Sandvik Mining QI240 Operator’s Manual SN 1884BG – PDF DOWNLOAD

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Sandvik Mining QI240 Operator’s Manual SN 1884BG – PDF DOWNLOAD

FILE DETAILS:

Sandvik Mining QI240 Operator’s Manual SN 1884BG – PDF DOWNLOAD

Language : English
Pages : 268
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Sandvik Mining QI240 Operator’s Manual SN 1884BG – PDF DOWNLOAD

1 0 Safety Section – Introduction 11
1 1 The purpose of these instructions 12
1 2 Identification of the product 12
1 2 1 Product type and serial number 12
1 2 2 Product manufacturer 13
1 2 3 Manuals 13
1 2 4 How to identify the right manual for the product 14
1 2 5 Validity of the manuals 14
1 3 Copyright notice 14
1 4 Definitions 14
2 0 Safety Section – Safety and Environmental Instructions 17
2 1 Safety labels and signals 18
2 1 1 Signal words 18
2 1 2 General hazard symbol 18
2 1 3 Symbols for mandatory actions 19
2 1 4 Symbols for prohibited actions 20
2 1 5 Hazard symbols 20
2 1 6 Labels on the product 22
2 1 7 Visual and audible signals 26
2 2 User obligations 26
2 2 1 Managing work related hazards 27
2 2 2 Scheduled safety inspections and preventive maintenance 28
2 2 3 Personal protective equipment 29
2 3 Product limitations 30
2 3 1 Intended use 30
2 3 2 Foreseeable misuse 30
2 3 3 Prohibited use 30
2 3 4 30
2 3 5 Maximum inclination angles during tramming and parking 30
2 3 6 Maximum inclination angles during operation 31
2 3 7 Modifications 31
2 4 Hazard zones 32
2 5 Safeguarding 33
2 5 1 Guards 33
2 5 2 Protective Devices 36
2 6 Complementary protective measures 37
2 6 1 Use of Emergency stop function 37
2 6 2 Emergency exit 39
2 6 3 Safe access to machinery and three point support 39
2 6 4 Isolation and energy dissipation 40
2 6 5 Fire risk control measures 42
2 7 Protection against emission hazards 43
2 7 1 Noise 43
2 7 2 Vibration 44
2 7 3 Dust 44
2 8 Emergency procedures and methods for unblocking 45
2 9 Safety considerations for maintenance 46
2 10 Environment 49
2 10 1 Decommissioning 49
2 10 2 Dismantling 49
2 10 3 Disposal 50
2 11 Potential product related hazards identified by the user 51
2 12 Incident reporting 52
3 0 Transport &Technical Data 53
3 1 Transport 54
3 1 1 Special Considerations For Transport Of The QI240 54
3 1 2 Machine Preparation for Transport 54
3 1 3 Folding the main conveyor and Positioning into Transport Position 57
3 1 4 Removing the belt troughs and Fold the Side Conveyor 59
3 1 5 Unfolding the hopper sides 60
3 1 6 Fold ladder 1 and ladder 2 62
3 1 7 Tracking the machine onto and off the transport vehicle 64
3 1 8 Transport and Working Dimensions 65
3 2 Technical Information 67
3 2 1 Standard Features 67
3 2 2 Options 67
3 3 Identification of Main Units 67
3 4 Technical Data and General Information 68
3 4 1 Hopper 68
3 4 2 Feeder 68
3 4 3 Pre Screen 68
3 4 4 4 Hammer Impact Crusher type Sandvik CI411 68
3 4 5 Main Conveyor 68
3 4 6 Pan Feeder 69
3 4 7 Tracks 69
3 4 8 Optional CAT C9 69
3 4 9 Optional Magnetic Separator Type Eriez CP 20/100-SC2 69
3 4 10 Side Conveyor 69
3 5 General Technical Data: 70
3 6 Options 70
3 6 1 Wheel Dolly System 70
3 6 2 Neodynium Magnetic Separator 70
3 6 3 Arctic Packages 70
3 6 4 Tropical/High ambient package 70
