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Qi240 Manual Eng

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100% found this document useful (2 votes)

784 views268 pages

Qi240 Manual Eng

extramil

Uploaded by

landago

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 268

Translation of the

Original Instructions

Operator’s manual
qi240
serial number 1884BG
WARNING
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.
julie

DECLARATION OF CONFORMITY

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 Codes

2006/42/EC Machinery Directive
2004/108/EC ElectroMagnetic Compatibility (EMC)

EC Type-examination and Certificates

ISO21873-2

Technical file
We 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 the
manufacturer’s written agreement.
Date: / /

P Coleman, PDC Manager P Colton, Operations Director

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

Reg No. 4636796

VAT No. GB 806 399 995
Sandvik 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 or
copied 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, Ballygawley
Co. Tyrone
N. Ireland
BT70 2HW
Telephone: (+44) 028 855 67799
Facsimile: (+44) 028 855 67007
e-mail: [email protected]
Contents
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

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 5
ID:QI240.en.ver.2
Contents
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

4.0 Product Overview 71

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

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

6.0 Operation 109

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

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

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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

8.0 Trouble Shooting and Engine Warranty 167

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

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

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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

10.0 Electrical and Hydraulic 237

10.1 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
10.2 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
10.2.1 Hydraulic Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
10.2.2 Hydraulic Hose Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

11.0 OEM Section 267

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

10 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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qi240

1.0 Safety Section - Introduction

1.1 The purpose of these instructions

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

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 is
anything you do not understand, ask your employer or your local Sandvik representative to explain
it. All sections of this manual contain information which is vital for your safety. The manual must be
replaced immediately if lost, damaged or unreadable. For replacement copies, please contact
[email protected]
and provide the machine serial number, what type of manuals are required eg operators and
language version required.

The instructions set forth in the operator’s and other manuals are to be used as a part of the training
material during orientation. By following these instructions, safe practices will result, maintenance
cost 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 Ltd

Tullyvannon,
Ballygawley,
Co.Tyrone
Northern Ireland
BT70 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 type
and serial number” on page 12). Make sure that the model corresponds to the one given on the cover
of this manual.

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 the
product are made.

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

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

1.3 Copyright notice

This publication is copyright of Sandvik Mining and Construction - © Sandvik Mining and
Construction. It must not be copied, reproduced, or otherwise made available in full or in part to any
third 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.

16 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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qi240

2.0 Safety Section - Safety and

Environmental Instructions

2.1 Safety labels and signals

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

2.1.1 Signal words

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

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

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

NOTICE
The signal word “NOTICE” indicates a situation which, if not avoided, could result in damage to
property 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 the
message that follows, and inform other users.

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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 are
indicated 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

Read the Manual Wear High Visibility Vest
Overalls

Disconnect Power Switch Off and Lockout

Wear Respirator
Source From Supply Equipment

2.1.4 Symbols for prohibited actions

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

No Climbing No Smoking Do Not Touch

Limited or Restricted
No Open Flames Do Not Weld
Access

Do Not Remove Safety

Guard
2.1.5 Hazard symbols

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

Crushing Hazard -
Crushing Hazard - Feet Chemical Burn Hazard
Hands

Electrical Shock/
Electrical Hazard Entanglement Hazard
Electrocution Hazard

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Entanglement Hazard Falling Hazard Falling Load Hazard

Hazardous or Poisonous
Flammable Hazard Flying Material Hazard
Material Hazard

Silica or Other Dust

Lifting Hazard Skin Injection Hazard
Hazard

Trip Hazard Magnet Hazard

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 of
safety labels daily. Safety labels and instructions which have faded, been damaged, been
painted over, come loose or that do not meet the legibility requirements for safe viewing
distance, 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 codes
and language version required.

22 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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12-55-0392 12-55-0389
12-55-0001 12-55-0004 12-55-0398 12-55-0390 12-55-0001 12-55-0004 12-55-0014 12-55-0005 12-55-0408

12-55-0283

12-55-0405

12-55-0408

ID:QI240.en.ver.2
12-55-0405

12-55-0405

12-55-0408

12-55-0001 12-55-0004

12-55-0283

12-55-0396 12-55-0366 12-55-0044 12-55-0361 12-55-0359 12-55-0360

12-55-0005 12-55-0295 12-55-0387

23
Safety
Safety

24
12-55-0044 12-55-0283
12-55-0408
12-55-0001 12-55-0398 12-55-0364 12-55-0365
12-55-0393 12-55-0001 12-55-0004

12-55-0410 12-55-0283
12-55-0379

12-55-0014

ID:QI240.en.ver.2
12-55-0405

12-55-0283

12-55-0001 12-55-0004 12-55-0387 12-55-0005 12-55-0407 12-55-0410 12-55-0362

12-55-0372
qi240
qi240

12-55-0388
12-55-0391

ID:QI240.en.ver.2
12-55-0011

12-55-0260

12-55-0008

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
Service Engineer Selection for PSVS Diagnosis
The use of the PSVS controls is ONLY Permitted by trained and authorised Service Engineers.

WARNING RANDOM OPERATION OF MACHINERY HAZARD

Hazard 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.

1
1
12-55-0003 12-55-0002
2 00:00:10

3 2
4
5 7 8 9 10 11 12, 13
6

LH Track Main Natural Fines Impactor Primary

Hydraulic Oil Cooler
forward Conveyor Conveyor ON Inlet Raise Feeder ON
Fan Forward
ON*
1 2 3 4 5 6 4
Hydraulic Oil Cooler LH Track - - Impactor - 4
Fan Return backward Inlet Lower

Main Conveyor UnderPan PreScreen - RH Track Auxiliary

Top Apron Lower Feeder ON ON backward (jack legs 4i
Close & main
conv) I
7 8 9 10 11 12 13
Main Conveyor - Auxiliary - RH Track -
Top Apron Raise (side conv forward
Open & hopper
doors)** 4ii 4iii
* Will also operate overhead magnet if fitted (optional).

** Auxiliary hydraulic power for the folding/unfolding of the side conveyor and the raising/lowering of the left,
right and rear hopper sides.

12-55-0385
12-55-403

12-55-0382 12-55-0385 12-55-0044 12-55-0246 12-55-0225 12-55-0403

12-55-0007 12-55-0006

25
Safety
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 for
ten seconds before the engine will crank to start.

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

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

2.2 User obligations

WARNING
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.

The safe use of a product depends on, among other things, a combination of the design and
construction measures taken by the manufacturer, the skills of the operators and protective
measures taken by the user. Instructions are an essential and integral part of the product and they
must be always available for users. It is important to pass on the information for use to any
subsequent 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 impair
judgement 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 need
more 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

26 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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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 reported
to your local Sandvik representative without a delay. See also the section, “Incident reporting” on
page 52.

The following safety guidelines apply to each person working with the product or in the vicinity of the
product. Every single person is responsible for his or her own safety and for the safety of his or her
colleagues. In case of violation of any safety guidelines or regulations, everyone has a duty to warn
others 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 or
shift. This assessment, also known as a Real Time Hazard Analysis, ensures that the user stops and
thinks 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

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. Look
for defects and damage before any operation so that any problems can be reported and fixed. For
more 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 performance
of the product. Follow the specified instructions for the maintenance and inspection of product. For
more information, see section, “Maintenance Schedule” on page 118, in Maintenance Manual.

WARNING!

Use of unauthorised parts present an uncontrolled risk and could cause death or
severe injury. The use of unauthorised parts will also invalidate warranty. It is the
user’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 protective
equipment, 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 of
the product.

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

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 of
perfornance. 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

WARNING
TIPPING HAZARD

Never exceed the specifies maximum inclination angles. The maximum

angles 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 maximum
inclination angles.

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

10 degrees side tilt or 20 degrees front tilt.

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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

WARNING
MODIFICATION HAZARD
Unauthorised modifications could lead to death, severe injury or property
damage.
Always contact a Sandvik representative in order to get advance written
approval for any modification

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

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

If modifications and alterations that affect the maintenance, operation, safety, and usability of the
product are made without the written permission of the manufacturer, the manufacturer is not
responsible for any incidents resulting in death, injury, or property damage brought about by such
modifications and corrections.

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

Should you consider a modification or alterations necessary, you must contact the organisation that
manufactured and designed the product. No modification is permitted unless you first obtain the
written 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

32
2.4

HAZARD
AREA HAZARD
DO NOT AREA
ENTER DO NOT
Hazard zones

ENTER
Material
20m Ejection Material
Area Ejection
Area

5m distance from
feeder

HAZARD
HAZARD AREA
AREA DO NOT ENTER

ID:QI240.en.ver.2
DO NOT
mechanical hazards, falling loads and ejected materials.

Material Ejection Area

ENTER

Material Ejection Area ACCESS HAZARD

AREA 20m EXCLUSION ZONE
ZONE DO NOT
ENTER
from any point of the machine for
TO personnel NOT operating the
Material
CONTROL Ejection machine
Area
PANEL

20m
Limit access to the equipment and its surrounds by erecting barrier guards to reduce the risk of other
qi240
qi240 Safety

2.5 Safeguarding

2.5.1 Guards

WARNING
TAMPERING HAZARD

Bypassing or overriding of a safeguard or a device could cause death or

severe injury.
Do not make any alterations to protective devices. Make sure that they are in
place and work properly before operating the machine.

