QA441 Operations Manual 24 06 15 English PDF

Original Instructions
Operator’s Manual
qa441
MANQA441OMEN
240615
qa441
© Copyright 2015 Sandvik 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. All data and information in this manual may be
changed without further notice. Reservation for misprints.
Sandvik Construction Mobile Crushers and Screens Ltd.

Tullyvannon, Ballygawley, Co.Tyrone, Northern Ireland, BT70 2HW
Tel. +44 (0) 28 8556 7799, Fax +44 (0) 28 8556 7007
W: www.sandvikmobiles.com
E: info.mobilecs@sandvik.com
1 Safety
1.1Safety principles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
1.1.1 Signal words - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
1.1.2 General hazard symbol - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
1.1.3 Essentials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
1.1.4 Safety hazards pertaining to the equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
1.1.5 Colour coded safety signs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
1.1.6 Symbols for prohibited actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
1.1.7 Symbols for mandatory actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
1.1.8 Symbols for hazards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
1.2Features for operator safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
1.3Environmental safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
1.3.1 Hazardous materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
1.3.2 Battery disposal- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
1.3.3 Machine disposal- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
1.4Personal protective equipment (PPE) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
1.5Organisational safety measures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

1.5.1 Fire risk control measures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
1.6Personnel qualifications, requirements and responsibilities - - - - - - - - - - - - - - - - 18

1.7Safety advice regarding specific operational phases - - - - - - - - - - - - - - - - - - - - - - 19
1.7.1 Standard Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
1.7.2 Blockage or malfunction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
1.7.3 Unguarded areas- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
1.7.4 Fire risk control measures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
1.8Special work, including maintenance, parts disposal and hazardous materials - - 21

1.8.1 Securing equipment before performing maintenance - - - - - - - - - - - - - - - - - - - - - - - - 21
1.8.2 Maintenance site conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
1.8.3 Replacement & removal of components- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
1.8.4 Climbing and falling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
1.8.5 Safety considerations during maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
1.8.6 Safety considerations during cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
1.8.7 Removal of safety devices, guards and decals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
1.8.8 Surrounding structures- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
1.8.9 Safety when refuelling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
1.9Specific hazards- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
1.9.1 Electrical energy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
1.9.2 Automotive batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
1.9.3 Gas, dust, steam, smoke and noise- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
1.9.4 Welding or Naked Flames - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
1.9.5 Hydraulic equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
1.9.6 Hazardous substances- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
1.10Vibration levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
1.11Hazard exclusion zones - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
1.12Measured noise levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
Copyright © Sandvik Construction Mobile Crushers and Screens Ltd 1

QA441 - en - 240615
1.13Safety decals - Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
1.14Emergency stop locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44

1.14.1 Operation of an emergency stop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
1.14.2 To reset an emergency stop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
1.15Machine guarding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
1.15.1 Outer guards- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
1.15.2 Inner guards - access guards removed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
2. TRANSPORT & TECHNICAL DATA

2.1 Special considerations for transport - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
2.1.1 Machine preparation for transport - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
2.1.2 Moving the machine on or off transport vehicle- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
2.1.3 Machine Transportation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
2.1.4 Vibrating grid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
2.1.5 Exhaust extension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56
2.1.6 Jacking legs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
2.1.7 Fines conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
2.1.8 Side conveyors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
2.1.9 Main conveyor and screenbox height - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
2.1.10 Maintenance Platforms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67
2.1.11 Reject grid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 74
2.1.12 Ladder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76
2.2 Machine data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
2.3 Transport dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80

2.3.1 Option - 4m (13ft) Tipping grid and inlet chute - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80
2.3.2 Option - 4.5m (15ft) Tipping grid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81
2.3.3 Option - Vibrating grid and inlet chute - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82
3. PRODUCT OVERVIEW
3.1 Machine layout indicating main components- - - - - - - - - - - - - - - - - - - - - - - - - - - - 84
3.1.1 General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84
3.1.2 Main components - overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84
3.2 Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
3.2.1 Common applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
3.2.2 Machine application and limitations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
3.3 Screening machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86

3.3.1 Machine description- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86
3.3.2 Operation description- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86
3.4 Main control devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87

3.4.1 Electrical controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87
3.4.2 Hydraulic controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87
3.5 Operational controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89

3.6 Machine mode switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90
2 Copyright © Sandvik Construction Mobile Crushers and Screens Ltd

QA441 - en - 240615
3.7 Display screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91
3.7.1 Auxiliary mode home screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91
3.7.2 Operation mode home screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92
3.7.3 Track mode home screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92
3.7.4 Engine information- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93
3.7.5 Machine diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 94
3.7.6 Service mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101
3.7.7 Active error display screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101
3.8 Reject grid radio control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 102
3.9 Track controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103
3.10 Machine working dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 104

3.10.1 Option - 4m (13ft) Tipping grid and inlet chute - - - - - - - - - - - - - - - - - - - - - - - - - - - - 104
3.10.2 Option - 4.5m (15ft) Tipping grid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 105
3.10.3 Option - Vibrating grid and inlet chute - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 106
4. COMMISSIONING & SHUT DOWN

4.1 General Safety- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 108
4.2 Pre-commissioning instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 109

4.2.1 Pre-start instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 109
4.3 Engine starting procedure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 111

4.3.1 Before starting engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 111
4.3.2 Engine start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 112
4.3.3 Engine controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 113
4.4 Moving machine on the tracks- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115

4.4.1 Before moving the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115
4.4.2 Radio remote control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116
4.4.3 Wired umbilical control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117
4.4.4 Track control mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 118
4.4.5 Operating track control- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 118
4.5 Preparing for screening operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 121

4.5.1 Vibrating grid- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 122
4.5.2 Exhaust extension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 124
4.5.3 Jacking legs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 126
4.5.4 Fines conveyor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 128
4.5.5 Side conveyors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 131
4.5.6 Set up the main conveyor and screen-box height - - - - - - - - - - - - - - - - - - - - - - - - - - 134
4.5.7 Maintenance Platforms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 136
4.5.8 Reject grid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 142
4.5.9 Ladder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 144
4.5.10 Screen-box angle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 144
4.6 Shut down the machine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 146

4.6.1 Automatic shut down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147
4.6.2 Manual shut down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 148

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4.7 Lockout and tag procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 150
4.7.1 How to fit a single tag- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 150
4.7.2 To remove a single tag- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 150
4.7.3 How to fit a gang tag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 151
4.7.4 To remove a gang tag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 151
5. OPERATIONS
5.1 Operations - minimum safety requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - 154
5.2 Screening operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 155

5.2.1 Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 155
5.2.2 Machine starting sequence - Automatic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 157
5.2.3 Machine starting sequence - Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 158
5.2.4 Operation Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 160
5.2.5 Operation and shut down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 161
5.2.6 Machine blockage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 162
5.2.7 Loading material into machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 164
5.3 Set up the conveyor speeds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 166

5.3.1 Side conveyor speed adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 166
5.3.2 Main conveyor speed adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 166
5.3.3 Hopper feeder conveyor speed adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 167
5.4 Installation and removal of the optional vibrating grid mesh - - - - - - - - - - - - - - 168
5.5 Radio remote grid operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 169
5.6 Switching off operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171

5.6.1 Automatic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171
5.6.2 Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171
5.6.3 Isolate and lockout- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171
6. MAINTENANCE
6.1 Introduction - machine maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 174
6.2 Reference information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 177
6.3 Maintenance schedules - power module maintenance - - - - - - - - - - - - - - - - - - - 178

6.3.1 Daily (8 hour) maintenance schedule- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 178
6.3.2 Weekly (40 hour) maintenance schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 178
6.3.3 Every 250 hour maintenance schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 179
6.3.5 Every 1000 hour maintenance schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 180
6.4 Maintenance schedules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 181

6.4.1 Daily maintenance schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 181
6.4.2 Weekly maintenance schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 183

QA441 - en - 240615
6.5 Engine oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 187
6.6 Diesel fuel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 189
6.7 Hydraulic fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 191
6.8 Engine coolant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 192
6.9 Air cleaner servicing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 193
6.10 Inspect the hydraulic return filter indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - 196
6.11 Grease the bearings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 197
6.12 Fuel filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 200
6.13 Hydraulic tank filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 201
6.14 Conveyors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 203

6.14.1 Conveyor precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 203
6.14.2 Feed conveyor belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 204
6.14.3 Main conveyor belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 206
6.14.4 Side conveyor belts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 208
6.14.5 Tail conveyor belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 210
6.14.6 Belt scrapers- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 212
6.14.7 Inspecting / adjusting belt sealing rubbers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 213
6.14.8 Optional magnetic conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214
6.15 Installation and removal of the screenbox mesh - - - - - - - - - - - - - - - - - - - - - - - 215

6.15.1 Set up access to the screenbox - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 216
6.15.2 Removal of the screenbox mesh - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 218
6.15.3 Installation of the screenbox mesh - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 220
6.15.4 Screen mesh tension and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 222
6.16 Tracks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 223

6.16.1 Inspection of the tracks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 223
6.16.2 Track adjustment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 224
6.16.3 Track tension check- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 225
6.16.4 Increasing the track tension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 226
6.16.5 Releasing the track tension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 226
6.17 Track gearbox - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 227

6.17.1 Check and fill gearbox - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 228
6.17.2 Drain gearbox oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 228
6.18 Vibrating grid in hopper [option] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 229

6.18.1 General torque reference chart - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 229
6.19 Lubricants and fluids - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 230
6.20 Machine error messages and fault codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - 231

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7. TROUBLE SHOOTING
7.1 Fault finding tables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 236
7.1.1 Starting and running - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 237
7.1.2 Moving the machine on the tracks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 238
7.1.3 Conveyors - maintenance platforms - legs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 239
7.1.4 Loading and operating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 241
7.1.5 Screen box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 242
7.1.6 Electrical, radio, umbilical controls- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 243
7.2 Problems not listed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 244
8. ENGINE
8.1 Engine in power pack - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 246
8.1.1 Engine manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 246
8.1.2 Engine alternatives - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 246
9. ELECTRICAL AND HYDRAULIC INFORMATION

9.1 Schematic diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 248
9.1.1 Electrical schematic diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 248
9.1.2 Hydraulic schematic diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 248
10. INFORMATION AND DATA SHEETS

10.1 Original equipment manufacturer information - - - - - - - - - - - - - - - - - - - - - - - - 250
10.2 Hazardous substances - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 251

10.3 Variations and options (if applicable) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 252

QA441 - en - 240615
All machines Operator’s manual
1 Safety
Operator - 1.1 Safety principles All machines
1.1 Safety principles

SANDVIK put safety first.
This is to ensure maximum safety measures are taken, ALWAYS read this section carefully BEFORE
carrying out any work on the equipment or making any adjustments.
Note: This equipment is manufactured in accordance with the Machinery Directive 2006/
42/EC of 01.01.2010. The customer should make sure that this equipment is in
conformance with local and national legislation if used outside of the EU.
This section includes explanations of safety symbols, signs, signals and labels used on the product
and information for use.
1.1.1 Signal words
The following signal words and symbols are used to identify safety messages throughout these
instructions:
DANGER
The signal word DANGER indicates a hazardous situation which, if not avoided, will
result in serious injury or death.
WARNING
The signal word WARNING indicates a hazardous situation which, if not avoided, could
result in serious injury or death.
NOTICE
The signal word NOTICE indicates a situation which, if not avoided, could result in
damage to property or environment.
When you see ANY of the signal words in this manual, be alert; your safety is involved.
Carefully read and understand the message that follows, and inform other users.
1.1.2 General hazard symbol
This general HAZARD or other hazard symbol identifies important

safety messages in this manual.
When you see ANY of the hazard symbols in this manual, be alert; your safety is involved. Carefully
read and understand the message that follows, and inform other users.
8 Copyright © Sandvik Construction

All machines-en-240615
All machines Operator - 1.1 Safety principles
1.1.3 Essentials
DANGER
INHALATION, BREATHING HAZARD!
Breathing or inhaling silica dust particles will cause death or serious
injury.
Ensure suitable breathing equipment is used throughout any
procedures carried out. ALL necessary precautions MUST be taken to
reduce the risk of breathing dust or particles.
Read this manual and familiarize yourself with any associated

documentation. If in ANY doubt ask. Do not take ANY personal risk.
Only trained competent persons should be allowed to install, set,
operate, maintain, and decomposing this equipment. Make sure that a
copy of this manual is available for any persons installing, using,
maintaining or repairing this equipment.
Training should be provided to make sure that safe working practices
are followed. Initial commissioning and starting must only be
undertaken by a authorised person who has read and fully understands
the information provided in the manual pack. ALWAYS follow the
procedures outlined in the operating and maintenance instructions.
To avoid the risk of electric shock, ALWAYS isolate this equipment

from the supply source before removing any guards or covers or
performing any maintenance or adjustment to the equipment.
Note: The equipment manufacturer declines all responsibility for injury or damage if the
instructions and precautions in this manual are not followed.
1.1.4 Safety hazards pertaining to the equipment
The following safety symbols may be posted on the equipment and

contained in the manuals. You MUST observe all safety symbols,
labels, and instructions at ALL times.
• Make sure safety instructions and safety labels attached to the equipment are always complete
and legible.
• Keep safety instructions and safety labels clean and visible at all times.
• Replace any illegible or missing safety instructions and safety labels before operating the
equipment.
• Ensure replacement parts include safety instructions and labels.
Copyright © Sandvik Construction 9

