Operator's manual - Crushing Tigers

qi2

40

Operator’s manual

Translation of the Original Instructions

serial number 1884BG

IGNORING INSTRUCTIONS HAZARD

To avoid death or injury you MUST read, understand and follow the Manual before installing, inspecting, operating, servicing, testing, cleaning, transporting, storing, dismantling or disposing of the product or a part or accessory of the product.

WARNING

julie

We hereby declare that the machinery

Machine Nomination, Type of machine: qi240

Serial Number: 1884BG

Intended use: IMPACTOR

is in conformity with the following Directives, Standards and Codes2006/42/EC Machinery Directive2004/108/EC ElectroMagnetic Compatibility (EMC)

EC Type-examination and CertificatesISO21873-2

Technical fileWe confirm that the technical file has been compiled in accordance with 2006/42/EC Annex VII

P Coleman, PDC Engineering Manager for Screeners and Feeders, Tullyvannon, Ballygawley, Co Tyrone N. Ireland BT70 2HW.Is authorized to make the technical file available on request by competent authority of the EC Member States in accordance with 2006/42/EC. The documents will be delivered as electronic files.

P Colton, Operations Director, Tullyvannon, Ballygawley, Co Tyrone N. Ireland BT70 2HW.confirms the manufacturing process to ensure compliance of the manufactured machinery with the technical file.

This declaration remains valid as long as no modification is carried out without themanufacturer’s written agreement.Date: / /

P Coleman, PDC Manager P Colton, Operations Director

DECLARATION OF CONFORMITY

Manufacturer: Sandvik Mining and Construction Mobile Crushers and Screens LimitedCompany, Address Tullyvannon, Ballygawley, Co Tyrone, Northern Ireland. BT70 2HW

Reg No. 4636796VAT No. GB 806 399 995Sandvik Mining and Construction document template: Declaration of Conformity 08 Dec 2009 - English www.sandvik.com

QI240 © Copyright Sandvik Mining and Construction Mobile Crushers and Screens Ltd.All rights reserved. No parts of this document may be reproduced orcopied in any form or by any means without written permission from Sandvik Mining and Construction Mobile Crushers and Screens Ltd.All data and information in this manual may be changed without further notice. Reservations for misprints.

For further information, please contact:

Sandvik Mining and Construction Mobile Crushers and Screens Ltd.Tullyvannon, BallygawleyCo. TyroneN. IrelandBT70 2HWTelephone: (+44) 028 855 67799Facsimile: (+44) 028 855 67007e-mail: [email protected]

Contents
1.0 Safety Section - Introduction 11
1.1 The purpose of these instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.2 Identification of the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.2.1 Product type and serial number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.2.2 Product manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.2.3 Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.2.4 How to identify the right manual for the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141.2.5 Validity of the manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Copyright notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141.4 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.0 Safety Section - Safety and Environmental Instructions 172.1 Safety labels and signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.1.1 Signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.1.2 General hazard symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.1.3 Symbols for mandatory actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.1.4 Symbols for prohibited actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202.1.5 Hazard symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202.1.6 Labels on the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.1.7 Visual and audible signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.2 User obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262.2.1 Managing work related hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272.2.2 Scheduled safety inspections and preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 282.2.3 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.3 Product limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302.3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302.3.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302.3.3 Prohibited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302.3.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302.3.5 Maximum inclination angles during tramming and parking . . . . . . . . . . . . . . . . . . . . . . . . . . 302.3.6 Maximum inclination angles during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312.3.7 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.4 Hazard zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322.5 Safeguarding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.5.1 Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332.5.2 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.6 Complementary protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372.6.1 Use of Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372.6.2 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392.6.3 Safe access to machinery and three point support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392.6.4 Isolation and energy dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402.6.5 Fire risk control measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.7 Protection against emission hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432.7.1 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432.7.2 Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442.7.3 Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.8 Emergency procedures and methods for unblocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452.9 Safety considerations for maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462.10 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

2.10.1 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492.10.2 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492.10.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.11 Potential product related hazards identified by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512.12 Incident reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.0 Transport &Technical Data 533.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.1.1 Special Considerations For Transport Of The QI240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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Contents
3.1.2 Machine Preparation for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543.1.3 Folding the main conveyor and Positioning into Transport Position . . . . . . . . . . . . . . . . . . . 573.1.4 Removing the belt troughs and Fold the Side Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 593.1.5 Unfolding the hopper sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603.1.6 Fold ladder 1 and ladder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623.1.7 Tracking the machine onto and off the transport vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643.1.8 Transport and Working Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.2 Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673.2.1 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673.2.2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.3 Identification of Main Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673.4 Technical Data and General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.4.1 Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683.4.2 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683.4.3 Pre Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683.4.4 4 Hammer Impact Crusher type Sandvik CI411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683.4.5 Main Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683.4.6 Pan Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693.4.7 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693.4.8 Optional CAT C9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693.4.9 Optional Magnetic Separator Type Eriez CP 20/100-SC2. . . . . . . . . . . . . . . . . . . . . . . . . . . 693.4.10 Side Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.5 General Technical Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

3.6.1 Wheel Dolly System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.2 Neodynium Magnetic Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.3 Arctic Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.4 Tropical/High ambient package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.5 Hardox Wear Plates for hopper walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.6 Dust Suppression canvas covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.7 Central Auto Lube (crusher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.8 Central Auto Lube (conveyors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.9 Remote Diesel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.10 Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.11 Double deck recirculation system (final spec TBC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.12 No Magnet Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703.6.13 No Side Conveyor Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.0 Product Overview 714.1 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724.2 Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.2.1 Identification and Operation of the QI240 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744.2.2 Main Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744.2.3 Hydraulic Control Banks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.2.4 Radio Remote Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784.2.5 Umbilical Remote Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

5.0 Commissioning and Shut Down 815.1 Commissioning & Shutdown Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

5.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . 825.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

5.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 835.2.1 Preparation for Machine STARTUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 835.2.2 Engine Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845.2.3 Setting Language of Control Panel Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 855.2.4 Setting the date/time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 855.2.5 Sequence For Tracking Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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5.3 Initial Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.3.1 Remove the Loose Items - Located in the Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905.3.2 Set Up ladder 1 and ladder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 915.3.3 Restarting the engine to activate Auxillary Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925.3.4 Folding the hopper sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 935.3.5 Unfold the Side Conveyor and fitting the belt troughs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 945.3.6 Unfolding the main conveyor and Positioning into Working Position. . . . . . . . . . . . . . . . . . . 965.3.7 Belt Tension Check during Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005.3.8 Diverter Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

5.4 Machine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1045.5 Machine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

5.5.1 Auto Stop Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1045.5.2 Preparing the machine for transport or for the machine to be moved to another location. .

1055.5.3 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

5.6 Location Of Emergency Stops On QI240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

6.0 Operation 1096.1 Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

6.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1106.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 1106.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

6.2 Loading the feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116.2.1 Avoid damage to equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

6.3 Common Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1146.3.1 Construction, Demolition and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1146.3.2 Minerals and Quarrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1146.3.3 Maximum Feed size for Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

6.4 Feed and Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1156.5 Operating the QI240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

6.5.1 Start-up Sequence For Running the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1166.6 Automatic Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

6.6.1 MMPRO S menu Flow chart in automatic Run mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1206.7 Manual Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

6.7.1 Feeder Load Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1226.7.2 Machine Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1236.7.3 Tail Level adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1246.7.4 Diverter Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1256.7.5 Fault Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6.8 Clearing Crusher Chamber Jam’s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1276.8.1 Managing Work Related Hazards with a Risk Assessment. . . . . . . . . . . . . . . . . . . . . . . . . 127

7.0 Maintenance 1297.1 Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

7.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1307.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 1307.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

7.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1317.2.1 Testing the Emergency stop function and Battery Isolator . . . . . . . . . . . . . . . . . . . . . . . . . 1347.2.2 Belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1357.2.3 Maintenace to the CI411 Impactor using DC Maintenance Motor . . . . . . . . . . . . . . . . . . . . 1387.2.4 Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1407.2.5 Radio Remote Control battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1407.2.6 Working at height hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1417.2.7 Air Cleaner Inspection, Daily Inspection Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1417.2.8 Air Cleaner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1427.2.9 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1437.2.10 Checking Fuel Level, Adding Fuel and Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . 144


Contents
7.2.11 Emptying the Fuel Filter Water Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1457.2.12 Special Considerations For Maintenance Or Repair with Welding . . . . . . . . . . . . . . . . . . 146
7.3 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1477.3.1 Hydraulic Oil daily check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1487.3.2 Hydraulic Oil is added as follows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1497.3.3 Changing The Return Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1507.3.4 Changing The Suction Filters and the Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1517.3.5 HPTO Clutch Hydraulic Oil daily check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1537.3.6 HPTO Clutch adding hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1537.3.7 HPTO CLutch Lubrication tank Suction Filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1537.3.8 HPTO Oil filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

7.4 Track Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1557.4.1 Checking the Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1557.4.2 Tighten the Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1567.4.3 Loosen the Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1567.4.4 Track Drive Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

7.5 Tensioning the Side Conveyor Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1587.5.1 Tensioning The Main Conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1597.5.2 Tracking the Conveyor Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1607.5.3 Hydraulic Oil Requirements for QI240 Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1627.5.4 Hydraulic Oil Requirements for HPTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1637.5.5 Lubricants and Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1637.5.6 Greasing Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1647.5.7 Care of chrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

8.0 Trouble Shooting and Engine Warranty 1678.1 Trouble Shooting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

8.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1688.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 1688.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1688.1.4 Using the Proportional Spool Valve System (PSVS) controls to Diagnose Hydraulic or Electrical

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1698.1.5 Service Engineer Selection for PSVS Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1698.1.6 PSVS Diagnosis for Hydraulic or Electrical Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1698.1.7 Engine Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

8.2 Commissioning and Engine Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1738.2.1 Commissioning and Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

8.3 CAT Register Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1748.3.1 CAT C Series Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

9.0 Spare Parts 1779.1 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

9.1.1 Spare Parts illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1789.1.2 Ordering Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1789.1.3 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 1799.1.4 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

9.2 Top Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1809.2.1 Hydraulic Water Pump Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

9.3 Hopper Wing Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1829.4 Chassis Complete. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

9.4.1 Chassis Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1869.4.2 Oil Cooler Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1879.4.3 Tension Pulley Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1889.4.4 Pulley Mounting Complete. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1899.4.5 Tension Pulley Frame Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

9.5 Walkway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1919.6 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1929.7 Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194


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Contents
9.8 Pan Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1989.9 Main conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
9.9.1 Main conveyor Lower Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2009.9.2 Main Conveyor Upper section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2029.9.3 Main conveyor Head Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

9.10 Side Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2069.10.1 Side Conveyor Lower Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2089.10.2 Side Conveyor Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

9.11 Pre Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2129.12 Diverter Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2149.13 Belt Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2159.14 Drive Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2169.15 CI411 Impactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2189.16 QI240 Powerpack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

9.16.1 Diesel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2269.16.2 Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2279.16.3 Clutch Lube Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

9.17 Magnet Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2299.17.1 CAT Engine Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2309.17.2 Engine Filter Kits - CAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

10.0 Electrical and Hydraulic 23710.1 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23810.2 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

10.2.1 Hydraulic Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26010.2.2 Hydraulic Hose Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

11.0 OEM Section 26711.1 OEM Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

11.1.1 CI411 Impact Crusher Operation and Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . 26811.1.2 CI411 Impact Crusher Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26811.1.3 CI411 Interlock Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26811.1.4 CI411 Daily log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26811.1.5 Eriez Magnetic Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26811.1.6 HPTO clutch Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26811.1.7 Crawler Tracks Operation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26811.1.8 M-PROS Control System Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26811.1.9 Optional Extra’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268


Contents


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1.0 Safety Section - Introduction

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1.1 The purpose of these instructions

The purpose of these instructions is to promote intended safe, proper and optimal use of Sandvikproducts and to help the user to identify, avoid and prevent hazardous situations and relatedconsequences.

These instructions must be followed along with any instructions given in local laws and regulations,any orders given by local authorities and all protective measures specific for the site.

Read and understand the complete manual carefully and follow given instructions strictly. If there isanything you do not understand, ask your employer or your local Sandvik representative to explainit. All sections of this manual contain information which is vital for your safety. The manual must bereplaced immediately if lost, damaged or unreadable. For replacement copies, please [email protected] provide the machine serial number, what type of manuals are required eg operators andlanguage version required.

The instructions set forth in the operator’s and other manuals are to be used as a part of the trainingmaterial during orientation. By following these instructions, safe practices will result, maintenancecost and downtime will be minimised and the reliability and lifetime of the equipment will be optimised.

1.2 Identification of the product

1.2.1 Product type and serial number

The model and serial number of the product are shown on the identification plate.


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1.2.2 Product manufacturer

Business name and full address -

Sandvik Mining and Construction Mobile Crushers and Screens LtdTullyvannon,Ballygawley,Co.TyroneNorthern IrelandBT70 2HW

Telephone number -

+44 (0) 28 8556 7799

Fax -

+44 (0) 28 8556 7007

Website -

www.miningandconstruction.sandvik.com

www.sandvik.com

Declaration of conformity (Refer to page 3).

1.2.3 Manuals

Product documentation includes the following manuals:

• The operator's manual includes operating instructions, operator's safety considerations and maintenance tasks for which an operator would be responsible. It does not include maintenance procedures that should be performed with less than daily frequency.

• The maintenance manual includes the preventive maintenance schedule and a description of all scheduled maintenance tasks. It also includes fluid and lubricant specifications and capacities. It does not include occasional service, breakdown, or repair procedures.

• The parts manual includes part lists and illustrations for spare parts.

The model and serial number are shown on the identification plate (refer to section, “Product typeand serial number” on page 12). Make sure that the model corresponds to the one given on the coverof this manual.


Safety qi240

1.2.4 How to identify the right manual for the product.

• operator's manual (e.g. Product model)

• maintenance manual (e.g. Product model)

• parts manual (e.g. product model + serial number)

1.2.5 Validity of the manuals

This manual, and especially the safety information is valid only, if no unauthorised changes to theproduct are made.

Continuing improvement and advancement of product design might have caused changes to yourproduct which are not included in this publication. Note also that if a third party has made changes tothe product after delivery from the manufacturer, this publication does not include information onthese changes or their influences on the product.

Whenever a question arises regarding your product, or this manual, please consult your localSandvik representative for the latest available information.

1.3 Copyright notice

This publication is copyright of Sandvik Mining and Construction - © Sandvik Mining andConstruction. It must not be copied, reproduced, or otherwise made available in full or in part to anythird party without Sandvik Mining and Construction's prior written consent.

All Rights Reserved.

1.4 Definitions

• Product: Machine, machinery, partly completed machinery, component or tool, including related services.

• User: The owner, operator or authorised and trained person involved in the transportation, installation, operation, maintenance and disposal of the product.

• Information for use: The information in this manual, the safety labels and signals on the product and other related information used separately or in combination to convey information to the user.

• Harm: Physical injury or damage to health. This is always in relation to people, not to equipment or property.


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• Hazard: Potential source of harm.

• Risk: Combination of a probability of occurrence of harm and the severity of that harm.

• Risk of property damage: Combination of a probability of occurrence of property damage and the severity of that property damage.

• Environmental risk: Combination of a probability of occurrence of environmental damage and the severity of that environmental damage.

• Hazard zone: Any space within and/or around the product in which a person is exposed to a hazard.

• Intended use of a product: Use of a product in accordance with the information provided in the instructions for use.

• Reasonably foreseeable misuse: Use of a product in a way that is not intended by the designer, but which may result from readily predictable human behaviour.

• Prohibited use: Any use which is not intended use, especially use that is specifically prohibited in the information for use or use which is plainly dangerous.

• Safe working procedures: Practices and methods developed for the users by their employer for work to be performed. It details how specific risks in the workplace will be managed, taking into account information for use supplied with the product as well as local acts, laws and regulations.

• Safeguard: Guard or protective device.

• Guard: Physical barrier, designed as part of the product, to provide protection.

• Protective device: Safeguard other than a guard, which reduces the risk either alone or in conjunction with a guard; e.g. interlocking device, hold-to-run control, limiting device.

• Emergency stop: Function which is intended to 1) avoid dangerous situations or to reduce existing hazards to persons and damage to product or work in progress 2) To be initiated by a single human action.

• Emission value: Numerical value quantifying an emission generated by a product (e.g. noise, vibration, hazardous substances, radiation).

• Exposure value: Quantifies the exposure of persons to emissions when the product is in use. Exposure values can be estimated using the emission values.

• Respirator: Approved respiratory protective device.


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2.0 Safety Section - Safety and Environmental Instructions

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2.1 Safety labels and signals

This section includes explanations of safety symbols, signs, signals and labels used on the productand information for use.

2.1.1 Signal words

The following signal words and symbols are used to identify safety messages in these instructions:

The signal word “DANGER” indicates a hazardous situation which, if not avoided, will result in deathor severe injury.

The signal word “WARNING” indicates a hazardous situation which, if not avoided, could result indeath or severe injury.

The signal word “NOTICE” indicates a situation which, if not avoided, could result in damage toproperty or environment.

2.1.2 General hazard symbol

This general hazard symbol identifies important safety messages in this manual.

When you see this symbol, be alert; your safety is involved. Carefully read and understand themessage that follows, and inform other users.

DANGER

WARNING

NOTICE


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2.1.3 Symbols for mandatory actions

Mandatory actions symbols specify actions to be taken to avoid a hazard. Mandatory actions areindicated by white symbols on a blue background.

Wear Safety Gloves Wear Eye Protection Wear Safety Helmet

Wear Safety Harness Wear Ear Protection Wear Safety Boots

Wear Close Fitting Overalls

Read the Manual Wear High Visibility Vest

Wear RespiratorDisconnect Power

Source From SupplySwitch Off and Lockout

Equipment


Safety qi240

2.1.4 Symbols for prohibited actions

Prohibited action symbols indicate actions which are prohibited in order to avoid a hazard. Prohibitedactions are indicated by a red circle with a red diagonal line across the circle. The action which isprohibited will always be in black.

2.1.5 Hazard symbols

Hazard symbols are indicated by a yellow triangle with black symbols and black frames.

No Climbing No Smoking Do Not Touch

No Open FlamesLimited or Restricted

AccessDo Not Weld

Do Not Remove Safety Guard

Crushing Hazard - Hands

Crushing Hazard - Feet Chemical Burn Hazard

Electrical HazardElectrical Shock/

Electrocution HazardEntanglement Hazard


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Entanglement Hazard Falling Hazard Falling Load Hazard

Flammable Hazard Flying Material HazardHazardous or Poisonous

Material Hazard

Lifting Hazard Skin Injection HazardSilica or Other Dust

Hazard

Trip Hazard Magnet Hazard


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2.1.6 Labels on the product

Safety labels communicate the following:

• The severity level of the risk (i.e. signal word ”DANGER” or ”WARNING”)

• The nature of the hazard (i.e. the type of hazard – cutting parts, high pressure, falling objects, dust, live parts, etc)

• The consequence of interaction with the hazard (i.e. cut, injection, crushing, explosion, electrocution etc)

• How to avoid the hazard

IMPORTANT! Keep the safety labels clean and visible at all times. Check the condition ofsafety labels daily. Safety labels and instructions which have faded, been damaged, beenpainted over, come loose or that do not meet the legibility requirements for safe viewingdistance, must be replaced before operating the product.

Replacement of labels -

For replacement labels, please contact:

[email protected] and provide the machine serial number, label part codesand language version required.