Main Conveyor Side Conveyor drive

Engine surround Drive belt guard coupling guard Prescreen shaft guard
Skirting guards

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
Main Conveyor
Return roller guards
Hopper door lift ram
guards
Main Conveyor tunnel Jack leg cover plate Track covers Main Conveyor Lower section Side Conveyor Return
and side face guards guarding and tunneling roller guard

34
Safety
qi240

Hopper door lift ram guards Oil cooler guard Main Conveyor Skirting guards

ID:QI240.en.ver.2
Main Conveyor Drive
coupling guard

Main Conveyor tunnel

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
Primary feeder
motor guard Side Conveyor tail section guarding Track covers and side face guards

* All panel doors are also considered guards

35
Safety
Safety qi240

2.5.2 Protective Devices

ISOLATOR ON

ISOLATOR OFF

a. Prior to operation, all safety devices (control devices or guards) temporarily

removed for set-up, maintenance or repair purposes MUST be refitted and
checked immediately upon completion of the maintenance and repair work.

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

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

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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

Control Panel
Emergency Stop

Emergency Stop
Reset Button

Engine Kill Switch

Umbilical Tracking
Lead Engine Kill
Switch

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2.6.2 Emergency exit

The QI240 is not permitted to operate inside buildings or dwellings. The area surronding the QI240
must 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 as

a 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 or
otherwise safety-oriented ladders and working platforms.

f. ONLY use walkways/platforms provided on the equipment. ALWAYS perform

work from an approved, safe and secure platform.

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

h. Keep all handles, steps, handrails, platforms, landing areas, and ladders free from
dirt, 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, loose
connections, chafe marks and damage. Any defects found MUST be repaired
immediately.

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 under
any condition in which shutting off the engine and removing the ignition key does not completely cut
power 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

ISOLATOR ON

ISOLATOR OFF

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.

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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 the
machine at the same time.

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

DANGER
IMPACT HAZARD

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

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

2.6.5 Fire risk control measures

WARNING
FIRE AND EXPLOSION HAZARD

Explosion hazard can exist in addition to the fire hazard.

Ignition sources like smoking, open flames, welding work and sparks
together with combustible materials like fuel, can cause fire and if not
avoided, could lead to death or severe injury.

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

During maintenance appropriate fire prevention and protection measures

must be followed including but not limited to trained personnel, proper fire
extinguishing equipment and agents. Before any maintenance or repairs
requiring ignition sources like welding or flame cutting, a proper risk
assessment must be carried out prior to the start of the work to control the risk.

Smoking and open fire are prohibited in the vicinity of the product. Access to all fire-fighting
equipment 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 fires
must not be extinguished with water. In most cases special extinguishing agents, dry powders or
deoxygenating are required.

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

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2.7 Protection against emission hazards

2.7.1 Noise

DANGER
NOISE HAZARD

Noise level emitted by the machine exceeds 80 dB(A). Continuous

exposure to noise will cause hearing impairment.

Always wear approved hearing protection.

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

3 Metre (9'9") Radius 96dB

2 Metre (6'6") Radius 99dB

1 Metre (3'3") Radius 112dB

86dB

90dB

94dB

96dB

92dB

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. The
readings were with all systems running situated on the factory assembly line. The product and local
conditions will affect the noise levels.

2.7.2 Vibration
WARNING! VIBRATION HAZARD!

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

2.7.3 Dust

DANGER

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

In any workplace where respirators are necessary to protect the health of the employee, the employer
must establish and implement a written respiratory protection program with worksite-specific
procedures 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 dust
suppression system is not working properly, stop working immediately.

Regularly clean your working environment properly to minimize the dust level in the air. Always make
sure 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 are
the most harmful. They may be so fine that you cannot see them. Remember, you must protect
yourself from the danger of breathing or inhaling dust.

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2.8 Emergency procedures and methods for unblocking

Blockage or Malfunction:

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

2.9 Safety considerations for maintenance

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

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

Daily inspections and tasks allowed for operators (which do not require special skills) are in the
Maintence 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 special

knowledge and experience of hydraulic systems.

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

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

Repair damaged lines, hoses, or screwed connections IMMEDIATELY

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

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

d. Hydraulic and compressed air lines MUST be laid and fitted properly. Make sure
that no connections are interchanged. The fittings, lengths and quality of the
hoses 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

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Battery Maintenance

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

b. Recharge the battery in a well ventilated area.

c. The battery contains sulphuric acid, an electrolyte which can cause severe burns
and 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.

DANGER

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

If fluid is injected under the skin, it must be surgically removed or gangrene

will result. GET MEDICAL HELP IMMEDIATELY.

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

Electric maintenance

a. External Considerations and Hazards

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

DANGER
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.

b. Machine - Electrical

1. Work on the electrical system or equipment MUST ONLY be carried out by a

skilled and qualified electrician or by specially instructed personnel under the
control and supervision of such an electrician and in accordance with applicable
electrical engineering rules.
2. Before starting any maintenance or repair work, the power supply to the
equipment MUST be isolated. Check the de-energized parts to make sure they do
not 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 cables
MUST be fixed immediately.
4. Use ONLY original fuses with the specified current rating. Switch off the
equipment IMMEDIATELY if trouble occurs in the electrical system.
5. This equipment is wired on a negative earth. ALWAYS observe correct polarity.

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2.10 Environment

2.10.1 Decommissioning

Hazardous Substances:

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

b. A full list of Hazardous Substances associated with this equipment can be found in
the 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 Original

Equipment Manufacturer's manuals, or the spare parts suppliers' instructions.

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

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

PROHIBITED.

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

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

e. NEVER work or stand under suspended loads.

f. KEEP AWAY from the feeder hopper and product conveyor discharge, where
there 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 to
reduce the risk of residual mechanical hazards, falling lifted loads, and ejected
materials.

2.10.3 Disposal
This 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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• 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.

2.12 Incident reporting

Product safety issues to be reported are events where a product manufactured by Sandvik Mining
and 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 maintenance
or misuse shall be reported to your local Sandvik representative as well.

Reporting is mandatory to ensure safe working conditions for employees, to provide information for
the 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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3.0 Transport &Technical Data

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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

WARNING 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 has
read and fully understood this and all the preceeding sections in the
manual

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

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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, .

Locating Pins

Hydraulic
control lever

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

c. Remove the locating pins. Remove the Ladder.

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

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Ladder fix
Point

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

Locating Pins in first

hole position.

Hydraulic
control lever

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

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

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

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Insert Locating Pins in

first hole position.

Hydraulic
control lever

g. Restart the engine refer to “5.2.2 Engine Start-up Sequence” on page 84, to lower
the main coneyor by operating the hydraulic lever until the weight of the main
conveyor 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 and
adjust the length to remove the torque arm on both sides

Locating
Pin
Ladder fix
Point

Torque Arm

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c. Remove the ladder.

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

Spray Bar

Main Conveyor

Bolt locations

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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 energy
dissipation” on page 39. . Remove the Belt troughs from the mid section of the
side conveyor.

Remove these
items first

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

HC2

Slide stop top

locating pin position

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

d. Restart the engine refer to “5.2.2 Engine Start-up Sequence” on page 84 to fold
the side conveyor to the transport position by operating hydraulic control lever
HC2

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

Locating
pins

3.1.5 Unfolding the hopper sides

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

Remove the
Wedges
HC1

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

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

Locating Pin to prop

side hoppers

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 energy
dissipation” on page 39. Using a secure platform if needed, the additional
supervisor can remove the locating pins and move the prop outwards to allow it to
clear the support plate.

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

HC1

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3.1.6 Fold ladder 1 and ladder 2

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

Ladder 2 support

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

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

Loosen the bolts

Secure
with bolts

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

Ladder 1 support

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

d. Place all loose items into the feeder.

Ladder 1 support
Torque Arm x 2 - required for
the main conveyor

Side Conveyor Ladder 2 support

Belt Troughs

Place into Control

Panel Cabinet
CI411 Litting Tool

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 component

damage or loss.

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3.1.7 Tracking the machine onto and off the transport vehicle

DANGER
CRUSH HAZARD
Moving 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.

Follow the Sequence for the tracking procedure (refer to “5.2.5 Sequence For Tracking Machine” on
page 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 transport
straps or chains are installed. DO NOT secure by tying down over the tracks. Lashing down is the
responsibility of the driver of the low loader.

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

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3.1.8 Transport and Working Dimensions

TRANSPORT

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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 CI411

Side Conveyor Main Conveyor

Pre Screen

Magnetic
Engine Seperator
Pan feeder Tracks

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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")

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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 System

Transport system that enables machine to be transported without con loader or other transport
means

3.6.2 Neodynium Magnetic Separator

Self cleaning
Belt width 800 mm
Driven 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 walls

High 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

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 2 3 4 5 6 8 7

1. Main Conveyor

2. Magnetic separator

3. Diesel Tank

4. Powerpack

5. HSI Crusher Unit

6. Pre Screen

7. Primary Feeder

8. Side Conveyor

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18 11 17 16 15 14 11 13 12 10 9

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

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

Control Panel
Emergency Stop

Emergency Stop
Reset Button

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 the
machine.

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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 which
will 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

HC7

HC3 HC6 HC5 HC4

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

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 Control
battery 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.

NOTICE DAMAGE TO MACHINE WILL RESULT IF MISUSED.

This switch should only be used in emergency situations. Machine will

require 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 the
Crusher” on page 116 for restart procedure.

