Sandvik QH331 Operators Manual_1884BG – PDF DOWNLOAD

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Sandvik QH331 Operators Manual_1884BG – PDF DOWNLOAD

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Sandvik QH331 Operators Manual_1884BG – PDF DOWNLOAD

Language : English
Pages :256
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Sandvik QH331 Operators Manual_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……………………………………………………………… 25
2.2 User obligations……………………………………………………………………………. 25
2.2.1 Managing work related hazards…………………………………………………………… 26
2.2.2 Scheduled safety inspections and preventive maintenance……………………………………. 27
2.2.3 Personal protective equipment…………………………………………………………… 28
2.3 Product limitations…………………………………………………………………………. 29
2.3.1 Intended use………………………………………………………………………….. 29
2.3.2 Foreseeable misuse…………………………………………………………………….. 29
2.3.3 Prohibited use………………………………………………………………………… 29
2.3.4……………………………………………………………………………………… 29
2.3.5 Maximum inclination angles during tramming and parking…………………………………….. 29
2.3.6 Maximum inclination angles during operation………………………………………………. 30
2.3.7 Modifications…………………………………………………………………………. 30
2.4 Hazard zones……………………………………………………………………………….. 31
2.5 Safeguarding……………………………………………………………………………….. 32
2.5.1 Guards……………………………………………………………………………….. 32
2.5.2 Protective devices…………………………………………………………………….. 34
2.6 Complementary protective measures…………………………………………………………….. 35
2.6.1 Use of Emergency stop function………………………………………………………….. 35
2.6.2 Emergency exit………………………………………………………………………… 37
2.6.3 Safe access to machinery and three point support………………………………………….. 37
2.6.4 Isolation and energy dissipation………………………………………………………… 38
2.6.5 Fire risk control measures……………………………………………………………… 40
2.7 Protection against emission hazards…………………………………………………………… 41
2.7.1 Noise………………………………………………………………………………… 41
2.7.2 Vibration…………………………………………………………………………….. 42
2.7.3 Dust…………………………………………………………………………………. 42
2.8 Emergency procedures and methods for unblocking………………………………………………… 43
2.9 Safety considerations for maintenance…………………………………………………………. 44
2.10 Environment……………………………………………………………………………….. 47
2.10.1 Decommissioning………………………………………………………………………. 47
2.10.2 Dismantling………………………………………………………………………….. 47
2.10.3 Disposal…………………………………………………………………………….. 48
2.11 Potential product related hazards identified by the user……………………………………….. 49
2.12 Incident reporting…………………………………………………………………………. 50
3.0 Technical and Transport…………………………………………………………………………. 51
3.1 Transport………………………………………………………………………………….. 52
3.1.1 Special Considerations For Transport Of The QH331…………………………………………. 52
3.1.2 Machine Preparation for Transport……………………………………………………….. 52
3.1.3 Preparing the Feed Conveyor…………………………………………………………….. 54
3.1.4 Preparing the feed Conveyor maintenance platform………………………………………….. 55
3.1.5 Preparing the ladders………………………………………………………………….. 56
3.1.6 Tracking the machine onto and off the transport vehicle……………………………………. 58
3.2 Technical Information……………………………………………………………………….. 59
3.2.1 Standard Features……………………………………………………………………… 59
3.2.2 Options………………………………………………………………………………. 59
3.2.3 Transport and Working Dimensions………………………………………………………… 61
3.3 Identification of Main Units…………………………………………………………………. 63
3.4 Specification of Main Units………………………………………………………………….. 64
3.4.1 Feeder Hopper…………………………………………………………………………. 64
3.4.2 Feed Conveyor…………………………………………………………………………. 64
3.4.3 Crusher………………………………………………………………………………. 64
3.4.4 Main Conveyor…………………………………………………………………………. 64
3.4.5 Tracks……………………………………………………………………………….. 64
3.4.6 Power Unit……………………………………………………………………………. 64
4.1 Product Overview……………………………………………………………………………. 66
4.1.1 Major Components………………………………………………………………………. 66
4.1.2 Identification and Operation of the QH331 Controls………………………………………… 67
4.1.3 Main Control Panel…………………………………………………………………….. 67
4.1.4 Hydraulic Controls…………………………………………………………………….. 69
4.1.5 Radio Remote Control Unit………………………………………………………………. 70
4.1.6 Umbilical Remote Control Unit…………………………………………………………… 71
4.0 Product Overview……………………………………………………………………………….. 65
5.0 Commissioning and Shut Down……………………………………………………………………… 73
5.1 Commissioning & Shutdown Safety………………………………………………………………. 74
5.1.1 Who is at Risk………………………………………………………………………… 74
5.1.2 Managing Work related Hazards with a Risk Assessment………………………………………. 74
5.1.3 When carrying out maintenance or adjustment………………………………………………. 74