1.1.5 Colour coded safety signs
Signs located on the machine and used throughout this manual are colour coded relating to the
information they convey, as follows:
PROHIBITED - YOU CAN NOT DO.
MANDATORY - YOU MUST DO.
HAZARD - YOU MUST BE AWARE OF.
1.1.6 Symbols for prohibited actions
Prohibited actions used throughout this manual are indicated by a red circle with a red
diagonal line across the circle. The action which is prohibited will always be in black as
follows:
No climbing No smoking Do not touch No open flames
Do not use hand to

Do not remove Limited or restricted
Do not weld test for hydraulic
safety guard access
leaks

All machines Operator - 1.1 Safety principles
1.1.7 Symbols for mandatory actions
Mandatory actions used throughout this manual are indicated by white symbols on a blue
background as follows:
Wear safety Wear eye Wear safety Wear safety Wear ear
gloves protection helmet harness protection
Disconnect
Wear safety Wear close Wear high
Wear respirator power source
boots fitting overalls visibility vest
from supply
Switch off and Use card for

Read the Safe distance
lockout hydraulic leak
manual from hazard
equipment testing

1.1.8 Symbols for hazards
Hazard symbols used throughout this manual are indicated by a yellow triangle with black symbols
and black frames as follows:
Crushing Crushing Chemical burn Electrical

Noise hazard
hazard - hands hazard - feet hazard hazard
Entanglement Entanglement Falling load

Falling hazard Ignition hazard
hazard hazard hazard
Flying material Skin injection Silica or other

Lifting hazard Tripping hazard
hazard hazard dust hazard
Falling material Crushing Hanging load

Magnet hazard Tipping hazard
Explosion High pressure Hot surface

General hazard Poison hazard
Hot Coolant Electrocution

Tipping hazard Tipping hazard
under pressure hazard

All machines Operator - 1.2 Features for operator safety
1.2 Features for operator safety

Note: Safety features associated with this equipment have been assessed in accordance
with ISO21873-2.
Emergency stop buttons have been installed to prevent death or

serious injury. Ensure Emergency stop buttons are visible and not
obstructed in any way. Ensure all personnel are trained in the
operation and location of emergency stops.
DO NOT use this equipment if any safety guards or devices have been
removed or not installed properly. Safety guards have been installed to
prevent death or serious injury. All safety guards must be fitted and
secured in their correct positions.
Operating this equipment with any safety guards or devices which
have been removed or installed improperly could result in death or
serious injury.
Steps, handrails, tread plates, and fixed guards are provided where
persons are required to climb on the machine. For maintenance access
ONLY.
If for any reason other areas of the machine need to be accessed, DO a

full recorded risk assessment and take the appropriate safety
measures.

Operator - 1.3 Environmental safety All machines
1.3 Environmental safety

To avoid unnecessary engine emissions, you MUST regularly service the machine as specified in the
machine maintenance sections contained in this manual.
1.3.1 Hazardous materials
FIRE IGNITION HAZARD!

Diesel spillage MUST be cleaned up immediately due to fire hazard.
Follow local and national regulations.
ONLY use fluids and lubrication products recommended in the

maintenance schedule or OEM manuals.
Read and understand the instructions and information in the

Hazardous substances section.
WARNING
POISON AND CONTAMINATION HAZARD!
Drinking from storage containers that have held equipment fluids or
other harmful substances could cause serious injury or death. DO
NOT store fuels, fluids and other materials used in the operation of
this machine in food or beverage containers.
Fuels, fluids and other materials used in the operation of this machine
may contain chemicals which could cause serious injury or death and
or environmental damage if disposed of in an irresponsible manner.
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.
ALWAYS dispose of fuels, fluids or other materials used in the
operation of this machine in accordance with local and national legal
regulations.
DO NOT pour waste onto the ground, down a drain or into any water
source.
Observe local heath and safety data information and OEM data
information detailed in the Information and Data Sheets section of this
manual when working with components or substance that may
contain chemicals.
Use leak proof containers when draining fluids.

All machines Operator - 1.3 Environmental safety
1.3.2 Battery disposal
All batteries must be disposed of via a local re-cycling scheme.
Batteries must not be disposed of in normal waste which may go to

landfill.
1.3.3 Machine disposal
This equipment MUST ONLY be disposed of at a specialist machine breaker.

Operator - 1.4 Personal protective equipment (PPE) All machines
1.4 Personal protective equipment (PPE)

Entanglement hazard
DANGER
PERSONNEL HAZARD!
DO NOT wear, loose clothing or jewellery of ANY kind.
Long hair MUST BE tied back.
ALWAYS wear (CE approved) minimum Personal Protective Equipment
(PPE).
Minimum required personal protective equipment
The following (CE approved P.P.E.) MUST BE WORN by everyone, as a minimum requirement when
working on or around the machinery, within 10m (33ft): Additional PPE may be required for specific
tasks, which will be detailed in the relevant section throughout the manual.
Safety gloves Eye protection Safety helmet Respirator Ear protection
Close fitting High visibility

Safety boots
overalls vest

All machines Operator - 1.5 Organisational safety measures
1.5 Organisational safety measures
The following safety measures MUST be observed at all times:
Understand the service procedure before commencing work.

Keep area clean and dry.
NEVER lubricate, clean, service, or adjust machinery while it is moving.
Allow machinery to cool before performing any maintenance or
adjustments.
MAKE SURE all parts are properly installed and are in good condition.
Replace worn and broken parts IMMEDIATELY.
Remove any build up of grease, oil and debris from equipment.
During maintenance, use ONLY the correct tool for the job.
NEVER make any modifications, additions, or conversions which may
affect safety.
Disconnect battery ground cable before making adjustments on

electrical systems or welding on the equipment.
If clothing, tools, or any body parts become entangled in machinery,

IMMEDIATELY press an emergency stop button to disengage all power.
Operate controls to relieve pressure. Switch off engine and implement
lockout procedures.
If equipment exhibits any unusual movement or sound, stop equipment,

lock out IMMEDIATELY, and report the malfunction to your supervisor.
1.5.1 Fire risk control measures
Carry out a site specific risk assessment to identify any fire hazards present and the actions required
to remove/reduce the risk.
Follow local and national regulations regarding fire safety training as identified in the risk
assessment.
Fire extinguishing equipment must be available and easily accessible to the machine operator as
identified in the risk assessment.

Operator - 1.6 Personnel qualifications, requirements and responsibilities All machines
1.6 Personnel qualifications, requirements and responsibilities
WARNING
PERSONNEL HAZARD
Lack of knowledge or understanding could cause serious injury, death
or damage to the machine.
ONLY trained, competent, reliable and authorized personnel should
operate or maintain this machine.
If necessary seek clarification from your supervisor and or a Sandvik
representative, before attempting ANY operations or maintenance.
Failure to do so may also invalidate the manufacturers warranties.
Statutory minimum working age limits must be observed.
Work on electrical system and its equipment MUST ONLY be carried out
by a skilled electrician or by personnel under the supervision and
guidance of a skilled electrician and in accordance with electrical
engineering rules and regulations. You MUST fully understand the
electrical system, refer to the electrical and hydraulic section.
Work on the hydraulic system MUST ONLY be carried out by persons
with training and authorisation to maintain the hydraulic equipment.
You MUST fully understand the hydraulic system, refer to the electrical
and hydraulic section.

All machines Operator - 1.7 Safety advice regarding specific operational phases
1.7 Safety advice regarding specific operational phases
1.7.1 Standard Operation
Take the necessary steps to ensure the equipment is ONLY used when it
is in a safe and reliable state.
Operate the equipment ONLY for its designed purpose, and only if all
guarding, protective, and safety devices, emergency shut-off equipment,
sound proofing elements and exhausts, are in place and fully functional.
ENSURE local barriers are erected to stop unauthorised entry to the

equipment or work area.
Attach a hazard sign(s) to the equipment in appropriate positions to alert

all persons of potential hazards.
BEFORE starting the engine ensure it is safe to do so.
1.7.2 Blockage or malfunction
In the event of material blockage, any malfunction or operational

difficulty, stop equipment and lockout immediately. Rectify problem
immediately, refer to the operation section. Contact your dealer for advice
and assistance if required.
1.7.3 Unguarded areas
Limit access to the equipment and its surroundings by erecting barrier

guards, minimum distance 1.5m (5ft) away, to reduce the risk of other
mechanical hazards, falling loads and ejected materials.
Switch off and lockout equipment before removing any safety devices or
guarding. Make sure all safety devices and guards are installed correctly
before lock out is removed.

Operator - 1.7 Safety advice regarding specific operational phases All machines
DANGER
ENTANGLEMENT HAZARD
Working in close proximity to running machinery could cause serious
injury or death.
DO NOT work close to machinery unless it is completely stopped.
(PPE).
1.7.4 Fire risk control measures
Carry out a site specific risk assessment to identify any fire hazards present and the actions required
to remove/reduce the risk.
Follow local and national regulations regarding fire safety training as identified in the risk
assessment.
Fire extinguishing equipment must be available and easily accessible to the machine operator as
identified in the risk assessment.

All machines Operator - 1.8 Special work, including maintenance, parts disposal and
hazardous materials
1.8 Special work, including maintenance, parts disposal and hazardous ma-
terials
Observe adjustment, maintenance and service intervals detailed

throughout this manual, unless:
• - Failure of warning lights, horns, gauges, display screens or indicators calls
for immediate action.
• - Adverse conditions require more frequent servicing.
USE ONLY Original Equipment Manufacturer's (OEM) recommended
replacement parts and equipment.
Make sure only properly trained personnel undertake these tasks.
1.8.1 Securing equipment before performing maintenance
When undertaking maintenance and repair work, equipment must first be made safe.
PERSONNEL HAZARD
Switch off engine and remove ignition key.
Switch off at isolation point, refer to the commissioning and shut down
section.
Implement tag and lockout procedures, refer to the commissioning and
shut down section.
Attach hazard sign(s) to equipment in appropriate positions to alert all
personnel of potential hazards.

Operator - 1.8 Special work, including maintenance, parts disposal and All machines
1.8.2 Maintenance site conditions
Prior to starting any maintenance work, ENSURE equipment is positioned

on stable and level ground and has been secured against inadvertent
movement and buckling.
1.8.3 Replacement & removal of components
ALWAYS observe handling instructions detailed throughout this manual,

OEM manuals, or spare parts suppliers' instructions.
Do a full risk assessment and take all necessary safety measures.
NEVER allow untrained staff to attempt to remove or replace any part of

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

equipment is PROHIBITED, this could cause serious injury or death.
To avoid the risk of accidents, individual parts and large assemblies

being moved for replacement purposes should be carefully attached to
lifting equipment and secured. ONLY use suitable lifting equipment
supplied or approved by OEM.
NEVER work or stand under suspended loads.
KEEP AWAY from the feeder hopper and product conveyor discharge,
where there is risk of serious injury or death from contact with ejected
debris.
1.8.4 Climbing and falling
LIMIT ACCESS to the equipment and its surroundings by erecting barrier

guards to reduce the risk of residual mechanical hazards, falling lifted
loads, and ejected materials.
Falling from and/or onto this equipment could result in serious injury or
death.
When reaching any points 2m (6ft) or more above ground level, ALWAYS
use CE certified safety harness.

hazardous materials
NEVER climb on the equipment while it is in operation or use equipment

parts as a climbing aid.
ALWAYS keep the area around the equipment clear of debris and trip
hazards.
Keep all handles, steps, handrails, platforms, landing areas, and ladders
free from dirt, oil, snow and ice.
Beware of moving haulage and loading equipment in the vicinity of the
equipment.
When carrying out overhead assembly work, ALWAYS use specially
designed or otherwise safety-oriented ladders and maintenance
platforms.
ONLY use Maintenance Platforms provided on the equipment. ALWAYS
perform work from an approved, safe and secure platform.

Operator - 1.8 Special work, including maintenance, parts disposal and All machines
1.8.5 Safety considerations during maintenance
It is essential that you take the following steps to MAKE SURE you and
others are safe. DO full risk assessments and take all necessary safety
measures.
During maintenance, RESTRICT ACCESS to essential staff only. Where

appropriate, erect barrier guards and post warnings.
The fastening of loads and instructing or guiding of crane operators

should be entrusted to qualified persons only.
The observer providing instructions must be within sight or sound of the
operator and positioned to have an all around view of the operation.
ALWAYS make sure any safety device such as locking wedges, securing
chains, bars, or struts are utilized as indicated in throughout this manual.
Make sure that any part of the equipment raised for any reason is
prevented from falling by securing it in a safe reliable manner.
Never work alone.
1.8.6 Safety considerations during cleaning
This machine MUST be isolated prior to cleaning.

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.
DO NOT direct power washers near to or into control boxes and electrical
devices.
1.8.7 Removal of safety devices, guards and decals
Prior to operation, all safety devices, control devices, decals and guards,
temporarily removed for set-up, maintenance or repair purposes MUST
be refitted and checked immediately upon completion of the maintenance
or repair work.
To avoid serious personal injury or death, NEVER operate the equipment
with safety devices, decal or guards removed or unsecured.
ALWAYS report any defects regarding guards, safety devices, decals or
control devices.

hazardous materials
1.8.8 Surrounding structures
This equipment MUST ONLY be operated in a position away from

buildings, permanent structures or high ground to eliminate the risk of
persons falling onto the equipment or its surrounds.
All temporary maintenance platforms erected around the equipment
MUST be removed prior to operation.
1.8.9 Safety when refuelling
WARNING
FIRE HAZARD
Smoking is PROHIBITED when refuelling or handling diesel fuel.
Smoking and or using other naked flames in the vicinity of flammable
materials and or fuels, could cause serious injury or death.
NEVER remove the filler cap or refuel with the engine running.
NEVER add gasoline or any other fuels mixed to diesel due to increased
fire or explosion risks and damage to the engine.
DO NOT carry out maintenance on the fuel system near naked lights or
sources of sparks, such as welding equipment.
IMMEDIATELY clean up spilt fuel and dispose of correctly to minimize
any environmental impact. To avoid spillage use drip trays.
ONLY refuel with diesel from approved storage and supply equipment.