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12-55-0408

12-55-0001

12-55-0004

12-55-0001

12-55-0004

12-55-000112-55-0004

12-55-036112-55-0005

12-55-0005

12-55-0044

12-55-0014

12-55-0366

12-55-0359

12-55-0360

12-55-0283

12-55-0283

12-55-0044

12-55-0295

12-55-0387

12-55-0389

12-55-0390

12-55-0392

12-55-0396

12-55-0398

12-55-0408

12-55-0408

12-55-0405

12-55-0405

12-55-0405


Safety qi240

12-55-0407

12-55-0001

12-55-0004

12-55-0005

12-55-0014

12-55-0044

12-55-0001

12-55-0005

12-55-0001

12-55-0004

12-55-0410

12-55-0372

12-55-0364

12-55-0365

12-55-0379

12-55-0410

12-55-0362

12-55-0283

12-55-0283

12-55-0387

12-55-0393

12-55-0398

12-55-0283

12-55-0408

12-55-0405


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Safety qi240

2.1.7 Visual and audible signals

Sirens and Beacons:

There are two siren’s and two beacon’s on the QI240.

When the key is turned to start the QI240 engine, the siren will sound and the beacon will flash forten seconds before the engine will crank to start.

When the track controller [umbilical or remote] is switched on and the required control panel buttonis pressed to track the machine, the siren will sound and the beacon will flash for ten seconds, inwhich time the machine will not be able to be tracked. The siren and beacon will then be oncontinuously once the tracking mode is selected.

These visual and audible safety devices should be checked at the start of every working day. For theirlocation refer to “Complementary protective measures” on page 37.

2.2 User obligations

The safe use of a product depends on, among other things, a combination of the design andconstruction measures taken by the manufacturer, the skills of the operators and protectivemeasures taken by the user. Instructions are an essential and integral part of the product and theymust be always available for users. It is important to pass on the information for use to anysubsequent user of this product. Specify the place of manual on the product.

Sandvik prohibits the consumption of drugs and/or alcohol or any other substance likely to impairjudgement while using, being in the hazard zone of, or supervising the use of a Sandvik product.

Safety information covers the following: transport, assembly, installation, commissioning, use,settings, operation, cleaning, troubleshooting, maintenance and disposal of machinery. If you needmore detailed instructions, you must contact your local Sandvik representative.

As part of ensuring the safe use of the product, you as the user are responsible for the following:

• Use of Personal Protective Equipment (PPE)

• Scheduled testing and maintenance of safeguards and protective devices

• Provision and use of additional safeguards

IGNORING INSTRUCTIONS HAZARD

If you do not understand any information related to your duties in the operator’s or maintenance manual you MUST make sure that you get clarification from a person who is well trained with regard to the task you want to do. When necessary, you or your representative must contact a Sandvik representative to seek clarification as to how you should do the task.

WARNING


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• Regular training regarding site safety and safe working procedures

In addition, you must always be familiar with the following:

• Site organisation and supervision

• Workplace safety, including safe working procedures

• Permit-to-work systems

All near-miss incidents and accidents where a Sandvik product has been involved must be reportedto your local Sandvik representative without a delay. See also the section, “Incident reporting” onpage 52.

The following safety guidelines apply to each person working with the product or in the vicinity of theproduct. Every single person is responsible for his or her own safety and for the safety of his or hercolleagues. In case of violation of any safety guidelines or regulations, everyone has a duty to warnothers and report near misses or any safety violation to the responsible supervisor.

2.2.1 Managing work related hazards

The user must always perform a local risk assessment before every new task, e.g. work phase orshift. This assessment, also known as a Real Time Hazard Analysis, ensures that the user stops andthinks about what he or she is going to do before starting to work:

• Identify potential hazards that could impact you, your colleagues, the environment, your product and/or work method while you are performing the task.

• Assess the risks and implement the actions needed to eliminate or reduce the risks.

Only competent persons may carry out operation and other tasks. The employer must:

• Provide training and orientation

• Validate training methods

• Verify competence and skills

• Monitor and evaluate user performance regularly


Safety qi240

2.2.2 Scheduled safety inspections and preventive maintenance

It is important to thoroughly inspect the product before use to make sure it is safe to operate. Lookfor defects and damage before any operation so that any problems can be reported and fixed. Formore information, see the section, “6.0 Operation” on page 109, in the operator’s manual.

Scheduled maintenance is an essential procedure to ensure and maintain safety and performanceof the product. Follow the specified instructions for the maintenance and inspection of product. Formore information, see section, “Maintenance Schedule” on page 118, in Maintenance Manual.

WARNING!

Use of unauthorised parts present an uncontrolled risk and could cause death orsevere injury. The use of unauthorised parts will also invalidate warranty. It is theuser’s responsibility to use only authorised parts as listed in the parts manual.


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2.2.3 Personal protective equipment

Operators and anyone in the vicinity of the product MUST wear approved personal protectiveequipment, which includes but is not limited to:

Safety helmet

Eye-protector

Hearing protectors

Close fitting overall

Safety footwear

Protective gloves

High visibility vest / jacket

Respirator

Do not wear loose clothing or jewellery that can get caught on controls or pulled into moving parts ofthe product.

Tie back long hair. Long hair can get entangled, which could cause death or severe injury.


Safety qi240

2.3 Product limitations

2.3.1 Intended use

Refer to “6.2 Common Applications” on page 111.

2.3.2 Foreseeable misuse

The QI240 has been designed with selected compontents to operate at a optimum level ofperfornance. The user must never limit or bypass or override any safety aspect of the product (e.g.removing a guard ). Refer to “6.3 Common Applications” on page 114.

2.3.3 Prohibited use

• Use which is not in accordance with intended as described in “2.3.1 Intended use” on page 30.

• Bypassing or overriding a safety device or a safety feature of the machine for any reason.

• Use of product without required and approved personal protective equipment.

2.3.4

2.3.5 Maximum inclination angles during tramming and parking

10 degrees side tilt or 20 degrees front tilt.

TIPPING HAZARD

Never exceed the specifies maximum inclination angles. The maximumangles are allowed only when the booms are in the tramming position.

The rig must not be trammed or parked on a slope that exceeds the maximuminclination angles.

WARNING

This equipment must never be tracked on gradients that are more than:


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2.3.6 Maximum inclination angles during operation

The QI240 is designed for operation on a solid, level surface. It is important that the machine is placed on solid ground that is capable of carrying the weight of the machine and that the machine is placed on level ground. An appropriate site must be identified prior to delivery and unloading of the machine.

2.3.7 Modifications

All modifications and corrections not authorised in the product manuals or which may affect themaintenance, operation, safety, and availability of the product need to be approved in writing by themanufacturer before implementation. Approval requires careful risk assessment taking intoconsideration any new risks that the modifications may bring.

Changes and modifications without proper risk assessment, elimination or reduction of risk andwithout appropriate safety measures may lead to death, serious personal injuries or damage toproperty or environment. Unauthorised modifications will also void the warranty.

If modifications and alterations that affect the maintenance, operation, safety, and usability of theproduct are made without the written permission of the manufacturer, the manufacturer is notresponsible for any incidents resulting in death, injury, or property damage brought about by suchmodifications and corrections.

If a modification or correction as described above has been implemented without the manufacturingorganisation’s permission, it’s effect on warranty liability will be considered case-by-case. Thus, thewarranty application may be rejected altogether.

Should you consider a modification or alterations necessary, you must contact the organisation thatmanufactured and designed the product. No modification is permitted unless you first obtain thewritten approval of the manufacturer.

In order to plan and implement the modification you must deliver adequate documentation:• Product model/type

• Serial number of product

• Description of the modification or correction

• Related blueprints

• Related photos

• And other material if necessary

MODIFICATION HAZARD

Unauthorised modifications could lead to death, severe injury or propertydamage.

Always contact a Sandvik representative in order to get advance writtenapproval for any modification

WARNING


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2.4 Hazard zones

Limit access to the equipment and its surrounds by erecting barrier guards to reduce the risk of othermechanical hazards, falling loads and ejected materials.

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2.5 Safeguarding

2.5.1 Guards

TAMPERING HAZARD

Bypassing or overriding of a safeguard or a device could cause death orsevere injury.Do not make any alterations to protective devices. Make sure that they are inplace and work properly before operating the machine.

WARNING


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Main C

onveyorS

kirting guardsE

ngine surroundD

rive belt guardP

rescreen shaft guard

Main C

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eturn roller guards

Main C

onveyor tunnel and side face guards

Track covers

Hopper door lift ram

guards

Side C

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roller guard

Side C

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Jack leg cover plateM

ain Conveyor Low

er section guarding and tunneling


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Safety qi240

2.5.2 Protective Devices

a. Prior to operation, all safety devices (control devices or guards) temporarilyremoved for set-up, maintenance or repair purposes MUST be refitted andchecked immediately upon completion of the maintenance and repair work.

b. To avoid serious personal injury or death, NEVER operate the equipment withsafety devices or guards removed or unsecured.

c. ALWAYS report any defects regarding guards, safety devices or control devices.

ISOLATOR ON

ISOLATOR OFF


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2.6 Complementary protective measures

2.6.1 Use of Emergency stop function

There are five Emergency Stops on the QI240 and one engine kill switch on the remote control.

BEACON SIREN

BEACON SIREN


Safety qi240

Control Panel Emergency Stop

Engine Kill Switch

Umbilical Tracking Lead Engine Kill Switch

Emergency StopReset Button


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2.6.2 Emergency exit

The QI240 is not permitted to operate inside buildings or dwellings. The area surronding the QI240must always be clear of obsructions eg containers, unnecessary stockpiles etc.

2.6.3 Safe access to machinery and three point support

No climbing on the machine is allowed.

The maintenance platforms should never be used to observe the machine operation.

a. Falling from and/or onto this equipment could result in death or serious injury.

b. NEVER climb on the equipment while it is in operation or use equipment parts asa climbing aid.

c. ALWAYS keep the area around the equipment clear of debris and trip hazards.

d. Beware of moving haulage and loading equipment in the area of the equipment.

e. For carrying out overhead assembly work, ALWAYS use specially designed orotherwise safety-oriented ladders and working platforms.

f. ONLY use walkways/platforms provided on the equipment. ALWAYS performwork from an approved, safe and secure platform.

g. When reaching any points 2m (approximately 6 feet) or more above the groundlevel, ALWAYS use CE certified safety harness.

h. Keep all handles, steps, handrails, platforms, landing areas, and ladders free fromdirt, oil, snow and ice.

i. This equipment MUST be isolated prior to cleaning.

j. DO NOT direct power washers near or into control boxes and devices.

k. After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, looseconnections, chafe marks and damage. Any defects found MUST be repairedimmediately.


Safety qi240

2.6.4 Isolation and energy dissipation

Lockout and Tag Procedure:

Utilise the procedure below whenever the QI240 is being operated under alternate power, or underany condition in which shutting off the engine and removing the ignition key does not completely cutpower to the machine. Under such circumstances, to properly immobilise the QI240:

• Position all hydraulic controls in the neutral position

• Ensure that all supports and slide stops are securely fixed in position

• Switch off machine ignition and remove ignition key

• Turn off Isolator Switch (See Photo Below)

• Lockout the isolator with a padlock and use a Tag to detail the work being done.

• User must retain padlock key on his/her person during immobilisation

Note! The above procedure MUST be utilised to safely immobilise the QI240 when it is under alternate power. Failure to utilise the above procedure may result in damage to the QI240, serious personal injuries or death.

ISOLATOR ON

ISOLATOR OFF


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Removal of the Lockout and Tag:

Once the work has finished; remove ONLY your lock and tag, as other people may be working on themachine at the same time.

The machine can only be started when the last lock and tag is removed.

Note! Refer to Start-up Sequence for Running the Machine, refer to “5.2.2 Engine Start Up Procedure” on page 86.

IMPACT HAZARD

Before moving the machine, visually check to make sure no one is standing inthe surrounding area.

DANGER


Safety qi240

2.6.5 Fire risk control measures

Smoking and open fire are prohibited in the vicinity of the product. Access to all fire-fightingequipment must be granted at all times, especially during maintenance and repair works.

All fire-fighting equipment musto be inspected and serviced regularly according to local regulations.Damaged fire-fighting equipment and used fire extinguishers must be replaced immediately.

Know the various types of fires and the appropriate fire fighting methods. Be aware that various firesmust not be extinguished with water. In most cases special extinguishing agents, dry powders ordeoxygenating are required.

All personnel must be trained regularly in fire-fighting methods in cooperation with local authoritiesand rescue organisations. In case of fire, the fire alarm must be activated and all available personnellmust contribute in the fire-fighting according to the predetermined fire plan of the workplace.

FIRE AND EXPLOSION HAZARD

Explosion hazard can exist in addition to the fire hazard.

Ignition sources like smoking, open flames, welding work and sparkstogether with combustible materials like fuel, can cause fire and if notavoided, could lead to death or severe injury.

Ignition sources are prohibited in the vicinity of the machine ready for operation or inoperation.

During maintenance appropriate fire prevention and protection measuresmust be followed including but not limited to trained personnel, proper fireextinguishing equipment and agents. Before any maintenance or repairsrequiring ignition sources like welding or flame cutting, a proper riskassessment must be carried out prior to the start of the work to control the risk.

WARNING


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qi240 Safety

2.7 Protection against emission hazards

2.7.1 Noise

The above diagram indicates the measured noise levels at a measured distance; i.e. 3 m(approximately 12 feet) - 96 dB, indicates that at 3 meters the sound measured was 96 decibels. Thereadings were with all systems running situated on the factory assembly line. The product and localconditions will affect the noise levels.

NOISE HAZARD

Noise level emitted by the machine exceeds 80 dB(A). Continuousexposure to noise will cause hearing impairment.

Always wear approved hearing protection.

DANGER

Ear protection must be worn if you are within 10 meters (approximately 33 feet) ofthe machine when the engine and other parts of the machine are running.

3 Metre (9'9") Radius



86dB

90dB

94dB

92dB

96dB

112dB

99dB

96dB


Safety qi240

2.7.2 Vibration

2.7.3 Dust

Breathing or inhaling dust particles will cause death or severe injury. Always work with a respiratorapproved by the respirator manufacturer for the job you are doing. It is essential that the respiratorthat you use protects you from the tiny dust particles which cause silicosis and which may causeother serious lung diseases. You should not use the product until you are sure your respirator isworking properly. This means the respirator must be checked to make sure that it is clean, that itsfilter has been changed, and to otherwise make sure the respirator will protect you in the way it ismeant to.

In any workplace where respirators are necessary to protect the health of the employee, the employermust establish and implement a written respiratory protection program with worksite-specificprocedures and elements including but not limited to the selection of respirators, proper usage,maintenance and care, cleaning and disinfecting and training.

Make sure the dust suppression system in your equipment is working properly. If the dustsuppression system is not working properly, stop working immediately.

Regularly clean your working environment properly to minimize the dust level in the air. Always makesure dust has been cleaned off your boots and clothes when you leave your shift.

Respiratory silica dust is a hazard, which requires special attention. The smallest particles of dust arethe most harmful. They may be so fine that you cannot see them. Remember, you must protectyourself from the danger of breathing or inhaling dust.

WARNING! VIBRATION HAZARD!

Exposure to vibration could cause severe health effects. Follow the maintenanceschedule and keep the machine in good operating condition. Participate in thehealth surveillance and training programs offered by your employer.

DANGER

DUST HAZARD

Breathing dust will cause death or severe injury.

Always wear approved respirator.

If machine is equipt with a dust suppression system make sure the dust suppressionsystem is working properly.

DANGER


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qi240 Safety

2.8 Emergency procedures and methods for unblocking

Blockage or Malfunction:

In the event of material blockage, any malfunction or operational difficulty, stop theequipment and lockout immediately. Repair any defects or hazardous conditionsimmediately.


Safety qi240

2.9 Safety considerations for maintenance

Before carrying out any maintenance read and understands the maintenance instructions. Make surethat you have the skills and authorization needed before starting any maintenance work. Themaintenance instructions support maintenance personnel in respect of preventive maintenance forthe product. It provides instructions for scheduled mechanical inspections to the maintenance andoperating personnel for components and equipment installed.

Ensure all necessary machinery isolations (Refer to “2.6.4 Isolation and energy dissipation” on page40) have been carried out prior to commencing any maintenance work. Before carrying out anymaintenance work ensure that necessary original spare parts or materials are available, or can beordered and supplied in time to meet the work schedule. Note all completed maintenance activitiesin a maintenance log or maintenance program.

Daily inspections and tasks allowed for operators (which do not require special skills) are in theMaintence Chapter refer to “ 7.0 Maintenance” on page 129.

Any tasks not mentioned in this chapter should not be attempted by operators.

Hydraulic Maintenance

a. Work on hydraulic equipment must be carried out by persons having specialknowledge and experience of hydraulic systems.

b. ALWAYS relieve pressure from the hydraulic system before carrying out any kindof maintenance or adjustment.

c. BEFORE carrying out any repair work, depressurise all system sections andpressure pipes (i.e. hydraulic system, compressed air system, etc.) requiringremoval, in accordance with the specific instructions for the unit concerned.

d. Hydraulic and compressed air lines MUST be laid and fitted properly. Make surethat no connections are interchanged. The fittings, lengths and quality of thehoses MUST comply with the technical requirements.

e. ONLY fit replacement components of a type recommended by the manufacturer.

f. ALWAYS practice extreme cleanliness when servicing hydraulic components

Splashed oil creates the risk of a fire, which could result in death or seriousinjury.

Check all lines, hoses and screwed connections regularly for leaks or otherdamage.

Repair damaged lines, hoses, or screwed connections IMMEDIATELY

WARNING


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qi240 Safety

Battery Maintenance

a. ALWAYS disconnect battery leads before carrying out any maintenance to theelectrical system.

b. Recharge the battery in a well ventilated area.

c. The battery contains sulphuric acid, an electrolyte which can cause severe burnsand produce explosive gases.

d. AVOID contact with the skin, eyes or clothing.

e. Smoking is PROHIBITED when maintaining the battery.

f. ALWAYS wear appropriate personal protective equipment.

Electric maintenance

a. External Considerations and Hazards

When working with the equipment, maintain a safe distance from overhead electric lines. If overheadcables are in the area, a risk assessment MUST be completed prior to operating the equipment.

Hydraulic fluid under pressure can penetrate the skin, which will result indeath or serious injury.

If fluid is injected under the skin, it must be surgically removed or gangrenewill result. GET MEDICAL HELP IMMEDIATELY.

ALWAYS use a piece of cardboard to check for leaks. DO NOT USE YOURHAND

DANGER


Safety qi240

b. Machine - Electrical

1. Work on the electrical system or equipment MUST ONLY be carried out by askilled and qualified electrician or by specially instructed personnel under thecontrol and supervision of such an electrician and in accordance with applicableelectrical engineering rules.

2. Before starting any maintenance or repair work, the power supply to theequipment MUST be isolated. Check the de-energized parts to make sure they donot have any power. In addition to insulating any adjacent parts or elements,ground or short circuit them to avoid the risk of electrical shock.

3. The electrical equipment is to be inspected and checked at regular intervals.Defects such as loose connections or scorched or otherwise damaged cablesMUST be fixed immediately.

4. Use ONLY original fuses with the specified current rating. Switch off theequipment IMMEDIATELY if trouble occurs in the electrical system.

5. This equipment is wired on a negative earth. ALWAYS observe correct polarity.

•

Contact with overhead electric lines will cause death or serious injury.

If your equipment comes into contact with a live wire, you MUST:

• Vacate the area;

• Warn others against approaching and touching the equipment;

• Report the incident and have the live wire shut off.

