Diagnose Hydraulic or Electrical Faults 206
8 3 1 Service Engineer Selection for PSVS Diagnosis 206
8 3 2 PSVS Diagnosis for Hydraulic or Electrical Faults 206
8 4 Commissioning and Engine Warranty 208
8 4 1 Commissioning and Warranty Registration 208
8 5 CAT Register Instructions 209
8 5 1 CAT C Series Warranty Statement 210
8 0 Trouble Shooting and Engine Warranty 201
9 0 Spare Parts 213
9 1 Spare Parts 214
9 1 1 Spare Parts illustrations 214
9 1 2 Ordering Procedure: 214
9 1 3 Managing Work related Hazards with a Risk Assessment 215
9 1 4 When carrying out maintenance or adjustment 215
9 2 Machine Assemblies 216
9 3 Top Level 216
9 4 Hydraulic Water Pump 217
9 5 Vbelt Guard 218
9 6 Pre Screen 220
9 7 Chassis Complete 222
9 7 1 Chassis Tower 224
9 7 2 crusher Drive Tensioning 226
9 7 3 Jack Leg 228
9 8 Maintenance Platform 229
9 9 Impactor Assemly Complete 230
9 9 1 Crusher Inlet Chute 232
9 9 2 diverter Chute 233
9 9 3 Impactor Chute 234
9 10 Hydraulic Control Box 235
9 11 Natural Fines Conveyor 236
9 12 Powerunit 238
9 12 1 Powerpack 240
9 12 2 Clutch Lube Tank 244
9 12 3 Diesel tank 245
9 12 4 Hydraulic tank 246
9 13 Eriez Magnet 247
9 14 Hopper Wing Plate 248
9 15 Main Conveyor 250
9 15 1 Main Conveyor Lower Section 252
9 15 2 Main Conveyor Upper Section 254
9 15 3 Main Conveyor Extension 256
9 16 Primary Feeder 258
9 16 1 Feeder 260
9 17 Pan Feeeder 264
9 18 HS System – Recirculating Oversize [ Option where Fitted ] 266
9 18 1 Recirculation conveyor 268
9 18 2 HS System – Mounting Frame recirculating oversize 273
9 18 3 Recirculation Fines conveyor 274
9 18 4 Recirculation Screen 278
9 19 Stock Pile Conveyor 284
9 20 Transfer Conveyor 1440-35-00 286
9 21 Transfer Conveyor 1442-35-00 288
9 21 1 HS System – Recirculating Mid & Oversize [ Option where fitted ] 290
9 21 2 Transfer Conveyor – Recirculating Over & Midsize 292
9 21 3 Engine Filter Kits – CAT C13 TIER 3A) 294
9 21 4 Engine Filter Kits – CAT C13 TIER 3B 296
10 0 Electrical and Hydraulic 299
10 1 Electrical Schematics 300
10 2 Hydraulics 322
10 2 1 Hydraulic Circuit Diagrams 322
10 3 Hydraulic Hose Kits 323
11 1 OEM Appendices 340
11 1 1 CI322 Impactor Crusher Operation 340
11 1 2 CI322 Impactor Crusher Maintenance Manual 340
11 1 3 CI322 Impactor Crusher Spare Parts 340
11 1 4 CI322 Impactor Crusher Wear Parts 340
11 1 5 Eriez Magnetic Separator 340
11 1 6 Roxon Vibrating Feeder 340
11 1 7 Crawler Tracks Operation Manual 340
11 1 8 M-PROS Control System Spare Parts 340
11 1 9 Optional Extra’s 340
11 0 OEM Section 339
S.V 06/24