3 6 5 Hardox Wear Plates for hopper walls 70
3 6 6 Dust Suppression canvas covers 70
3 6 7 Central Auto Lube (crusher) 70
3 6 8 Central Auto Lube (conveyors) 70
3 6 9 Remote Diesel Pump 70
3 6 10 Water Pump 70
3 6 11 Double deck recirculation system (final spec TBC) 70
3 6 12 No Magnet Fitted 70
3 6 13 No Side Conveyor Fitted 70
4 1 Product Overview 72
4 2 Major Components 72
4 2 1 Identification and Operation of the QI240 Controls 74
4 2 2 Main Control Panel 74
4 2 3 Hydraulic Control Banks 76
4 2 4 Radio Remote Control Unit 78
4 2 5 Umbilical Remote Control Unit 79
5 0 Commissioning and Shut Down 81
5 1 Commissioning & Shutdown Safety 82
5 1 1 Who is at Risk 82
5 1 2 Managing Work related Hazards with a Risk Assessment 82
5 1 3 When carrying out maintenance or adjustment 82
5 2 Commissioning 83
5 2 1 Preparation for Machine STARTUP 83
5 2 2 Engine Start-up Sequence 84
5 2 3 Setting Language of Control Panel Display 85
5 2 4 Setting the date/time 85
5 2 5 Sequence For Tracking Machine 87
5 3 Initial Setup and Operation 90
5 3 1 Remove the Loose Items – Located in the Feeder 90
5 3 2 Set Up ladder 1 and ladder 2 91
5 3 3 Restarting the engine to activate Auxillary Controls 92
5 3 4 Folding the hopper sides 93
5 3 5 Unfold the Side Conveyor and fitting the belt troughs 94
5 3 6 Unfolding the main conveyor and Positioning into Working Position 96
5 3 7 Belt Tension Check during Commissioning 100
5 3 8 Diverter Chute 103
5 4 Machine operation 104
5 5 Machine Shut Down 104
5 5 1 Auto Stop Sequence 104
5 5 2 Preparing the machine for transport or for the machine to be moved to another location 105
5 5 3 Emergency Stop 106
5 6 Location Of Emergency Stops On QI240 107
6 1 Operation Safety 110
6 1 1 Who is at Risk 110
6 1 2 Managing Work related Hazards with a Risk Assessment 110
6 1 3 When carrying out maintenance or adjustment 110
6 2 Loading the feeder 111
6 2 1 Avoid damage to equipment 111
6 3 Common Applications 114
6 3 1 Construction, Demolition and recycling 114
6 3 2 Minerals and Quarrying 114
6 3 3 Maximum Feed size for Crusher 114
6 4 Feed and Jams 115
6 5 Operating the QI240 116
6 5 1 Start-up Sequence For Running the Crusher 116
6 6 Automatic Run Mode 118
6 6 1 MMPRO S menu Flow chart in automatic Run mode 120
6 7 Manual Operating Mode 121
6 7 1 Feeder Load Control 122
6 7 2 Machine Adjustment 123
6 7 3 Tail Level adjustment 124
6 7 4 Diverter Chute 125
6 7 5 Fault Logs 126
6 8 Clearing Crusher Chamber Jam’s 127
6 8 1 Managing Work Related Hazards with a Risk Assessment 127
6 0 Operation 109
7 0 Maintenance 129
7 1 Maintenance Safety 130
7 1 1 Who is at Risk 130
7 1 2 Managing Work related Hazards with a Risk Assessment 130
7 1 3 When carrying out maintenance or adjustment 130
7 2 Maintenance Schedule 131
7 2 1 Testing the Emergency stop function and Battery Isolator 134
7 2 2 Belt Tension 135
7 2 3 Maintenace to the CI411 Impactor using DC Maintenance Motor 138
7 2 4 Engine Maintenance 140
7 2 5 Radio Remote Control battery Charging 140
7 2 6 Working at height hazard 141
7 2 7 Air Cleaner Inspection, Daily Inspection Required 141
7 2 8 Air Cleaner Maintenance 142
7 2 9 Battery Maintenance 143
7 2 10 Checking Fuel Level, Adding Fuel and Draining fuel tank 144
7 2 11 Emptying the Fuel Filter Water Trap 145