Operator - 1.9 Specific hazards All machines
1.9 Specific hazards
1.9.1 Electrical energy
External considerations and hazards
When working with the machine, maintain a safe distance from overhead electric lines. Be aware that
electricity can jump across gaps. If unsure, seek advise from a competent person or source. If
overhead cables are in the vicinity, a risk assessment MUST be completed prior to operating the
machine. Make sure you follow all local and national regulations.
DANGER
ELECTROCUTION HAZARD!
Contact with overhead electric lines will cause serious injury or death.
If your machine comes into contact with a live wire, you MUST:
- Vacate the area.
- Warn others against approaching and touching the machine.
- Report the incident and have the live wire shut off.
Machine - Electrical
Work on electrical system and its equipment MUST ONLY be carried out
by a skilled electrician or by personnel under the supervision and
guidance of a skilled electrician and in accordance with electrical
engineering rules and regulations.
Before starting any maintenance or repair work, the power supply to the
equipment MUST be isolated. Check the de-energized parts to ensure
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.
The electrical equipment is to be inspected and checked at regular
intervals. Defects such as loose connections, scorched or otherwise
damaged cables MUST be repaired, or replaced immediately. A trained
competent person must do this.
Use ONLY original fuses with the specified current rating. Switch off the
equipment IMMEDIATELY if trouble occurs in the electrical system.
This equipment is wired on a negative earth. ALWAYS observe correct
polarity.

All machines Operator - 1.9 Specific hazards
1.9.2 Automotive batteries
Automotive batteries contains sulphuric acid, an electrolyte which can

cause severe burns and produce explosive gases when being charged.
Recharge batteries in a well ventilated area.
Do not short circuit batteries as this could cause a large spark and
explosion.
Smoking is PROHIBITED when maintaining automotive batteries.
AVOID contact with the skin, eyes or clothing.
ALWAYS wear appropriate PPE, Refer to 1.4 Personal protective
equipment (PPE).
ALWAYS Isolate and disconnect the battery leads before carrying out
any maintenance to the electrical system.
When disconnecting the batteries, disconnect the negative first and
when connecting make sure the negative is connected last.
Batteries must not be disposed of in normal waste which may go to

landfill.
All batteries must be disposed of via a local re-cycling scheme.
1.9.3 Gas, dust, steam, smoke and noise
DANGER
INHALATION, BREATHING HAZARD!
Breathing or inhaling silica dust particles will cause death or serious
injury. ALWAYS work with a respirator approved by the respirator
manufacturer for the job you are doing.
Ensure suitable breathing equipment is used throughout any procedures
carried out. ALL necessary precautions MUST be taken to reduce the risk
of breathing dust or particles.
Dust found on the equipment or produced during work on the equipment
MUST NOT be removed with compressed air.
Dust waste MUST ONLY be handled by authorized personnel. When
disposing of dust waste, the material must be dampened, placed in a
sealed container and marked to ensure proper disposal.

ALWAYS operate internal combustion engines outside or in a well

ventilated area.
If, during maintenance, the equipment must be operated in an enclosed
area, MAKE SURE there is sufficient ventilation or provide forced
ventilation.
Observe ALL local and national safety regulations. Contact your local
authority for additional information.

All machines Operator - 1.9 Specific hazards
1.9.4 Welding or Naked Flames
WARNING
FIRE HAZARD
Welding or using other naked flames in the vicinity of the equipment
creates the risk of an explosion or fire, which could result in serious
injury or death from fire or explosion.
AVOID all naked flames in the vicinity of this equipment.
Welding, flame cutting and grinding work on the equipment MUST ONLY
be carried out if this has been expressly authorized.
Before carrying out welding, flame cutting and grinding operations, clean
equipment and its surroundings from dust and debris and other
flammable substances and ensure the premises are adequately
ventilated.
Before welding, the battery MUST be isolated and disconnected.
On machines and engines with electronic controls they must have these
controls isolated and disconnected before welding. Disconnect at the
plugs and sockets at machine control panel, engine control unit and
input/output module. Refer also to the engine manufacturer’s manual.
1.9.5 Hydraulic equipment
DANGER
SKIN PENETRATION HAZARD
Hydraulic fluid under pressure can penetrate the skin, which will result in
serious injury or death.
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.
Work on hydraulic equipment must be carried out by persons with
training and authorisation to maintain the hydraulic equipment. Do a full
risk assessment and take all necessary safety measures.
WARNING
FIRE HAZARD
Splashed or spilled oil creates the risk of a fire, which could result in
Check all lines, hoses and screwed connections regularly for leaks or
other damage.
Repair damaged lines, hoses, or screwed connections IMMEDIATELY.

WARNING
STORED ENERGY HAZARD
Latent stored pressure energy may be contained in hydraulic systems
when they are off.
ALWAYS relieve pressure from the hydraulic system before carrying out
any kind of maintenance or adjustment.
BEFORE carrying out any repair work, depressurize all system sections
and pressure hoses (hydraulic and compressed air system) requiring
removal, in accordance with the specific instructions for the unit
concerned.
ONLY fit replacement components of a type recommended by the
manufacturer.
Hydraulic and compressed air lines MUST be laid and fitted properly.
Make sure no connections are interchanged. The fittings, lengths and
quality of the hoses MUST comply with the technical requirements.
ALWAYS practice extreme cleanliness when servicing hydraulic
components. Make sure all measures are taken to avoid spillage and
leaks.
1.9.6 Hazardous substances
For more information, refer to 1.3 Environmental safety and the Hazardous substances section.

All machines Operator - 1.10 Vibration levels
1.10 Vibration levels

There are no circumstances where an operator needs to be on or holding the machine during the
crushing operation or moving the machine.

qa441 1.11 Hazard exclusion zones
1.11 Hazard exclusion zones
X X
A
A
X
X
B A
A
X X
A = Access area to the machine controls, only when not loading material.
B = 20m (66ft) clearance to limit access to equipment and surroundings. Erect barriers around the
perimeter of the machine. NO persons allowed within this exclusion zone unless operating machine.
X = 5m (17ft) hazard area at machine loading and material outlet areas. DO NOT ENTER when
machine is operating.

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1.12 Measured noise levels
qa441
1.12 Measured noise levels
NOISE HAZARD
Ear protection MUST be worn if you are within 10m (33ft) of the machine
when the engine and other parts of the machine are running.
The indicated measured noise levels are at 1m (3.5ft), 3m (9.8ft) and 7m (23ft) using a Casella CEL-
244 [Type 2] meter with an empty machine all systems running situated in an open area with
minimum reflective surfaces and structures.
Note that product processing and local conditions will have an affect on the noise levels experienced.

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qa441 1.12 Measured noise levels
Background Average Noise Machine Running Average Noise

Ref
Level (Laeq) [dB] Level (Laeq) [dB]
1 62.8 88.2
2 61.3 90.8
3 58.2 90.1
4 59.2 89.3
5 56.3 91.9
6 58.5 93.4
7 55.9 89.1
8 56.3 86.3
9 62.5 87.6
10 60.9 89.9
11 61.8 87.3
12 56.7 87.5
13 56.7 89.1
14 58.5 91.7
15 55.3 87.3
16 56 87.5
17 61.8 82.7
18 61.3 85.5
19 62.1 84.1
20 50.4 88.1
21 56.2 87.6
22 56.5 88.1
23 58 86.7
24 56.2 80.3
25 62 97.4

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1.13 Safety decals - Locations
qa441
11
11
2
15
1
10
21
22
19
1
710
8
18
11
10
17
8

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qa441 1.13 Safety decals - Locations
11
99
11

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qa441
17
8
11
10
3
2
20
23
10
12
4
8
7
21
19
22
16
10
14
15
2
11
6
11

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11
8
17
913
17
1
5
9
11

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qa441
Item Part No. Image
1 DE0027
2 DE1007
3 DE1043
DANGER
BURN HAZARD
Hot surface
4 DE8000 Contact may cause burn
Do not touch
DE8000
DANGER
CRUSHING HAZARD
Risk of serious injury or
5 DE8001 death
KEEP AWAY from machine
during all phases of
operation
DE8001
DANGER
CRUSHING/SHEARING
HAZARD
6 DE8003 Moving parts can crush or
cut causing serious injury
DO NOT reach into the
moving parts
DE8003
DANGER
CRUSHING HAZARD
Risk of serious injury
7 DE8006 DO NOT place hands or
feet under jacking legs.
KEEP HANDS AND FEET
CLEAR before lowering or
raising jacking legs
DE8006
DANGER
ENTANGLEMENT HAZARD
Contact with conveyor will
8 DE8008 result in serious injury or
death
DO NOT reach into the
conveyor
DO NOT operate machine
without guarding fitted
DE8008

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Item Part No. Image
DANGER
ENTANGLEMENT HAZARD
9 DE8010 death
KEEP AWAY from machine
during operation
DE8010
DANGER
ENTANGLEMENT HAZARD
10 DE8011 death
ALL GUARDING must be
fitted before machine is
started
DE8011
DANGER
FALLING MATERIAL HAZARD
Risk of serious injury or death
11 DE8012 KEEP AWAY from machine
during operation
DO NOT walk near material
discharge areas
DE8012
DANGER
SKIN INJECTION HAZARD
Fluid under pressure can
12 DE8016 penetrate the skin causing
serious injury
Seek medical help or
Gangrene can set in
DO NOT use your hand to
check for leaks
DE8016
WARNING
AUTOMATIC MACHINE
MAY START WITHOUT
13 DE8020 WARNING
Exit danger areas when
beacon/siren is activated
DE8020
WARNING
FALL HAZARD
Falling from this machine can
14 DE8022 result in serious injury or death

DO NOT climb onto the machine
without carrying out a site specific
risk assessment
SWITCH OFF, LOCKOUT AND
TAGOUT machine before doing
any maintenance
READ THE MANUAL
DE8022
WARNING
NOISE HAZARD
Risk of hearing loss or
15 DE8023 degradation over long periods
of time
EXCEEDS 90dB(A)
Use approved hearing
protection
DE8023
DANGER
BURN HAZARD
Hot Surface
Contact may cause burns
16 DE8025 Do not touch
DE8025

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qa441
Item Part No. Image
DANGER
CRUSH HAZARD
Risk of serious injury
DO NOT place hands or feet
under jacking legs
KEEP HANDS AND FEET
17 DE8029 CLEAR BEFORE lowering or
raising jacking legs
DE8029
DANGER
BURN HAZARD
Hot surface
Contact may cause burn
Do not touch
18 DE8051
DANGER
SKIN INJECTION HAZARD
Fluid under pressure can
penetrate the skin causing
serious injury
Seek medical help or
Gangrene can set in
DO NOT use your hand to
check for leaks
DE8051
DANGER DANGER
CRUSHING HAZARD CRUSHING HAZARD
Risk of serious injury or Risk of serious injury or
19 DE8052 death
TIPPING HAZARD due to
machine roll-over
death
TIPPING HAZARD due to
machine roll-over
Maximum tracking gradient Maximum tracking gradient
20° front to back 10° left to right
Read the manual Read the manual
DE8052
WARNING
READ AND UNDERSTAND
THE MANUAL AND
DECALS before operating or
doing maintenance on this
machine
IF IN DOUBT ASK
20 DE8055
WARNING
LOCKOUT PROCEDURE
1. Switch off engine
2. Remove the ignition key
3. Keep the ignition key on
person during lockout
4. Position appropriate
maintenance warning signs
(i.e. tagout)
5. NEVER work alone
DE8055
DANGER
DUST HAZARD
Breathing dust will cause
death or severe injury
Always wear an approved
respirator
21 DE8057
WARNING
LOOSE ITEMS
Risk of injury or death from
items falling during machine
movement
REMOVE OR SECURE
loose items prior to moving
machine
Refer to manual
DE8057

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Item Part No. Image
WARNING
AUTOMATIC MACHINE
MAY START WITHOUT
WARNING
Exit danger areas when
beacon/siren is activated
22 DE8058
WARNING
LOOSE OR ILL-FITTING
CLOTHING CAN GET CAUGHT
IN RUNNING MACHINERY
Always wear correctly fitting
(E.N/A.N.S.I approved)
Personal Protective Equipment.
DE8058
NOTICE
RISK OF EQUIPMENT DAMAGE
In ambient temperatures below
23 DE8103 0°c run engine off load and at
half speed to achive operating
temperature.
Failure to do so will result in
equipment damage.
Refer to operators manual
DE8103

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1.14 Emergency stop locations
qa441
1.14 Emergency stop locations

QA441-en-240615
qa441 1.14 Emergency stop locations
1.14.1 Operation of an emergency stop
1. Push emergency stop button to stop

machine.
2. Turn the ignition key and isolation switch to

‘0’ the OFF position as soon as possible. 2
1.14.2 To reset an emergency stop
WARNING
PERSONNEL HAZARD
Make sure the reason for the use of the emergency stop has been cleared
or rectified before the emergency stop is reset.
Turn emergency stop clockwise and release.