• 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.

Engine Kill
Switch

B
A

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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 Remote
Control 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 Kill
Switch

Manual Track
Buttons

AutoTrack
master Switch

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5.0 Commissioning and Shut Down

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5.1 Commissioning & Shutdown 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.

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

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:

• 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

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.

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

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

It is recommended that set up of the QI240 be carried out by a representative of Sandvik

Mining and Construction Mobile Crushers and Screens Ltd. or by trained and authorised
representative 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 is
placed on solid ground that must be capable of carrying the weight of the machine and that the
machine 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 the
machine.

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5.2.2 Engine Start-up Sequence

a. Ensure all Emergency Stops are released and that the switch on the remote control is also
turned 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 are
shown respectively (Fig. 5.1). It should take a few seconds. If there is a problem it will be shown on
the display.

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

( Fig. 5.1 ) Splash Display

Emergency Stop Reset Button

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 & beacon
will flash for 10 seconds before the engine will start. (If engine turns and does not start, turn off the
ignition and wait for a few seconds, then try and start again.)

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5.2.3 Setting Language of Control Panel Display.

Software version

Control Panel Serial Number

Button 3

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

Press Button 3 to select the language required. The country flag or a greeting will appear). To return
to 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.

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

• 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.

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

• 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.

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

• 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.

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

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• 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 Control
Unit” on page 79.

DANGER
CRUSH HAZARD
Moving 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.

The operator must be fully trained in the operation of this equipment. When tracking, the operator
must be in a position to have an all round view of the operation. A additional supervisor should assist
where this is not possible. Make sure the site is clear of non essential persons. Erect barriers around
the area and post warning signs where site conditions warrant this. Make sure the tracking alarm
makes a clear sound.
This equipment must never be tracked on gradients that are more than:

10 degrees side tilt OR 20 degrees front tilt

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).

( Fig. 5.2 )

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

Button 1
Manual Handset Activate

Button 2
Radio Receiver Activate Engine RPM
Lower / Raise
Radio Receiver Signal
Strength Indication
Radio Receiver Activate

(Fig. 5.3)

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

Switch

e. After the 10 seconds the button 1 icon will then have a green halo. Tracking will now be active
with 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.

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g. For Radio remote control press button 2 (shown in Fig. 5.3). The yellow halo will not appear
until 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 few
seconds as shown below (Fig. 5.4)

Remote Wait for

Control Green
on “1” Light to
flash

(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 is
ready to use.

Activate Remote

(Fig. 5.5)
Transmitter signal strength

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).

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5.3 Initial Setup and Operation

WARNING
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.

DANGER
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.

5.3.1 Remove the Loose Items - Located in the Feeder

Ladder 1 support Ladder 2 support
Torque Arm x 2 - required for
the main conveyor

Side Conveyor
Belt Troughs

CI411 Litting Tool

Located in Control
Panel Cabinet

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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 and
remove the secure fixings which holds the ladder and the two swing doors together. Secure the
ladder support to ladder 1 and then swing the ladder down and secure with bolts to the ladder
support.

Secure with bolts

Ladder 1 support

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

Secure with bolts

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

Ladder 2 support

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 the
main menu and press button 4 (fig 5.6) to activate Auxiliary function. The siren will sound
continously when in this menu mode.

Button 4
Auxiliary Function

(Fig 5.6)
(Fig 5 6)
b. Wait 10 seconds for the controls to be activated, then the green shadow will appear around
symbol.

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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

HC 1

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

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

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

Support Plate

Locating Pin to prop

side hoppers

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

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

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h. Using a secure platform if needed, an additional supervisor can insert the two wedges (as
shown 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 (refer
to above), by operating hydraulic control levers HC1.

Insert the
Wedges

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 torque
arm length to allow the locating pins to be removed. Remove the torque arm and place in a safe
location.

Locating
pins

Raquet
Torque Arm

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

HC2

Slide stop top

position
locating pin

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

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

e.Restart the engine and refer to “5.3 Initial Setup and Operation” on page 90) to
lower the side conveyor onto the slide stop, by operating the hydraulic control lever
HC2.

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

Attach this
item first

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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 energy
dissipation” on page 39. Attach the Spray Bars for the Main Conveyor.

Spray Bar

Main Conveyor

Bolt locations

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

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

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

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Locating
Pin Ladder fix
Point

Torque Arm

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

Hydraulic
control lever

Locating Pins

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

Ladder fix
Point

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

h. Remove locating pins and remove the ladder

Locating Pins

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

Hydraulic
control lever

Locating Pins

Second hole

j. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 39. Attach the ladder [supplied] into the ladder fix point or use a
secure 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 90
and lower the main conveyor onto the locating pin.

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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

Torque Arm

Locknuts

Replacing Belt
1. 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

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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
12. Close flywheel guards
13. 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.
14. Shut down the impactor, refer to “5.5 Machine Shut Down” on page 104.
15. Wait for pulleys to stop
16. Implement the LOCKOUT and TAG Procedure, refer to
“2.6.4 Isolation and energy dissipation” on page 40
17. Open flywheel guards
18. Remeasure between the two marked points on the belt
19. Adjust belt accordingly (refer to “Adjusting the Belt” below)
20. Tighten the locknuts on the torque arm
21. Close the guards

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Adjusting the Belt

Before inspecting the V Belt Tension

Implement the LOCKOUT and TAG Procedure, refer to

“2.6.4 Isolation and energy dissipation” on page 40

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-
up Sequence” on page 84), only on maintenance for 1 - 2 minutes.
4. Shut down the impactor, refer to “5.5 Machine Shut Down” on page 104.
5. Wait for pulleys to stop
6. Implement the LOCKOUT and TAG Procedure, refer to
“2.6.4 Isolation and energy dissipation” on page 40
7. Open flywheel guards.
8. 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 5.3mm
9. Tighten the locknuts on the torque arm
10. Close flywheel guards
11. Run the impactor, at a low engine speed (rpm) (refer to “5.2.2 Engine Start-
up Sequence” on page 84), only on maintenance for 1 - 2 minutes.
12. Shut down the impactor, refer to “5.5 Machine Shut Down” on page 104.
13. Wait for pulleys to stop
14. Implement the LOCKOUT and TAG Procedure, refer to
“2.6.4 Isolation and energy dissipation” on page 40
15. Open flywheel guards.
16. Remeasure between the two marked points on the belt
17. Adjust belt accordingly.
18. Tighten the locknuts on the torque arm
19. Close the guards

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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 be
crushed. The operator has a choice as to how the QI240 will stockpile this graded material with the
use of the Diverter Chute and Side Conveyor.

Diverter Chute Handle

Position 1

Position 2

Position 3

When changing the position of the Diverter Chute ALWAYS

a. Implement the Lockout and Tag procedure, refer to “2.6.4 Isolation and energy
dissipation” 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 away
from 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.

Postion 3 - 100% of the graded material is mixed with the crushed material from the impactor
travelling on the main conveyor to be stock piled together.

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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 and
crusher chamber and that the conveyors are not producing a stock pile.

WARNING
FLYING MATERIAL HAZARD
There 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 HAZARD
There 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.

5.5.1 Auto Stop Sequence

Button 5

(Fig. 5.7)

1. Navigate to the Auto Start Stop menu display. By pressing button 1 on the main
menu 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 main
conveyor will stop.

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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.

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5.5.3 Emergency Stop

In the event of an accident or any serious problem with the machine you should press the nearest
emergency 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 the
safety 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 energy
dissipation” 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-up
Sequence” 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.

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Control Panel
Emergency Stop

Emergency Stop
Reset Button

Engine Kill Switch

Umbilical Tracking
Lead Engine Kill
Switch

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6.0 Operation

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.

6.1.1 Who is at Risk

• Operators, Maintenance Personnel,

• Subcontractors and anybody else in the vicinity of the machine

6.1.2 Managing Work related Hazards with a Risk Assessment

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:

• 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

6.1.3 When carrying out maintenance or adjustment

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

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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

Never use the bucket to force material into the crusher.
NOTICE 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.

• 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

WRONG! too Far into feeder WRONG! Too High UP

Fig 1

WRONG! Bucket in contact with feeder CORRECT!

Load from side

WARNING
FLYING MATERIAL HAZARD
Risk 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

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6.3 Common Applications

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.

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

Maximum feed size for crusher = 400mm x 400mm x 400mm [ slab size of
NOTICE 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.

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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 fragments
Never use wedges etc. to clear jams in the feed opening. Stones and fragments can be
thrown up at high speed from the impactor chamber

Explosives
Never 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 crushing
Never 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.

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 Emergency
stop function” on page 37) are fully functional
3. Inspect the machine at least once per shift for damaged or defective
components. If any damage is observed, or if the machine exhibits any
malfunction or other unexpected operation, notify management and your
maintenance department immediately.

6.5.1 Start-up Sequence For Running the Crusher

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:

• 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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a. Make sure all Emergency Stops (“2.6.1 Use of Emergency stop function” on page 37) are
released 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 are
shown respectively (Fig 6.5). It should take a few seconds. If there is a problem it will be shown on
the display.

(Fig 6.5)

Button 1 - Auto Mode

Button 2 - Tracks Mode
Button 3 - Fault Log
Button 4 - Customer Parameters
Button 5 - Engine Readings
Button 6 - Maintenance & Service Mode
Button 7 - Open Impactor / DC Motor

Fuel Level is also shown on footer as a percentage.