5.2 Commissioning………………………………………………………………………………. 75
5.2.1 Preparation for Machine STARTUP…………………………………………………………. 75
5.2.2 Engine Start-up Sequence……………………………………………………………….. 76
5.2.3 Setting Language of Control Panel Display………………………………………………… 77
5.2.4 Setting the date/time………………………………………………………………….. 78
5.2.5 Sequence For Tracking Machine…………………………………………………………… 79
5.2.6 Initial Setup and Operation…………………………………………………………….. 82
5.2.7 Set Up ladder 1 and ladder 2……………………………………………………………. 83
5.2.8 Preparing the feed Conveyor maintenance platform………………………………………….. 85
5.2.9 Restarting the Engine to activate Auxillary Controls………………………………………. 86
5.2.10 Preparing the Feed Conveyor……………………………………………………………. 86
5.2.11 Belt Tension Check during Commissioning…………………………………………………. 89
5.3 Machine operation…………………………………………………………………………… 92
5.4 Machine Shut Down…………………………………………………………………………… 92
5.4.1 Auto Stop Sequence…………………………………………………………………….. 92
5.4.2 Preparing the machine for transport or for the machine to be moved to another location………… 93
5.4.3 Emergency Stop………………………………………………………………………… 93
5.5 Location Of Emergency Stops On qh331………………………………………………………….. 94
5.5.1 Preparing the machine for transport or for the machine to be moved to another location………… 95
6.1 Operation Safety…………………………………………………………………………….100
6.1.1 Who is at Risk…………………………………………………………………………100
6.1.2 Managing Work related Hazards with a Risk Assessment……………………………………….100
6.1.3 When carrying out maintenance or adjustment……………………………………………….100
6.2 Loading the feeder…………………………………………………………………………..101
6.2.1 Avoid damage to equipment……………………………………………………………….101
6.3 Common Applications………………………………………………………………………….103
6.3.1 Construction, Demolition and recycling……………………………………………………103
6.3.2 Minerals and Quarrying………………………………………………………………….103
6.3.3 Maximum Feed size for Crusher……………………………………………………………103
6.4 Feed and Jams……………………………………………………………………………….104
6.5 Operating the QH331………………………………………………………………………….105
6.5.1 Start-up Sequence For Running the Crusher…………………………………………………105
6.5.2 Auto Run Mode………………………………………………………………………….107
6.5.3 Auto Start Up Sequence………………………………………………………………….108
6.5.4 Auto Stop Sequence……………………………………………………………………..109
6.5.5 Manual Run Mode………………………………………………………………………..110
6.5.6 Manual Start Up………………………………………………………………………..111
6.5.7 Feed Conveyor Adjustment………………………………………………………………..113
6.5.8 Hopper Level Adjustment…………………………………………………………………114
6.5.9 Tail Conveyor Level Sensor………………………………………………………………115
6.6 Machine Shut Down……………………………………………………………………………116
6.6.1 Manual Stop Sequence……………………………………………………………………116
6.7 Clearing Crusher Chamber Jam’s………………………………………………………………..117
6.7.1 Managing Work Related Hazards with a Risk Assessment……………………………………….117
6.7.2 Auto Run Closed Side Setting (CSS) Adjustment……………………………………………..118
6.7.3 Main Operations Menu……………………………………………………………………119
6.0 Operation……………………………………………………………………………………… 99
7.0 Maintenance…………………………………………………………………………………….121
7.1 Maintenance Safety…………………………………………………………………………..122
7.1.1 Who is at Risk…………………………………………………………………………122
7.1.2 Managing Work related Hazards with a Risk Assessment……………………………………….122
7.1.3 When carrying out maintenance or adjustment……………………………………………….122
7.2 Maintenance Schedule…………………………………………………………………………123
7.2.1 Power Unit Engine and Hydraulic………………………………………………………….123
7.2.2 Crusher & Feeder……………………………………………………………………….124
7.2.3 Testing the Emergency stop function and Battery Isolator……………………………………126
7.2.4 Conveyors and General…………………………………………………………………..128
7.2.5 Belt Tension…………………………………………………………………………..129
7.2.6 Engine Maintenance……………………………………………………………………..132
7.2.7 Radio Remote Control battery Charging…………………………………………………….132
7.2.8 Air Cleaner Maintenance…………………………………………………………………133
7.2.9 Battery Maintenance…………………………………………………………………….134
7.2.10 Check / Adding Fuel……………………………………………………………………134
7.2.11 Emptying the Fuel Filter Water Trap……………………………………………………..135
7.2.12 Special Considerations For Maintenance Or Repair with Welding………………………………136
7.3 Hydraulic System…………………………………………………………………………….137
7.3.1 Hydraulic Oil………………………………………………………………………….137
7.3.2 Hydraulic oil is added as follows:……………………………………………………….138
7.3.3 Changing The Return Line Filter………………………………………………………….139
7.3.4 Changing The Suction Filters and the Hydraulic Oil…………………………………………140
7.4 Lubrication System…………………………………………………………………………..142