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1.15 Machine guarding
qa441
1.15 Machine guarding
DANGER
DO NOT use this equipment if any safety guards or devices have been
removed or not installed properly. Safety guards have been installed to
prevent death or serious injury. All safety guards must be fitted and
secured in their correct positions.
Operating this equipment with any safety guards or devices that have been
removed or installed improperly could result in death or serious injury.
1.15.1 Outer guards
B C
A G
E
F
D G
A. Head drum B. Conveyor skirt
C. Nip point D. Return roller
E. Conveyor skirt F. Tail drum
G. Access H. Under side

QA441-en-240615
qa441 1.15 Machine guarding
1.15.2 Inner guards - access guards removed
I. Hopper tail drum J. Belt nip point

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2. Transport & technical data qa441
2. Transport & technical data

QA441 - en - 240615
qa441 2. Transport & technical data
2.1 Special considerations for transport
WARNING
TRANSPORT HAZARD
Transport the machine utilising a vehicle capable of hauling at least the
listed gross weight of the machine, refer to the identification plate on the
machine. Failure may result in damage to the machine, haulage vehicle,
and may result in serious personal injury or death.
ALWAYS observe local and national regulations concerning the
transportation of heavy equipment. Make sure all appropriate permits,
licenses and endorsements are obtained and maintained before
transporting.
2.1.1 Machine preparation for transport
WARNING
PERSONNEL HAZARD
Lack of knowledge or understanding could cause serious injury, death or
damage to the machine.
DO NOT prepare machine for transportation until you have READ and
FULLY understood this manual. If necessary seek clarification from your
supervisor and or a Sandvik representative, before continuing. Failure to
do so may also invalidate the manufacturers warranties.
WARNING
PERSONNEL HAZARD
Working on or in close proximity to the machine whilst it is on and or
operating could cause serious injury or death.
Stop machine, isolate, remove ignition key and tag out, before continuing.
Refer to 4.7 Lockout and tag procedure.
Make sure all guards are in place and secure.
Visually check machine to make sure there is no component damage. Make sure all personnel are
away from the machine, drives, tracks and auxiliary equipment.
Make sure screen box, feeder and conveyor belts are free of material, remove if necessary. Check
the machine for loose debris and remove if necessary.
Make sure engine pre-start checks are carried out in accordance with engine manufacturer's
instruction manual and the daily machine checks are made, refer to 6.3.1 Daily (8 hour) maintenance
schedule

QA441 - en - 240615
.
WARNING
FALLING HAZARD
Falling from heights could cause serious injury or death.
Some of the steps in this procedure requires working at height, make sure
the following applies when working off the ground:
Access platforms are in place.
All hand rails are fixed in position.
All ladders are lowered and fixed in position.
A safety harness is worn.
Care should be taken while folding and unfolding maintenance platform,
refer to ???
Follow the instructions listed below:
Make sure that the machine is OFF. Never do maintenance while the
machine is ON
STOP THE MACHINE, ISOLATE, REMOVE THE IGNITION KEY, AND TAG-
OUT, BEFORE ALL MAINTENANCE IS STARTED ON THIS MACHINE.
a. Make sure that all bolts and fixings are tight and that all safety devices operating
correctly. Never start this machine without the safety devices operating correctly.
b. Remove all tools and equipment from the transport area.
c. Make sure all persons are away from the machine, drives, tracks and auxiliary
equipment.
d. Make sure that the pre-start checks outlined in the engine manufacturer's instruction
manual are completed.
e. Check the oil levels in the engine.
f. To remove a tag from the machine, refer to 4.7 Lockout and tag procedure.

QA441 - en - 240615
2.1.2 Moving the machine on or off transport vehicle
DANGER
CRUSHING HAZARD
Personnel on the machine or in exclusion zones when machine is
operational, are at risk of serious injury or death.
DO NOT UNDER ANY CIRCUMSTANCES operate machine when
ANY personnel or objects are on the machine or personnel are in
the exclusion zones, 20m (66ft).
DO a thorough site inspection prior to commencing ANY machine
moving operations.
a. Follow start up and tracking procedure, refer to 4.4 Moving machine on the tracks.
The machine can be driven on or off the transport vehicle at the pre-set tracking
speed.
b. Before tracking machine off a transport vehicle make sure all temporary sealing and
transport straps and chains are removed.
c. After tracking machine onto transport vehicle make sure all temporary sealing,
transport straps and chains are installed.
Note: Securing the machine to the transport vehicle is the responsibility of the vehicle
driver. DO NOT secure by using the tracks. Always check the travelling height before
starting the journey.

QA441 - en - 240615
2.1.3 Machine Transportation
Make sure that the machine is in the transport position:
1. Make sure the vibrating grid is in the transport position if fitted, refer to 2.1.4
Vibrating grid.
2. Make sure the tipping grid is set to the lowest level, refer to 4.5.8 Reject grid.
3. Set the screen box and main conveyor height to the lowest position, refer to 2.1.9
Main conveyor and screenbox height.
4. Make sure the fines conveyor is in the transport position, refer to 2.1.7 Fines
conveyor.
5. Make sure the maintenance platforms are in the transport position, refer to 2.1.10
Maintenance Platforms.
6. Make sure the side conveyors feed are in transport position, refer 2.1.8 Side
conveyors.
7. Adjust the exhaust extension, refer to 2.1.5 Exhaust extension.
8. Make sure the legs are in the transport position, refer to 2.1.5 Exhaust extension.
Before transporting on the road, the load dimensions must be checked to make sure that they are
within the local and national legal transport limits.

QA441 - en - 240615
2.1.4 Vibrating grid
WARNING
PERSONNEL HAZARD
WARNING
PERSONNEL HAZARD
WARNING
FALLING HAZARD
Care should be taken while folding and unfolding maintenance platform.
1. Turn the machine OFF -> Refer to 4.6 Shut down the machine.
2. Lock out and tag the machine -> Refer to 4.7 Lockout and tag procedure.

QA441 - en - 240615
3. Remove the bolts and the nuts with the

washers from the positions shown.
4. Remove tag if safe to do so -> Refer to 4.7 Lockout and tag procedure.
5. Start the machine -> Refer to 4.3 Engine starting procedure.
6. Move the lever to lift grid flares down. .
7. Grid flares shown down.

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2.1.5 Exhaust extension
WARNING
PERSONNEL HAZARD
WARNING
FALLING HAZARD
WARNING
HOT SURFACE HAZARD
The exhaust could still be hot after operation and cause severe burns if
touched.
Make sure that the exhaust is cool before maintenance is started.

QA441 - en - 240615
1. Exhaust extension shown in transport

position.
2. Loosen clip and rotate exhaust extension.

QA441 - en - 240615
2.1.6 Jacking legs
WARNING
CRUSHING HAZARD
Personnel near or on machine whilst raising the legs, may cause serious
injury or death.
DO NOT UNDER ANY CIRCUMSTANCES operate the jacking legs when
ANY personnel or objects are on or near the machine.
A MINIMUM of two persons are required for the following procedure, one to
carry out the procedure and one to view for potential hazards.
DO a thorough site inspection prior to commencing ANY work operations.
1. Adjust the hopper and chassis legs for transportation of the machine. Make sure the locating
pins are removed.
2. Start the machine, refer to 4.3 Engine starting procedure.
3. Select auxiliary mode on control panel.
Note! A time delay and audible warning will occur before the next control can be operated.
4. Move the lever to the right to raise the leg.
5. Move the lever to the right to raise the leg.

QA441 - en - 240615
8. Install the locating pins and clips.

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2.1.7 Fines conveyor
WARNING
PERSONNEL HAZARD
WARNING
FALLING HAZARD
1. Stop the machine -> Refer to 4.6 Shut down the machine.
2. Lockout machine -> Refer to 4.7 Lockout and tag procedure.
3. Remove the locating pins with the clips.

QA441 - en - 240615
4. Remove the locating pins with the clips.
5. Remove lockout from the isolator and Refer to 4.3 Engine starting procedure.
start the engine.
6. Set machine mode switch to auxiliary.
7. Move the fines conveyor down/up lever

to the transport position.
10.Secure the locating pins and clips in the

position shown.

QA441 - en - 240615
2.1.8 Side conveyors
WARNING
PERSONNEL HAZARD
WARNING
FALLING HAZARD
3. Loosen nut to release side conveyor.
4. Remove lockout from the isolator and Refer to 4.3 Engine starting procedure.
start the engine ->

QA441 - en - 240615
6. Move the fines conveyor lever midway to

the transport position.
7. Release the support rod.
8. Move the rollers and lock them in place

with the locating pin.

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9. Remove the lower side flares. Put the

flares into transport position, install the
locating pins.
10.Set machine mode switch to auxiliary.
11.Move the lever to put the side conveyor

into transport position.
12.Stop the machine -> Refer to 4.6 Shut down the machine.
13.Lockout machine -> Refer to 4.7 Lockout and tag procedure.
14.Secure the side conveyor for transport.

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2.1.9 Main conveyor and screenbox height
WARNING
PERSONNEL HAZARD
WARNING
FALLING HAZARD
1. Remove the pins and clips that secure the

conveyor in position.

QA441 - en - 240615
2. Remove the pins and clips that secure the

screen box in position.
4. Start the machine in operation mode -> Refer to 4.3 Engine starting procedure.
6. Move the levers to lift the tail/main

conveyor and the screen box DOWN, to
the transport position.

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2.1.10 Maintenance Platforms
WARNING
PERSONNEL HAZARD
WARNING
FALLING HAZARD
WARNING
operator and positioned to have an all round view of the operation.
ALWAYS make sure safety device such as locking wedges, securing
Make sure that part of the equipment raised for reason is prevented from
falling by securing it in a safe reliable manner.
Never work alone.

QA441 - en - 240615
4. Move the levers to lower the screen box,

to the transport position.
7. Use suitable access platforms as defined

by a site specific risk assessment, to the
hand rail.
8. Remove the retaining bolts.
9. Remove the locking pins and retaining

bolts on both sides.
10.Remove the rear hand rail from the
machine.

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11.Remove the locking pins.
12.Remove the retaining bolts on both sides.
13.Fold the front floor section.
14.Remove the infill plate retaining bolts on

both sides.

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15.Fold the infill plate into the transport

position and secure.
16.Fold ladder into the transport position. Refer to 2.1.12 Ladder
17.Remove all the securing pins with the R-

clips.
18.Remove tag if safe to do so -> Refer to 4.7 Lockout and tag procedure.
19.Start the machine in operation mode -> Refer to 4.3 Engine starting procedure.
20.Set the mode control to auxiliary.
21.Move the lever to fold the right hand

maintenance platform DOWN.

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22.Move the lever to fold the left hand

maintenance platform DOWN.
23.Turn the machine OFF -> Refer to 4.6 Shut down the machine.
24.Remove all the R-clips and the locating

pins so the rail is able to fold.
Note! Do not remove the pivot locating pin,

only remove the locating pin in the
position shown on each support end.
25.Secure the access gate.
26.Close gate on non access side.

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27.Fold UP the rail and install all the locating

pins and clips.
28.Make sure the maintenance platform
locating pins are removed.
29.Hook the ladder on the maintenance

platform and secure.
30.Hook the rear hand rail on the

maintenance platform and secure.
31.Remove tag if safe to do so -> Refer to 4.7 Lockout and tag procedure.
32.Start the machine in operation mode -> Refer to 4.3 Engine starting procedure.
33.Set the mode control to auxiliary.

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34.Lower the end fines conveyor.
35.Fold the end fines conveyor up.
36.Raise the end fines conveyor and secure

it.

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2.1.11 Reject grid
WARNING
PERSONNEL HAZARD
WARNING
FALLING HAZARD
1. Make sure the machine is ON -> Refer to 4.3 Engine starting procedure.

QA441 - en - 240615
3. Move the grid lever and adjust the angle

reject grid UP.
6. Remove the clips and securing pins then

lower the support leg as necessary, and
secure with the clips and securing pins.
7. Move the grid lever and lower the reject

grid DOWN.

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2.1.12 Ladder
1. Remove retaining clips and pins, pivot the

lower part of the ladder up.
2. Secure the retaining clips and pins.