DANGER


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qi240 Safety

2.10 Environment

2.10.1 Decommissioning

Hazardous Substances:

a. MAKE SURE that correct procedures are formulated to safely handle hazardousmaterials in strict accordance with the manufacturer's instructions and allapplicable regulations by correctly identifying, labelling, storing, using anddisposing of the materials.

b. A full list of Hazardous Substances associated with this equipment can be found inthe appendix of this document.

Warning Concerning Crystalline Silica And Similar Particulates:

• The QI240’S operation may produce dust containing crystalline silica or other potentially harmful particulates. ALWAYS utilise appropriate and properly-fitted and approved Personal Protective Equipment, (e.g. respirators). Refer to “2.2.3 Personal protective equipment” on page 29.

• DO NOT linger in areas where dust is produced, blown or otherwise found. NEVER inhale dust produced by the operation of the QI240.

Note! Inhalation of crystalline silica dust is potentially harmful to human health, and may result in serious pulmonary disease or other deleterious chronic lung obstruction, serious personal injuries or death.

2.10.2 Dismantling

Replacement & Removal of Components:

a. ALWAYS observe handling instructions itemised in this manual, the OriginalEquipment Manufacturer's manuals, or the spare parts suppliers' instructions.

b. NEVER allow untrained staff to attempt to remove or replace any part of theequipment.

c. The removal of large or heavy components without adequate lifting equipment isPROHIBITED.

d. To avoid the risk of accidents, individual parts and large assemblies being movedfor replacement purposes should be carefully attached to lifting tackle and


Safety qi240

secured. ONLY use suitable and technically adequate lifting gear supplied orapproved by Original Equipment Manufacturer.

e. NEVER work or stand under suspended loads.

f. KEEP AWAY from the feeder hopper and product conveyor discharge, wherethere is risk of serious injury or death from contact with ejected debris.

g. LIMIT ACCESS to the equipment and its surrounds by erecting barrier guards toreduce the risk of residual mechanical hazards, falling lifted loads, and ejectedmaterials.

2.10.3 DisposalThis equipment MUST ONLY be disposed at a specialist machine breaker

Handling And Disposal Of Hazardous Components And Materials

• The QI240’s battery contains sulphuric acid, which can cause severe burns, and produces explosive gases. Inspect the machine’s battery regularly, and assure that it is properly connected and maintained. NEVER allow battery parts to come into contact with unprotected skin, eyes or clothing, use Personal Protective Equipment, refer to “2.2.3 Personal protective equipment” on page 29. NEVER attempt maintenance or repair to the QI240’S battery while the battery is connected.

• The QI240 includes an internal combustion engine, which produces exhaust fumes containing potentially harmful gases and particulates. NEVER operate the machine’s engine in an area lacking adequate ventilation, whether indoors or outside.

• Prior to welding, cutting, or grinding, ALWAYS assure that dust and other flammable substances are removed from the work site. ALWAYS assure that the area where welding, cutting or grinding is conducted is properly ventilated. Failure to observe these precautions may increase the risk of explosion or fire, and may result in serious personal injuries or death.

• Keep flammable materials, chemicals, etc. away from the QI240 at all times.

Special Considerations Concerning Dust Disposal:

• ALWAYS utilise appropriate and properly-fitted Personal Protective Equipment (e.g. respirators). Refer to “2.2.3 Personal protective equipment” on page 29.


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qi240 Safety

• Always dispose of dust produced by the operation of the QI240 by applying water, placing dampened dust in a marked, sealed container, and removing it from the work site.

• NEVER disperse dust by blowing it; doing so may exacerbate dusty conditions in the proximity of the QI240, and may also cause dust to enter areas where unprotected persons may be working, creating an increased risk of injury or death.

• ALWAYS assure that dust is removed from clothing, boots, etc. before leaving the work site.

• Liquids such as oil, fuel and battery liquids cause pollution. Follow the local, regional and national regulations for waste disposal.

• Avoid running the engine at idle if it is not needed. Avoid unnecessary exhaust fumes.

• Observe the law in your country when disposing used of machine components.

2.11 Potential product related hazards identified by the user

Operational Safety Considerations:

• Ensure that a copy of all operating instructions, including the Engine Operations Manual, is kept current and maintained with the QI240 at all times. If the manual is unavailable obtain a replacement from Sandvik.

• Operators MUST read and understand all operating instructions, and must always work utilising indicated safety precautions and procedures.

• Operators and anyone in the area of the QI240 must ALWAYS use appropriate Personal Protective Equipment, refer to “2.2.3 Personal protective equipment” on page 29.

• Operators MUST be familiar with and understand all warnings and labels affixed to the QI240. Failure to do so may result in serious personal injuries or death. If warnings or labels are damaged or illegible, operators must notify management immediately and urgently obtain replacements.

• ALWAYS ensure, prior to operation of the QI240, that all safety devices are in place and operational.

• If in doubt concerning the efficient, proper or safe operation of the QI240, contact your Sandvik Dealer.

• Perform tasks only when safety is ensured.

• Contact your supervisor and local Sandvik representative.


Safety qi240

2.12 Incident reporting

Product safety issues to be reported are events where a product manufactured by Sandvik Miningand Construction has been involved in an accident or near-miss incident. Safety-related feedback,such as, unauthorised modifications, missing manuals and safety labels, negligence of maintenanceor misuse shall be reported to your local Sandvik representative as well.

Reporting is mandatory to ensure safe working conditions for employees, to provide information forthe risk assessment process and to initiate product improvements.

Contact your local Sandvik representative to report safety issues, such as those mentioned above.


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qi240


3.0 Transport &Technical Data

Transport and Technical qi240

3.1 Transport

3.1.1 Special Considerations For Transport Of The QI240

• Do not attempt to transport the QI240 utilizing a vehicle not specified for hauling at least the listed gross weight of the machine. Failure to use transportation with sufficient hauling capacity may result in damage to the QI240 and the hauling vehicle, and may result in serious personal injuries or death.

• ALWAYS observe applicable local and national regulations concerning the transportation of heavy equipment. Ensure that all appropriate permits, licenses and endorsements are obtained and maintained before transporting the QI240.

3.1.2 Machine Preparation for Transport

Follow the procedure for preparing the machine for shut down, refer to“6.8 Clearing Crusher Chamber Jam’s” on page 127.

Before attempting to set-up the machine ensure that the operator hasread and fully understood this and all the preceeding sections in themanual

WARNING

WORKING AT HEIGHT HAZARDFalling may cause injury or death. Always use a secure platform. Make sure correct procedures are followed FOR the tasks that are done at height.

DANGER


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qi240 Transport and Technical

a. Restart the engine refer to “5.2.2 Engine Start-up Sequence” on page 84 and raise the main conveyor upwards and off the locating pins by operating hydraulic lever 8, .

b. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 40.. Attach the ladder [supplied] into the ladder fix point or use asecure platform

c. Remove the locating pins. Remove the Ladder.

Hydrauliccontrol lever

Locating Pins

NOTICE Failure to remove the ladder will result in damage to the ladder as the maincoveyor will be lowered in the next operation.



d. Restart the engine refer to “5.2.2 Engine Start-up Sequence” on page 84, to lower the mainconeyor by operating the hydraulic lever until the first hole is algined with the outer box section hole.

e. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39..

f. Attach the ladder [supplied] into the ladder fix point or use a secure platform andinsert the locating pins.

Ladder fix Point

Locating Pins in first hole position.


NOTICE Failure to remove the ladder will result in damage to the ladder as the maincoveyor will be lowered in the next operation.


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g. Restart the engine refer to “5.2.2 Engine Start-up Sequence” on page 84, to lowerthe main coneyor by operating the hydraulic lever until the weight of the mainconveyor is resting on the locating pins.

3.1.3 Folding the main conveyor and Positioning into Transport Position

a. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and

energy dissipation” on page 39..

b. Attach the ladder [supplied] into the ladder fix point or use a secure platform andadjust the length to remove the torque arm on both sides


Insert Locating Pins in first hole position.

Ladder fix Point

LocatingPin

Torque Arm



c. Remove the ladder.

d. Restart the engine refer to “5.2.2 Engine Start-up Sequence” on page 84) to foldthe main conveyor, by operating hydraulic control HC5 refer to “4.2.3 HydraulicControl Banks” on page 76.

e. Remove the Spray Bars from the Main Conveyor. Place them into the feeder (“4.2 Major Components” on page 72)

Main Conveyor

Bolt locations

Spray Bar


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3.1.4 Removing the belt troughs and Fold the Side Conveyor.

a. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39. . Remove the Belt troughs from the mid section of theside conveyor.

b. Restart the engine refer to “5.2.2 Engine Start-up Sequence” on page 84 to Raisethe side conveyor off the slide stop, by operating the hydraulic control lever HC2.

Remove theseitems first

locating pinSlide stop top position

HC2



c. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39. . Remove locating pin from slide stop at the topposition. and relocate the slide stop to the bottom postion and re-insert thelocating pins.

d. Restart the engine refer to “5.2.2 Engine Start-up Sequence” on page 84 to foldthe side conveyor to the transport position by operating hydraulic control leverHC2

e. Adjust the torque arm length to allow the locating pins to be inserted. Adjust thetorque arm length to remove the slack on the two locating pins.

3.1.5 Unfolding the hopper sides

a. Restart the engine, refer to “5.3.3 Restarting the engine to activate AuxillaryControls” on page 92.. Raise the weight of the left and right hopper sides off thetwo wedges.

Locating pins

Remove the Wedges

HC1


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b. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39. Using a secure platform if needed, use a additionalsupervisor to remove the two wedges (see picture above).

c. Restart the engine, refer to “5.3.3 Restarting the engine to activate AuxillaryControls” on page 92. Fold down the hopper rear by operating hydraulic controllevers HC1.

d. Raise the left and right hoppper sides until their weight is off the support plates(refer to above).

e. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39. Using a secure platform if needed, the additionalsupervisor can remove the locating pins and move the prop outwards to allow it toclear the support plate.

f. Restart the engine, refer to “5.3.3 Restarting the engine to activate AuxillaryControls” on page 92. Fold down the hopper sides by operating hydraulic controllevers HC1.

Locating Pin to prop side hoppers

HC1



3.1.6 Fold ladder 1 and ladder 2

a. Fold Ladder 2 up, loosening the bolts and hinging up the last 2 steps.

b. Remove the Ladder 2 support, allow the ladder 2 to hang vertically down and securely tie theLadder 2 to the chassis.

a. Loosen the bolts and swing up the the last 2 steps section, and then tighten the bolts tosecure.

b. Seperate the ladder 2 support from the chassis and ladder 2 and store safely inthe feeder of the machine.

Ladder 2 support

Loosen the bolts

Securewith bolts

Ladder 1 support


ID:QI240.en.ver.2


c. Swing up the folded ladder 1, and secure the gates to the ladder with securefixings.

d. Place all loose items into the feeder.

e. Place all tools and manuals into the tool box and control panels.

f. Check the machine is in good mechanical condition and there is no componentdamage or loss.

Torque Arm x 2 - required forthe main conveyor

Side ConveyorBelt Troughs

Ladder 1 support

Ladder 2 support

Place into ControlPanel Cabinet

CI411 Litting Tool



3.1.7 Tracking the machine onto and off the transport vehicle

Follow the Sequence for the tracking procedure (refer to “5.2.5 Sequence For Tracking Machine” onpage 87)

Note! engine idle rpm on engine start up is sufficient to track the machine onto or off the transport vehicle. Any higher engine rpm is not recommended.

After tracking the machine onto the transport vehicle make sure all temporary sealing and transportstraps or chains are installed. DO NOT secure by tying down over the tracks. Lashing down is theresponsibility of the driver of the low loader.

Before tracking the machine off the transport vehicle make sure all temporary sealing and transportstraps or chains are removed.

CRUSH HAZARDMoving machine can crush objects and personnel.Before starting the machine visually check the machine and area around the machine to make sure there is no one standing in the area.

DANGER


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3.1.8 Transport and Working Dimensions

TRANSPORT



WORKING


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3.2 Technical Information

3.2.1 Standard Features

• Primary Impact Crusher, designed by Sandvik, utilising the very latest in finite crushing analysis with rigid one piece welded Crusher Frame, which has been heat-treated after welding for internal stress relief

• Hydrostatic crusher drive complete with reverse jaw movement, to quickly relieve blockages

• Fully hydraulic wedgetype system for Closed Side Setting (CSS) Adjustment

• Sandvik Feeder is controlled with a level monitoring system in the crusher, which will stop/start the feeder independently.

3.2.2 Options

• Dirt Conveyor

• Magnetic Separator

• Radio Controlled Tracks

3.3 Identification of Main Units

Hopper Feeder

Pre Screen

CI411

Main Conveyor

Pan feeder TracksEngine

MagneticSeperator

Side Conveyor



3.4 Technical Data and General Information

The QI240 is a Mobile Primary Impact Crusher constructed for high mobility and high output.

3.4.1 Hopper

Width 800 mm (2'7")

Length 3660 mm (12')

Hopper capacity 3.6 m3 (4.7yds3)

Hopper type hydraulically folding side and rear extension plate

3.4.2 Feeder

Type spring mounted vibrating feeder

Width 910 mm (3')

Length 2330 mm (7'8")

3.4.3 Pre Screen

Screenbox speed 990 rpm

2 bearing, high amplitude screen

2 screening decks

Screen deck measure

Top 1520 mm x 980 mm (5' x 3'3")

Bottom 1020 mm x 980 mm (3' 4" x 3'3")

3.4.4 4 Hammer Impact Crusher type Sandvik CI411

Feed opening 980 mm (39") x 650 mm (26")

Hydraulic inlet opening 980 mm (39") x 850 mm (33")

Crusher speed variable 573 rpm-707 rpm (30mps-37mps)

Curtain Adjustment Hydraulic system

Drive Direct drive

3.4.5 Main Conveyor

Belt EP500/3 ply 8+2 mm gradeX (1000mm(3'3"))

Discharge height 3600 mm (11'10")


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3.4.6 Pan Feeder

Type spring mounted vibrating feeder

Width 830 mm (2'9")

Length 2040mm (6'8")

Hydraulic Drive

HardoxTM 400 steel liners are fitted as standard

3.4.7 Tracks

Length 3800 mm (12'6")

Width 400 mm (16")

Drive Hydraulic motors

Control Remote handset

Standard cable control remote handset

Optional radio remote handset type Hetronic

3.4.8 Optional CAT C9

Engine power 260 Kw (350 Hp)

Diesel tank 660 ltrs (174 US gal)

Hydraulic tank 660 ltrs (174 US gal)

3.4.9 Optional Magnetic Separator Type Eriez CP 20/100-SC2

Weight 1200 kg

Length 2400 mm

Width 1002 mm

Height 428 mm

Type self cleaning suspended

Belt width 800 mm (32")

Gauss at 200 mm distance from belt 578 gauss

Gauss at 250 mm distance from belt 458 gauss

3.4.10 Side Conveyor

Belt EP400/3 ply 3+1.5 mm (650mm(26"))

Discharge height 2460 mm (8'1")



3.5 General Technical Data:

Operation Mode Transport Mode

Length: app.14,650 mm (48'1") app.14,100 mm (46'3")

Width: app.5,600 mm (18'4") app. 2,650 mm (8'8")

Height: app.4,130 mm (13'7") app. 3,400 mm (11'2")

Total weight: 38, 500 kg without options

Dust Suppression: Situated at main conveyor discharge & Impactor inlet.

3.6 Options

3.6.1 Wheel Dolly SystemTransport system that enables machine to be transported without con loader or other transport means

3.6.2 Neodynium Magnetic Separator

Self cleaningBelt width 800 mmDriven by hydraulic motor

3.6.3 Arctic Packages

-30oC (-22oF)-20oC (-4oF)

3.6.4 Tropical/High ambient package

3.6.5 Hardox Wear Plates for hopper wallsHigh Impact Sandvik Wear Rubber for hopper walls

3.6.6 Dust Suppression canvas covers

3.6.7 Central Auto Lube (crusher)

3.6.8 Central Auto Lube (conveyors)

3.6.9 Remote Diesel Pump

3.6.10 Water Pump

3.6.11 Double deck recirculation system (final spec TBC)

3.6.12 No Magnet Fitted

3.6.13 No Side Conveyor Fitted


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4.0 Product Overview

Product Overview qi240

4.1 Product Overview

This section has been designed to familiarise the user with the various controls and functions of the individual components that make up the QI240

4.2 Major Components

1. Main Conveyor

2. Magnetic separator

3. Diesel Tank

4. Powerpack

5. HSI Crusher Unit

6. Pre Screen

7. Primary Feeder

8. Side Conveyor

1 2 43 5 6 78


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qi240 Product Overview

9. Main Conveyor Torque Arm

10. Discharge Chute

11. Jacking Legs

12. Hydraulic Tank

13. Access Ladder

14. Starter Panel Cabinet

15. Oil Cooler

16. Hydraulic Block Cabinet

17. Access Ladder

18. Hopper Wing Plates

18 17 1516 14 13 12 10 911 11



4.2.1 Identification and Operation of the QI240 Controls

There are three sets of controls on the QI240:

1. The main control panel

2. Hydraulic control banks

3. The remote control which can be found in the control box upon delivery of the machine.

4.2.2 Main Control Panel

The main control panel consists of the following:

a. Ignition - This control is used to start and stop the machine

b. Emergency Stop, refer to “2.6.1 Use of Emergency stop function” on page 37.When pressed the engine will stop.

c. Display Panel- This panel is used to operate and observe the functions of themachine.


Emergency Stop Reset Button


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When the ignition switch is turned to the on position, the introductory display will appear.

All settings and procedures are accessed via the numbered buttons on this display panel.

To enter any command or access a new sub-menu display, simply press the relevant button.

To exit a particular sub-menu and go back one level, press the ESC button or a return button whichwill be highlighted.

Active programs/options are identified to the user by a green symbol.

Function is OFF Function is ON



4.2.3 Hydraulic Control Banks

HC1 - Left, Right and Rear hopper side plates - fold / unfold

HC2 - Side Conveyor - fold / unfold.

HC2 HC1


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HC3 - Front Jack Legs - Raise and Lower

HC4 - Rear Jack Legs - Raise and Lower

HC5 -Main Conveyor - Fold / unfold

HC6 -Safety device - Lock / Unlock . Impactor Hood - Open / CLose

HC7 - Upper Curtain - Raise / Lower . Lower Curtain - Raise / Lower

HC8 - Main Conveyor - Raise and Lower. Refer to “8.1.6 PSVS Diagnosis for Hydraulicor Electrical Faults” on page 169 on the use of the this hydraulic lever.

HC4HC3 HC5HC6

HC7

HC8



4.2.4 Radio Remote Control Unit

The radio remote control main function is to track the machine. Refer to “7.2.5 Radio Remote Controlbattery Charging” on page 140 to keep the battery power charge level high at all times.

There are several controls on the remote unit:

• A joystick for each track (LH/RH) used to drive the tracks either forward or back. The diagram below shows the direction of forward travel. The track joysticks control the track speed proportionally.

• An Engine Kill button that, if pressed will shut off the engine.

• A On/Off toggle switch for the feeder for operator convenience.

• An on-off key switch (A) that is used to turn the remote unit on or off.

• A green push button (B) that must be pressed to activate the remote.

DAMAGE TO MACHINE WILL RESULT IF MISUSED.

This switch should only be used in emergency situations. Machine willrequire extensive preparation before a restart of the conveyors is possible as

material build may occur. Refer to “6.5.1 Start-up Sequence For Running theCrusher” on page 116 for restart procedure.

NOTICE

AB

Engine KillSwitch


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4.2.5 Umbilical Remote Control Unit

The umbilical remote control has one function: to track the machine. Refer to “7.2.5 Radio RemoteControl battery Charging” on page 140 to keep the battery power charge level high at all times.