7 2 12 Special Considerations For Maintenance Or Repair with Welding 146
7 3 Hydraulic System 147
7 3 1 Hydraulic Oil daily check 148
7 3 2 Hydraulic Oil is added as follows 149
7 3 3 Changing The Return Line Filter 150
7 3 4 Changing The Suction Filters and the Hydraulic Oil 151
7 3 5 HPTO Clutch Hydraulic Oil daily check 153
7 3 6 HPTO Clutch adding hydraulic oil 153
7 3 7 HPTO CLutch Lubrication tank Suction Filter change 153
7 3 8 HPTO Oil filter Replacement 154
7 4 Track Maintenance 155
7 4 1 Checking the Track Tension 155
7 4 2 Tighten the Tracks 156
7 4 3 Loosen the Tracks 156
7 4 4 Track Drive Units 157
7 5 Tensioning the Side Conveyor Belt 158
7 5 1 Tensioning The Main Conveyor belt 159
7 5 2 Tracking the Conveyor Belts 160
7 5 3 Hydraulic Oil Requirements for QI240 Machines 162
7 5 4 Hydraulic Oil Requirements for HPTO Clutch 163
7 5 5 Lubricants and Fluids 163
7 5 6 Greasing Schedule 164
7 5 7 Care of chrome 166
8 1 Trouble Shooting Safety 168
8 1 1 Who is at Risk 168
8 1 2 Managing Work related Hazards with a Risk Assessment 168
8 1 3 When carrying out maintenance or adjustment 168
8 1 4 Using the Proportional Spool Valve System (PSVS) controls to Diagnose Hydraulic or Electrical Faults 169
8 1 5 Service Engineer Selection for PSVS Diagnosis 169
8 1 6 PSVS Diagnosis for Hydraulic or Electrical Faults 169
8 1 7 Engine Diagnostic Codes 171
8 2 Commissioning and Engine Warranty 173
8 2 1 Commissioning and Warranty Registration 173
8 3 CAT Register Instructions 174
8 3 1 CAT C Series Warranty Statement 175
8 0 Trouble Shooting and Engine Warranty 167
9 0 Spare Parts 177
9 1 Spare Parts 178
9 1 1 Spare Parts illustrations 178
9 1 2 Ordering Procedure: 178
9 1 3 Managing Work related Hazards with a Risk Assessment 179
9 1 4 When carrying out maintenance or adjustment 179
9 2 Top Level 180
9 2 1 Hydraulic Water Pump Option 181
9 3 Hopper Wing Plates 182
9 4 Chassis Complete 184
9 4 1 Chassis Tower 186
9 4 2 Oil Cooler Mount 187
9 4 3 Tension Pulley Mount 188
9 4 4 Pulley Mounting Complete 189
9 4 5 Tension Pulley Frame Complete 190
9 5 Walkway 191
9 6 Control Box 192
9 7 Feeder 194
9 8 Pan Feeder 198
9 9 Main conveyor 199
9 9 1 Main conveyor Lower Section 200
9 9 2 Main Conveyor Upper section 202
9 9 3 Main conveyor Head Section 204
9 10 Side Conveyor 206
9 10 1 Side Conveyor Lower Section 208
9 10 2 Side Conveyor Mid Section 210
9 11 Pre Screen 212
9 12 Diverter Chute 214
9 13 Belt Guard 215
9 14 Drive Pulley 216
9 15 CI411 Impactor 218
9 16 QI240 Powerpack 220
9 16 1 Diesel tank 226
9 16 2 Hydraulic Oil Tank 227
9 16 3 Clutch Lube Tank 228
9 17 Magnet Spares 229
9 17 1 CAT Engine Spare Parts 230
9 17 2 Engine Filter Kits – CAT 231
10 1 Electrical Schematics 238
10 2 Hydraulics 260
10 2 1 Hydraulic Circuit Diagrams 260
10 2 2 Hydraulic Hose Kits 261
10 0 Electrical and Hydraulic 237
11 1 OEM Appendices 268
11 1 1 CI411 Impact Crusher Operation and Maintenance Manual 268
11 1 2 CI411 Impact Crusher Spare Parts 268
11 1 3 CI411 Interlock Manual 268
11 1 4 CI411 Daily log 268
11 1 5 Eriez Magnetic Separator 268
11 1 6 HPTO clutch Manual 268
11 1 7 Crawler Tracks Operation Manual 268
11 1 8 M-PROS Control System Spare Parts 268
11 1 9 Optional Extra’s 268
11 0 OEM Section 267

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