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.

button 1

Crusher Auto Run

Mode start up

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.

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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.

button 5

button 2

button 3

(Fig 6.6)

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.

• 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.)

Button 1 - Auto Stop

Button 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 Feeder
Button 5 - Feeder Start/Stop (10 second pre-start warning)
Button 6 & 7 - Feeder Speed adjustment
Button 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.

6.6.1 MMPRO S menu Flow chart in automatic Run mode

Button1 Main
Menu

Escape
Escape Escape Escape Escape

AutoStart Feeder Feeder Unblocking Information

Stop Control Parameter Screen Screen
Screen Screen

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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.

(Fig 6.7)

button 1

Manual Run Mode

Button 2

Manual Mode Menu

button 1

button 2

button 3

Back to Run Mode display Forward to

Feeder Control
display
Button 1 - Crusher Start/Stop
Button 2 - Pan-Feeder Start/Stop
Button 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 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 Control

The Feeder Parameter display can accessed from the Feeder Control display by using the left and
right buttons.

Feeder Control display

Select right arrow (3) on

Feeder Control display

Feeder Parameter display

(Fig 6.8)

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

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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

Feeder Parameter display

Select right arrow (4) on Feeder

Parameter display to access
Machine Adjustment display

Machine Adjustment display

(Fig 6.9)

Button 1 - Open Crusher Inlet

Button 2 - Close Crusher Inlet
Button 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

6.7.3 Tail Level adjustment

Machine Adjustment display

(Fig 6.10)

Select right arrow (5) on

Machine Adjustment display to
access Tail Level Adjustment
display

Tail Level Adjustment display

Material level at
tail conveyor
Function
disabled

Decrease Set
Point
Feed conveyor
automatic
Increase Set restart
Point

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.

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6.7.4 Diverter Chute

Diverter Chute Handle

Position 1

Position 2

Position 3

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 away
from 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.

Postion 3 - 100% of the graded material is mixed with the crushed material from the impactor
travelling on the main conveyor to be stock piled together.

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 while
the 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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6.8 Clearing Crusher Chamber Jam’s

6.8.1 Managing Work Related Hazards with a Risk Assessment

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:

• 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

Button1 Main
Menu

Escape
Escape Escape Escape Escape

AutoStart Feeder Feeder Unblocking Information

Stop Control Parameter Screen Screen
Screen Screen

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

Button 1

Button 2

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.

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7.0 Maintenance

7.1 Maintenance Safety

7.1.1 Who is at Risk

• Operators, Maintenance Personnel

• Subcontractors and anybody else in the vicinity of the machine

7.1.2 Managing Work related Hazards with a Risk Assessment

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:

• 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

7.1.3 When carrying out maintenance or adjustment

Implement the LOCKOUT and TAG Procedure, refer to

“2.6.4 Isolation and energy dissipation” on page 40.

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qi240 Maintenance

7.2 Maintenance Schedule

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

Months 2000 hrs

Every 6 Months
Every 3 Months
Every 250 Hrs

When Needed
Every 12
1000 Hrs
Weekly

500 Hrs
Daily
POWERUNIT - Engine
After First 50 Hours Carry Out Full Service on
Engine 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 If  
Required) Change Safety Cartridge Every 3rd
Time *
Fuel Water Trap System - Drain *  
Engine Fuel Filters - Change (More Frequent If  
Required)
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 

* Daily inspections required in severe environments

Months 2000 hrs

Every 6 Months
Every 3 Months
Every 250 Hrs

When Needed
Every 12
1000 Hrs
Weekly

500 Hrs
Daily
CRUSHER
V-Belt Tension - During Initial commissioning 
Check [ after 2~3 hours with material ] *
V-Belt Tension - Check 
Check Tightness of Hammers Daily During First  
40hrs 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 

* Refer to “7.2.2 Belt Tension” on page 135

** Refer to “7.5.6 Greasing Schedule” on page 164
NOTICE DAMAGE to the Impactor will occur if the wrong grease specification is used in
autolube systems. If the autolube option is fitted to the qi240, the grease
specified for the CI411 impactor MUST BE USED in the Autolube system.
Refer to “7.5.5 Lubricants and Fluids” on page 163 for the correct
specification.

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Months 2000 hrs

Every 6 Months
Every 3 Months
Every 250 Hrs

When Needed
Every 12
1000 Hrs
Weekly

500 Hrs
Daily
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 on 

Track Bolts & Gearbox Oil Levels
Replace Gearbox Oil 
General Guard Condition and Effectiveness - Check 
** Refer to “7.5.6 Greasing Schedule” on page 164

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 correctly
at 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 operational
these faulty items must be repaired before satrt up of machie.

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qi240 Maintenance

7.2.2 Belt Tension

Before inspecting the V Belt Tension

Implement the LOCKOUT and TAG Procedure, refer to

“2.6.4 Isolation and energy dissipation” on page 40

Torque Arm

Locknuts

Replacing Belt
1. 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 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.
6. Shut down the impactor, refer to “5.5 Machine Shut Down” on page 104.
7. Wait for pulleys to stop rotating

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
12. Close flywheel guards
13. 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.
14. Shut down the impactor, refer to “5.5 Machine Shut Down” on page 104.
15. Wait for pulleys to stop rotating
16. Implement the LOCKOUT and TAG Procedure, refer to
“2.6.4 Isolation and energy dissipation” on page 40
17. Open flywheel guards
18. Remeasure between the two marked points on the belt
19. Adjust belt accordingly (refer to “Adjusting the Belt” below)
20. Tighten the locknuts on the torque arm
21. Close the guards

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Adjusting the Belt

Before inspecting the V Belt Tension

Implement the LOCKOUT and TAG Procedure, refer to

“2.6.4 Isolation and energy dissipation” on page 40

1. Open flywheel guards.

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 CI411
impactor. The QI240 has a DC Maintenance Motor fitted to allow impactor maintenance with the
Engine turned off.

Control panel Chamber Switch

power on

To activate the DC motor

a. 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 timelock
prevents the impactor from being opened for pre determinded time period for
safety 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

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

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

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.

7.2.4 Engine Maintenance

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

WARNING
SAFETY HAZARD
Risk 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.

Please refer to the Engine Maintenance Manual in order to carry out the following important areas of
Engine 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’ the
battery charge cycle is complete.

d. Put the recharge unit in the support as shown

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7.2.6 Working at height hazard

DANGER
WORKING AT HEIGHT HAZARD
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.

7.2.7 Air Cleaner Inspection, Daily Inspection Required

1. Use a secure platform Inspection refer to “7.2.6 Working at height hazard” on

page 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 energy
dissipation” on page 40.
3. Use a secure platform and follow the instructions in “7.2.8 Air Cleaner
Maintenance” on page 142.

7.2.8 Air Cleaner Maintenance

DANGER

Breathing or inhaling dust particles will cause death or severe injury. Always work with a respirator
approved by the respirator manufacturer for the job you are doing. It is essential that the respirator
that you use protects you from the tiny dust particles which cause silicosis and which may cause
other serious lung diseases. You should not use the product until you are sure your respirator is
working properly. This means the respirator must be checked to make sure that it is clean, that its
filter has been changed, and to otherwise make sure the respirator will protect you in the way it is
meant to. Refer to “2.7.3 Dust” on page 44.
NOTICE DO NOT USE compressed air to clean the filter elements or filter body.
DAMAGE to the engine will result.

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

b. Wear the correct Personal Protective Equipment (refer to “2.2.3 Personal

protective 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.

Access Cover Retentation latches

Primary Filter Safety Filter

142 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Maintenance

7.2.9 Battery Maintenance

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

WARNING
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.

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

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

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

7.2.10 Checking Fuel Level, Adding Fuel and Draining fuel tank

WARNING
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.

Filler Cap

Drain bung

Checking Fuel -The fuel level of the machine can be checked by viewing the Control Panel display
guage. 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 energy
dissipation” 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.

144 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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qi240 Maintenance

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

7.2.11 Emptying the Fuel Filter Water Trap

Water trap

WARNING
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, refer
to “2.9 Safety considerations for maintenance” on page 46.

a. Unscrew the drain bung at the bottom of the water trap and allow the water to
drain 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.

WARNING
CHEMICAL HAZARD
Diesel 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.

7.2.12 Special Considerations For Maintenance Or Repair with Welding

Before welding;
Refer to the CI411 maintance manual for welding operations of the CI411 Impactor

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:

• 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.

• 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

ISOLATOR

LCD

146 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Maintenance

7.3 Hydraulic System

It is essential the Hydraulic System is regularly serviced in accordance with

NOTICE the Maintenance Schedule. When Maintenance is being carried out on the
hydraulics it is essential that extreme care regarding cleanliness is
practiced. Contamination of the hydraulic System will reduce working life of
hydraulic components and will increase the chances of Hydraulic Motor/
Pump Failure

WARNING
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 Personal
protective equipment” on page 29, when performing any adjustment or
maintenance on the Hydraulic System.

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 the
indicator is below the Lower Black Line, hydraulic oil must be added.