There are several controls on the remote unit:

• Auto Track Switch to automatically drive the tracks either forward or backwards at the maximum speed [ speed depends on engine rpm ]. The machine will continously track until this switch has been moved to the neutral position.

• Manual track buttons for each track (LH/RH) used to drive the tracks either forward or back. These buttons will control the track speed proportionally but will only work when the Auto Track Switch is in the neutral postion.

• An Engine Kill button that, if pressed will shut off the engine

The diagram below shows the direction of forward travel.

Engine KillSwitch

AutoTrackmaster Switch

Manual TrackButtons



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qi240


5.0 Commissioning and Shut Down

Commissioning and Shut Down qi240

5.1 Commissioning & Shutdown Safety

Please refer to“ 2.0 Safety Section - Safety and Environmental Instructions” on page 17 of thismanual for additional information on safe operation, maintenance and repair of the machine. Toensure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work on theequipment or making any adjustments. Do not attempt operation, maintenance or repair with out firstconsulting all pertinent safety information.

5.1.1 Who is at Risk

• Operators, Maintenance Personnel,

• Subcontractors and anybody else in the vicinity of the machine

5.1.2 Managing Work related Hazards with a Risk Assessment

5.1.3 When carrying out maintenance or adjustment

Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy dissipation” on page 39.

You must always perform a local risk assessment before starting a task. Thisassessment, makes sure that you stop and think about what you are going to bedoing before you begin work:

• Identify potential hazards that could impact you, your workmates, the environment, your equipment and/or work method while you are performing the task.

• Assess the hazards to determine what scale of control is required (apply controls to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal protective equipment” on page 29.

• Do not wear loose or baggy clothing which could become caught in the moving parts of the machine

• Do not Climb on The Machine – Always use the Access Points and Platforms or other approved Access Equipment as required


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qi240 Commissioning and Shut Down

5.2 Commissioning

Read And Follow All Instructions Concerning Set Up Of Your QI240. Failure To Do SoMay Result In Damage To The Machine, May Result In Serious Injury Or Death, And MayInvalidate Manufacturer’s Warranties.

The Following Instructions Assume Transport Of The QI240 From A Low Loader-typeVehicle In Close Proximity To The Job Site; If The Machine Is Transported In A DifferentManner, Contact The Manufacturer For Additional Set Up Instructions.

It is recommended that set up of the QI240 be carried out by a representative of SandvikMining and Construction Mobile Crushers and Screens Ltd. or by trained and authorisedrepresentative of the dealer.

5.2.1 Preparation for Machine STARTUP

SURFACE PREPARATION:

The QI240 is designed for operation on a solid, level surface. It is important that the machine isplaced on solid ground that must be capable of carrying the weight of the machine and that themachine is placed on level ground. The machine should be level to within 2 degrees from left to right.An appropriate site must be identified prior to delivery and unloading of the machine.

VISUAL INSPECTION:

Before powering up the engine a visual inspection of the QI240 should be performed. Inspection should ensure that:

1. All safety equipment is installed and functioning properly.

2. Any loose items delivered with the QI240 have been secured or removed from themachine.



5.2.2 Engine Start-up Sequence

a. Ensure all Emergency Stops are released and that the switch on the remote control is alsoturned off. Refer to “2.6.1 Use of Emergency stop function” on page 37.

b. Turn on the ignition switch (but do not start the engine) and check the following displays areshown respectively (Fig. 5.1). It should take a few seconds. If there is a problem it will be shown onthe display.

c. Press the blue Emergency Stop Reset button which will be illuminated to reset the emergencystop system. The emergency stop system can only be reset when the splash display is shown.

d. If the emergegency stop system is not reset the display below will have a warning message.The ignition switrch must be turned off and steps a) to c) repeated.

e. Now start the machine, turn the ignition switch fully clockwise. The siren will sound & beaconwill flash for 10 seconds before the engine will start. (If engine turns and does not start, turn off theignition and wait for a few seconds, then try and start again.)

( Fig. 5.1 )Emergency Stop Reset Button Splash Display


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5.2.3 Setting Language of Control Panel Display.

From the Main menu display (Fig 5.1.) press and hold the ESC button for 10 seconds to access theinformation page.

Press Button 3 to select the language required. The country flag or a greeting will appear). To returnto main menu press ESC.

5.2.4 Setting the date/time

From the Main Menu page, press Esc and hold for 10 seconds.

• Hold and press button 8 until the value you wish to edit changes to red.

• The “Hours” field will be highlighted first and begin to flash. To increase the hours press the Up arrow button. To decrease the hours press the Down arrow button.

• Press the right arrow button to move to the next field.

• The “minutes” field will begin to flash. To increase the minutes press the Up arrow button. To decrease the minutes press the Down arrow button.


• The “seconds” field will begin to flash. To increase the seconds press the Up arrow button. To decrease the seconds press the Down arrow button.


• The “Days” field will begin to flash.To increase the Days press the Up arrow button. To decrease the Days press the Down arrow button.


• The “Months” field will begin to flash. To increase the Months press the Up arrow button. To decrease the Months press the Down arrow button.


Software version

Control Panel Serial Number

Button 3



• The “Years” field will begin to flash.To increase theYears press the Up arrow button. To decrease the Years press the Down arrow button.

• Finally press the right arrow button to store the new date/time. The red highlighted option will disappear from the date/time fields.


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5.2.5 Sequence For Tracking Machine

Refer to “4.2.4 Radio Remote Control Unit” on page 78 and “4.2.5 Umbilical Remote ControlUnit” on page 79.

The operator must be fully trained in the operation of this equipment. When tracking, the operatormust be in a position to have an all round view of the operation. A additional supervisor should assistwhere this is not possible. Make sure the site is clear of non essential persons. Erect barriers aroundthe area and post warning signs where site conditions warrant this. Make sure the tracking alarmmakes a clear sound.

a. Start the engine if required. Refer to “5.2.2 Engine Start-up Sequence” on page 84

b. Switch on the tracking mode by pushing button 2 as shown (Fig. 5.2).

CRUSH HAZARDMoving machine can crush objects and personell.Before moving the machine visually check the area around the machine to make sure there is no one standing in the vicinity.

DANGER

This equipment must never be tracked on gradients that are more than:

10 degrees side tilt OR 20 degrees front tilt

( Fig. 5.2 )



c. The display as shown (Fig. 5.3) will appear.

d. For Umbilical remote control, press the switch on the unit as shown next. Then pressbutton 1 (Fig. 5.3), the siren and beacons will sound and flash for 10 seconds. During the 10seconds a yellow halo will appear around button 1 icon.

e. After the 10 seconds the button 1 icon will then have a green halo. Tracking will now be activewith the proportional controls on the umbilical control unit.

f. To disable tracking press button 1 again and the green halo around the icon will disappear.

(Fig. 5.3)

Button 2Radio Receiver Activate

Radio Receiver SignalStrength IndicationRadio Receiver Activate

Button 1Manual Handset Activate

Engine RPMLower / Raise

Switch


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g. For Radio remote control press button 2 (shown in Fig. 5.3). The yellow halo will not appearuntil signal strength is good and the remote is turned on.

h. Turn the transmitter to the On ‘I’ and wait for the green light to flash consistently after a fewseconds as shown below (Fig. 5.4)

i. The Icon on button 2 will now have a yellow Halo. A green icon on the display shown in Fig.5.3 will now be flashing to remind you to press the green activate remote button in Fig. 5.5.

j. Activate the radio transmitter by pushing the green button on the unit as shown below (Fig.5.5). The siren will sound & beacon flash. It will take 10 seconds before the radio transmitter isready to use.

k. The icon will change to a green halo. Radio tracking is now available.

l. Tracking will now be active with the proportional controls on the umbilical control unit

m. To disable tracking simply press button 2 and the halo will disappear (shown in Fig. 5.2).

(Fig. 5.4)

RemoteControlon “1”

Wait forGreenLight toflash

(Fig. 5.5)Transmitter signal strength

Activate Remote



5.3 Initial Setup and Operation

5.3.1 Remove the Loose Items - Located in the Feeder

Before attempting to set-up the machine ensure that the operator has read and fully understood this and all the preceeding sections in the manual.

WARNING

Make sure correct procedures are followed FOR the tasks that are done at height. Falling may cause injury or death. Always use a secure platform.

DANGER

Torque Arm x 2 - required forthe main conveyor

Side ConveyorBelt Troughs

CI411 Litting Tool

Located in ControlPanel Cabinet

Ladder 2 supportLadder 1 support


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5.3.2 Set Up ladder 1 and ladder 2

a. To set up ladder 1 from the transport position, attach the ladder support to the chassis andremove the secure fixings which holds the ladder and the two swing doors together. Secure theladder support to ladder 1 and then swing the ladder down and secure with bolts to the laddersupport.

b. Lossen the bolts and lower of the the last 2 steps section, and then tighten the bolts to secure.

Ladder 1 support

Secure with bolts

Secure with bolts



a. To set up ladder 2 from the transport position, attach the ladder support to the chassis andthen attach the support to ladder 2 with the bolts..

b. Loosen the bolts and lower the last section of steps, then tighten the bolts to secure.

5.3.3 Restarting the engine to activate Auxillary Controls

a. Restart the engine, Refer to “5.2.2 Engine Start-up Sequence” on page 84 and go to themain menu and press button 4 (fig 5.6) to activate Auxiliary function. The siren will soundcontinously when in this menu mode.

b. Wait 10 seconds for the controls to be activated, then the green shadow will appear aroundsymbol.

Ladder 2 support

(Fig 5 6)

Button 4Auxiliary Function

(Fig 5.6)


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5.3.4 Folding the hopper sides

a. Restart the engine, refer to “5.3 Initial Setup and Operation” on page 90.

b. Fold up the left and right hopper sides in turn by operating hydraulic control levers HC1

c. Using a secure platform if needed, an additional supervisor is required to guide the sidehopper props to rest on the support plate.

d. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39

e. Insert locating pins to prop the sides (1 each side) securely in position (see picturebelow )

)

f. Restart the engine, refer to “5.3 Initial Setup and Operation” on page 90. Fold up thehopper rear by operating hydraulic control levers HC1.

g. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39

HC 1

Locating Pin to prop side hoppers

Support Plate



h. Using a secure platform if needed, an additional supervisor can insert the two wedges (asshown in the picture below) to secure the rear hopper in place.

i. Restart the engine, refer to “5.3 Initial Setup and Operation” on page 90.

j. Lower the left and right hoppper sides until their weight is resting on the support plates (referto above), by operating hydraulic control levers HC1.

5.3.5 Unfold the Side Conveyor and fitting the belt troughs

a. Remove the two locating pins holding the rachet torque arm. If necessary adjust the torquearm length to allow the locating pins to be removed. Remove the torque arm and place in a safelocation.

Insert the Wedges

Locating pins

RaquetTorque Arm


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b. Restart the engine and refer to “5.3 Initial Setup and Operation” on page 90 to unfold theside conveyor by operating hydraulic control lever HC2.

c. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39.

d. Remove locating pin from slide stop at the bottom and relocate the slide stop tothe top postion and re-insert locating pins.

e.Restart the engine and refer to “5.3 Initial Setup and Operation” on page 90) tolower the side conveyor onto the slide stop, by operating the hydraulic control leverHC2.

f. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39. . Attach the Belt troughs to the mid section of the sideconveyor.

Slide stop top positionlocating pin

HC2

Attach thisitem first



5.3.6 Unfolding the main conveyor and Positioning into Working Position

a. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39. Attach the Spray Bars for the Main Conveyor.

b. Restart the engine and refer to “5.3 Initial Setup and Operation” on page 90) to unfold themain conveyor, by operating hydraulic control HC5 refer to “4.2.3 Hydraulic Control Banks” onpage 76

c.Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39.

d.Attach the ladder [supplied] into the ladder fix point or use a secure platform toassemble the torque arm to each side and adjust the length to make sure the slack isremoved from the torque arm.

Main Conveyor

Spray Bar

Bolt locations


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e. Remove the ladder and restart the engine and refer to “5.3 Initial Setup and Operation” onpage 90) to raise the Main Conveyor by operating lever 8 until the weight of the main conveyor is offthe locating pins. .

Ladder fix Point

LocatingPin

Torque Arm


Locating Pins



f. Attach the ladder [supplied] into the ladder fix point or use a secure platform.

g. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39.

h. Remove locating pins and remove the ladder

Ladder fix Point

Locating Pins


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i. Restart the engine and refer to “5.3 Initial Setup and Operation” on page 90 to lower themain conveyor down by operating hydraulic lever until the second hole is aligned with the outer boxsection hole.

j. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 39. Attach the ladder [supplied] into the ladder fix point or use asecure platform. Re insert the locating pins, and then remove the ladder.

k. Restart the engine and refer to “5.3 Initial Setup and Operation” on page 90and lower the main conveyor onto the locating pin.


Locating Pins

Second hole



5.3.7 Belt Tension Check during Commissioning

Refer to “ 6.0 Operation” on page 109 to Operate the machine with product for 2~3 hours.

Before inspecting the V Belt Tension

Implement the LOCKOUT and TAG Procedure, refer to “2.6.4 Isolation and energy dissipation” on page 40

Replacing Belt1. Open flywheel guards.

2. Slacken the belt by loosening the locknuts on the torque arm.

3. Remove old belt and place the new belt around the pulleys, taking up slack

with the torque arm, and tightening the locknuts.

4. Close flywheel guards

5. Run the impactor, at low engine speed (rpm) (refer to “5.2.2 Engine Start-

up Sequence” on page 84), only on maintenance for 1 - 2 minutes.

6. Shut down the impactor, refer to “5.5 Machine Shut Down” on page 104.

7. Wait for pulleys to stop

Torque Arm

Locknuts


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8. Implement the LOCKOUT and TAG Procedure, refer to

“2.6.4 Isolation and energy dissipation” on page 40

9. Open flywheel guards

10. Mark the belt on the tight side main span at two points, 1000mm apart.

Tension the belt until the distance between the marks has increased by the

value 7.2mm

11. Tighten the locknuts on the torque arm









18. Remeasure between the two marked points on the belt

19. Adjust belt accordingly (refer to “Adjusting the Belt” below)


21. Close the guards



Adjusting the Belt



1. Open flywheel guards.

2. Take-up slack with the torque arm, and tighten the locknuts.

3. Run the impactor, at a low engine speed (rpm) (refer to “5.2.2 Engine Start-









value 5.3mm











17. Adjust belt accordingly.




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5.3.8 Diverter Chute

The feeder section of the QI240 will separate the smaller sized material away from the material to becrushed. The operator has a choice as to how the QI240 will stockpile this graded material with theuse of the Diverter Chute and Side Conveyor.

When changing the position of the Diverter Chute ALWAYS

a. Implement the Lockout and Tag procedure, refer to “2.6.4 Isolation and energydissipation” on page 39.

b. Make sure that the locking pin on the Diverter chute handle is securely attached.

Postion 1 - All graded material is directed onto the Side Conveyor to be stock piled separately awayfrom the main conveyor stock pile.

Postion 2 - 50% of the graded material is mixed with the crushed material from the impactor travelling on the main conveyor to be stock piled together.


Diverter Chute Handle

Position 1

Position 2

Position 3



5.4 Machine operation

Refer to “6.5 Operating the QI240” on page 116

5.5 Machine Shut Down

It is recommend to operate the QI240 until all material has been removed from the feeder andcrusher chamber and that the conveyors are not producing a stock pile.

5.5.1 Auto Stop Sequence

1. Navigate to the Auto Start Stop menu display. By pressing button 1 on the mainmenu display (see Fig. 5.6)

2. Press button 5 to stop, Fig 5.7

3. The machine will stop the functions of the machine in the correct sequence.

4. Within a preset time the crusher will stop, the engine will ramp down and the mainconveyor will stop.

FLYING MATERIAL HAZARDThere Is Risk Of Serious Injury Or Death Due To Rejected Material.Keep away from the Feeder area and the conveyor belts areas, only full trained and authorised operators in loading the machine and collecting processed material should be in this area.

CRUSH HAZARDThere is Risk of Serious Injury or Death due to Other Heavy Machinery Working In The Area. Keep away from the Feeder area and the conveyor belts areas, only fully trained and authorised operators in loading the machine and collecting processed material should be in this area.

WARNING

Button 5

(Fig. 5.7)


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5.5.2 Preparing the machine for transport or for the machine to be moved to another location

Follow the instructions in “3.1.2 Machine Preparation for Transport” on page 54.



5.5.3 Emergency Stop

In the event of an accident or any serious problem with the machine you should press the nearestemergency stop button, refer to “2.6.1 Use of Emergency stop function” on page 37.

EMERGENCY STOP:

a. Engage the nearest emergency stop, the location of which can be found in thesafety section.

b.Switch off the engine and remove the ignition key.

c. Implement the lockout and tag procedure, refer to “2.6.4 Isolation and energydissipation” on page 39.

d. Only when the machine is fully switched off, should an attempt be made to solve the problem.

RESTART AFTER EMERGENCY STOP:

a. Ensure that the problem has been solved

b. Ensure that all personnel are clear of the machine.

c. Ensure that all safety devices are correctly fitted and fully functional.

d. Release all emergency stops.

e. Re-start the engine in accordance with the correct procedure, refer to “5.2.2 Engine Start-upSequence” on page 84.


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5.6 Location Of Emergency Stops On QI240

There are five Emergency Stops on the QI240 and one Engine Kill Switch on the remote control.




Engine Kill Switch

Umbilical Tracking Lead Engine Kill Switch

Emergency StopReset Button


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qi240


6.0 Operation

Operation qi240

6.1 Operation Safety

Please refer to“ 2.0 Safety Section - Safety and Environmental Instructions” on page 17 of this manual for additional information on safe operation, maintenance and repair of the machine. To ensure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work on the equipment or making any adjustments. Do not attempt operation, maintenance or repair with out first consulting all pertinent safety information.






Implement the LOCKOUT and TAG Procedure, refer to “2.6.4 Isolation and energy dissipation” on page 39.

You must always perform a local risk assessment before starting a task. This assessment, makes sure that you stop and think about what you are going to be doing before you begin work:







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qi240 Operation

6.2 Loading the feeder

Loading the mobile unit correctly is essential in order to achieve adequate material delivery to the crushing chamber. This is extra important when loading large stones.

6.2.1 Avoid damage to equipment

• Always lower the bucket close to the feeder when loading.

• Always load at regular intervals. Always fill up the feeder before it is empty.

• Load mixed sized materials.

• Try to keep the crusher full at all times.

• Adjust the feeder speed if necessary.

• Avoid interruptions, load material at a steady flow.

• Remove the stockpile of crushed material before it reaches discharge conveyor

Never use the bucket to force material into the crusher.Never drop the material from height into the feeder.Accidental contact between bucket and feeder may cause vibrations that can damage the feeder. Never load on the “grizzly” section in the feeder. Ref to fig 1 Never load directly into the crusher.

NOTICE


Operation qi240

WRONG! Too High UP

WRONG! Bucket in contact with feeder CORRECT!

Fig 1

Load from side

WRONG! too Far into feeder

FLYING MATERIAL HAZARDRisk of damage to the machine loading the feeder or personnel Injury of the driver.It may be possible for the impactor to eject material to the rear of the qi240.