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2.2 Machine data
Hopper
Level volume 7.5m³/ 9.8yd³
Max volume 11.33m³/ 14.8yd³
Type Hydraulically tipping grid
Grid area 2200x3600mm (7’2” x 11’9”)
Grid area with sides raised 2200x4400mm (7’2” x 14’5”)
Tipping grid angle standard 96º
Tipping grid angle vibrating grid 34º
Feed conveyor belt

Width 1200mm (3’11”)
Length (drum centres) 3890mm (12’9”)
Motor 125cc
Gear box ratio R 26:1
Head drum Ø 325mm (1ft)
Tail drum Ø 270mm (10½")
Main conveyor
Width 1000mm (3’3”)
Length (drum centres) 12390mm (40’ 7”)
Drive drum Ø 282mm (11")
Motor 490cc
Fines conveyor
Discharge height 4988mm (16’4”)
Width 1200mm (3’11”)
Drive Hydraulic motor 395cc
Head drum Ø 228mm (9")
Length (drum centres) 7976mm (26’1”)

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Screen
Type 2 Bearing, “Doublescreen”
Primary screen size* Top deck: 3048x1524mm (10'x5')
Bottom Deck: 3048x1524mm (10'x5'")

Secondary screen size* Top deck: 3048x1524mm (10'x5')
Bottom deck: 3048x1524mm (10'x5”)

Tensioning System Ratchet
Speed 1200rpm
Throw 7.24mm (0.3in)
Motor 49.1cc
Side conveyors
Discharge height 5000mm (16’4”)
Width 700mm (2’3”)
Drive Hydraulic motor 395cc
Head drum Ø 228mm (9")
Length (drum centres) 10551mm (34’ 7”)
Tracks
Length to centres 3800mm (12’5”)
Width 500mm (1’7”)
Tank capacities
Diesel tank size 290Litres / 76.5US gall
Hydraulic tank size 370Litres / 98US gall

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Performance
Max feed size 200mm (8")
Capacity (up to) 600tonnes/h (661US ton/h)
Travel speed 1.06Km/H (0.66 MPH)
Max slope climbing 20º
Max slope side to side 10º

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2.3 Transport dimensions

2.3.1 Option - 4m (13ft) Tipping grid and inlet chute
G
H
M
B C D
E
F
L
K
J
I
mm (ft - in) mm (ft - in)

A 18490 60' 8" H 930 3' 1"
B 6290 20' 8" I 3000 9' 10"
C 4590 15' 1" J 2750 9'
D 7600 24' 11" K 500 1' 8"
E 1070 3' 6" L 1470 4’ 10”
F 1250 4' 1" M 2700 8’ 10”
G 3500 11’ 6”

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2.3.2 Option - 4.5m (15ft) Tipping grid
G
H
M
B C D
E
F
L
K
J
I

A 18680 61' 3" H 930 3' 1"
B 6480 21' 3" I 3000 9' 10"
C 4590 15' 1" J 2750 9'
D 7600 24' 11" K 500 1' 8"
E 1070 3' 6" L 1470 4’ 10”
F 1250 4' 1" M 2700 8’ 10”
G 3500 11’ 6”

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2.3.3 Option - Vibrating grid and inlet chute
G
J
I
B C D
E
F
N
M
L
K

A 18490 60' 8" H 2620 8’ 7”
B 6290 20' 8" I 1950 6' 5"
C 4590 15' 1" J 930 3’ 1”
D 7600 24' 11" K 3000 9' 10"
E 1070 3' 6" L 2750 9'
F 1340 4' 9" M 500 1' 8"
G 3500 11’ 6” N 1510 5’

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3. Product Overview qa441
3. Product Overview

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qa441 3. Product Overview
3.1 Machine layout indicating main components

3.1.1 General information
For more technical information on the machine, refer to section 2, Transport and Technical
Data.
3.1.2 Main components - overview
K G J
A C
E
B
I F H
A. Reject grid
B. Hopper and feed conveyor
C. Power pack
D. Screen box x2
E. Fines conveyor
F. Control levers
G. Main conveyor
H. Control levers (on opposite side)
I. Tracks
J. Maintenance platform
K. Side conveyors

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3.2 Applications
3.2.1 Common applications
• Natural aggregate
• Crushed rock
• Recycling of demolition material
• Sand and gravel
This list is by no means exhaustive. Contact Sandvik Construction for further details of
performance figures and advice on your material.
3.2.2 Machine application and limitations
This machine has been designed and constructed to screen materials as described in 3.2
Applications, such as stone, sand and gravel to a predetermined size. The machine must
not be used for any other purpose without first contacting Sandvik Construction.
The machine must not be operated until the instructions supplied with the machine are read
and fully understood.
In low ambient light conditions, set up sufficient lighting to make the operation safe.

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3.3 Screening machine

3.3.1 Machine description
This machine is a self contained tracked machine built to withstand the rigours and
conditions of operating in quarries and within the construction industry. The machine utilises
a diesel engine to provide the power to the hydraulic power pack and to generate 12 volt DC
electricity for the electrical systems of the machine.
The tracks, hopper, conveyors, screen boxes and all other working parts of the machine are
all hydraulically driven.
Where possible all of the moving parts of this machine are guarded, where not, warnings are
provided. The safety section of this manual must be read and fully understood. Any residual
organisational, personal and environmental issues must be fully addressed as detailed in
the safety section.
This equipment has been manufactured and assessed to be in accordance with the
Machinery Directive 2006/42/EC.
3.3.2 Operation description
Material is loaded normally by excavator into the hopper where material falls onto the feeder
conveyor. The material is then fed onto the main conveyor.
The material travels up the main conveyor and transfers onto the screen box, the material
passes over a series of meshes which separates the material into 3 grades.
The larger and medium grades are separated onto the overside and mid conveyors leaving
the fines to travel up the fines conveyor. Each material grade falls into separate stockpiles
around the machine.

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3.4 Main control devices
3.4.1 Electrical controls
This machine is equipped with a protection controls which will shutdown the engine. With
this system sensors are used on critical elements. Should the system reach factory preset
limits the system will experience a safety shutdown and turn the engine off.
If a safety shutdown occurs, the condition causing the engine to shut

down must be corrected before any attempt is made to restart it.
3.4.2 Hydraulic controls
DANGER
If fluid is injected under the skin, it must be surgically removed or gangrene
will result. GET MEDICAL HELP IMMEDIATELY.
HAND.
Work on hydraulic equipment must be carried out by persons with training
and authorisation to maintain the hydraulic equipment. Do a full risk
assessment and take all necessary safety measures.
• Legs (Hopper)
• Legs (Chassis)
• Maintenance platform
• Left hand conveyor fold
• Primary screen slide

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• Fines conveyor fold
• Fines conveyor lift
• Primary screen angle
• Main conveyor screen lift
• Maintenance platform
• Right hand conveyor fold
• Mesh change
• Vibrating reject grid flair
• Reject grid up/down

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3.5 Operational controls
C
D
A
B
H
G
E
I
A. Information and extra operations display.
B. Selection buttons for information and operation display.
C. Machine mode switch: auxiliary, operation, track.
D. Component operation numbers and colour key.
E. Key operated Power, Heater coils, Start engine, Engine run.
F. Component start and stop sequence buttons 1 to 5.
G. Automatic start and stop sequence button 5.
H. Engine speed control.
I. Battery isolator switch and lockout.

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3.6 Machine mode switch
A. Auxiliary mode for setting up machine and

preparing it for transport. A
B. Operation for screening and position for starting B

the engine.
C. Track for moving the machine on the tracks.

C

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3.7 Display screen
Icons on the screen show green when an item is available and red when activated.
A. Screen display
A
B. Four buttons to navigate
between display pages and
operate functions
C. 4-way screen control
D. OK button [Not used]
B [4] C D
3.7.1 Auxiliary mode home screen
Auxiliary mode.
Engine information button.
Working lights button [Red = on].
Machine diagnostics button.
Service function not available.
Engine speed.
Engine operation hours.

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3.7.2 Operation mode home screen
Operation mode.
Service function button.
Engine speed.
3.7.3 Track mode home screen
Track mode.
Service function not available.
Engine speed.

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3.7.4 Engine information
Press engine information button to display the information relating to the engine.
Battery charge.
Oil pressure.
Air filter.
Hydraulic fluid level.
Coolant level.
Water in fuel.
Coolant temperature.
Pre heater for engine starting.
Press button to exit and go to home page from any

screen page.
The engine information icons display green normally and display red
and an error message with a fault code is displayed if there is a
fault.
Refer to 6.20 Machine error messages and fault codes.

screen page.

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3.7.5 Machine diagnostics
Press machine diagnosis button to make checks on control systems.
Track control - page 1
To check a track control system, connect and switch on either

the umbilical track control or switch on the radio control before
the engine is started.
A blank control will be displayed initially. When a button is
pressed on the track control the display screen button lights up,
when the correct input signal is received from the control unit.
Screen page number.
Press button for next page.

screen page.
Radio signals - page 2
If the radio controls are operational, the display

shows transmitted and received radio codes.
Screen page number.

screen page
Reject grid control - page 3
To check the grid control radio system.

A blank control is displayed.
Press a button on the grid control.

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The display screen button lights up, when the correct input
signal is received from the control.
If the radio grid control is not operational, the

automatic grid operation can be switched on and
off using the up or down arrow of the 4-way screen
control button.
Screen page number.

screen page.

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Sensors - Page 4
Use the left or right arrows of the 4-way screen

control to move the white highlight box around the
screen to the item required.
Stockpile level sensor [option].
Green stockpile low level, feeder start.
Red stockpile high level, feeder stop.
Speed wheel sensor [option] on feed conveyor.
Hydraulic fluid temperature sensor.

Other icons on screen:
Screen page number.
Press button for next page 4 screen.

screen page.
Press button up arrow to turn highlighted item off or

down arrow to turn on.
Note! A sensor that is not installed or being used should be switched off, shown by a red cross
through it.

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Stockpile sensor [option] - page 4
[If a stockpile sensor is fitted]
On and Off:

stockpile level indicator.
With the stockpile sensor selected, use the up arrow

of the 4-way screen control button to switch it off or
the down arrow button to switch it on
Note! When the sensor is switched off, the feeder is on
continuously and will not stop regardless of the stop
setting.
Note! A sensor that is not installed or being used should be

switched off, shown by a red cross through it.
Press button up arrow to turn highlighted item off or

down arrow to turn on.
Screen page number.

screen page.
Stockpile start setting:

control to move the white highlight box around
green start.
With the stockpile start selected, use the up or down

arrow of the 4-way screen control to adjust the start
stockpile level.
Press the up arrow to increase the value, down

arrow to decrease.

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Stockpile stop setting:

control to move the white highlight box around red
stop.
With the stockpile stop selected, use the up or down

arrow of the 4-way screen control button to adjust
the stop stockpile level.
Press the up arrow to increase the value, down

arrow to decrease.
Speed wheel on feeder [option] - page 4

[If a speed wheel is fitted]

level indicator of the speed wheel.
With the speed wheel sensor selected, use the up

arrow of the 4-way screen control button to switch
the sensor off or the down arrow button to switch it
on to display the speed.
If the speed falls below the minimum pre-set speed it
will stop the feeder.
Note! If the speed wheel sensor is off, the feeder will not stop
if a low speed is detected.

Press up arrow to turn highlighted item off or down

arrow to turn on.
Screen page number.

screen page.

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Hydraulic fluid temperature sensor - page 4

hydraulic fluid temperature indicator.
With the hydraulic fluid sensor selected, use the up

arrow of the 4-way screen control button to switch it
off or the down arrow button to switch it on.
Note! When the sensor is switched off, the hydraulic fluid
cooler is on continuously.

Press up arrow to turn highlighted item off or down

arrow to turn on.
Screen page number.

screen page.
Hydraulic valve operation - page 5

Displays the current valve status.
Green circle indicates the operation is functioning correctly.
Grey circle indicates the operation is off.
Red indicates an error and an error code will be shown.
Screen page number.

screen page.

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Hydraulic valve operation - page 6
Displays the current valve status.

Green circle indicates the operation is functioning correctly.
Grey circle indicates the operation is off.
Red indicates an error and an error code will be shown.
Screen page number.

screen page.
Display system information
The installed display, software and panel versions are displayed

for reference.
Press button for page 1.
Press button for home page.

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3.7.6 Service mode
From the normal operation mode screen, press

and hold service button for 4 seconds to
enable the service mode functions.
Indicates service mode enabled.

The beacon and siren are on whilst in service
mode.
Indicates service mode is not available. It is only

available via operation mode
Press the numbered button to operate only the individual

colour coded section of the machine.
individual sections of the machine can now be operated
independently.
Note! The individual section of the machine will start

immediately.
Press service button again to return to operation

mode.
3.7.7 Active error display screen
When the system detects a fault, a message is displayed on the

screen.
Each fault is identified by a fault code number, description and
icon.
Refer to 6.20 Machine error messages and fault codes for more
information.
Press button to acknowledge the error and for home

page.
Note! If the cause of the error is not cleared, the active error
message will re-appear.

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3.8 Reject grid radio control
Move reject grid UP
Move reject grid DOWN
Automatic reject grid cycle, [moves up holds for short

time then down]
Engine stop
Sound alarm when held
Transmitting indicator
Transmitting code indicator

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3.9 Track controls
Remote charging socket for connecting lead to

re-charge radio battery when required.
Note! The radio handset must be fully

charged at regular intervals. The steady
green LED shows handset is charged.
On/off switch for the track remote handset.
When operating the handset, the yellow buttons are for forward movement and the blue
ones for reverse. These correspond to the yellow and blue direction indicators on the
machine.
The tracks can be operated using the wired umbilical control or the radio remote control.
Note! The track control must be connected and switched on before starting the engine.
Red button is engine stop ONLY. For emergency stops refer 1.14 Emergency stop locations.
EXTEC SCREENS & CRUSHERS LTD.
LED indicator:
Off - No buttons pressed
On steady green - Track direction button active
On steady red - Engine stop button active
Flashing red - Error detected in button

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3.10 Machine working dimensions

3.10.1 Option - 4m (13ft) Tipping grid and inlet chute
A
F
F
G
E
B
D
H

A 18720 61' 5" E 6590 21' 7"
B 5290 17' 4" F 5300 17’ 5”
C 18890 62' G 1370 4’ 6”
D 4890 16' H 2780 9’ 1”

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3.10.2 Option - 4.5m (15ft) Tipping grid

A 18720 61' 5" E 6590 21' 7"
B 5290 17' 4" F 5300 17’ 5”
C 18890 62' G 1370 4’ 6”
D 4890 16' H 2780 9’ 1”

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3.10.3 Option - Vibrating grid and inlet chute
A
F
F
G
E
B
D
H

A 18720 61' 5" E 6590 21' 7"
B 5290 17' 4" F 5300 17’ 5”
C 18890 62' G 1460 4’ 9”
D 4890 16' H 2020 6’ 8”

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4. Commissioning & Shut Down qa441
4. Commissioning & Shut Down
Copyright © Sandvik Construction Mobile Crushers and Screens Ltd. 107

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qa441 4. Commissioning & Shut Down
4.1 General Safety

The following safety instructions apply throughout this section, additional and or variations in safety
measures that are specific to their relevant sub sections will be detailed in the body of the text.
WARNING
PERSONNEL HAZARD
DO NOT START COMMISSIONING until you have READ and FULLY
understood this manual. If necessary seek clarification from your supervisor
and or a Sandvik representative, before attempting ANY operations or
maintenance. Failure to do so may also invalidate the manufacturers
warranties.
WARNING
PERSONNEL HAZARD
Not using the minimum Personal Protective Equipment (PPE) could cause
serious injury or death, refer to 1.4 Personal protective equipment (PPE).
Make sure that the minimum Personal Protective Equipment (PPE) is used
when working on or within 20m (66ft) of the machine, refer to Hazard
exclusion zones in safety section 1.
108 Copyright © Sandvik Construction Mobile Crushers and Screens Ltd.