Indicator

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ID:QI240.en.ver.2
qi240 Maintenance

7.3.2 Hydraulic Oil is added as follows

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

b. Implement the Lock out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” 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 pressure
in the tank.

d. Make sure that the Return Line Filters (HT2), and the area around the return line
filters, 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 rise
upwards , to remove the cover push back down and turn the cover. Hydraulic oil
must be added through the uncovered Return Line Filter, to make sure the
hydraulic oil is filtered on entering the tank.

f. Fill the tank to the Upper black markings on HT3. Make sure that the correct grade
of Hydraulic Oil has been selected (“7.5.3 Hydraulic Oil Requirements for QI240
Machines” on page 162)
HT1
Filter cover bolts Return line filter cover

HT2

HT3

7.3.3 Changing The Return Line Filter

Filter cover bolts Return line filter cover

Lifting handles

Filter Element

a. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” 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 pressure
in the tank.

c. Make sure that the Return Line Filters (HT2), and the area around the return line
filters, 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 rise
upwards , 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.

WARNING
SKIN INJECTION HAZARD

Fluid at high pressure can penetrate the skin, causing serious allergic reaction
and even death.
Wear the correct Personal Protective Equipment, refer to
“2.2.3 Personal protective equipment” on page 29.

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

g. Re-fit the new filter.

h. Replace cover and tighten bolts.

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

7.3.4 Changing The Suction Filters and the Hydraulic Oil.

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

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 energy
dissipation” on page 40.

Wear the correct Personal Protective Equipment, refer to

“2.2.3 Personal protective equipment” on page 29.

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

HT1

HT3
Drain Bungs

Inspection Plates

c. Slowly unscrew the Hydraulic Breather Cap HT1 to release any build up of
pressure 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 under
the tank. Dispose of waste in accordance to environmental statement.

e. Remove the tank inspection plates.

f. Unscrew and remove the Suction Filters

Suction
filters

qty 3

g. It is recommended that the Hydraulic Tank be flushed out with clean Hydraulic Oil
to rid the tank of all contaminants. Dispose of waste in accordance to
environmental 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 Line
Filter” on page 150.

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

l. Re-attach the Hydraulic Breather Filter HT1.

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

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 the
indicator is below the Lower Black Line, hydraulic oil must be added.
tank cover plate

Indicator

7.3.6 HPTO Clutch adding hydraulic oil

a. Implement the Lock out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” 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 and
the tank cover plate and add the required quantity of new HPTO clutch oil. Refer
to “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 and
the tank cover plate.

c. Drain the oil into a suitable container by removing the Drain Bungs located under
the 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 Oil
to rid the tank of all contaminants. Dispose of waste in accordance to
environmental 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 Oil
Requirements for HPTO Clutch” on page 163.

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

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 environmental
statement.

e. Twist on the new filter.

f. Restart the engine, Refer to “5.2.2 Engine Start-up Sequence” on page 84 and
let 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.

7.4 Track Maintenance

ALWAYS
1. 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 adequately
support the machine.
3. Make certain the machine is tracked at least 10m in either direction on a
daily 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.

NEVER
1. 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 Conditions
If your machine will be working in materials which cause corrosion to carbon steel you must replace
standard tracks with lubricated tracks to avoid seizure of the track joints. Lubricated tracks are
available as an optional extra from new or as a retrofit for customers entering adverse working
conditions.Contact Sandvik Mining and Construction Mobile Crushers and Screens Ltd.

7.4.1 Checking the Track Tension

Cover Plate

Track Cover Plate

Track Sag

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 energy
dissipation” on page 40.

c. Measure the sag on the top part of the track on the longest section unsupported
track 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 the
track sag is below 5mm the tracks need loosened.

7.4.2 Tighten the Tracks

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

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

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

d. Drive 50 metres forward and 50 metres backwards and repeat the above
procedure 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 energy
dissipation” on page 40. Loosen the two screws and remove the aperture cover
from the side of the track frame.

b. Loosen the grease fitting, by turning in an anti-clockwise direction, using gradual

increments 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 by
turning in a clockwise direction and clean away all traces of extruded grease. Be
sure 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 fitting
loosened may help to expel the grease.

7.4.4 Track Drive Units

The first oil replacement for the gearbox is to be carried out after 100 hrs. Thereafter replace the oil
every 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.

Oil Level

Maximum Level

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.

Ventingl

Drain Portl

7.5 Tensioning the Side Conveyor Belt

WARNING 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.

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

1. Implement the LOCKOUT and TAG PROCEDURE, refer to “2.6.4 Isolation and
energy dissipation” on page 40.
2. Loosen bearing bolts on both bearings of the idler drum just enough to allow
movement for adjustment.
3. Start the engine and start the conveyor (“6.5.1 Start-up Sequence For Running the
Crusher” 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 and
energy dissipation” on page 40.Re-tighten the bearing bolts..

Adjuster

Bearing Bolts

7.5.1 Tensioning The Main Conveyor belt

NIP POINT HAZARD
WARNING
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.

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

1. implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40
2. Use a secure platform, refer to “7.2.6 Working at height hazard” on page 141, to
loosen locknut ‘b’ on the left and right hand sides.
3. Tighten the belt by adjusting both belt adjusters ‘a’ (one on right and left hand
side) 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 Running
the Crusher” on page 116)
6. Inspect the tension of the belt and if more tension is required repeat steps
1. to 6. as necessary.

Adjuster A
Locknut B

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 should
NOTICE
be remedied immediately. If action isn’t taken the belt life will be
shortened and through put wont be as efficient due to spillage.

DANGER

WORKING AT HEIGHT HAZARD

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.

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 are
mounted at 90 Degrees to the conveyor frame about the central axis.
3. Run appropriate conveyor and observe the way the belt is tracking.

WARNING
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.

IF THE BELT IS TRACKING TO THE LEFT ADJUST THE LEFT ADJUSTER. IF THE BELT IS
TRACKING 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 and
energy dissipation” on page 39.
12. Remove the guard and re-tighten the bearing bolts.
13. Re- fit and secure the guard.

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. The
maximum recommended operating temperature with this oil type is about +80°C (175°F) and
minimum recommended starting temperature is about -20°C(-5°F), which makes it suitable for use
all year round in most operating conditions. Below are some examples of oil brands meeting these
requirements:

• 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), the
use of a special hydraulic oil of ISO VG 32 class is recommended the max.allowable operating
temperature with this oil type is about +65°C (150°F) and min. allowable starting temperature is
about -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 special
hydraulic oil of ISO VG 68 class is recommended. The max. allowable operating temperature with
this 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

7.5.4 Hydraulic Oil Requirements for HPTO Clutch

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

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

7.5.5 Lubricants and Fluids

INTERNATIONAL
COMPONENT SAMPLE
SPEC
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

SAE 30 Caterpillar TDTO (SAE 30
Fluid Clutch
ONLY)
Impactor CI4112 Contact Sandvik Castrol Optimol PD2

Drive Belt System - Idler Contact Sandvik Mobil Unirex N3 NLGI3

Drum

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

7.5.6 Greasing Schedule

Number of Quantity of
Description Frequency
bearings Grease
1 - Side Conveyor 250 hours 4 7

2 - Impactor RH/LH
a) Curtain Pivot Points Rh/ 250 Hours 2 7g
Lh
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 250 Hours 2 7g

bearings
c) Idler Pulley 40 Hours 2 3g

The frequency of the schedule above is recommend for normal working conditions. The frequency
should change if the machine is operating in
• conditions which deviate in temperatures,
• environments with excessive contamination
• excessive operating temperatures

Visually inspect all bearings daily.

3
4 2

3
2 - located behind guard 1

Grease Point 7 a

b c

7.5.7 Care of chrome

The following information should be used in order to maximise the life of the Chrome Rods. All
hydraulic rods must be greased to protect against corrosion.A full protective coverage of the chrome
is 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
Cleaning
Nitric Solvent (without Chlorate) is recommended in necessary cleaning of Chrome. The use of
anything else may harm or reduce the protection of the chrome.

WARNING
SAFETY HAZARD
Nitric Solvents contains corrosive chemicals.
Do not allow contact with any exposed body parts.

Wear the correct Personal Protective Equipment, refer to “2.2.3 Personal

protective equipment” on page 29.

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*

8.0 Trouble Shooting and Engine Warranty

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 167
ID:QI240.en.ver.2
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.

8.1.1 Who is at Risk

• Operators, Maintenance Personnel,

• Subcontractors and anybody else in the vicinity of the machine

8.1.2 Managing Work related Hazards with a Risk Assessment

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:

• 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

8.1.3 When carrying out maintenance or adjustment

Implement the LOCKOUT and TAG Procedure, refer to

“2.6.4 Isolation and energy dissipation” on page 39.

168 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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
Overview
The function of the PSVS controls is to receive electrical commands from the Control panel and
then the PSVS controls will operate the hydraulic control levers. This allows the operator to
diagnose non responsive commands from the Control Panel.
The PSVS levers are self returning, so if a constant function is required then the corresponding
lever needs to be manually held in position for the same duration. Once the lever is released the
flow of hydraulic oil to the function is stopped.

8.1.5 Service Engineer Selection for PSVS Diagnosis

The use of the PSVS controls is ONLY Permitted by trained and authorised Service Engineers.

WARNING RANDOM OPERATION OF MACHINERY HAZARD

8.1.6 PSVS Diagnosis for Hydraulic or Electrical Faults

If 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 electrical
fault. If the PSVS control lever moves and the function does not work, then the fault is hydraulic
related. Alternatively manually operate the corresponding lever as shown below. If the Main
conveyor 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 to
return to normal operation.