It is recommended to load the feeder from the sides only

WARNING


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qi240 Operation


Operation qi240

6.3 Common Applications

6.3.1 Construction, Demolition and recycling

• Concrete / Rebar

• Asphalt

• Bricks

6.3.2 Minerals and Quarrying

• Granite

• Limestone

• Sandstone

• Slate

6.3.3 Maximum Feed size for Crusher

The QI240 may not be modified for use in non-aggregate sorting applications. unauthorized modification of the machine, or use of the QI240 in applications other than indicated applications, will void all warranties provided by the manufacturer. the manufacturer assumes no responsibility for damage to the QI240, or for personal injuries, resulting from use of the QI240 in unauthorized applications. Risks associated with misuse of the QI240 rest exclusively with the end user.

Maximum feed size for crusher = 400mm x 400mm x 400mm [ slab size of 400mm x 250mm x 800mm ]. Feed size larger than the stated values could either jam in the crushing chamber and or cause major feed spillage from the feeder. Refer to “6.4 Feed and Jams” on page 115.

NOTICE


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qi240 Operation

6.4 Feed and Jams

WARNING! Never Feed combustible processing material into the impactor when the impactor chamber is empty, avoid feeding solitary round rocks

Flying fragmentsNever use wedges etc. to clear jams in the feed opening. Stones and fragments can be thrown up at high speed from the impactor chamber

ExplosivesNever remove blocking boulders from the impactor by blasting.Blasting may cause personal injury and seriously damage bearings or other parts. Sandvik takes no responsibility for damage to personnel or to the equipment when blasting is used.

Risk of crushingNever stand inside the impactor when it is blocked or jammed, even if the machine has been stopped. You may be pulled sharply downwards together with the material in the crushing chamber and crushed.

WARNING!

CI411 HSI crushers must never be “choke” fed. It is essential the feed material is fed gradually and evenly across the complete width of the feed hopper / opening.

Changes in feed conditions could require adjustment of the feeding system and or the setting of the Curtains within the crusher. The first curtain should only show signs of compressing the curtain hanger springs intermittently (every few minutes) when at maximum loading.


Operation qi240

6.5 Operating the QI240

Before Commencing general operation it is recommended that the following checks are carried out.

• ENGINE OIL LEVEL (refer to engine manual)

• HYDRAULIC OIL LEVEL (“7.3.1 Hydraulic Oil daily check” on page 148) ( “7.3.5 HPTO Clutch Hydraulic Oil daily check” on page 153)

• DIESEL LEVEL (“7.2.10 Checking Fuel Level, Adding Fuel and Draining fuel tank” on page 144)

• NORMAL DAILY CHECKS (“7.2 Maintenance Schedule” on page 131)

• VISUAL INSPECTION:

1. Ensure that there are no loose bolts and no loose guards and

2. All safety devices such as EMERGENCY STOPS (“2.6.1 Use of Emergencystop function” on page 37) are fully functional

3. Inspect the machine at least once per shift for damaged or defectivecomponents. If any damage is observed, or if the machine exhibits anymalfunction or other unexpected operation, notify management and yourmaintenance department immediately.

6.5.1 Start-up Sequence For Running the Crusher








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qi240 Operation

a. Make sure all Emergency Stops (“2.6.1 Use of Emergency stop function” on page 37) arereleased and that the Engine kill switch on the remote control is also turned off.

b. Turn on the ignition switch (but do not start the engine) and check the following displays areshown respectively (Fig 6.5). It should take a few seconds. If there is a problem it will be shown onthe display.

Button 1 - Auto ModeButton 2 - Tracks ModeButton 3 - Fault LogButton 4 - Customer ParametersButton 5 - Engine ReadingsButton 6 - Maintenance & Service ModeButton 7 - Open Impactor / DC Motor

Fuel Level is also shown on footer as a percentage.

(Fig 6.5)


Operation qi240

6.6 Automatic Run Mode

Select Auto Run by pressing button 1 on the Crusher Run Menu display as shown below. Selecting this option allows the software to utilise pre-determined settings to operate the machine. The auto run display will appear as shown below.

To start automatic Run mode PRESS BUTTON 1

The engine will ramp to clutch engagement speed. Once the speed is eached, a 10 second warning will sound and the clutch will start to engage; when the control system has detected the clutch has engaged the engine will then ramp to the operating speed.

Crusher Auto Run Mode start up

button 1

button 1


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qi240 Operation

After the Engine has reached the operating speed the main conveyor will start after a 10 second warning, then the display will automatically switch to Feeder Control display (Fig. 6.6) . This display enables the operator to select the pre-screen (button 2) and side conveyor (button 3), once the pre-screen is started the Feeder icon (button 5) will flash to indicate to the operator that the Feed Conveyor is now available to start.

The qi240 will now be runinng in Automatic Run Mode, the following adjustments can be made however the operator must perform the following tasks before adjusting the Automatic run mode.



• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal protective equipment” on page 29.)

Button 1 - Auto StopButton 2 - Pre-Screen Start/Stop (10 second pre-start warning)Button 3 - Side Conveyor Start/Stop (10 second pre-start warning)Button 4 - Radio Control On/Off for the FeederButton 5 - Feeder Start/Stop (10 second pre-start warning)Button 6 & 7 - Feeder Speed adjustmentButton 8 - Engine Speed adjustment (adjust engine speed with crusher speed feedback)

When button 5 (Feeder Start/Stop) is pressed the icon will flash. Machine sirens will sound and the beacons will flash for 10 seconds, when time has expired the feeder conveyor will start.

To stop the crusher in Auto Mode - Press button 1 to begin the Auto Stop sequence.The Feed conveyor will stop, followed by the Pre-screen, side conveyor (if enabled), Panfeeder and main conveyor. The engine will then ramp to a set engine speed and the clutch will disengage. During this shutdown sequence there will be intermittent beeping to indicate that the plant is shutting down.

(Fig 6.6)

button 2

button 3

button 5


Operation qi240

6.6.1 MMPRO S menu Flow chart in automatic Run mode

Main�

Menu�

Auto�Start�Stop�

Feeder�Control�Screen�

Feeder�Parameter�Screen�

Unblocking�Screen�

Information�Screen�

Escape� Escape� Escape� Escape�Escape�

Button�1�


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qi240 Operation

6.7 Manual Operating Mode

Manual run gives the operator manual control of startup and shutdown of the machine, but will only allow the functions to be switched on or off in the correct sequence. To access the run mode display press button 1 on the main menu display. The operator can now access the Manual Mode Menu by pressing Button 2.

Button 1 - Crusher Start/StopButton 2 - Pan-Feeder Start/StopButton 3 - Main Conveyor Start

Button 1 icon will be flashing to highlight to the operator that the crusher start function is available. Once selected the engine will automatically go to the present clutch engagement speed,and as soon as this speed is achieved there will be a 10 second warning before enabling the clutch.

Note! Engine speed can not be adjusted when the crusher is in this mode of operation.

When the system has detected that the crusher is engaged, the operator can then continue with the

Manual Mode Menu

button 1

Manual Run ModeButton 2

button 1

button 2

button 3

Back to Run Mode display Forward to Feeder Control display

(Fig 6.7)


Operation qi240

manual start up sequence.

Engine speed buttons will appear giving the operator the option to increase the engine speed and at the same time Button 2 will flash highlighting to the operator that the pre-screen function is available to start. When button 2 is pressed a 10 second warning will sound and then the pre-screen will start.

Once the pre-screen has started, Button 3 will then flash indicating to the operator that the Main Conveyor is ready to be enabled - once selected the 10 second warning will sound until the Main Conveyor starts.

As soon as the Main Conveyor is running and the engine is above minimum speed the menu display will automatically switch to the feeder control display.

6.7.1 Feeder Load ControlThe Feeder Parameter display can accessed from the Feeder Control display by using the left and right buttons.

Button 1 & 2 - Feeder High Load - Set the value for the feeder kick down value.Button 3 - Enable feeder load control systemButton 4 - Sandvik Service Parameter Adjust (Code required)Button 5 & 6 - Feeder Low Load - Set the value for the feeder kick up valueButton 8 - Customer Service Parameter Adjust

Feeder Parameter display

Select right arrow (3) on Feeder Control display

Feeder Control display

(Fig 6.8)


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qi240 Operation

Feeder Load control On/Off (Button 3): When the operator selects this function the control system will regulate the feeder speed in relation with engine load. The load settings can be adjusted by pressing buttons 1 - 2, increasing the load control value and buttons 5 - 6, decreasing the load control value. When the load control is on, the icon will be highlighted in green.

6.7.2 Machine Adjustment

Button 1 - Open Crusher InletButton 2 - Close Crusher InletButton 3 - Open Apron (only available when the feed conveyor is off)Button 4 - Close Apron (only available when the feed conveyor is off)Button 5 - Conveyor Raise (Not available while the machine is in run mode)Button 6 - Conveyor Lower (Not available while the machine is in run mode)Button 7 - Engine Values

Feeder Parameter display

Select right arrow (4) on Feeder Parameter display to access Machine Adjustment display

Machine Adjustment display

(Fig 6.9)


Operation qi240

6.7.3 Tail Level adjustment

Button 3 & 4 will adjust the set point at which the conveyor will stop running when material has reached a certain height from the end of the conveyor.

Note! If the level is set to 200mm, it will disable the function and “OFF” will be displayed on the display.

When button 8 is pressed and the arrows around the icon are green, this will allow the feed conveyor to automatically restart if the material at the level sensor drops below the set point. If arrows around the icon are red, the feed conveyor needs to be manually restarted from the control panel.

Select right arrow (5) on Machine Adjustment display to access Tail Level Adjustment display

Machine Adjustment display

Tail Level Adjustment display

Decrease Set Point

Increase Set Point

Function disabled

Material level at tail conveyor

Feed conveyor automatic restart

(Fig 6.10)


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qi240 Operation

6.7.4 Diverter Chute

The feeder section of the QI240 will separate the smaller sized material away from the material to becrushed. The operator has a choice as to how the QI240 will stockpile this graded material with theuse of the Diverter Chute and Side Conveyor.

When changing the position of the Diverter Chute ALWAYS -

• Implement the Lockout and Tag procedure, refer to “2.6.4 Isolation and energy dissipation” on page 39.

• Make sure that the locking pin on the Diverter chute handle is securely attached.

Postion 1 - All graded material is directed onto the Side Conveyor to be stock piled separately awayfrom the main conveyor stock pile.



Diverter Chute Handle

Position 3

Position 2

Position 1


Operation qi240

6.7.5 Fault Logs

To access fault logs, select button 3 on the main menu.(if required access the main menu by pressing the ESC (Escape) button

This section shows details of faults such as fault number: “xx”, time and date the fault occurred whilethe system was running.

This system records the last 25 faults reported to the machine and the operator is able to scroll through the fault logs by using the Up/Down buttons whilst in this mode.

Faults are automatically highlighted to the operator on the main menu display when they occur with a clear description of the fault so the operator can take action.

To clear the fault message from the display the user must confirm that action has been taken and they can reset the display by pressing the OK button. If the fault is not cleared then the warning will reappear and another entry is recorded in the log.


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qi240 Operation

6.8 Clearing Crusher Chamber Jam’s

6.8.1 Managing Work Related Hazards with a Risk Assessment







Main�

Menu�

Auto�Start�Stop�

Feeder�Control�Screen�

Feeder�Parameter�Screen�

Unblocking�Screen�

Information�Screen�

Escape� Escape� Escape� Escape�Escape�

Button�1�


Operation qi240

Navigate to the unblocking display. Refer to “6.7.2 Machine Adjustment” on page 123

Press button 1 to Open Impactor Inlet Chute

Press button 2 to Close Impactor Inlet Chute

If the above steps do not clear the blockage contact Sandvik.

Button 1

Button 2


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qi240


7.0 Maintenance

Maintenance qi240

7.1 Maintenance Safety

Please refer to“ 2.0 Safety Section - Safety and Environmental Instructions” on page 17 of thismanual for additional information on safe operation, maintenance and repair of the machine. Toensure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work on theequipment or making any adjustments. Do not attempt operation, maintenance or repair with out firstconsulting all pertinent safety information.


• Operators, Maintenance Personnel• Subcontractors and anybody else in the vicinity of the machine






• Assess the hazards to determine what scale of control is required, apply controls to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal protective equipment” on page 29




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qi240 Maintenance

7.2 Maintenance Schedule

Only Trained and Authorised Personnel are allowed to carry out maintenance.

* Daily inspections required in severe environments

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POWERUNIT - Engine

After First 50 Hours Carry Out Full Service onEngine and Hydraulic System

Engine Oil Level - Check

Engine Oil & Filter - Change

Engine Coolant Level - Check

Engine Air Filter and Pre-Cleaner - Check *

Air Filter Element - Change (More Frequent IfRequired) Change Safety Cartridge Every 3rdTime *

Fuel Water Trap System - Drain *

Engine Fuel Filters - Change (More Frequent IfRequired)

Battery Fluid Level and Terminal - Check

See Engine Manual for Other Maintenance

POWERUNIT - Hydraulics

Hydraulic Oil - Check Level

Hydraulic Tank Breather- Check/Change *

Hydraulic Oil - Check Temperature (Max 70oC)

Hydraulic Oil Condition Test - Check

Hydraulic Oil – Replace (Or As Needed)

Hydraulic Hoses and Component - Check

Hydraulic Return Line Filter - Change

Fluid Clutch Oil - Change

Fluid Clutch Filter - Change

Fluid Clutch Oil - Check Level


Maintenance qi240

* Refer to “7.2.2 Belt Tension” on page 135** Refer to “7.5.6 Greasing Schedule” on page 164

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CRUSHER

V-Belt Tension - During Initial commissioning Check [ after 2~3 hours with material ] *

V-Belt Tension - Check

Check Tightness of Hammers Daily During First40hrs Operation. Then Weekly.

Check Crushing Chamber Wear

Lubricate Crusher Shaft Bearings ** and read NOTICE below

Check Tension and Idler Pulleys - Alignment

See Crusher Manual for Other Maintenance

FEEDER

Levelness of Feeder When Running (See Manual)

Vibration Unit - Check Oil Level

Vibration Unit - Change Oil (After 1st 100 hrs)

Vibration Unit - Check Breather

Liner Plates & General Condition

See Feeder Manual for Other Maintenance

CONVEYORS

Belt Alignment and Condition - Check

Belt Tension - Check

Skirting and Scraper Rubber Condition - Check

Drive and Tail Drum Bearings - Grease **

Rollers - Check

Overband Magnet Unit Included

DAMAGE to the Impactor will occur if the wrong grease specification is used inautolube systems. If the autolube option is fitted to the qi240, the greasespecified for the CI411 impactor MUST BE USED in the Autolube system.Refer to “7.5.5 Lubricants and Fluids” on page 163 for the correctspecification.

NOTICE


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qi240 Maintenance

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PRE SCREEN

Screen Mesh Tension

Screen Mesh Wear

Screen Tuning - Inspect

Screen Springs - Inspect

Top Deck and Hardox Bolts

Check wear on bottom deck Rubber

Screen Chutes

Screen Bearing - Grease **

PAN FEEDER

Levelness of Feeder When Running (See Manual)

Liner Plates & General Condition

Lubricate Feeder Mechanism Bearings **

See Pan Feeder Manual for other Maintenance

HPTO CLUTCH

Check Oil Level

Check Breather for clogs or obstructions

Check Ventilation holes in bellhousing for clogs or obstructions

Replace system Oil and Oil Filter

Replace the breather on top of the HPTO housing

Oil sample analysis

Every 5000 hours Internally inspect and service Refer to HPTO manual in OEM Chapter

GENERAL

Wear Rubber - Check

Replace Gearbox Oil on New Machines 100 Hours

Check Tension on Track Chains, Tightness onTrack Bolts & Gearbox Oil Levels

Replace Gearbox Oil

General Guard Condition and Effectiveness - Check

** Refer to “7.5.6 Greasing Schedule” on page 164


Maintenance qi240

7.2.1 Testing the Emergency stop function and Battery Isolator

There are five Emergency-Stops on the qi240. Check that each Emergency stop is operating correctlyat the start of each day of work when the machine is empty.

Check that the Isolator when engaged isolats the battery.If any Emergency stop or isolator fails to work correctly, DO NOT allow the machine to be operationalthese faulty items must be repaired before satrt up of machie.


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qi240 Maintenance

7.2.2 Belt Tension



Replacing Belt1. Open flywheel guards.

2. Slacken the belt by loosening the locknuts on the torque arm.

3. Remove old belt and place the new belt around the pulleys, taking up slack

with the torque arm, and tightening the locknuts.


5. Run the impactor in maintenance mode for 1 - 2 minutes, at low engine

speed (rpm) (refer to “5.2.2 Engine Start-up Sequence” on page 84)(refer

to “6.7 Manual Operating Mode” on page 121.


7. Wait for pulleys to stop rotating

Torque Arm

Locknuts


Maintenance qi240






value 7.2mm.






15. Wait for pulleys to stop rotating





19. Adjust belt accordingly (refer to “Adjusting the Belt” below)




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qi240 Maintenance

Adjusting the Belt




2. Take-up slack with the torque arm, and tighten the locknuts.










value 5.3mm











17. Adjust belt accordingly.




Maintenance qi240

7.2.3 Maintenace to the CI411 Impactor using DC Maintenance Motor

Refer to the OEM section of this manual for the detailed instruction for the maintenace of the CI411impactor. The QI240 has a DC Maintenance Motor fitted to allow impactor maintenance with theEngine turned off.

To activate the DC motora. Turn the ignition key to the control panel power on position.

b. Make sure all Emergency stops are working correctly

c. Remove Safety Key Switch from the chamber switch

d. This will engage the mechanical timelock on the CI411 impactor. This timelockprevents the impactor from being opened for pre determinded time period forsafety reasons. Refer to the CI411 manuals for futher information.

e. Turn the ignition key to power off postion

f. Turn the ignition key to the control panel power on position.

g. A display message should appear “ Chamber Opened “

h. Button 7 on the main menu will now have a icon of the impactor

Control panel power on

Chamber Switch


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qi240 Maintenance

i. Press button 7 to Enable or Dis-able the maintenance motor. A Green Halo willappear when the function is enabled.

j. The DC pump can be directly operated by the two push buttons mounted on themachine.

k. Remember this function will not work until the mechanical timelock has expired.Refer to d) above.

l. Once Maintenance has been completed return the Safety key switch.


Maintenance qi240

7.2.4 Engine Maintenance

When you purchased your QI240 you will have been provided with an accompanying OperationManual for the engine. If for any reason you were not supplied with an engine manual or if you havelost it please contact your local dealer to arrange replacement.

Please refer to the Engine Maintenance Manual in order to carry out the following important areas ofEngine Maintenance.

• Changing The Fuel Filter• Checking Engine Oil Level• Changing Engine Oil• Changing Engine Oil Filter• Cleaning/Replacing The Air Cleaner• Cleaning/Replacing The Air Cleaner Elements

7.2.5 Radio Remote Control battery Charging

a. Remove the battery and install it into the recharge unit.

b. Connect the recharge unit as shown.

c. Press ‘CHARGE’ or ‘FAST CHARGE’ when the LED is green on ‘READY’ thebattery charge cycle is complete.

d. Put the recharge unit in the support as shown

SAFETY HAZARDRisk of personnel Injury and or Damage to the Engine.No Engine Maintenance should be attempted before fully reading and understanding the accompanying engine Maintenance Manual.

WARNING


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qi240 Maintenance

7.2.6 Working at height hazard

7.2.7 Air Cleaner Inspection, Daily Inspection Required

1. Use a secure platform Inspection refer to “7.2.6 Working at height hazard” onpage 141 and inspect the indicator.

2. Follow the instructions on the indicator. If Air Cleaner maintenance is required,Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 40.