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4.2 Pre-commissioning instructions
4.2.1 Pre-start instructions
WARNING
PERSONNEL HAZARD
Stop machine, isolate, remove ignition key and tag out, before carrying out
the pre-start checks. Refer to 4.7 Lockout and tag procedure
WARNING
FALLING HAZARD
Some of the steps in this procedure require working at height, if this is the
case, make sure:
- Access platforms are in place.
- All hand rails are fixed in position.
- All ladders are lowered and fixed in position.
- A safety harness is worn.
NOTICE
RISK OF PROPERTY DAMAGE.
It is recommended that set up of this machine be carried out by a representative of Sandvik
Mobile Crushing and Screening Ltd. or by a qualified representative of the dealer.
NOTICE
RISK OF PROPERTY DAMAGE.
The following instructions assume transportation of this machine using a low loader type
vehicle, delivered in close proximity to the site. If a machine is to be transported in any other
way, contact the manufacturer for additional instructions.

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1. Make sure that this manual is read and understood.
2. Do NOT attempt to start this machine until you are aware of ALL aspects of its operation.
3. Remove any temporary sealing and transport straps.
4. Visually inspect machine for the following:
• All machine components are in place and secure.
• There are no signs of ANY fluid or oil leaks including hydraulic hoses.
5. Check machine is in good mechanical condition and there is no component damage or loss.
6. Make sure that all bolts and fixings are tight and that all guards are in place with all safety
devices operating correctly.
7. Make sure that the hopper, screen box and conveyors are all free of material.
8. Carry out a full daily maintenance routine, Refer to 6.4.1 Daily maintenance schedule.
9. Remove all tools and equipment from the operational area.
10. Make sure all persons are away from the machine, drives, tracks and auxiliary equipment.
11. Make sure the checks and pre-start procedures outlined in the engine manufacturers
instruction manual are complied with.
12. Make sure all the locating pins are in the correct positions.
13. Make sure all the operating levers are in an OFF position.
14. Make sure all the levers and ball valves are in the OFF or NEUTRAL positions.
15. Make sure skirting rubbers, scrapers and conveyor belts are in good condition and work
properly.
16. Remove any lockout tags from the machine if safe to do so, refer to 4.7 Lockout and tag
procedure.

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4.3 Engine starting procedure
4.3.1 Before starting engine
Make sure all emergency stops are re-set, providing it is safe to do so, refer to 1.14.1 Operation of
an emergency stop.
DANGER
PERSONNEL HAZARD
Persons on machine or in exclusion zones when starting machine, may
cause serious injury or death.
DO NOT UNDER ANY CIRCUMSTANCES start the machine when ANY
persons are standing on the machine or in the exclusion zones.
Make sure machine is NOT tagged out. DO NOT start machine if it is tagged
out. Refer to Hazard exclusion zones in safety section 1.
WARNING
TIPPING HAZARD
Operating machine on unsuitable ground could cause serious injury or
death.
Machine MUST NEVER be tracked on gradients more than:
• 10° left or right.
• 16° front or 16° back.
Both tracks MUST BE in contact with firm level ground, suitable for carrying
the machine weight and accessories.

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4.3.2 Engine start
1. Make sure the scheduled maintenance Refer to section 6.3 Maintenance schedules -
checks are done > power module maintenance.
2. Before starting the engine, check that the

dummy plug is fitted. It is located at the
hopper end of the machine. It must be
plugged in for all operations except if the
umbilical track control is to be used.
Note Dummy plug can be found in cabinet.
3. The alternative plug with umbilical track

control can be plugged in if it is to be
used.
Note Make sure that all emergency stops are released. The dummy plug is not to be used to
isolate the unit refer to 4.7 Lockout and tag procedure.

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4.3.3 Engine controls
5
6
1
2
7
1. Release latch and remove door to access the engine controls.
Note The controls are behind the conveyor if folded down for transport.
2. Turn battery isolation switch to the ON position.
3. Set the engine speed control down to the slowest position.
4. Set mode control switch to screening operation position.
5. Insert the ignition key into the ignition switch and turn it clockwise to the first
power ON position indicated.
6. Turn the key clockwise to the heater position and hold if the engine pre-heat
is required.

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7. Turn the key clockwise to the crank position and hold until the pre-start
warning time count down is complete and the engine starts, then release the
key.
8. The key should return to the power ON position.
Note The engine will only start when the mode control switch is set to operation.
Note If the engine fails to start the ignition key must be turned to the off position
and the complete ignition cycle re-started.
NOTICE
When operating the machine at low temperatures of 0°C (32°F) or below,
run all systems empty for approximately 15 minutes to allow the hydraulic
systems to reach working temperature. DO NOT load any material into the
machine until the hydraulic systems are at working temperature. Failure to
comply with this or any other instructions in this manual may cause
damage to the machine and may invalidate any warranty.

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4.4 Moving machine on the tracks
4.4.1 Before moving the machine
Note: A minimum of two persons are required to carry out the following procedures, one
to carry out the operations (operator) and one to warn of any potential hazards or
dangers (observer).
• Make sure loading / unloading site is clear of non-essential personnel. Erect barriers around
the area and post warning signs where site conditions warrant this and perform necessary site
specific risk assessments.
• Loading / unloading and tracking must only be carried out on firm flat ground.
• For the weight of the machine, refer to the specification plate fixed to the machine and
accessories.
• When tracking, the operator and observer must be in a position to have an all round view of the
operation.
• Operator must be fully trained in the use of this equipment.
• An observer must warn of any potential hazards or dangers.
Only move the machine when all side conveyors are in the transport position, refer to 2.1.1
Machine preparation for transport.
• For safety reasons, it is essential to check round the machine prior to and during tracking, for
obstacles or personnel which may be endangered by moving the machine.
DANGER
MOVING MACHINE HAZARD
No persons should be on the machine or in the exclusion zone whilst the
machine is being moved as this may cause injury or death.
DO NOT UNDER ANY CIRCUMSTANCES move the machine when ANY
WARNING
RADIO INTERFERENCE HAZARD
There is a small possibility the radio frequency on the remote controllers
may operate other machinery. Use the wire connected umbilical controller
if this is an issue.

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WARNING
TIPPING HAZARD
Operating machine on unsuitable ground can cause serious injury or death.
Machine MUST NEVER be tracked on gradients more than: 10° left to right or
16° front, 16° back. Both tracks MUST BE in contact with firm level ground
which is suitable for carrying the machine weight.
Set up either the radio remote handset or the wired umbilical control to move the machine to
the required position. Refer to 4.4.2 Radio remote control or 4.4.3 Wired umbilical control.
Note If required plug in the wired umbilical control, before starting the engine. If the wired
umbilical control is being used DO NOT switch on the radio track control as this will stop
the umbilical operating. If this occurs, the mode control switch will require setting to
operation mode then to track mode again.
4.4.2 Radio remote control
Note Switch on the radio remote control

before starting the engine.
1. Switch on the track radio remote control

for use if required, before starting the
engine.
2. The remote charging socket for
1 2
connecting lead to re-charge battery when
required.
Note The radio control must be fully charged at regular intervals.

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4.4.3 Wired umbilical control
Note Connect the wired umbilical control if

required, before starting the engine.
1. Remove the dummy plug from the socket,

located at the hopper end of the machine.
3 4
2. Connect the wired umbilical control.
3. Switch on the wired umbilical control for

use.
Note The dummy plug must be inserted for all other machine operations. The dummy plug is not
to be used to isolate the unit refer to 4.7 Lockout and tag procedure.

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4.4.4 Track control mode
1. Start the engine > 1. Refer to 4.3 Engine starting procedure.
2
2. Set the mode control switch to track. A
pre-start warning time count down timer
will display before the tracks will operate.
3. Raise the engine speed using the hand

throttle.
Note Tracking speed is proportional to

engine speed always track the machine 3
at a speed relevant to the conditions.
Only use maximum engine speed for
long distances if safe to do so.
Use slow engine speed for loading onto
a trailer or in confined spaces.
Note If the hydraulic oil cooler is functioning

a higher engine speed will be required.
4.4.5 Operating track control
DANGER
MOVING MACHINE HAZARD
No persons should be on the machine or in the exclusion zone whilst the
machine is being moved as this may cause injury or death.
DO NOT UNDER ANY CIRCUMSTANCES move the machine when ANY
NOTICE
Make sure the jacking legs are up and clear from the ground. If machine is
moved with them down it will damage the machine.
1. Check round the machine for obstacles or personnel which may be endangered by moving
the machine.
2. When moving machine, make sure that it is only moved over firm ground suitable for carrying
the weight of the machine. Prior to operating the machine, it is essential that both tracks are in
contact with firm level ground to avoid excessive vibration or rocking of the machine. DO NOT
MOVE THE MACHINE ACROSS EXCESSIVELY SLOPING GROUND.

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3. The yellow and blue control buttons correspond to the yellow and blue direction indicators on
the machine.
4. The yellow buttons on the left and right are for forward movement of the individual track. The
central yellow button for moving forward in a straight line.
5. The blue buttons are for reverse movement of the individual track or if pressed together for
moving in a straight line.

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Note The engine speed control must only be used in the maximum position when moving the
machine in a straight line in an open clear area. If the machine is being manoeuvred on or
off a trailer or in a confined space, set the engine to a slower speed.
6. When the machine is moved to the

required position, set mode control to
operation.
7. Set engine speed down to idle.
8. Turn the machine OFF > 8. Refer to 4.6 Shut down the machine.
9. Switch off the track control.
10. If the wired umbilical control has been

used, disconnect and store the control.
11. Insert the dummy plug into the socket. The 10 11
dummy plug must be inserted for all other
machine operations.

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4.5 Preparing for screening operation
Note: Make sure Sandvik service personnel are available at the initial set up the machine.
WARNING
FALLING HAZARD
Some of the steps in this procedure requires working at height, make
sure the following applies when working off the ground:
Care should be taken while folding and unfolding maintenance
platform.
WARNING
PERSONNEL HAZARD
Stop machine, isolate, remove ignition key and tag out as required, before
preparing crusher for operation. Refer to 4.6 Shut down the machine and
4.7 Lockout and tag procedure.
NOTICE
The machine must always be set up and operated on flat, firm, solid, level
ground when operating in its standard mode. Failure to comply with this or
any other instructions in this manual may cause damage to the machine
and may invalidate any warranty.
1. If fitted setup the Vibrating Grid, refer to 4.5.1 Vibrating grid.
2. Lower the jacking legs to the working position, refer to 4.5.3 Jacking legs.
3. Set up the maintenance platforms, refer to 4.5.7 Maintenance Platforms.
4. Set up the fines conveyor, refer to 4.5.4 Fines conveyor.
5. Set up the main conveyor and screen-box height, refer to 4.5.6 Set up the main conveyor and
screen-box height.
6. Set up the side conveyors, refer to 4.5.5 Side conveyors.
7. If fitted setup the reject grid, refer to 4.5.8 Reject grid.

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4.5.1 Vibrating grid
WARNING
PERSONNEL HAZARD
WARNING
PERSONNEL HAZARD
WARNING
FALLING HAZARD

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4. Move the lever to lift grid flares UP into

position.
7. Install the bolts and the nuts with the

washers in the position shown

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4.5.2 Exhaust extension
WARNING
PERSONNEL HAZARD
WARNING
FALLING HAZARD
Care should be taken while folding and unfolding maintenance
platform.
WARNING
HOT SURFACE HAZARD
The exhaust could still be hot after operation and cause severe burns if
touched.
Make sure that the exhaust is cool before maintenance is started.

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1. Exhaust extension shown in working

position.
2. Loosen clip and rotate exhaust extension.

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4.5.3 Jacking legs
WARNING
PERSONNEL HAZARD
Refer to 4.6 Shut down the machine and 4.7 Lockout and tag procedure.
WARNING
CRUSHING HAZARD
Personnel near or on machine whilst raising the legs, may cause serious
injury or death.
DO NOT UNDER ANY CIRCUMSTANCES operate the jacking legs when
ANY personnel or objects are on or near the machine.
A MINIMUM of two persons are required for the following procedure, one to
carry out the procedure and one to view for potential hazards.
DO a thorough site inspection prior to commencing ANY work operations.
NOTICE
Make sure that the machine is on firm level ground with enough space for
the machine to fit in its working position.
.
1. Remove the clips and locating pins from

all legs.

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3. Set the mode control to auxiliary.
4. Adjust the jacking legs to support the

machine as necessary.
5. When the jacking legs are down, install the

locating pins and clips in all jacking legs.
6. Turn machine OFF -> Refer to 4.6 Shut down the machine.