1
2

3
4 7 8 9 10 11 12 13
5
6

PSVS

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 169
ID:QI240.en.ver.2
Trouble Shooting qi240

LH Track Main Dirt Conveyor Impactor Primary

Hydraulic Oil Cooler
forward Conveyor ON Inlet Raise Feeder ON
Fan Forward
ON
1 2 3 4 5 6

Hydraulic Oil Cooler LH Track - - Impactor -

Fan Reverse backward Inlet Lower

Top Apron Main Conveyor UnderPan PreScreen Recirculation RH Track Jack

Open Raise Feeder ON ON Screen ON forward Legs

7 8 9 10 11 12 13
Main Conveyor - Auxillary - RH Track -
Top Apron
Lower hydraulic backward
Close
power ON*

* 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.

170 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Trouble Shooting

8.1.7 Engine Diagnostic Codes

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 171
ID:QI240.en.ver.2
Trouble Shooting qi240

172 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Trouble Shooting

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].

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 173
ID:QI240.en.ver.2
Trouble Shooting qi240

8.3 CAT Register Instructions

174 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Trouble Shooting

8.3.1 CAT C Series Warranty Statement

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 175
ID:QI240.en.ver.2
Trouble Shooting qi240

9.0 Spare Parts

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 takes
the form of a number of ‘exploded’ illustrations of the various machine assemblies. Components
illustrated 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]

9.1.3 Managing Work related Hazards with a Risk Assessment

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:

• 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

9.1.4 When carrying out maintenance or adjustment

Implement the LOCKOUT and TAG Procedure, refer to

“2.6.4 Isolation and energy dissipation” on page 39.

9.2 Top Level

9.2.1 Hydraulic Water Pump Option

9.3 Hopper Wing Plates

9.4 Chassis Complete

9.4.1 Chassis Tower

9.4.2 Oil Cooler Mount

9.4.3 Tension Pulley Mount

9.4.4 Pulley Mounting Complete

9.4.5 Tension Pulley Frame Complete

9.5 Walkway

9.6 Control Box

9.7 Feeder
Item No. Part No. Description
Pos. Nr. QTY Art. Nr. Benämning

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

5
8
9

23
10
2
4
2

22
4

25 26 24

12
3

27 21 20
14
13

16
18
19

Item No. Description

Pos. Nr. QTY PartNo
Benämning
1 1 713.1955-901 Frame Of Vibrating Unit
2 2 713.1957-001 Shaft
3 4 713.0665-001 Bearing 22313CC W33A15
4 4 713.0666-001 Interm ring
5 4 713.0667-001 Fling ring
6 4 713.0668-001 Wear ring
7 4 713.0669-001 O-ring 139.3x5.7
8 4 713.0671-001 Cover
9 4 990.0852-001 Shaft Seal A70x90x10
10 4 713.0673-001 O-ring 54.2x3
11 4 713.0674-001 V-ring V-75S
12 4 713.1965-001 Counterweight
13 2 713.0676-001 Gear wheel
14 2 713.0677-001 Lock washer MB11
15 2 713.0678-001 Shaft nut KM11
16 4 990.0068-001 Greasing nipple M10X1
17 36 990.0176-005 Screw M12x40 DIN933 - 8.8A3G
18 1 713.1958-901 Counterweight Guard
19 1 713.0680-901 Guard of counterweight
20 52 990.0174-005 Screw M10x40 DIN933 - 8.8A3G
21 52 990.0269-001 Washer 11 DIN126 - A3G
22 44 990.0186-001 Nut M10 DIN985-8A3F
23 8 990.0222-008 Screw M16x80 DIN931 - 8.8A3G
24 6 990.0270-001 Washer 14 DIN126 - A3G
25 6 990.0187-001 Nut M12 DIN985-8A3F
26 2 990.0221-006 Screw M12x70 DIN931 - 8.8A3G
27 2 713.0709-001 Key C 16x10x90 DIN6885
28 2 713.0710-001 Key C-16x10x55
29 1 713.1168-901 Adapter
30 1 990.0632-001 Coupling Juboflex 632508
31 1 726.0573-901 Adapter
32 1 713.0755-001 Tension plate
33 1 713.0756-001 Silicone
34 6 713.1174-001 Nordlock NL16 DIN 25201
35 2 990.0064-001 Breather FFHU2015
36 2 723.0294-001 Bearing tube oil cauce
37 2 990.0065-001 Oil plug R1/2"
38 1 713.0705-001 Filling plug. breather
39 2 713.0706-001 Plug T8 DN20 R3/4" 5031
40 1 713.0704-001 Oil sight window TLA5G MINTOR
41 1 713.0759-001 Gear oil ISO VG220+EP
42 1 713.1363-001 Shaft oil ISO VG220+EP
43 2 713.1761-001 Hexagon nipple R 3/4
44 2 713.1760-001 Equal socket Rp3/4
45 1 HM1046 Eaton DAM 74328
46 4 840.0047-00 Screw M6S 12x40 8.8 ISO 4017
47 4 847.0147-00 Washer BRB 13x24 HB200 ISO 7089
48 5 845.0030-00 Nut Lock ISO 7040 M12 FZB
49 2 840.0048-00 Screws M6S 12x45 8.8 ISO 1417

6
45

10 11
18
47 25 49

9
5
4
7
46 47 48

31
23

35 44 43
17

3
36
18

4
37
32
28

8
21 22 20
26

16 15 14 13
38
2
39
1

40
33

19
27
12

9.8 Pan Feeder

9.9 Main conveyor

9.9.1 Main conveyor Lower Section

9.9.2 Main Conveyor Upper section

9.9.3 Main conveyor Head Section

9.10 Side Conveyor

9.10.1 Side Conveyor Lower Section

9.10.2 Side Conveyor Mid Section

9.11 Pre Screen

9.12 Diverter Chute

9.13 Belt Guard

9.14 Drive Pulley

9.15 CI411 Impactor

9.16 QI240 Powerpack

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2a
4 CN7898 ENGINE OIL CAT DEO-ULS SAE 15W-40 ORSHELL RIMILAR R4T L 15W-40 36
3 CN6071 ANTIFREEZE SHELL SAFE 1000 IBCPRICE PER LITRE 36
2 EN9601 CAT C9 TIER 3A NEW BUILD SPECIFICATION 1
1 CB0101 QI240 CLUTCH CAT C9 (3A) POWERPACK 1
This drawing and all the enclosures belong to us. They must not be copied

given to a third party or used for manufacturing purposes without our per-

ITEM PART No. DESCRIPTION QTY

mission. As to infringements hereof, legal action will be taken with the
or duplicated - neither in original, nor in modified form - shown to or

Parts List
DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) D esigned. Drawn By. Checked. Approved. Scale. Projection. Material
SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK %, 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
WELD CLASSES ACCORDING TO CASTINGS W eight. 4126.76 kg Sheet.
1 of. 1
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
3 .2 15/08/2011 A2
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
QI240 TIER 3A EU PRE-BUY POWERPACK

support of the existing law.

Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
ORIGINAL ISSUE
Spare Parts

DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm

ASSY

222
REV ECO DESCRIPTION DATE CHANGED BY FABRICATION
MACHINED
±1.0mm
±0.25mm
±2.0mm
±0.5mm
±3.0mm
±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
QI2403APPEUPB
REVISION HISTORY ANGULAR ±1.0° ±0.5° ±0.25°
ENGLAND, PHONE 01283 212121
qi240

ENGINES USED IN THIS POWERPACK FIT SOOT GUARD UP SIDE

EN9601 CAT C9 TIER 3A EU PRE-BUY DOWN FOR TRANSPORT
EN9696 CAT C9 TIER 3A LESSER REG COUNTRIES
EN9697 CAT C9 TIER 3A US FLEX
EN9698 CAT C9 TIER 3A EU FLEX

47 B17110000 CAT C9.3 TIER IV 12" CLUTCH BRACE 1

46 EN9933 24V PUMP 1
45 BT10027_1 PTTECH 12" CLUTCH MANIFOLD - CHYMA-24V-004 1
44 B16570000 PT TECH 12 INCH MANIFOLD MOUNTING BRACKET 1
43 BT10028 PT TECH TORSIONAL COUPLING TO SUIT CAT C9 1
FCACT5-F5B-A113
42 EN9921 O' RING I/D Ø82.5mm, 3mm DIA MATERIAL 1
41 EN9922 O' RING I/D Ø127mm, 3mm DIA MATERIAL 2
40 CB0195 HYDRAULIC DRIVE POWERPACK SEALING RUBBER 1
KIT(CLUTCH TYPE)
39 HP8856 75CC PUMP SAE B 13 TOOTH 11053569P 1
38 HF9917 PT-TECH WET CLUTCH FILTER ASSEMBLY - CHYFA-001-D 1
37 HP8828 19cc ANTI-CLOCKWISE PUMP (SD NO. 1112046500) 1
36 10-24-1131 SAUER DANFOSS LOAD SENSING SERIES 45 AXIAL PUMP 2
130CC
35 B17650000 SOOT GUARD 1
34 B17550000 C9-3A BELT GUARD BRACKET 1
33 B17530000 C9-3A BELT GUARD 1
32 EN9624 IN LINE CHECK VALVE (38MM/50MM) 1
31 EN9623 90 ELBOW / ADAPTOR (38MM OUTLET) 1