3. Use a secure platform and follow the instructions in “7.2.8 Air CleanerMaintenance” on page 142.

WORKING AT HEIGHT HAZARDMake sure correct procedures are followed FOR the tasks that are done at height. Falling may cause injury or death. Always use a secure platform.

DANGER


Maintenance qi240

7.2.8 Air Cleaner Maintenance

Breathing or inhaling dust particles will cause death or severe injury. Always work with a respiratorapproved by the respirator manufacturer for the job you are doing. It is essential that the respiratorthat you use protects you from the tiny dust particles which cause silicosis and which may causeother serious lung diseases. You should not use the product until you are sure your respirator isworking properly. This means the respirator must be checked to make sure that it is clean, that itsfilter has been changed, and to otherwise make sure the respirator will protect you in the way it ismeant to. Refer to “2.7.3 Dust” on page 44.

a. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 40.

b. Wear the correct Personal Protective Equipment (refer to “2.2.3 Personalprotective equipment” on page 29).

c. Use a secure platform to access the air filter.

d. Remove the access cover using the retension latches

e. Remove the Primary Air Filter and any excess dust

f. Insert new Primary Filter

g. Also inspect the Safety Filter and replace if necessary

h. Re fit the access cover and secure with retension latches.

DANGER

NOTICE DO NOT USE compressed air to clean the filter elements or filter body.DAMAGE to the engine will result.

Access Cover

Primary Filter Safety Filter

Retentation latches


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qi240 Maintenance

7.2.9 Battery Maintenance

It is recommended that the batterries should be inspected on a weekly basis.

a. Maintain Water Level. If your battery has removable vent caps, you should regularly check thewater level and add water when it is low. Always use distilled water to fill the battery in order toprevent chemicals from contaminating the battery. Be careful not to overfill the vent wells. The fluidshould cover the lead plates in the battery.

b. Keep Terminals Clean. If dirty or corroded, clean the connections with a scraper and wirebrush.

c. Keep Battery case clean. Keep the top of the battery clean of heavy dirt and oil.

SAFETY HAZARD

Battery contains corrosive chemicals and stored electrical energy.

Before carrying out any maintenance on the battery, stop the Engine, disconnect the Ground Cable (-), then disconnect the Positive Cable (+).Wear the correct Personal Protective Equipment, refer to “2.2.3 Personal protective equipment” on page 29.

WARNING


Maintenance qi240

7.2.10 Checking Fuel Level, Adding Fuel and Draining fuel tank

Checking Fuel -The fuel level of the machine can be checked by viewing the Control Panel displayguage. It is recommended that the tank should be filled at the end of every working day.

Adding Fuel:

a. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 40.

b. The tank is filled by removing the filler cap, funnelling in the fuel until the indicator“I” is at its highest level and replacing the filler cap.

Refer to “2.9 Safety considerations for maintenance” on page 46 for more information.

Draining the Fuel Tank:

Note! the diesel tank capacity is approx 660 litres.

a. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy

dissipation” on page 40

b. Remove the filler cap, select a suitable container which can store 660 litres of fuel

and place it under the Drain Bung.

c. Remove the Drain Bung and allow the tank to fully empty.

FLAMEABLE LIQUID HAZARD

Fuel is flammable and therefore is easily ignited and fires or explosions can result.

Smoking and Welding is strictly prohibited while refuelling.

Wear the correct Personal Protective Equipment, refer to “2.2.3 Personal protective equipment” on page 29.

WARNING

Drain bung

I

Filler Cap


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qi240 Maintenance

d. Perform any required maintenance on the tank and replace the drain bung beforerefuelling and replace the filler cap.

7.2.11 Emptying the Fuel Filter Water Trap

a. Unscrew the drain bung at the bottom of the water trap and allow the water todrain out.Ensure that the water in drained into a suitable container.

b. Tighten the drain bung when pure diesel starts to come out.

c. Dispose of waste in accordance with Environmental statement.

Water trap

FLAMEABLE LIQUID HAZARD.

Liquid likely to start a fire if exposed to sparks.

Restrict all other activity until liquid is secured in a suitable container, referto “2.9 Safety considerations for maintenance” on page 46.

WARNING

CHEMICAL HAZARDDiesel fuel is a chemical which should not contact your skin.Wear the correct Personal Protective Equipment, refer to “2.2.3 Personal protective equipment” on page 29.

WARNING


Maintenance qi240

7.2.12 Special Considerations For Maintenance Or Repair with WeldingBefore welding;Refer to the CI411 maintance manual for welding operations of the CI411 Impactor



• Assess the hazards to determine what scale of control is required (apply controls to manage the risk.)


• Disconnect LCD plug from the back of the Main Control Panel (See Photo below).

• Implement the Lock out and Tag Procedure, refer to “2.6.4 Isolation and energy dissipation” on page 40

LCD

ISOLATOR


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qi240 Maintenance

7.3 Hydraulic System

It is essential the Hydraulic System is regularly serviced in accordance withthe Maintenance Schedule. When Maintenance is being carried out on thehydraulics it is essential that extreme care regarding cleanliness ispracticed. Contamination of the hydraulic System will reduce working life ofhydraulic components and will increase the chances of Hydraulic Motor/Pump Failure

NOTICE

SKIN INJECTION HAZARD

Hydraulic fluid at high pressure can penetrate the skin, causing serious allergic reaction and even death.

Always use a piece of cardboard to inspect for the signs of suspected leaks. Never use any part of your body.If fluid is injected into the skin, you must seek medical treatment immediately.

WARNING

FLUID AT HIGH PRESSSURE HAZARD

Hydraulic fluid at high pressure can penetrate the skin, causing serious allergic reaction and even death.

Always relieve the hydraulic pressure of the system after shutting the machine down and before starting maintenance work on the hydraulic system.

If fluid is injected into the skin, you must seek medical treatment immediately.

WARNING

Wear the correct Personal Protective Equipment, refer to “2.2.3 Personalprotective equipment” on page 29, when performing any adjustment ormaintenance on the Hydraulic System.

WARNING


Maintenance qi240

7.3.1 Hydraulic Oil daily check

The hydraulic oil level must be checked on a daily basis. This is done by checking the indicator. If theindicator is below the Lower Black Line, hydraulic oil must be added.

Indicator


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qi240 Maintenance

7.3.2 Hydraulic Oil is added as follows

a. All cylinders that can be retracted should be retracted. Make sure that themachine is on level ground

b. Implement the Lock out and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 40. Wear the correct Personal Protective Equipment,refer to “2.2.3 Personal protective equipment” on page 29.

c. Slowly unscrew Hydraulic Breather Filter (HT1) to release any build up of pressurein the tank.

d. Make sure that the Return Line Filters (HT2), and the area around the return linefilters, are clean. If there is dust or dirt present, use a clean cloth to remove.

e. Loosen the filter cover bolts, the cover of the Return Line Filter will start to riseupwards , to remove the cover push back down and turn the cover. Hydraulic oilmust be added through the uncovered Return Line Filter, to make sure thehydraulic oil is filtered on entering the tank.

f. Fill the tank to the Upper black markings on HT3. Make sure that the correct gradeof Hydraulic Oil has been selected (“7.5.3 Hydraulic Oil Requirements for QI240Machines” on page 162)

HT1

HT2

Return line filter coverFilter cover bolts

HT3


Maintenance qi240

7.3.3 Changing The Return Line Filter

a. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 40. Wear the correct Personal Protective Equipment(refer to “2.2.3 Personal protective equipment” on page 29).

b. Slowly unscrew Hydraulic Breather Filter (HT1) to release any build up of pressurein the tank.

c. Make sure that the Return Line Filters (HT2), and the area around the return linefilters, are clean. Use a clean cloth to clean with if there is dust or dirt present.

d. Loosen the filter cover bolts, the cover of the Return Line Filter will start to riseupwards , to remove the cover push back down and turn the cover.

e. Lift out the filter element using the lifting handles.

f. Wash out the filter cover and dry with an air hose.

g. Re-fit the new filter.

h. Replace cover and tighten bolts.

i. Re-attach the Hydraulic Breather Filter OR replace if necessary.

Return line filter coverFilter cover bolts

Lifting handles

Filter Element

SKIN INJECTION HAZARD

Fluid at high pressure can penetrate the skin, causing serious allergic reaction and even death.


If fluid is injected into the skin, you must seek medical treatment immediately.

WARNING


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qi240 Maintenance

7.3.4 Changing The Suction Filters and the Hydraulic Oil.

a. All cylinders that can be retracted should be retracted.

b. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 40.


(The Hydraulic system will drain more efficiently when the Hydraulic Oil is at a normaloperating temperature. It is therefore recommended that the Hydraulic Oil is changedfollowing a period of operation.)

c. Slowly unscrew the Hydraulic Breather Cap HT1 to release any build up ofpressure in the tank.

Note! The Hydraulic Oil Tank capacity is approx. 660 Litres.

d. Drain the oil into a suitable container by removing the Drain Bungs located underthe tank. Dispose of waste in accordance to environmental statement.

e. Remove the tank inspection plates.

In the event of hydraulic pump or hydraulic motor failure, hydraulic oil andall hydraulic filters must be replaced in order to avoid contamination of thehydraulic system.

NOTICENOTICE

HT1

HT3Drain Bungs

Inspection Plates


Maintenance qi240

f. Unscrew and remove the Suction Filters

g. It is recommended that the Hydraulic Tank be flushed out with clean Hydraulic Oilto rid the tank of all contaminants. Dispose of waste in accordance toenvironmental statement.

h. Re ffit the drain bungs and Fit new Suction Filters.

i. Re-attach the tank inspection plates.

j. Change Return Line Filter Element. Refer to “7.3.3 Changing The Return LineFilter” on page 150.

k. Re-fill the tank with clean Hydraulic Oil between the upper and lower black lineson HT3.

l. Re-attach the Hydraulic Breather Filter HT1.

m. Start the machine and after a short period of operation re-check the hydraulic oillevel, refer to “7.3.1 Hydraulic Oil daily check” on page 148.

Suctionfilters

qty 3


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qi240 Maintenance

7.3.5 HPTO Clutch Hydraulic Oil daily check

The hydraulic oil level must be checked on a daily basis. This is done by checking the indicator. If theindicator is below the Lower Black Line, hydraulic oil must be added.

7.3.6 HPTO Clutch adding hydraulic oil

a. Implement the Lock out and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 40. Wear the correct Personal Protective Equipment,refer to “2.2.3 Personal protective equipment” on page 29.

b. Make sure the area around the tank cover plate is clean. Remove the fixings andthe tank cover plate and add the required quantity of new HPTO clutch oil. Referto “7.5.4 Hydraulic Oil Requirements for HPTO Clutch” on page 163.

c. Replace the tank cover plate and secure the fixings.

7.3.7 HPTO CLutch Lubrication tank Suction Filter change


b. Make sure the area around the tank cover plate is clean. Remove the fixings andthe tank cover plate.

c. Drain the oil into a suitable container by removing the Drain Bungs located underthe tank. Dispose of waste in accordance to environmental statement.

Note! The HPTO Clutch Hydraulic Oil Tank capacity is approx. 80 Litres.

d. It is recommended that the Hydraulic Tank be flushed out with clean Hydraulic Oilto rid the tank of all contaminants. Dispose of waste in accordance toenvironmental statement.

e. Screw off the old suction filter and replace with a new suction filter.

f. and add the required quantity of new HPTO clutch oil. Refer to “7.5.4 Hydraulic OilRequirements for HPTO Clutch” on page 163.

g. Replace the tank cover plate and secure the fixings.

Indicator

tank cover plate


Maintenance qi240

7.3.8 HPTO Oil filter Replacement


b. Make sure the area around the filter is clean.

c. Place a suitable container under the filter to catch any oil spillage.

d. Twist the old filter off and dispose of waste in accordance to environmentalstatement.

e. Twist on the new filter.

f. Restart the engine, Refer to “5.2.2 Engine Start-up Sequence” on page 84 andlet the engine idle for 5 minutes to allow the filter ti fill.

g. The oil pressure will fall slight until the filter has re-filled.


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qi240 Maintenance

7.4 Track Maintenance

ALWAYS1. Park the machine on flat, level ground. If it is necessary to park the machine on a

gradient, the tracks should be solidly blocked.

2. Make sure the terrain the machine is working on is firm enough to adequatelysupport the machine.

3. Make certain the machine is tracked at least 10m in either direction on adaily basis to minimise the risk of track chain seizure.

4. Make sure the track systems are free from debris before moving the machine.

5. Make certain the tracks are not frozen to the ground before moving the machine.

NEVER1. Attempt to track the machine if there is any build up of material around the tracks

and drivesprockets.

2. Attempt to track the machine if the tracks are frozen to the ground.

3. Push or tow the machine when unable to free itself.

Working ConditionsIf your machine will be working in materials which cause corrosion to carbon steel you must replacestandard tracks with lubricated tracks to avoid seizure of the track joints. Lubricated tracks areavailable as an optional extra from new or as a retrofit for customers entering adverse workingconditions.Contact Sandvik Mining and Construction Mobile Crushers and Screens Ltd.

7.4.1 Checking the Track Tension

a. Track the QI240 a minimum of 2 metres in a forward direction on level ground.

b. Implement the Lock Out and Tag Procedure, refer to“2.6.4 Isolation and energydissipation” on page 40.

c. Measure the sag on the top part of the track on the longest section unsupportedtrack as shown.

d. The sag should be between 5mm and 15mm.

e. IF the measured track sag is above 15mm the tracks need tightened; and if thetrack sag is below 5mm the tracks need loosened.

Track Cover PlateTrack Sag

Cover Plate


Maintenance qi240

7.4.2 Tighten the Tracks

a. implement the Lock Out and Tag Procedure, refer to“2.6.4 Isolation and energydissipation” on page 40. Loosen the two screws and remove the aperture coverfrom the side of the track frame.

b. Ensure the grease fitting and grease gun adaptor are clean; ingress of dirt into thegrease fitting can result in failure.

c. Connect a grease gun to the grease fitting and add grease until the track tensionis within the specified values given in the previous section.

d. Drive 50 metres forward and 50 metres backwards and repeat the aboveprocedure if the track slackens.

e. Replace the aperture cover.

7.4.3 Loosen the Tracks

a. Implement the Lock Out and Tag Procedure, refer to“2.6.4 Isolation and energydissipation” on page 40. Loosen the two screws and remove the aperture coverfrom the side of the track frame.

b. Loosen the grease fitting, by turning in an anti-clockwise direction, using gradualincrements until the grease begins to be expelled.

c. Care must be taken not to loosen the grease fitting too quickly.

d. When the correct track tension has been obtained, tighten the grease fitting byturning in a clockwise direction and clean away all traces of extruded grease. Besure not to overtighten the grease fitting.

e. Replace the aperture cover.

If tracks fail to loosen after the grease fitting has been loosened: DO NOT attempt to remove the tracks or disassemble the track tensioner. It is possible that running the tracks a short distance in both directions with the grease fittingloosened may help to expel the grease.


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7.4.4 Track Drive Units

The first oil replacement for the gearbox is to be carried out after 100 hrs. Thereafter replace the oilevery 1000 hrs or at least once a year. The oil level should be checked every 250 hrs or every month – whichever comes first.

a. Oil Filling

• To fill, track the machine until the gearbox casing is level with a plug positioned at12 o’clock as shown below.

• Implement the Lock Out and Tag Procedure, refer to“2.6.4 Isolation and energy dissipation” on page 40.

• Unscrew the 2 plugs and fill from the upper plug until oil reaches the level of the lower hole.

b. Oil Draining

• Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy dissipation” on page 39.

• To drain, track the machine until a plug is at 6 o’clock position as shown below.

• Unscrew both plugs and allow all oil to discharge into a suitable container. Dispose of waste oil in a safe approved way.

Oil Level

Maximum Level

Ventingl

Drain Portl


Maintenance qi240

7.5 Tensioning the Side Conveyor Belt

Before tensioning the belts ensure that they are free from obstructions and that any excess materialis removed. If any rips/tears are discovered do not operate the machine until the belt has beenrepaired.

1. Implement the LOCKOUT and TAG PROCEDURE, refer to “2.6.4 Isolation andenergy dissipation” on page 40.

2. Loosen bearing bolts on both bearings of the idler drum just enough to allowmovement for adjustment.

3. Start the engine and start the conveyor (“6.5.1 Start-up Sequence For Running theCrusher” on page 116).

4. Tighten both belt adjusters evenly until the required belt tension is obtained.

5. Implement the LOCKOUT and TAG PROCEDURE refer to“2.6.4 Isolation andenergy dissipation” on page 40.Re-tighten the bearing bolts..

NIP POINT HAZARD Conveyor belt tension can only be VISUALLY checked with the conveyor belt running. Adjustment of conveyor belt tension should only be attempted by trained and authorised personnel. If you have any concerns regarding training on the procedure, or the performance of the adjustments themselves, contact your distributor or the manufacturer. DO NOT attempt to adjust conveyor belt tension without first undertaking proper instruction and/or obtaining adequate supervision.

WARNING

Adjuster

Bearing Bolts


ID:QI240.en.ver.2

qi240 Maintenance

7.5.1 Tensioning The Main Conveyor belt

Before tensioning the belts ensure that they are free from obstructions and that any excess materialis washed away. If any rips/tears are discovered do not operate the machine until the belt has beenrepaired.

1. implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energydissipation” on page 40

2. Use a secure platform, refer to “7.2.6 Working at height hazard” on page 141, toloosen locknut ‘b’ on the left and right hand sides.

3. Tighten the belt by adjusting both belt adjusters ‘a’ (one on right and left handside) evenly.

4. Re-Tighten locknut ‘b’ (one on right and left hand side).

5. Start the engine and start the conveyor. (“6.5.1 Start-up Sequence For Runningthe Crusher” on page 116)

6. Inspect the tension of the belt and if more tension is required repeat steps

1. to 6. as necessary.

NIP POINT HAZARD

Conveyor belt tension can only be VISUALLY checked with the conveyorbelt running. Adjustment of conveyor belt tension should only beattempted by trained and authorised personnel. If you have any concernsregarding training on the procedure, or the performance of theadjustments themselves, contact your distributor or the manufacturer.

DO NOT attempt to adjust conveyor belt tension without first undertaking proper instruction and/or obtaining adequate supervision.

WARNING

Locknut BAdjuster A


Maintenance qi240

7.5.2 Tracking the Conveyor Belts

There are several factors that can have an effect on the tracking of the conveyor belts:• Misalignment of trough roller sets,• Misalignment of return rollers• AND / OR incorrectly adjusted Drum Bearings.

Conveyor Plan View Conveyor Section View

If a conveyor belt is tracking off to the left or right the situation shouldbe remedied immediately. If action isn’t taken the belt life will beshortened and through put wont be as efficient due to spillage.

NOTICE

WORKING AT HEIGHT HAZARDMake sure correct procedures are followed FOR the tasks that are done at height. Falling may cause injury or death. Always use a secure platform.

DANGER


ID:QI240.en.ver.2

qi240 Maintenance

Required Action;

1. Implement the Lockout and Tag Procedure, refer to“2.6.4 Isolation and energy

dissipation” on page 40.

2. Check alignment of the trough sets and return rollers and make sure that they aremounted at 90 Degrees to the conveyor frame about the central axis.

3. Run appropriate conveyor and observe the way the belt is tracking.

IF THE BELT IS TRACKING TO THE LEFT ADJUST THE LEFT ADJUSTER. IF THE BELT ISTRACKING TO THE RIGHT ADJUST THE RIGHT ADJUSTER.

4. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy

dissipation” on page 40.