7.4.1 Lubrication Oil………………………………………………………………………..143
7.4.2 Changing the Lubrication Oil…………………………………………………………….144
7.4.3 Track Maintenance………………………………………………………………………145
7.4.4 Checking the Track Tension………………………………………………………………146
7.4.5 Tighten the Tracks……………………………………………………………………..147
7.4.6 Loosen the Tracks………………………………………………………………………147
7.4.7 Track Drive Units………………………………………………………………………148
7.5 Conveyor Belt Maintenance…………………………………………………………………….149
7.5.1 Tensioning the Feed Conveyor Belt………………………………………………………..149
7.5.2 Tensioning The Main Conveyor belt………………………………………………………..150
7.5.3 Tracking the Belts……………………………………………………………………..152
7.5.4 Maintenance Data……………………………………………………………………….154
7.5.5 Hydraulic Oil Requirements for QH331 Machines……………………………………………..154
7.6 Lubricants and Fluids………………………………………………………………………..157
7.6.1 Greasing Schedule………………………………………………………………………158
7.6.2 Care of chrome…………………………………………………………………………160
8.1 Trouble Shooting Safety………………………………………………………………………162
8.1.1 Who is at Risk…………………………………………………………………………162
8.1.2 Managing Work related Hazards with a Risk Assessment……………………………………….162
8.1.3 When carrying out maintenance or adjustment……………………………………………….162
8.1.4 Diagnostic Screen………………………………………………………………………163
8.1.5 Engine Status………………………………………………………………………….164
8.2 Service Log and Faults……………………………………………………………………….165
8.3 Machine Shutdown Faults………………………………………………………………………170
8.3.1 FC 101Emergency Stop Alarm………………………………………………………………170
8.4 Using the Proportional Spool Valve System (PSVS) controls to Diagnose Hydraulic or Electrical Faults….171
8.4.1 Service Engineer Selection for PSVS Diagnosis……………………………………………..171
8.4.2 PSVS Diagnosis for Hydraulic or Electrical Faults………………………………………….171
8.5 Commissioning and Engine Warranty……………………………………………………………..173
8.5.1 Commissioning and Warranty Registration…………………………………………………..173
8.6 CAT Register Instructions…………………………………………………………………….174
8.6.1 CAT C Series Warranty Statement………………………………………………………….175
8.0 Trouble Shooting and Warranty…………………………………………………………………….161
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 Machine Assemblies…………………………………………………………………………..180
9.2.1 Top Level……………………………………………………………………………..180
9.2.2 QH331 Chassis assembly………………………………………………………………….182
9.2.3 Mid Section Walkway…………………………………………………………………….184
9.2.4 R.H.S. Maintenance Platform……………………………………………………………..186
9.2.5 Rear Maintenance Platform……………………………………………………………….188
9.2.6 Lubrication Tank……………………………………………………………………….189
9.2.7 Clutch Lubrication Tank…………………………………………………………………190
9.2.8 Cone Assembly………………………………………………………………………….192
9.2.9 Cone Discharge Chute……………………………………………………………………194
9.2.10 Chassis Tower…………………………………………………………………………196
9.2.11 Hydraulic Tank………………………………………………………………………..198
9.2.12 Diesel Tank…………………………………………………………………………..200
9.2.13 Feed Conveyor…………………………………………………………………………202
9.2.14 Feeder Support Frame…………………………………………………………………..205
9.2.15 Main Conveyor…………………………………………………………………………206
9.2.16 Main Conveyor lower section…………………………………………………………….208
9.2.17 Control Cabinet……………………………………………………………………….210
9.2.18 Power Unit……………………………………………………………………………212
9.2.19 Flywheel guard………………………………………………………………………..217
9.2.20 Tensioning Device……………………………………………………………………..218
9.2.21 Tensioning Pulley……………………………………………………………………..219
9.2.22 Active Turnbuckle Assembly……………………………………………………………..220
9.2.23 Engine Filter Kits – CAT C9 3A………………………………………………………….221
9.2.24 Engine Filter Kits – CAT C9.3 3B………………………………………………………..222
10.1 Electrical Schematics……………………………………………………………………….224
10.2 Hydraulic………………………………………………………………………………….246
10.2.1 Hydraulic circuit……………………………………………………………………..246
10.2.2 Hydraulic hose kits……………………………………………………………………247
10.0 Electrical and Hydraulic………………………………………………………………………..223
11.1 OEM Appendices……………………………………………………………………………..254
11.1.1 CH430 CONE Crusher Operation……………………………………………………………254
11.1.2 CH430 CONE Crusher maintenance Manual……………………………………………………254
11.1.3 CH430 CONE Crusher Spare Parts………………………………………………………….254
11.1.4 CH430 CONE Crusher Wear Parts…………………………………………………………..254
11.1.5 Crawler Tracks Operation Manual…………………………………………………………254
11.1.6 M-PROS Control System Spare Parts……………………………………………………….254
11.1.7 Optional Extra’s………………………………………………………………………254
11.0 OEM Section……………………………………………………………………………………253

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