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4.5.4 Fines conveyor
WARNING
PERSONNEL HAZARD
WARNING
FALLING HAZARD
3. Make sure that all transport equipment,

straps and pins are removed from the
fines conveyor

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4. Make sure the fines conveyor has enough

space and is free to un-fold. Set up safety
barriers and exclusion zone if necessary.
5. Remove the securing pins and clips from

the position shown.
NOTICE
Make sure that the fines conveyor has enough space to un-fold. Make sure
the fines and main conveyors, with the screen box are in the full raised
position. If not this may damage the equipment.

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9. Move the fines conveyor down/up and

main conveyor/screen box levers to the
UP position. Raise them to the full raised
position.
10. Move the conveyor fold lever to unfold it
DOWN.
11. Move the conveyor down/up lever to set it
to the necessary working height (4
positions).
12. Move the lever and lower the main
conveyor/screen box DOWN to access the
locating pin positions.
15. Install the locating pins with the clips in the

position shown.
16. Install the locating pins with the clips in the

position shown.
NOTICE
To prevent damage to the equipment during operation, make sure all
locating pins are in position and installed correctly.

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4.5.5 Side conveyors
WARNING
PERSONNEL HAZARD
WARNING
FALLING HAZARD
NOTICE
Make sure that the side conveyors have enough space to un-fold. If not this may
damage the equipment

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4. Move the lever to un-fold the side

conveyor OUT, midway.
7. Put the flares into working position.
8. Secure the locating pins.
9. Move the rollers and lock in place with the

locating pin.

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10. Install the support rod. (DO NOT tighten

the nut).

conveyor to working position.

conveyor OUT, midway.

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4.5.6 Set up the main conveyor and screen-box height
WARNING
PERSONNEL HAZARD
4. Move the levers to lift the tail/main

conveyor and the screen box UP, to the
working position.
7. Install the pins and clips to secure the

screen box in position.

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8. Install the pins and clips to secure the

conveyor in position.
NOTICE
To prevent damage to the equipment during operation, make sure all
locating pins are in position and installed correctly.

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4.5.7 Maintenance Platforms
WARNING
PERSONNEL HAZARD
death.
Care must be taken while folding and unfolding maintenance platforms.
WARNING
FALLING HAZARD
WARNING
operator and positioned to have an all round view of the operation.
ALWAYS make sure safety device such as locking wedges, securing
Make sure that part of the equipment raised for reason is prevented from
falling by securing it in a safe reliable manner.
Never work alone.

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3. Remove rear hand rail from the

maintenance platform.
8. Lower and unfold the tail conveyor
11. Remove all the R-clips and the locating

pins so the rail is able to fold.
Note Do not remove the pivot locating pin,

only remove the locating pin in the
position shown on each support end.

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12. Fold down the rail and install all the

locating pins and clips.
13. Make sure the maintenance platform
locating pins are removed.
14. Open access gate.
15. Open gate on non access side.

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19. Move the lever to fold the left hand

maintenance platform UP.
20. Move the lever to fold the right hand

maintenance platform UP.
23. Install all the securing pins with the R-

clips.

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24.Fold the infill plate down into working

position.
25.Secure the infill plate retaining bolts both

sides.
26.Remove the locking pins.

27.Fold the front floor section into working
position.
28.Secure the locking pins.
29.Secure the retaining bolts both sides.

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30.Put the handrail into working position.

31.Secure the retaining bolts.
32.Secure the locking pins both sides.

33.Secure the retaining bolts both sides.

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4.5.8 Reject grid
WARNING
PERSONNEL HAZARD
death.
Make sure persons are clear of the maintenance platforms folding zones
as this may cause injury or trapped limbs.
1. Make sure the machine is ON -> Refer to 4.3 Engine starting procedure.

reject grid UP.

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4. Remove the clips and securing pins then

adjust the support leg as necessary.
5. With the support legs in the required

position, install the securing pins and clips.

reject grid DOWN on to the legs.

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4.5.9 Ladder
1. Remove the retaining clips and pins, pivot

the lower part on the ladder into working
position.
1. Secure the retaining clips and pins.
4.5.10 Screen-box angle
WARNING
PERSONNEL HAZARD
death.
Make sure persons are clear of the maintenance platforms folding zones
as this may cause injury or trapped limbs.

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3. Make sure the locating pins are removed.
5. Move the levers to adjust the screen box,

to position.
8. Make sure the locating pins are secured

with clips in the position shown

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4.6 Shut down the machine

Operate the machine until all material has been removed from the feeder and the conveyor is
not producing a stockpile.
WARNING
Keep away from the feeder area and the conveyor belt areas. Only fully
trained and authorised operators in loading the machine and collecting
processed material should be in this area.
There is a risk of serious injury or death due to other heavy machinery
working in the area.
Make sure the machine is off, locked and tagged, refer to 4.6 Shut down
the machineand 4.7 Lockout and tag procedure.

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4.6.1 Automatic shut down
1. Stop feeding material into the hopper.

2. Wait for all material to fully discharge from the hopper, screen box and all conveyors.
3. Press and hold button 5 for 3 seconds to

begin the automatic shut down sequence.
4. The machine will then shut down

automatically by going through the
sequence.
Note There is a time delay and audible

warning between each operation
sequence, indicated by the button light
flashing.
5. When all the green lights are ON,

indicates the machine systems have
stopped.
6. Set the engine speed to the slowest low

position and allow engine to idle for a few
minutes.
7. Select screening operation mode on

control panel.
8. Stop the engine by turning the ignition key

to the off position.

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Note When the machine is switched off wait a minimum of 60 seconds before the start sequence
is run again - An error code will show if started before the 60 seconds has expired. To
restart the engine refer to 4.3 Engine starting procedure.
4.6.2 Manual shut down
NOTICE
To stop the machine operation, it is ESSENTIAL that the correct shut down
sequence is followed in order to prevent damage to the machine.
2. Wait for all material to fully discharge from the hopper, screen box and all conveyors.
3. Press button 5 first to begin the shut down

sequence.
A green light indicates when this step is

complete.
4. Press the following buttons in sequence 4

to 1 to operate the manual shut down.
5. When all the green lights are ON,

indicates the machine systems have
stopped.
6. Set the engine speed to the slowest low

position and allow engine to idle for a few
minutes.

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.
7. Select screening operation mode on

control panel.
8. Stop the engine by turning the ignition key

to the off position.
Note When the machine is switched off wait a minimum of 60 seconds before the start sequence
is run again - An error code will show if started before the 60 seconds has expired. To
restart the engine refer to 4.3 Engine starting procedure.

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4.7 Lockout and tag procedure

Note The lock must have a 8mm (5/16in) diameter shackle.
4.7.1 How to fit a single tag
1. Make sure ignition key is in the ‘OFF’

position. Remove the ignition key and
keep it with you.
2. Turn isolation switch to the OFF position.

3. Attach your lock or tag across isolation switch
holes to show you are working on the
machine.
Note: Use a gang tag if more than one

person is at work on the machine,
refer to 4.7.3 How to fit a gang tag.
4.7.2 To remove a single tag
1. Make sure ALL maintenance and work has been completed and no persons are on or near the
machine.
2. Fit and secure all guards. Check all guards are operational
3. Unlock and remove your single lock or tag from isolation switch.
4. Replace the ignition key.
5. If a gang tag for multiple locks or tags has been used, refer to 4.7.4 To remove a gang tag.

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4.7.3 How to fit a gang tag
1. Make sure ignition key is in the OFF

position. Remove key and keep secure
until all personnel working on the machine
have finished and are clear from it.
2. Make sure the battery isolation switch is in

the OFF position.
3. Attach the gang tag as shown.

4. Each person attaches their lock to the
gang tag before they start work and keeps
their key with them at all times.
4.7.4 To remove a gang tag
1. Once each person finishes their work they remove only their own lock from the gang tag.
2. When the last person has finished their work and the last lock is removed, the gang tag may also
be removed.
3. Replace the ignition key, if all personnel have finished and are clear of the machine.

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5. Operations qa441
5. Operations

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qa441 5. Operations
5.1 Operations - minimum safety requirements

The following safety instructions apply throughout the operations section, additional and or variations
in safety measures that are specific to the relevant operations procedure will be detailed in the body
of the text.
DANGER
INHALATION, BREATHING HAZARD
Operating this machine generates dust. Breathing or inhaling silica dust
particles will cause death or serious injury.
Make sure suitable breathing equipment is used throughout ANY
operational activities. ALL necessary precautions MUST be taken to
reduce the risk of breathing dust or particles.
ALWAYS wear at least the minimum (CE approved) Personal Protective
Equipment (PPE), Refer to 1.4 Personal protective equipment (PPE).
WARNING
PERSONNEL HAZARD
DO NOT stand on machine whilst it is in operation.
Limit access to equipment and surroundings throughout operational
activities, refer to Hazard exclusion zones in the safety section 1.
Always make sure that all safety guards are installed and in correct working
order before operating this machine. Failure to do so could cause serious
injury or death.
DO NOT start any operational activity until you have read and fully
understand this manual, including the safety section.
If there is a operation procedure that is not fully understood contact
Sandvik before commencing with the operation.

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5. Operations qa441
5.2 Screening operation
NOTICE
DO NOT start these systems if they contain material, make sure any
material is cleared before starting. Failure to comply with this or any other
instructions in this manual may cause damage to the machine and may
invalidate any warranty.
WARNING
PERSONNEL HAZARD
5.2.1 Preparation
Note The machine has two starting sequences, automatic or manual mode. For normal
operations always select automatic
1. Set mode control switch to screen

operation position.
2. Start the engine > Refer to 4.3 Engine starting procedure.

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qa441 5. Operations
3. This screen will be displayed.
Note For an overview of the screen display,

refer to 3.7 Display screen.
4. Set engine speed control up to the fastest

position.
NOTICE
The highest speed position is factory set to 2150 RPM. Alterations to
these settings, to increase speed, may lead to premature machine failure
and subsequent warranty loss.
5. Start the machine, in automatic or manual
Refer to 4.3 Engine starting procedure
sequence

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5. Operations qa441
5.2.2 Machine starting sequence - Automatic
NOTICE
DO NOT start this system if it contains material, make sure any material is
cleared before starting. Failure to comply with this or any other
WARNING
PERSONNEL HAZARD
1. Press and hold button 1 for 3 seconds to

begin the automatic start sequence.
There is a time delay and audible warning

between each operation sequence,
indicated by a flashing green/red button
light.
2. When all the red lights are ON and the

feeder is operating the sequence is
complete.

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qa441 5. Operations
5.2.3 Machine starting sequence - Manual
NOTICE
DO NOT start this system if it contains material, make sure any material is
cleared before starting. Failure to comply with this or any other
WARNING
PERSONNEL HAZARD
1. Press button 1 and wait until the conveyors are

operating, indicated by red button light.
A time delay and audible warning will occur,

indicated by flashing green/red button light,
before the next control can be operated.

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5. Operations qa441
2. Press button 2 and wait until the flashing
green/red button changes to a
continuous red light indicating the
system is operating normally.
3. Follow the sequence of starting each

system by pressing button 3.
4. Wait while the button 3 light button

changes to a continuous red light, then
press 4.
5. Wait while the button 4 light button
changes to a continuous red light, then
press 5.
6. When all the red lights are ON and the feeder is

operating the sequence is complete.

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qa441 5. Operations
5.2.4 Operation Preparation
NOTICE
Make sure any material is cleared before starting. Failure to comply with
this or any other instructions in this manual may cause damage to the
machine and may invalidate any warranty.
WARNING
PERSONNEL HAZARD
1. Make sure the machine is set for operation

1 Refer 4.5 Preparing for screening operation
and scheduled maintenance checks are
and 6. Maintenance.
done ->
2. Make sure the mesh is installed as required-
2 Refer to 6.16.2 Track adjustment
>
3. Set up the exclusion zones, with safety
barriers and appropriate warnings, for stock 3 Refer to 1.12 Measured noise levels.
piles from all conveyors ->
4. Make sure you know the control panels
4 Refer to 3.5 Operational controls
information and navigation ->
5. To adjust the speed of the conveyors as
5 Refer to 5.3 Set up the conveyor speeds
necessary ->
6 Refer to 4.5.6 Set up the main conveyor and

6. Adjust screen box angle as necessary ->
screen-box height
7. Control the tipping/vibrating grid as

7 Refer to 5.2.7 Loading material into machine
necessary ->
8 Refer to 4.5 Preparing for screening

8. Follows the machine starting instructions ->
operation

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5. Operations qa441
5.2.5 Operation and shut down
WARNING
PERSONNEL HAZARD
1. When the machine is fully set up for 1 Load the machine with the material, refer to
operation -> 5.2.7 Loading material into machine .
2. When the operations are complete shut

2 Refer to 4.6 Shut down the machine
down the machine ->

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qa441 5. Operations
5.2.6 Machine blockage
WARNING
PERSONNEL HAZARD


Operate the equipment ONLY for its designed purpose, and only if all
guarding, protective, and safety devices, emergency shut-off equipment,
sound proofing elements and exhausts, are in place and fully functional.
death.
DO NOT start any operational activity until you have read and fully understand
this manual, including the safety section.
Follow the maintenance safety instructions in 6.1 Introduction - machine

maintenance, before attempting to clear a blockage.
If there is a operation procedure that is not fully understood contact Sandvik

before commencing with the operation.
Note A load sensing facility is incorporated into the hydraulic control value if any circuit becomes
overloaded. The feeder circuit will pause until the pressure in the relevant circuit has
reduced to an acceptable level.
WARNING
PERSONNEL HAZARD
When clearing the machine manually, it must be shut down, the

ignition key removed, locked out and tagged. Refer to 4.6 Shut
down the machine and 4.7 Lockout and tag procedure.