5. Remove the appropriate conveyor guards if applicable.

6. Loosen the appropriate bearing bolts.

7. Re- fit and secure the guard if applicable.

8. Adjust the bearing drum adjuster.

9. Restart the machine and run the conveyor inspect the tracking of the belt.

10. If more adjustment is required repeat steps 4. to 10.

11. Implement the Systems Immobilisation Procedure, refer to “2.6.4 Isolation andenergy dissipation” on page 39.

12. Remove the guard and re-tighten the bearing bolts.

13. Re- fit and secure the guard.

NIP POINT HAZARD

Conveyor belt tracking can only be visually checked with the conveyor belt running.

Adjustment of conveyor belt tracking should only be attempted by trained and authorised personnel. If you have any concerns regarding training on the procedure, or the performance of the adjustments themselves, contact your distributor or the manufacturer.

DO NOT attempt to adjust conveyor belt tracking without first undertaking proper instruction and/or obtaining adequate supervision.

WARNING


Maintenance qi240

7.5.3 Hydraulic Oil Requirements for QI240 Machines

a. Basic Requirements for the Hydraulic Oil Quality

• Viscosity recommended operating range – 12-60 cSt.• Min. viscosity 12 cSt at operating temperature.• Max. viscosity 1000 cSt at starting temperature (Intermittent).• Cleanliness level - ISO 4406 Class 22/18/13

Unless otherwise mentioned, the factory fill oil is a special hydraulic oil of ISO VG 46 class. Themaximum recommended operating temperature with this oil type is about +80°C (175°F) andminimum recommended starting temperature is about -20°C(-5°F), which makes it suitable for useall year round in most operating conditions. Below are some examples of oil brands meeting theserequirements:

• Maxol Multivis 46• BP Energol SHF 46• Esso Univis N 46• Shell Tellus Oil T 46• Mobil DTE 15

b. Winter Conditions.

In cold climate conditions, when the operating temperature of the oil stays below +60°C (140°F), theuse of a special hydraulic oil of ISO VG 32 class is recommended the max.allowable operatingtemperature with this oil type is about +65°C (150°F) and min. allowable starting temperature isabout -30°C (-20°F). Below are some examples of oil brands meeting these requirements:

• Maxol Multivis 32• BP Energol SHF 32• Esso Univis N 32• Mobil DTE 13• Shell Tellus Oil T 32

c. Summer Conditions.

In hot climate conditions, when the ambient temperature exceeds + 35°C (95°F), the use of a specialhydraulic oil of ISO VG 68 class is recommended. The max. allowable operating temperature withthis oil type is about +90°C (195°F) and min. allowable starting temperature is about -10°C (14°F).Below are some examples of oil brands meeting these requirements:

• Maxol Multivis 68• BP Energol SHF 68• Mobil DTE 16


ID:QI240.en.ver.2

qi240 Maintenance

7.5.4 Hydraulic Oil Requirements for HPTO Clutch

7.5.5 Lubricants and Fluids

Note! Fluid Clutch oil grade SAE 30 only to be used when oil temp never goes below 0 degrees.

Below 32° F (0° C) Above 32° F (0° C)

Mobilfluid LT Mobilfluid 424 - PREFERRED CHOICE

Caterpillar TDTO (10W ONLY) Caterpillar TDTO (SAE 30 ONLY)

Shell Donax TD Low Vis Shell Donax TD (TD ONLY)

ESSO Hydraul 50 ESSO Hydraul 56

Vermeer VMF Ultra Gold

COMPONENTINTERNATIONAL

SPEC SAMPLE

CAT ENGINE CAT CH4 (15W40) CAT CH4 DEO

CAT Anti-Freeze CAT EC-1 CAT ELC

General Grease Lithium EP2 Shell Alvania EP2

Track Gearbox SAE 80W-90 (GLS) Shell 80W/90

Primary Feeder ISO VG 220 Shell omala Oil 220

Pan Feeder Contact Sandvik Mobil Unirex N3 NLGI3

Fluid ClutchSAE 30 Caterpillar TDTO (SAE 30

ONLY)

Impactor CI4112 Contact Sandvik Castrol Optimol PD2

Drive Belt System - Idler Drum

Contact Sandvik Mobil Unirex N3 NLGI3

Using any fluid other than the approved oil may significantly affect theperformance and function of the HPTO unit and may void warranty.

NOTICE


Maintenance qi240

7.5.6 Greasing Schedule

The frequency of the schedule above is recommend for normal working conditions. The frequencyshould change if the machine is operating in

• conditions which deviate in temperatures,

• environments with excessive contamination

• excessive operating temperatures

Visually inspect all bearings daily.

Description FrequencyNumber of bearings

Quantity of Grease

1 - Side Conveyor 250 hours 4 7

2 - Impactor RH/LH

a) Curtain Pivot Points Rh/Lh

250 Hours 2 7g

b) Shaft Bearings Rh/Lh 40 Hours 1 44g

3 - Pre Screen 40 2 16

4 - Pan Feeder 100 4 7

5 - Main Conveyor 250 4 7

6 - Overband Magnet 250 4 7

7 - Drive Belt Pulley

a) Tension Pulley (Drum) 40 Hours 2 3g

b) Tension bracket pivot bearings

250 Hours 2 7g

c) Idler Pulley 40 Hours 2 3g


ID:QI240.en.ver.2

qi240 Maintenance

34 2

6

12 - located behind guard

3

5

6

Grease Point 7 a

b c


Maintenance qi240

7.5.7 Care of chrome

The following information should be used in order to maximise the life of the Chrome Rods. Allhydraulic rods must be greased to protect against corrosion.A full protective coverage of the chromeis required.

The grease must be applied at the following stages:• Assembly• Before Storage and Transportation• After Initial Setup• Every 100 Hours thereafter (the responsibility of the customer)

The greases below are recommended by the manufacturer: 1. Cazar K Adhesive Water Resistant Grease

2. Shell Alvania Grease Wk2

CleaningNitric Solvent (without Chlorate) is recommended in necessary cleaning of Chrome. The use ofanything else may harm or reduce the protection of the chrome.

Implement the lock out and tag procedure, refer to “2.6.4 Isolation and energy dissipation” on page 40, before starting this operation.

Only clean the chrome if contaminated*

SAFETY HAZARDNitric Solvents contains corrosive chemicals.Do not allow contact with any exposed body parts.


WARNING


ID:QI240.en.ver.2

qi240


8.0 Trouble Shooting and Engine Warranty

Trouble Shooting qi240

8.1 Trouble Shooting Safety

Please refer to“ 2.0 Safety Section - Safety and Environmental Instructions” on page 17 of this manual for additional information on safe operation, maintenance and repair of the machine. To ensure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work on the equipment or making any adjustments. Do not attempt operation, maintenance or repair with out first consulting all pertinent safety information.














ID:QI240.en.ver.2

qi240 Trouble Shooting

8.1.4 Using the Proportional Spool Valve System (PSVS) controls to Diagnose Hydraulic or Electrical Faults

OverviewThe function of the PSVS controls is to receive electrical commands from the Control panel andthen the PSVS controls will operate the hydraulic control levers. This allows the operator todiagnose non responsive commands from the Control Panel.The PSVS levers are self returning, so if a constant function is required then the correspondinglever needs to be manually held in position for the same duration. Once the lever is released theflow of hydraulic oil to the function is stopped.

8.1.5 Service Engineer Selection for PSVS DiagnosisThe use of the PSVS controls is ONLY Permitted by trained and authorised Service Engineers.

8.1.6 PSVS Diagnosis for Hydraulic or Electrical FaultsIf a desired function is not operating e.g. the main conveyor will not start from the Control Panel,check for movement of the relative PSVS control lever, no movement indicates a initial electricalfault. If the PSVS control lever moves and the function does not work, then the fault is hydraulicrelated. Alternatively manually operate the corresponding lever as shown below. If the Mainconveyor STARTS then the fault is electrical related.

Note! The levers for the hydraulic controls have been removed and are stored in the toolbox.They are easily attached and they should be removed before the machine is allowed toreturn to normal operation.

RANDOM OPERATION OF MACHINERY HAZARDHazard from random operation of machine components such as flying material from conveyors or crushing chambers, crushing from movements of the tracks, nip and entrapment hazard as conveyor may start at random.The PSVS controls MUST not be used to commission or operate the machine.When using the PSVS controls ONLY SERVICE PERSONNEL should be in the area of the machine.

WARNING

PSVS

7 8 9 10 11 12 13

12

3456



* Auxillary power for folding unfolding the side conveyor, operating the left, right and rear hopper sides. If the Control panel does not operate these functions, then a second person is required to maintain this hydraulic lever in the down postion, and then the Hydraulic control of the desired function is operated. Refer to “4.2.3 Hydraulic Control Banks” on page 76.

Hydraulic Oil Cooler Fan Forward

LH Track forward

Main Conveyor

ON

Dirt Conveyor ON

Impactor Inlet Raise

Primary Feeder ON

1 2 3 4 5 6

Hydraulic Oil Cooler Fan Reverse

LH Track backward

- - Impactor Inlet Lower

-

Top Apron Open

Main Conveyor Raise

UnderPan Feeder ON

PreScreen ON

Recirculation Screen ON

RH Track forward

Jack Legs

7 8 9 10 11 12 13

Top Apron Close

Main Conveyor Lower

- Auxillary hydraulic

power ON*

- RH Track backward

-


ID:QI240.en.ver.2


8.1.7 Engine Diagnostic Codes




ID:QI240.en.ver.2


8.2 Commissioning and Engine Warranty

8.2.1 Commissioning and Warranty Registration

The Sandvik Service Engineer who has been designated to Commission this QI240 will have an electronic version of the Commissioning and Warranty Registration form [CWR].



8.3 CAT Register Instructions


ID:QI240.en.ver.2


8.3.1 CAT C Series Warranty Statement




ID:QI240.en.ver.2

qi240

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 177ID:QI240.en.ver.2a

9.0 Spare Parts

Spare Parts qi240

9.1 Spare Parts

9.1.1 Spare Parts illustrations

This manual sets out details of available spares for the QI240 Crushing Machine. The parts list takesthe form of a number of ‘exploded’ illustrations of the various machine assemblies. Componentsillustrated have reference numbers, which can be cross-referenced with the corresponding Parts list.

This list includes:

a. Illustration Reference Number

b. Actual Part Number

c. Part Description

d. Quantity of Parts per Unit Assembly

9.1.2 Ordering Procedure:

To ensure correct delivery of your replacement part when ordering please quote:

a. Machine, Model and Serial Number

b. Year of Manufacture

c. Actual Part Number

d. Part Description

e. Illustration Reference Number and Page Number

f. Quantity Required

This information will enable us to supply the part with a minimum of delay.

contact email address

[email protected]


ID:QI240.en.ver.2a

qi240 Spare Parts








• Do not wear loose or baggy clothing which could become caught in the moving parts of the machine.



Spare Parts qi240

9.2 Top Level


ID:QI240.en.ver.2a

qi240 Spare Parts

9.2.1 Hydraulic Water Pump Option


Spare Parts qi240

9.3 Hopper Wing Plates


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.4 Chassis Complete


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.4.1 Chassis Tower


ID:QI240.en.ver.2a

qi240 Spare Parts

9.4.2 Oil Cooler Mount


Spare Parts qi240

9.4.3 Tension Pulley Mount


ID:QI240.en.ver.2a

qi240 Spare Parts

9.4.4 Pulley Mounting Complete


Spare Parts qi240

9.4.5 Tension Pulley Frame Complete


ID:QI240.en.ver.2a

qi240 Spare Parts

9.5 Walkway


Spare Parts qi240

9.6 Control Box


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.7 Feeder

Item No.Pos. Nr. QTY Part No.

Art. Nr.DescriptionBenämning

1 1 713.1945-901 Feeder Body

2 2 713.1951-001 Wear Plate

3 1 713.1953-001 Wear Plate

4 4 713.1028-001 Wear plate

5 83 990.0236-005 Screw M12x35 DIN7991 - 8.8A3G

6 83 990.0270-001 Washer 14 DIN126 - A3G

7 83 990.0187-001 Nut M12 DIN985-8A3F

8 1 726.0570-001 Wear Plate

9 1 726.0569-001 Wear Plate

10 1 726.0568-001 Wear Plate

11 1 726.0571-001 WEAR PLATE

12 1 713.1954-901 Vibrator Unit B13

13 4 713.1909-901 SPRING SUPPORT

14 1 SV1321X-P2-OP1 Upper Springbase

15 2 990.0851-001 Spring HF654X

16 2 723.1439-001 Spring cover

17 2 990.0271-001 Washer 18 DIN126 - A3G

18 2 990.0210-008 Screw M16x160 DIN931 - 8.8A3G

19 1 713.1913-001 Holder For Springbase

20 36 990.0276-001 Washer 17 DIN6916 - ZN

21 18 990.0627-001 Nut M16 DIN6915-10.9 ZN

22 1 726.0589-001 Chute Rubber

23 1 726.0588-001 Rubber clamp plate

24 6 990.0176-005 Screw M12x40 DIN933 - 8.8A3G

25 13 990.0270-001 Washer 14 DIN126 - A3G

26 6 990.0187-001 Nut M12 DIN985-8A3F

27 18 990.0110-001 Screw M16x60 DIN6914-10.9A3G


ID:QI240.en.ver.2a

qi240 Spare Parts

1

22

8

4

11

34

9

10

2322

19

18

12

6 7 515

16

14

2526

24

2021

27

13


Spare Parts qi240

Item No.Pos. Nr. QTY PartNo Description

Benämning1 1 713.1955-901 Frame Of Vibrating Unit

2 2 713.1957-001 Shaft3 4 713.0665-001 Bearing 22313CC W33A154 4 713.0666-001 Interm ring5 4 713.0667-001 Fling ring6 4 713.0668-001 Wear ring7 4 713.0669-001 O-ring 139.3x5.7

8 4 713.0671-001 Cover9 4 990.0852-001 Shaft Seal A70x90x1010 4 713.0673-001 O-ring 54.2x311 4 713.0674-001 V-ring V-75S12 4 713.1965-001 Counterweight

13 2 713.0676-001 Gear wheel14 2 713.0677-001 Lock washer MB1115 2 713.0678-001 Shaft nut KM1116 4 990.0068-001 Greasing nipple M10X1

17 36 990.0176-005 Screw M12x40 DIN933 - 8.8A3G18 1 713.1958-901 Counterweight Guard19 1 713.0680-901 Guard of counterweight

20 52 990.0174-005 Screw M10x40 DIN933 - 8.8A3G21 52 990.0269-001 Washer 11 DIN126 - A3G22 44 990.0186-001 Nut M10 DIN985-8A3F23 8 990.0222-008 Screw M16x80 DIN931 - 8.8A3G24 6 990.0270-001 Washer 14 DIN126 - A3G25 6 990.0187-001 Nut M12 DIN985-8A3F26 2 990.0221-006 Screw M12x70 DIN931 - 8.8A3G27 2 713.0709-001 Key C 16x10x90 DIN688528 2 713.0710-001 Key C-16x10x5529 1 713.1168-901 Adapter30 1 990.0632-001 Coupling Juboflex 63250831 1 726.0573-901 Adapter32 1 713.0755-001 Tension plate

33 1 713.0756-001 Silicone34 6 713.1174-001 Nordlock NL16 DIN 2520135 2 990.0064-001 Breather FFHU201536 2 723.0294-001 Bearing tube oil cauce37 2 990.0065-001 Oil plug R1/2"38 1 713.0705-001 Filling plug. breather39 2 713.0706-001 Plug T8 DN20 R3/4" 503140 1 713.0704-001 Oil sight window TLA5G MINTOR

41 1 713.0759-001 Gear oil ISO VG220+EP42 1 713.1363-001 Shaft oil ISO VG220+EP43 2 713.1761-001 Hexagon nipple R 3/444 2 713.1760-001 Equal socket Rp3/4

45 1 HM1046 Eaton DAM 7432846 4 840.0047-00 Screw M6S 12x40 8.8 ISO 401747 4 847.0147-00 Washer BRB 13x24 HB200 ISO 708948 5 845.0030-00 Nut Lock ISO 7040 M12 FZB49 2 840.0048-00 Screws M6S 12x45 8.8 ISO 1417


ID:QI240.en.ver.2a

qi240 Spare Parts

19

18

12

24 25 23

1615

1413

2

8

43

74

59

1011

6

40

3831 30

29

23

27

121

2220

37

36

17

2832 35

4443

39

34

26

33

4925

4748

4746

18

45


Spare Parts qi240

9.8 Pan Feeder


ID:QI240.en.ver.2a

qi240 Spare Parts

9.9 Main conveyor


Spare Parts qi240

9.9.1 Main conveyor Lower Section


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.9.2 Main Conveyor Upper section


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.9.3 Main conveyor Head Section


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.10 Side Conveyor


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.10.1 Side Conveyor Lower Section


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.10.2 Side Conveyor Mid Section


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.11 Pre Screen


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.12 Diverter Chute


ID:QI240.en.ver.2a

qi240 Spare Parts

9.13 Belt Guard


Spare Parts qi240

9.14 Drive Pulley


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.15 CI411 Impactor


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

9.16 QI240 Powerpack


ID:QI240.en.ver.2a

qi240 Spare Parts


Spare Parts qi240

support of the existing law.