ID:QI240.en.ver.2a
30 B17320000 CAT C9 (3A) TURBO COVER SUPPORT ASSY 1
29 B17310000 CAT C9 (3A) TURBO COVER ASSY 1

28 EN9759-QI240 ENGINE KIT C9 3A suits QI240 MODEL 1

27 EN9687 PSD 10 AIR CLEANER ASSEMBLY LONG VERTICAL (BLUE 1
MEDIA)
26 EX7014 3-TUBE WIRE WOUND OIL COOLER BECC0126380 1
25 B17300000 CAT C9 FUEL & CLUTCH FILTER BRACKET 1
24 B14620000 BRACKET ASSY - TIER IV CLUTCH FILTER 1
23 10-21-0320 SAUER DANFOSS (FHP320-2 BA G2 A25 N E7) - for 130B 2
22 HV8589 SAUER DANFOSS PROPORTIONAL FAN CONTROL HIC, 1
ALLOWING REVERSE FLOW RFD-120-PRV-24L-DE-S-210-6B
21 ex7008 BECOOL RADIATOR COMPLETE TO INC 1
BEC960,BECC0394240, BECC0180380
20 EL9686 LED WORKING LAMP 12/24V DURITE PT No 0-420-70 2
19 B16880000 EXTERNAL FILTER SHROUD FRONT 1
18 B16870000 EXTERNAL FILTER SHROUD ASSY REAR 1
17 B16820000 EXTERNAL DOUBLE FILTER BRKT 1
16 B16520000 TIER IV PP BULKHEAD BLANKING PLT 1
15 EL9716 12 VOLT HEAVY DUTY 725 BATTERY (725TX) COLD CLIMATE 2
USEAGE

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
14 FAN30 M30 FULL NUT 1
13 BT10027 PT TECH WET CLUTCH - HPTO 12 FLEX HOUSING ASSY 1
12 B16920000 POWERPACK HANDRAIL 1
11 B16000000 TIER 4 PROPORTIONAL VALVE MTG BRKT 1
10 B15880000 MOUNTING BRACKET(FUSE B0X) 1
9 B15850000 TIER 1V FLOOD LIGHT TRANSPORT BRKT ASSY 1
8 B15840000 TIER 1V FLOOD LIGHT MAST ASSY 1
7 B15830000 TIER 1V FLOOD LIGHT BASE ASSY 1 A 7883 BG CLUTCH DRIVE MODELS & BOMS UPDATED 28-09-11 mevans
6 B14040000 TIER IV C9.3 AIR FILTER SHROUD 1 REV ECO DESCRIPTION DATE CHANGED BY
5 B12370000 BATTERY CLAMP TO SUIT EL9716 12V HD BATTERIES 1 REVISION HISTORY
DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) D esigned. Drawn By. Checked. Approved. Scale. Projection. Material
4 B12360000 BATTERY HOLDER TO SUIT EL9716 12V HD BATTERIES 1 SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
$:22'
3 B18010000 BG CAT C9.3 TIER 4 ENGINE SUPPORT 1 WELD CLASSES ACCORDING TO CASTINGS W eight. 3784.45 kg Sheet. of.
1 3
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
2 CB0082 TIER IV C9.3 CLUTCH POWERPACK (QI240) 1 3 .2 05/04/2011 A2
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
Drawing No. Revision.
1 CB0200 BG CLUTCH DRIVE TIER IV CENTRAL CORE POWERPACK 1 TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm QI240 CLUTCH CAT C9 (3A) POWERPACK
ITEM PART No. DESCRIPTION QTY FABRICATION ±1.0mm ±2.0mm ±3.0mm
MACHINED ±0.25mm ±0.5mm ±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
CB0101 A
ENGLAND, PHONE 01283 212121
Parts List ANGULAR ±1.0° ±0.5° ±0.25°

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

223
Spare Parts
qi240

26 21 39 HIDDEN

ID:QI240.en.ver.2a
43
44
32
33
29
36 24 30
41 38
37
42
25
13
36
given to a third party or used for manufacturing purposes without our per-

46
mission. As to infringements hereof, legal action will be taken with the
to o

41
s o

D esigned. Drawn By. Checked. Approved. Scale. Projection. Material

44 DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS)
IF IN DOUBT ASK
od ed o

SCREW THREADS ARE ISO METRIC COURSE PITCH

MEDIUM FIT UNLESS OTHERWISE STATED.
$:22' 3rd ANGLE
WELD CLASSES ACCORDING TO CASTINGS W eight. 3784.45 kg Sheet.
2 of. 3
o g a, o

ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)

support of the existing law.
45 MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
3 .2
Date.
05/04/2011
Drawing Size.
A2
Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
QI240 CLUTCH CAT C9 (3A) POWERPACK
o dup cated e t e
DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm
Spare Parts

224
FABRICATION
MACHINED
±1.0mm
±0.25mm
±2.0mm
±0.5mm
±3.0mm
±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
CB0101 A
ENGLAND, PHONE 01283 212121
ANGULAR ±1.0° ±0.5° ±0.25°
qi240

40 1

14 7

9
5

17 11

ID:QI240.en.ver.2a
10
23
23
19 46

27
6
4

3
16

31 47
32
DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) D esigned. Drawn By. Checked. Approved. Scale. Projection. Material
SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
$:22'
WELD CLASSES ACCORDING TO CASTINGS W eight. 3784.45 kg Sheet. of.
3 3
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
3 .2 05/04/2011 A2
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
2 Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm QI240 CLUTCH CAT C9 (3A) POWERPACK
FABRICATION ±1.0mm ±2.0mm ±3.0mm
MACHINED ±0.25mm ±0.5mm ±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
CB0101 A
ENGLAND, PHONE 01283 212121
ANGULAR ±1.0° ±0.5° ±0.25°

225
Spare Parts
Spare Parts qi240

9.16.1 Diesel tank

9.16.2 Hydraulic Oil Tank

9.16.3 Clutch Lube Tank

9.17 Magnet Spares

9.17.1 CAT Engine Spare Parts

Qty per Part No Description
Engine

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)

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

Modified 13/03/2012 Tullyvannon,

Ballygawley,
Part no. 10-21-9006 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 EN1202 1
4 CAT Seconday Fuel Filter EN1203 1

5 Air filter element EN9617 1

6 Air filter safety element EN9618 1

Description QI240 PLANT AND ENGINE FILTER KIT (CAT C9 TIER 3A) - 500HRS
Revision 0.00

Modified 13/03/2012 Tullyvannon,

Ballygawley,
Part no. 10-21-9021 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 EN9556 1

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
11 HYD TANK BREATHER ELEMENT HF9524 1

Fuel Tank
12 HYD TANK BREATHER ELEMENT HF9524 1

Description QI240 PLANT AND ENGINE FILTER KIT (CAT C9.3 TIER 3B) - 500HRS
Revision 0.00

Modified 13/03/2012 Tullyvannon,

Ballygawley,
Part no. 10-21-9022 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 EN1202 1
4 CAT Seconday Fuel Filter EN1203 1

5 Air filter element EN9617 1

6 Air filter safety element EN9556 1

PT Tech Clutch
7 Clutch lub filter element HF9920 1
8 Clutch Breather HF9523 1
9 HYD TANK BREATHER ELEMENT HF9524 1

Hydraulic system
10 High pressure filter element 10-21-0321 2
11 Return filter element 10-21-0031 3
12 HYD TANK BREATHER ELEMENT HF9524 1

Fuel Tank
13 HYD TANK BREATHER ELEMENT HF9524 1

Description QI240 PLANT AND ENGINE FILTER KIT (CAT C9 TIER 3A) - 2000HRS
Revision 0.00

Modified 13/03/2012 Tullyvannon,

Ballygawley,
Part no. 10-21-9029 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 EN9556 1

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
11 HYD TANK BREATHER ELEMENT HF9524 1
12 1" SUCTION FILTER 10-21-0003 1
13 2 1/2" SUCTION FILTER 10-21-0007 3

Fuel Tank
14 HYD TANK BREATHER ELEMENT HF9524 1

Description QI240 PLANT AND ENGINE FILTER KIT (CAT C9.3 TIER 3B) - 2000HRS
Revision 0.00

Modified 13/03/2012 Tullyvannon,

Ballygawley,
Part no. 10-21-9030 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 EN1202 1
4 CAT Seconday Fuel Filter EN1203 1

5 Air filter element EN9617 1

6 Air filter safety element EN9556 1

PT Tech Clutch
7 Clutch lub filter element HF9920 1
8 Clutch Breather HF9523 1
9 HYD TANK BREATHER ELEMENT HF9524 1

Hydraulic system
10 High pressure filter element 10-21-0321 2
11 Return filter element 10-21-0031 3
12 HYD TANK BREATHER ELEMENT HF9524 1
13 1" SUCTION FILTER 10-21-0003 1
14 2 1/2" SUCTION FILTER 10-21-0007 3

Fuel Tank
15 HYD TANK BREATHER ELEMENT HF9524 1

10.0 Electrical and Hydraulic

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 237
ID:QI240.en.ver.2
Electrical and Hydraulics qi240

10.1 Electrical Schematics

238 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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qi240 Electrical and Hydraulics

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240 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Electrical and Hydraulics

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 241
ID:QI240.en.ver.2
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Gateway/Data Logger
GW3000

242 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Electrical and Hydraulics

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 243
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244 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Electrical and Hydraulics

Gateway/Data Logger
GW3000

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 245
ID:QI240.en.ver.2
Electrical and Hydraulics qi240