This drawing and all the enclosures belong to us. They must not be copiedor duplicated - neither in original, nor in modified form - shown to orgiven to a third party or used for manufacturing purposes without our per-mission. As to infringements hereof, legal action will be taken with the

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Spare Parts qi240

9.16.1 Diesel tank


ID:QI240.en.ver.2a

qi240 Spare Parts

9.16.2 Hydraulic Oil Tank


Spare Parts qi240

9.16.3 Clutch Lube Tank


ID:QI240.en.ver.2a

qi240 Spare Parts

9.17 Magnet Spares


Spare Parts qi240

9.17.1 CAT Engine Spare PartsQty per Part No DescriptionEngine

1 15-22-0021 Primary air filter 132-7167

1 15-22-0022 Secondary air filter 6I-2510

1 15-30-0136 Engine Oil Filter 1R-0716

1 15-30-0192 Water Trap 1R-0771 (C9 III & C11)

1 15-30-0132 Secondary fuel filter 1R-0751

1 15-30-0340 Priming Pump (Hand) 105-2508 (C9&11)

1 15-30-0341 Regulator (Temperature) 247-7133(C9&11)

1 15-30-0342 Coolant Level Sensor 165-6634 (C9 & 11)

1 15-30-0343 Start Motor 207-1556 (C9 & 11)

1 15-30-0344 Alternator 80amp 177-9953 (C9 & 11)

1 15-30-0345 Vee Belt Set 7M-7477 (C9)


ID:QI240.en.ver.2a

qi240 Spare Parts

9.17.2 Engine Filter Kits - CAT

Description CAT C9 TIER 3A ENGINE FILTER KIT - 250HRS

Revision 0.00

Modified 13/03/2012 Tullyvannon,

Ballygawley,

Part no. 10-21-9003 Co. Tyrone

N. Ireland

Tel: 028 8556779

Fax: 028 85567007

Ref no. Description Part no. Qty

CAT Engine

1 Engine oil filter EN1000 1

2 CAT Primary Fuel Filter EN1001 1

3 CAT Seconday Fuel Filter EN1002 1

4 Air filter element EN9617 1

5 Air filter safety element EN9618 1

Description CAT C9.3 TIER 3B ENGINE FILTER KIT - 250 HRS

Revision 0.00


Ballygawley,


N. Ireland

Tel: 028 8556779

Fax: 028 85567007


CAT Engine








Spare Parts qi240

Description QI240 PLANT AND ENGINE FILTER KIT (CAT C9 TIER 3A) - 500HRS

Revision 0.00


Ballygawley,


N. Ireland

Tel: 028 8556779

Fax: 028 85567007


CAT Engine






PT Tech Clutch

6 Clutch lub filter element HF9920 1

7 Clutch Breather HF9523 1

8 HYD TANK BREATHER ELEMENT HF9524 1

Hydraulic system

9 High pressure filter element 10-21-0321 2

10 Return filter element 10-21-0031 3


Fuel Tank12 HYD TANK BREATHER ELEMENT HF9524 1


ID:QI240.en.ver.2a

qi240 Spare Parts

Description QI240 PLANT AND ENGINE FILTER KIT (CAT C9.3 TIER 3B) - 500HRS

Revision 0.00


Ballygawley,


N. Ireland

Tel: 028 8556779

Fax: 028 85567007


CAT Engine







PT Tech Clutch




Hydraulic system






Spare Parts qi240

Description QI240 PLANT AND ENGINE FILTER KIT (CAT C9 TIER 3A) - 2000HRS

Revision 0.00


Ballygawley,


N. Ireland

Tel: 028 8556779

Fax: 028 85567007


CAT Engine






PT Tech Clutch




Hydraulic system




12 1" SUCTION FILTER 10-21-0003 1

13 2 1/2" SUCTION FILTER 10-21-0007 3



ID:QI240.en.ver.2a

qi240 Spare Parts

Description QI240 PLANT AND ENGINE FILTER KIT (CAT C9.3 TIER 3B) - 2000HRS

Revision 0.00


Ballygawley,


N. Ireland

Tel: 028 8556779

Fax: 028 85567007


CAT Engine







PT Tech Clutch




Hydraulic system




13 1" SUCTION FILTER 10-21-0003 1

14 2 1/2" SUCTION FILTER 10-21-0007 3



Spare Parts qi240


ID:QI240.en.ver.2a

qi240


10.0 Electrical and Hydraulic

Electrical and Hydraulics qi240

10.1 Electrical Schematics

M


ID:QI240.en.ver.2

qi240 Electrical and Hydraulics




ID:QI240.en.ver.2


GW

3000

Gateway/DataLogger


ID:QI240.en.ver.2



ID:QI240.en.ver.2


GW3000

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ID:QI240.en.ver.2


M




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M


ID:QI240.en.ver.2


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1K1

4T1

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ID:QI240.en.ver.2


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OU

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ID:QI240.en.ver.2


C201

C202

C210

C203

C211

C200

DriveLamps1

DriveLamps2

HopperLevel

SideConveyorPullStop

CrusherSpeedSensor

SideConveyorSpeedSensor



10.2 Hydraulics

10.2.1 Hydraulic Circuit Diagrams


ID:QI240.en.ver.2


10.2.2 Hydraulic Hose Kitst Number Rev

29-9250 0.02

Part No. Rev: Length: Coupling: OrientFront jacklegs

m jackleg CV to RH jackleg raise 10-29-1600 0.01 550 90+STm jack leg control valve to right hand jack leg lower 10-29-1616 0 650 90+STm jackleg CV to LH jackleg lower 10-29-1601 0.01 4480 90+STm jackleg CV to LH jackleg raise 10-29-1602 0.01 4660 90+STm jackleg CV to return manifold 10-29-1605 0 2190 90+STm danfoss CV to Pr on jackleg CV 10-29-1617 0 2170 90+ST 16S

Rear jacklegsm jackleg CV to raise LHD jackleg 10-29-1607 0.01 2940 90+STm jackleg CV to lower LHD jackleg 10-29-1608 0.01 2970 90+STm jackleg CV to RHD jackleg raise 10-29-1609 0 420 90+STm jackleg CV to RHD jackleg lower 10-29-1610 0 390 90+STm jackleg CV to return manifold 10-29-1614 0 1520 90+STm HPC on jackleg control valve to steel pipe 10-29-1618 0.01 2180 90+STt Number Rev

29-9251 0.01

Part No. Rev: Length: Coupling: Orient

m CV to rear hopper door raise 10-29-1620 0.01 3330 90+STm CV to rear hopper door lower 10-29-1621 0.01 3600 90+STm CV to BHD for LHD hopper door raise 10-29-1622 0.01 310 90+STm CV to BHD for LHD hopper door lower 10-29-1623 0.01 350 90+STm CV to BHD for RHD hopper door raise 10-29-1624 0.01 2420 90+STm CV to BHD for RHD hopper door lower 10-29-1625 0.01 2460 90+STm hopper door CV to return manifold 10-29-1628 1120 90+STm BHD to LHD door ram (btm port) 10-29-1629 0.01 350 ST+STm BHD to LHD door ram (top port) 10-29-1630 0.01 910 ST+STm BHD to RHD door ram (btm port) 10-29-1631 350 ST+STm BHD to RHD door ram (top port) 10-29-1632 0.01 910 ST+STt Number Rev

29-9252 0.02

QI240 Jack Leg Hose Kit

QI240 Hopper Door Hose K

QI240 Side Conveyor Hose



Number Rev

9-9254 0.03

Part No. Rev: Length: Coupling: Orient:

d from left hand track motor to bleed manifold 10-29-1690 0 2200 90+STd from right hand track motor to bleed manifold 10-29-2067 0 2600 90+ST

control box BHD to RH track Mtr (Fwd) 10-29-1696 0 2540 20s,90+3/4bsp,ST

control box BHD to RH track Mtr (Rev) 10-29-1697 0 2300 20s,90+3/4bsp,ST

control box BHD to LH track Mtr (Fwd) 10-29-1694 0 4070 20s,90+3/4bsp,ST

control box BHD to LH track Mtr (Rev) 10-29-1695 0 3770 20s,90+3/4bsp,ST

REFERES TO METRIC FITTINGS. ALL OTHERS PIPES ARE BSP. Number Rev

9-9255 0.02

Part No. Rev: Length Coupling Orient.

top tee on non return valve to feeder motor P (a port 10-29-1700 0 2200 90+STbtm tee on non return valve to feeder motor R (b por10-29-1701 0 1800 90+STfeeder motor bleed port to bleed return manifold 10-29-1703 0 3230 90+ST

Number Rev

9-9256 0.03

QI240 Track Hose Kit

QI240 Primary Feeder Hose

QI240 Pre Screen Hose Ki


ID:QI240.en.ver.2


Part Number Rev

10-29-9257 0.03

Part No. Rev: Length: Coupling: Orient: Typ

From first tee at non-return valve to port B on motor 1 10-29-1720 0 1180 90+ST 2SCFrom second tee at non-return valve to port B on motor 2 10-29-1721 0 1410 90+ST 2SCFrom port A on motor 1 to port A on motor 2 10-29-1722 0 590 90+ST 2SCFrom non-return valve to return manifold 10-29-1717 0 3350 45+ST 2SCFrom bleed port on motor 1 to tee at bleed port on motor 210-29-1724 0 350 90+ST 2SCFrom tee on at bleed port of motor 2 to bleed return manifold 10-29-1725 0.01 3830 90+ST 2SC

Grease PipesFrom bulkhead to top grease point on left hand side motor 10-29-2063 0 1150 90+ST 2SCFrom bulkhead to bottom grease point on left hand side motor 10-29-2064 0 1250 90+ST 2SCFrom bulkhead to top grease point on right hand side motor 10-29-2065 0 850 ST+ST 2SCFrom bulkhead to bottom grease point on right hand side motor 10-29-2066 0 950 ST+ST 2SC

FIT 1/8 BSP FITTINGS TO GREASE PIPESPart Number Rev

10-29-9258 0.03


From tee on magnet FCV to BHD 10-29-1738 0 3020 45+ST 2SCFrom BHD to bleed tee 10-29-1739 0 3200 90+ST 2SCFrom BHD to motor P port 10-29-1733 0 670 90+ST 2SCFrom BHD to motor R port 10-29-1734 0 600 90+ST 2SCFrom BHD to motor bleed port 10-29-1735 0.01 620 90+ST 2SCPart Number Rev

10-29-9259 0.03


Over centre valve port 1 tee to btm port right hand ram 10-29-1740 0.01 1030 ST+ST 2SCOver centre valve port 1 tee to btm port left hand ram 10-29-1741 0.01 1030 ST+ST 2SCFrom danfoss CV port A to over centre valve port 2 10-29-1742 0.01 6650 12S,ST+BSP90 2SCFrom danfoss CV port B to over centre valve port 3 10-29-1743 0.01 6820 12S,ST+BSP ST 2SCFrom btm tee to btm ports on folding rams 10-29-1744 0 880 90+ST 2SCFrom top tee to top ports on folding rams 10-29-1745 0 1110 ST+ST 2SCFrom BHD to btm tee of folding rams 10-29-1746 0.01 2265 90+ST 2SCFrom tail section BHD to head section BHD pressure 10-29-1747 0.01 3340 90+ST 4SPFrom tail section BHD to head section BHD return 10-29-1748 0.01 3290 90+ST 4SPFrom tail section BHD to head section BHD bleed 10-29-1749 0.01 3380 90+ST 2SCFrom BHD to conveyor motor pressure 10-29-1750 0 1020 90+ST 4SPFrom BHD to conveyor motor return 10-29-1751 0 1170 90+ST 4SPFrom BHD to conveyor motor bleed 10-29-1752 0 1280 90+ST 2SCFrom single bank CV to main conveyor BHD 10-29-1755 0.01 1530 90+ST 2SCFrom main conveyor bleed tee to bleed manifold 10-29-1763 0 3330 90+ST 2SC

Grease PipesHead drum non-drive side 10-29-1764 0 5900 90+ST 2SCHead drum drive side 10-29-1765 0 4800 90+ST 2SCTail drum non-drive side 10-29-1759 0.01 4880 90+ST 2SCTail drum drive side 10-29-1760 0.01 5990 90+ST 2SC

QI240 Main Conveyor Hose Kit

QI240 Pan Feeder Hose Kit

Note

QI240 Magnet Hose Kit

Note



10-29-9261 0.03

Part No. Rev: Length: Coupling: Orient: TypOil cooler steel pipe to return filter steel pipe 10-29-1788 0 1870 90+ST 1SN-Oil cooler steel pipe to return filter steel pipe 10-29-1789 0 2000 90+ST 1SN-From return manifold to oil cooler 10-29-1781 0.01 850 90+ST 1SN-From oil cooler motor to bleed return manifold 10-29-1801 0 2500 90+ST 2SC-

Oil cooler BHD to oil cooler motor P 10-29-1786 0 52016S 90+ 1/2 "

BSP, ST 2SC-

Oil cooler BHD to oil cooler motor R 10-29-1787 0 49016S 90+ 1/2 "

BSP, ST 2SC-Oil cooler loop pipe 10-29-1785 0 450 90+ST 2SC-Power Unit BHD Fan Bleed to Manifold 10-29-3272 0 1050 90+ST 2SC-

16S REFERES TO METRIC FITTINGS. ALL OTHERS PIPES ARE BSP. Part Number Rev

10-29-9262 0.05

Part No. Rev: Length: Coupling: Orient: TypLeft hand side of chassisFrom bleed return BHD to bleed manifold 10-29-1800 0 2450 90+ST 2SC-From front BHD recirc conveyor to rear BHD 10-29-1802 0 4150 90+ST 2SC-From seven bank steel pipe to recirc/stockpile conveyor P 10-29-1803 0 4100 ST+ST 2SC-From steel pipe to high pressure ball valve transfer conveyor P 10-29-1804 0 460 20S ST+ST 2SC-From high pressure ball valve to steel pipe return to manifold 10-29-1805 0.02 580 20S ST+90 2SC-Right hand side of chassisFrom cabinet bulkhead to recirc bulkhead - Aux 10-29-1806 0.01 1700 12S ST+ST 2SC-From cabinet bulkhead to recirc bulkhead - screens P 10-29-1807 0.02 1600 20S ST+ST 2SC-From high pressure ball valve to return manifold 10-29-1798 0.01 2930 90+ST 1SN-From tee at magnet FCV to high pressure ball valve fines conveyor P 10-29-1808 0.01 2100 90+ST 2SC-From danfoss 6 bank CV to main conveyor BHD pressure 10-29-1766 0 4850 90+ST 4SP-From main conveyor BHD return to magnet FCV 10-29-1767 0 590 90+ST 4SP-From main conveyor BHD to bleed tee 10-29-1768 0 750 90+ST 2SC-

20S REFERES TO METRIC FITTINGS. ALL OTHERS PIPES ARE BSP. Part Number Rev

10-29-9263 0.04

Part No. Rev: Length: Coupling: Orient: TypLeft hand side chassisFrom danfoss CV to recirc/stockpileconveyor P steel pipe 10-29-1810 0 2000 ST+ST 2SC-From steel pipe to centre return manifold 10-29-1829 0 1050 ST+ST 1SN-From steel pipe to bleed return manifold 10-29-1812 0.01 850 90+ST 2SC-From high pressure ball valve steel pipe to return manifold10-29-1813 0 1260 90+ST 2SC-From side conveyor FCV port A to tee on steel pipe 10-29-1814 0 1930 45+ST 2SC-From danfoss 7 CV to side conveyor fold CV 10-29-1809 0 1870 ST+ST 2SC-Right hand side of chassisFrom centre Bleed Manifold to Hydraulic Tank Bulhead 10-29-2058 0 2210 90+ST 2SC-Part Number Rev

10-29-9264 0.02

Part No. Rev: Length: Coupling: Orient: TypFrom bleed return manifold to steel pipe 10-29-1831 0 1030 90+ST 2SC-From tee at pre-screen non-return valve to return manifold10-29-1832 0 1250 90+ST 2SC-

QI240 Oil Cooler Hose Kit

Note

QI240 Front Of Chassis Hose Kit

Note

QI240 Centre Chassis Hose Kit

QI240 Rear Chassis Hose Kit


ID:QI240.en.ver.2


Number Rev

9-9265 0.03


m walkway BHD to chassis BHD for impactor inlet s 10-29-1866 0 1300 90+ 12S, ST

m tee to impactor inlet ram btm ports 10-29-1853 0.01 1410 90+STm tee to impactor inlet ram top ports 10-29-1854 0.01 1240 90+STm tees to rams of impactor box open/close 10-29-1867 0 800 45+STm double bank CV at oil cooler to tee top curtian 10-29-1868 0 2240 Block90+STm double bank CV at oil cooler to return manifold 10-29-1869 0 2200 90+STm tee to top curtain ram 10-29-1844 0 3850 90+STm double bank CV at oil cooler to btm curtain open

10-29-1845 0 2280 Block90+STm double bank CV at oil cooler to btm curtain close

10-29-1846 0 2400 Block90+STm bolt on bulk head to oil cooler control valve (24V p) 10-29-1847 0 1950 90+ST

m bulkhead at danfoss block to tee for top curtain (B- 10-29-1848 0 2100 12S,45+ST

m chassis BHD to impactor inlet tee 10-29-1823 0 2000 90+STm impactor box open/close tee to CV 10-29-1824 0 1920 90+STm chassis BHD to bottom curtain ram open/close 10-29-1825 0 2850 90+STm impactor hood open/close CV return to manifold 10-29-1826 0 2500 90+ST

O on oil cooler CV to P port on walkway CV actor hood) 10-29-1827 0 3860 90+ST

m Oil cooler CV to tee top curtain 10-29-1828 0 2460 Block90+ST

REFERES TO METRIC FITTINGS. ALL OTHERS PIPES ARE BSP. Number Rev9-9266

0.07

cription Part No. Rev: Length: Coupling: Orient:m 24v pump to bolt on bulkhead 10-29-1898 0 2475 90+STch Block (RTN) - BH 10-29-3519 0 1800 45+STc Pump 1

p - Pressure filter 10-29-3575 0.01 12001 1/4 BSP ST+ 90 flange

m 2" Bulkhead to pump 10-29-2048 0.01 2160 45+STp case drain to BHD 10-29-2050 0 3170 90+STc Pump 2

m pump 2 to high pressure filter 10-29-3237 0 13601 1/4 BSP ST+ 90 flange

QI240 Impactor Hose Kit

QI240 Power Unit Hose K



art Number Rev

0-29-9267 0.04


rom hydraulic tank to power unit (24v pump suction) 10-29-2057 0 2060 90+STrom hydraulic tank to power unit (Radiator pump suction)10-29-2054 0 1950 90+ST R

rom high pressure filter to steel pipe 10-29-1886 0.01 2680 90+ST

I

rom high pressure filter to steel pipe 10-29-1887 0.01 2780 90+ST

I

rom hyd tank to 2"BHD suction pump1 10-29-2055 0 870 90+ST Rrom hyd tank to 2"BHD suction pump2 10-29-2056 0 1240 90+ST Rrom 7 bank PVG to pump 1 (load sensing) 10-29-1889 0.01 4450 90+STrom 6 bank PVG to pump 2 (load sensing) 10-29-1890 0.01 4390 ST+STrom bolt on bulkhead to clutch oil tank (oil cooler clutch ock return) 10-29-1892 0.01 1310 90+STrom bolt on bulkhead to bleed manifold (radiator motor eed) 10-29-1894 0.02 950 90+ST

rom clutch to clutch tank (drain hose) 10-29-1896 0.01 730

3000series 45 flange+3000serie

s ST flangerom fan block BHD to return filter steel pipe 10-29-1950 0 460 90+STrom clutch silver pump to suction on clutch tank side ort 10-29-1953 0 1690 90+STrom Hyd Tank BHD to Hyd Tank (Case Drain Rtn) 10-29-1954 0 1900 45+STrom Hyd Tank BHD to Diesel Tank (return) 10-29-1968 0 1900 90+STrom Diesel Tank to Hyd Tank BHD (suction) 10-29-1969 0 1350 90+ST

Part Number Rev ECO

10-29-9268 0.01 2206

Part No. Revisio Length Coupling Orient.rom cabinet base to diesel pump 10-29-3609 0.01 240 ST-ST Rrom cabinet base to diesel tank top 10-29-2075 0.01 4380 90-ST Rrom cabinet to suction filter 10-29-3611 0 4500 ST-ST R

Part Number Rev

10-29-9275 0.01

Part No. Rev: Length: Coupling: Orient:rease Pipesside flange bearing to BHD 10-29-2013 0 600 90+STutside flange bearing to BHD 10-29-2014 0 600 90+STop idler grease points to BHD 10-29-2015 0 750 90+STutside pillow block bearing to BHD 10-29-2016 0 550 90+STside pillow block bearing to BHD 10-29-2017 0 770 90+ST

t f f i t l b i t i d t BHD 10 29 2018 0 6501/8" ST+ 1/4"

O

QI240 Crusher Drive Hose Kit

QI240 Hydraulic tank

QI240 Refuelling Pump Hos


ID:QI240.en.ver.2

qi240


11.0 OEM Section

OEM Manuals qi240


ID:QI240.en.ver.2

11.1 OEM Appendices

Please ensure you read this section carefully. It contains Manuals produced by OEM manufactures,therefore Sandvik has reservations for misprints. The OEM Manuals will be placed in the followingorder

11.1.1 CI411 Impact Crusher Operation and Maintenance Manual

11.1.2 CI411 Impact Crusher Spare Parts

11.1.3 CI411 Interlock Manual

11.1.4 CI411 Daily log

11.1.5 Eriez Magnetic Separator

11.1.6 HPTO clutch Manual

11.1.7 Crawler Tracks Operation Manual

11.1.8 M-PROS Control System Spare Parts

11.1.9 Optional Extra’s

Operator's manual - Crushing Tigers

Documents

Transcript of Operator's manual - Crushing Tigers