246 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Electrical and Hydraulics

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248 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Electrical and Hydraulics

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 249
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Electrical and Hydraulics qi240

250 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Electrical and Hydraulics

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252 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Electrical and Hydraulics

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254 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
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Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 255
ID:QI240.en.ver.2
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K14
1X1
RADIO
7XA

K7 K8 K9 K12 K13

T1
K6 K10

K4
K3
K2
K11
A102B

A102A
MC88

256 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
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4S1
2S1
LAYOUT OF PANEL LID

3S1
A101

JDP
1S1

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X10B
X47A

X10A
LAYOUT OF PANEL SIDES

X31B

Handset
GX1
X23A
X31A
X40A

HCP

MAX
20A

C200 Drive Lamps 1

C201 Drive Lamps 2

C202 Hopper Level

C210 Side Conveyor Pull Stop

ID:QI240.en.ver.2
C203 Crusher Speed Sensor

C211 Side Conveyor Speed Sensor

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
259
Electrical and Hydraulics
Electrical and Hydraulics qi240

10.2 Hydraulics

10.2.1 Hydraulic Circuit Diagrams

260 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
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10.2.2 Hydraulic Hose Kits

t Number Rev

29-9250 0.02 QI240 Jack Leg Hose Kit

Part No. Rev: Length: Coupling: Orient

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

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

29-9251 0.01 QI240 Hopper Door Hose K

Part No. Rev: Length: Coupling: Orient

m CV to rear hopper door raise 10-29-1620 0.01 3330 90+ST

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

29-9252 0.02 QI240 Side Conveyor Hose

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 261
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Electrical and Hydraulics qi240

Number Rev

9-9254 0.03 QI240 Track Hose Kit

Part No. Rev: Length: Coupling: Orient:

d from left hand track motor to bleed manifold 10-29-1690 0 2200 90+ST
d 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 QI240 Primary Feeder Hose

Part No. Rev: Length Coupling Orient.

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

9-9256 0.03 QI240 Pre Screen Hose Ki

262 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Electrical and Hydraulics

Part Number Rev

10-29-9257 0.03 QI240 Pan Feeder Hose Kit

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

Grease Pipes
From bulkhead to top grease point on left hand side motor 10-29-2063 0 1150 90+ST 2SC
From bulkhead to bottom grease point on left hand side
motor 10-29-2064 0 1250 90+ST 2SC
From bulkhead to top grease point on right hand side
motor 10-29-2065 0 850 ST+ST 2SC
From bulkhead to bottom grease point on right hand side
motor 10-29-2066 0 950 ST+ST 2SC
Note
FIT 1/8 BSP FITTINGS TO GREASE PIPES
Part Number Rev

10-29-9258 0.03 QI240 Magnet Hose Kit

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

From tee on magnet FCV to BHD 10-29-1738 0 3020 45+ST 2SC

From BHD to bleed tee 10-29-1739 0 3200 90+ST 2SC
From BHD to motor P port 10-29-1733 0 670 90+ST 2SC
From BHD to motor R port 10-29-1734 0 600 90+ST 2SC
From BHD to motor bleed port 10-29-1735 0.01 620 90+ST 2SC
Part Number Rev

10-29-9259 0.03 QI240 Main Conveyor Hose Kit

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

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

Grease Pipes
Head drum non-drive side 10-29-1764 0 5900 90+ST 2SC
Head drum drive side 10-29-1765 0 4800 90+ST 2SC
Tail drum non-drive side 10-29-1759 0.01 4880 90+ST 2SC
Tail drum drive side 10-29-1760 0.01 5990 90+ST 2SC
Note

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 263
ID:QI240.en.ver.2
Electrical and Hydraulics qi240

10-29-9261 0.03 QI240 Oil Cooler Hose Kit

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

Oil 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-
16S 90+ 1/2 "
Oil cooler BHD to oil cooler motor P 10-29-1786 0 520 BSP, ST 2SC-
16S 90+ 1/2 "
Oil cooler BHD to oil cooler motor R 10-29-1787 0 490 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-
Note
16S REFERES TO METRIC FITTINGS. ALL OTHERS PIPES ARE BSP.
Part Number Rev

10-29-9262 0.05 QI240 Front Of Chassis Hose Kit

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

Left hand side of chassis
From 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 chassis
From 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-
Note
20S REFERES TO METRIC FITTINGS. ALL OTHERS PIPES ARE BSP.
Part Number Rev

10-29-9263 0.04 QI240 Centre Chassis Hose Kit

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

Left hand side chassis
From 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 manifold 10-29-1813 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 chassis
From centre Bleed Manifold to Hydraulic Tank Bulhead 10-29-2058 0 2210 90+ST 2SC-
Part Number Rev

10-29-9264 0.02 QI240 Rear Chassis Hose Kit

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

From bleed return manifold to steel pipe 10-29-1831 0 1030 90+ST 2SC-
From tee at pre-screen non-return valve to return manifold 10-29-1832 0 1250 90+ST 2SC-

264 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI240.en.ver.2
qi240 Electrical and Hydraulics

Number Rev

9-9265 0.03 QI240 Impactor Hose Kit

Part No. Rev: Length: Coupling: Orient:

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+ST
m tee to impactor inlet ram top ports 10-29-1854 0.01 1240 90+ST
m tees to rams of impactor box open/close 10-29-1867 0 800 45+ST
m double bank CV at oil cooler to tee top curtian 10-29-1868 0 2240 Block90+ST
m double bank CV at oil cooler to return manifold 10-29-1869 0 2200 90+ST
m tee to top curtain ram 10-29-1844 0 3850 90+ST
m double bank CV at oil cooler to btm curtain open
10-29-1845 0 2280 Block90+ST
m double bank CV at oil cooler to btm curtain close
10-29-1846 0 2400 Block90+ST
m 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+ST
m impactor box open/close tee to CV 10-29-1824 0 1920 90+ST
m chassis BHD to bottom curtain ram open/close 10-29-1825 0 2850 90+ST
m 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 Rev
9-9266
QI240 Power Unit Hose K

0.07

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

m 24v pump to bolt on bulkhead 10-29-1898 0 2475 90+ST
ch Block (RTN) - BH 10-29-3519 0 1800 45+ST
c Pump 1

1 1/4 BSP ST+ 90

p - Pressure filter 10-29-3575 0.01 1200 flange
m 2" Bulkhead to pump 10-29-2048 0.01 2160 45+ST
p case drain to BHD 10-29-2050 0 3170 90+ST
c Pump 2

1 1/4 BSP ST+ 90

m pump 2 to high pressure filter 10-29-3237 0 1360 flange

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 265
ID:QI240.en.ver.2
Electrical and Hydraulics qi240

art Number Rev

0-29-9267 0.04 QI240 Hydraulic tank

Part No. Rev: Length: Coupling: Orient:

rom hydraulic tank to power unit (24v pump suction) 10-29-2057 0 2060 90+ST
rom hydraulic tank to power unit (Radiator pump suction) 10-29-2054 0 1950 90+ST R
I

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
rom hyd tank to 2"BHD suction pump1 10-29-2055 0 870 90+ST R
rom hyd tank to 2"BHD suction pump2 10-29-2056 0 1240 90+ST R
rom 7 bank PVG to pump 1 (load sensing) 10-29-1889 0.01 4450 90+ST
rom 6 bank PVG to pump 2 (load sensing) 10-29-1890 0.01 4390 ST+ST
rom bolt on bulkhead to clutch oil tank (oil cooler clutch
ock return) 10-29-1892 0.01 1310 90+ST
rom bolt on bulkhead to bleed manifold (radiator motor
eed) 10-29-1894 0.02 950 90+ST
3000series 45
flange+3000serie
rom clutch to clutch tank (drain hose) 10-29-1896 0.01 730 s ST flange
rom fan block BHD to return filter steel pipe 10-29-1950 0 460 90+ST
rom clutch silver pump to suction on clutch tank side
ort 10-29-1953 0 1690 90+ST
rom Hyd Tank BHD to Hyd Tank (Case Drain Rtn) 10-29-1954 0 1900 45+ST
rom Hyd Tank BHD to Diesel Tank (return) 10-29-1968 0 1900 90+ST
rom Diesel Tank to Hyd Tank BHD (suction) 10-29-1969 0 1350 90+ST
Part Number Rev ECO

10-29-9268 0.01 2206 QI240 Refuelling Pump Hos

Part No. Revisio Length Coupling Orient.

rom cabinet base to diesel pump 10-29-3609 0.01 240 ST-ST R
rom cabinet base to diesel tank top 10-29-2075 0.01 4380 90-ST R
rom cabinet to suction filter 10-29-3611 0 4500 ST-ST R
Part Number Rev

10-29-9275 0.01 QI240 Crusher Drive Hose Kit

Part No. Rev: Length: Coupling: Orient:

rease Pipes
side flange bearing to BHD 10-29-2013 0 600 90+ST
utside flange bearing to BHD 10-29-2014 0 600 90+ST
op idler grease points to BHD 10-29-2015 0 750 90+ST
utside pillow block bearing to BHD 10-29-2016 0 550 90+ST
side pillow block bearing to BHD 10-29-2017 0 770 90+ST
1/8" ST+ 1/4"
t f fi t lb i t i d t BHD 10 29 2018 0 650 O

11.0 OEM Section

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 following
order

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

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