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5. Operations qa441
If the machine becomes blocked -
• Make sure the hopper is OFF and has stopped.
• Make sure the screen box is OFF and has stopped.
• Make sure all the conveyors are OFF and have no material on them or the edges.
• Start machine again only when the material is removed and it is safe to do so.

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qa441 5. Operations
5.2.7 Loading material into machine
1. Follow the minimum safety requirements 1 Refer 5.1 Operations - minimum safety
during all operational activities -> requirements
2. Make sure the machine is set for 2 Refer to 4.5 Preparing for screening
operation > operation.
3 Make sure the machine is on firm ground and

3. Prior to loading material into the machine ->
not vibrating excessively
4 Refer to 4.6 Shut down the machine. Move

4. If necessary, shut down the machine -> the machine to more suitable ground if
necessary.
Note Make sure the feeder is ON, BEFORE the material is put on it. Load material into the
machine only from the green marked position.
5. DO NOT put material that is too large in the hopper.
6. DO NOT over fill the hopper.
7. Material is to be fed carefully, from Make sure the hopper is evenly loaded across
approximately 300mm (1ft) above the grid its length. This helps maximise area and
surface. material output.
NOTICE
If larger material is ON the hopper, refer to 4.6 Shut down the machine and 4.7 Lockout and
tag procedure. Remove the large pieces of material with the appropriate equipment. DO NOT
use excavators to force the material into feeder as all damage from this action will invalidate
all Sandvik Construction warranty.
For maximum output and minimum wear, it is recommended that the material is fed into the
screen box steady and consistently. STOP/ START OPERATION OF THE HOPPER FEEDER
MUST BE AVOIDED. All damage from this action will invalidate all Sandvik Construction
warranty.

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5. Operations qa441
Note The machine must always be loaded from the green marked position of the hopper from as
low as height as possible, this will make sure both speed and efficiency.

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qa441 5. Operations
5.3 Set up the conveyor speeds
WARNING
Make sure that NO material is on the machine as this may fall and cause
injury or death
5.3.1 Side conveyor speed adjustment
1. Start the machine in operation mode Refer to 4.3 Engine starting procedure
2. Turn the flow controller as necessary to

change to speed.
(Clockwise = Slower : Anti-Clockwise = Faster)
5.3.2 Main conveyor speed adjustment

change to speed.
(Clockwise = Slower : Anti-Clockwise = Faster

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5. Operations qa441
5.3.3 Hopper feeder conveyor speed adjustment

change to speed.
(Clockwise = Slower : Anti-Clockwise = Faster)

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qa441 5. Operations
5.4 Installation and removal of the optional vibrating grid mesh
WARNING
Make sure that NO material is on the machine as this may fall and
cause injury or death.
Make sure correct safe procedures are followed for the tasks that
are done at height. Falling may cause injury or death.
DO a site specific risk assessment.
Make sure the machine is off, locked and tagged, refer to 4.6 Shut
down the machineand 4.7 Lockout and tag procedure.
1. Loosen the tension bolts against the

tension blocks.
2. Make sure that the mesh clamp has
moved enough and releases the mesh.
3. Remove the mesh from the mesh clamp

DOWN then OUT.
4. When fitting the mesh, install the mesh
into the mesh clamp IN and UP.
5. Make sure that the mesh is installed
correctly in the mesh clamp.
6. Tighten the tension bolts against the
tension blocks, until the mesh is correctly
tightened.

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5. Operations qa441
5.5 Radio remote grid operation
WARNING
Make sure that NO material is on the machine as this may fall and cause
injury or death
Make sure the machine is ON refer to 4.3 Engine starting procedure and make sure it is set
for screening refer to 5.1 Operations - minimum safety requirements.
To move the grid UP, PRESS and HOLD until it is in

position.
To move the grid DOWN, PRESS and HOLD until it is in

position.
To move the grid automatically fully UP then DOWN.

This will move the grid UP to the FULL position stay UP
for a few seconds and then move the grid back DOWN to
the initial position.
If necessary use the engine stop to stop the complete

machine.
Note For position of emergency stops refer 1.14

Emergency stop locations.
Button sounds alarm when held.
Note To shake the reject grid, press the up and down buttons in short quick bursts.
NOTICE
DO NOT use this engine stop button to stop the machine as a normal
operation because repeated use could cause damage to the machine. All
damage from this action will invalidate all Sandvik Construction warranty.
If the radio grid control is not operational, the automatic grid operation can be switched on and off at
the machine operational controls.
Press machine diagnosis button and go to page 3

of the control system screens.

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qa441 5. Operations
For more information ->Refer to 3.7.5 Machine diagnostics.
The automatic grid operation can be switched on

and off using the up or down arrow of the 4-way
screen control button on the reject grid screen
page 3.
Press button to exit and go to home page from

any screen page.

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5. Operations qa441
5.6 Switching off operation
2. Wait for all material to fully discharge from hopper, screen box and all conveyors.
3. The machine has two stopping sequences, automatic or manual mode.
5.6.1 Automatic
1. To switch off the operation automatically, refer to 4.6.1 Automatic shut down.
5.6.2 Manual
1. To switch off manually, refer to4.6.2 Manual shut down.
5.6.3 Isolate and lockout
1. To isolate the machine and lockout from use, refer to4.7 Lockout and tag procedure.

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qa441 5. Operations

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6. Maintenance qa441
6. Maintenance

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qa441 6. Maintenance
6.1 Introduction - machine maintenance

The following safety instructions apply throughout the maintenance section, additional and or
variations in safety measures that are specific to the relevant maintenance procedure will be detailed
in the body of the text.
Maintenance is essential for safety and to make sure the best possible performance from your
machine by reducing the chances of breakdowns.
For maintenance schedules and procedures relating to Original Equipment Manufacturers, refer also
to section 10. Information and Data sheets.
WARNING
PERSONNEL HAZARD
Working on or in close proximity to the machine whilst it is on
and or operating could cause serious injury or death.
Stop machine, isolate, remove ignition key and tag out, before
carrying out any maintenance procedures. Refer to 4.6 Shut
down the machine.
Make sure at least the minimum Personal Protective Equipment
(PPE) is worn during maintenance and repair, Refer to 1.4
Personal protective equipment (PPE)
WARNING
FALLING HAZARD
Some maintenance requires working from height. Falling from
heights could cause serious injury or death.
When working at height, ensure the following:
WARNING
HOT SURFACE HAZARD
The engine could still be hot after operation and cause severe
burns if touched.
Make sure that the engine is cool before maintenance is started.

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WARNING
HYDRAULIC FLUID INJECTION HAZARD

High pressure hydraulic system. Fluid could penetrate the skin
and cause serious injury or death.
DO NOT use your hand to test for leaks.
ALWAYS use a piece of cardboard or similar.
WARNING
POISON AND CONTAMINATION HAZARD

may contain chemicals which could cause serious injury or death and or
environmental damage if disposed of in an irresponsible manner.
ALWAYS dispose of fuels, fluids or other materials used in the operation
of this machine in accordance with local and national legal regulations.
source.
information detailed in section 10. Information and Data sheets, of this
manual when working with components or substance that may contain
chemicals.
NOTICE
RISK OF EQUIPMENT DAMAGE.
Do all maintenance procedures as a minimum requirement.
Machines that operate in severe site or environmental conditions may require more
frequent maintenance routines.
Only use lubricants, fluids, filters and parts recommended by the Original Equipment
Manufacturer (OEM) or accelerated wear or damage could result. Never use grease
containing molybdenum disulphide.
Incorrect filling procedures can cause contamination and can damage the
equipment. Make sure that the fluid is filled correctly.
DO NOT start any maintenance until you have read and fully
understand this manual, in particular section 1 Safety
If there is a maintenance procedure that is not fully understood
contact Sandvik before commencing with the maintenance.

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Any adjustments must ONLY be carried out by trained personnel.

Any adjustments to the hydraulic system must ONLY be carried out
by trained Sandvik service engineers.
Make sure that oils and fluids are cleaned and disposed of
correctly in a way that meets the local and national environmental
regulations.
Batteries must not be disposed of in normal waste which may go
into land fill.

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6.2 Reference information
For information, maintenance schedules and procedures relating to components fitted on the
machine but from other Original Equipment Manufacturers, refer to 10. Information and Data
sheets.
For information relating to recommended lubricant and fluids used in the machine, refer to 6.19
Lubricants and fluids.
For information on schematic hydraulic and electrical diagrams, refer to section 9 and supplied
diagrams.

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6.3 Maintenance schedules - power module maintenance
NOTICE
Machines that operate in severe site or environmental conditions may
require more frequent maintenance routines.
6.3.1 Daily (8 hour) maintenance schedule
WARNING
Follow the maintenance safety instructions in 6.1 Introduction -
machine maintenance, before starting this maintenance schedule.
Make sure that this schedule is carried out before the machine is started each day (minimum
requirement).
1. Do the daily engine maintenance. Refer to the separate engine manufacturers operation and
maintenance manual.
2 . Inspect the engine oil level. Refer to 6.5 Engine oil
3 . Inspect the coolant level. Refer to 6.8 Engine coolant
4 . Inspect the air filter and pre-cleaner. Refer to 6.9 Air cleaner servicing
5 . Drain fuel water trap system. Refer to 6.6 Diesel fuel
6.3.2 Weekly (40 hour) maintenance schedule
WARNING
Make sure that this schedule is carried out on a weekly basis (minimum requirement).
1. Do the weekly engine maintenance. Refer to the separate engine manufacturers operation and
maintenance manual.
1. Inspect for oil and coolant leaks.
2 . Inspect the battery levels and condition.
3 . Inspect the drive belts for tension and wear.

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6.3.3 Every 250 hour maintenance schedule
WARNING
Make sure that this schedule is carried out on a 250 hour basis (minimum requirement).
1. Do the 250 hour engine maintenance. Refer to the separate engine manufacturers operation
and maintenance manual.
2 . Replace the engine oil and filter.
3 . Do an oil sample test.
4 . Replace the engine air filter.
5 . Replace the engine fuel filter.
6 . Replace the pre filter.
7 . Clean the fuel filter water trap.
WARNING
2 . Replace the crank case breather.

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WARNING
WARNING
2 . Replace the engine coolant level.

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6.4 Maintenance schedules
6.4.1 Daily maintenance schedule
WARNING
Make sure that this schedule is carried out before the machine is started each day (minimum
requirement).
3 . Inspect the machine and secure any loose components. Make sure all safety guards, hand rails
and doors are present and secured.
4 . Lubrication system - Test the lubrication system if fitted. Refer to OEM.
5 . Alarms / warnings - Test all emergency stops, function stops and warnings. Refer to 1.14
Emergency stop locations and 4.3.3 Engine controls.
6 . Hydraulic tank - Inspect and clean, check top up level. Refer to 6.7 Hydraulic fluid
7 . Hydraulics - Inspect oil temperature. Refer to TEDD display.
8 . Hydraulics - Inspect and clean oil/water coolers (radiators)
9 . Electrical - Visually inspect electrical components for damage and corrosion, clean away dust
as necessary.
10 . Conveyors - Visually inspect all belts, and rollers for damage or unwanted material, clear as
necessary.
11 . Conveyors - Inspect the belt alignment, condition and tension. Refer to 6.14 Conveyors
12 . Tail and drive drums - Visually inspect bearings, grease as necessary
13 . Screenbox - Visually inspect and check the security of fixings, bearing housings, and capping
rubbers.
14 . Screenbox - Inspect the mesh condition and tension. Refer to 6.15 Installation and removal of
the screenbox mesh
15 . Screenbox - Visually inspect the mesh, make sure it is clear of material.
16 . Screenbox - Visually inspect for leaks of oil or fluid.
17 . Belt feeder and hopper - Visually inspect the hopper condition.
18 . Belt feeder and hopper - Inspect the belt alignment and tension.
19 . Belt feeder and hopper - Inspect the feeder gearbox oil.
20 . Grid (if fitted) - Inspect the condition of the unit and bars.
21 . Vibrating grid (if fitted) - Inspect the condition of the unit and grid bars.
22 . Vibrating grid (if fitted) - Inspect the grid bars bolt tension and the tension of the screen.
23 . Vibrating grid (if fitted) - Inspect the hydraulic function and the vibration mounts.

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24 . Check air pre-cleaner - Inspect and clean as necessary.
25 . Diesel tank - Check top up level. Refer to 6.6 Diesel fuel.
26 . Batteries - Make sure radio control batteries are fully charged, monitor the battery life.

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6.4.2 Weekly maintenance schedule
WARNING
Make sure that this schedule is carried out on a weekly basis (minimum requirement).
1. Do the daily maintenance checks and procedures. Refer to 6.4.1 Daily maintenance
schedule.
2. Hydraulics - Check the service indicators on the hydraulic filters. Refer to 6.13 Hydraulic tank
filters
3. Hydraulics - Visually inspect for leaks and damage on hoses and components.
4. Hydraulics - Check the air breather. Refer to 6.13 Hydraulic tank filters
5. Conveyors - Inspect the rollers, skirting and scraper rubber condition. Refer to 6.14
Conveyors
6. Conveyors - Inspect the impact bars for damage and replace if necessary.
7. Conveyors - Visually inspect there is NO dust or debris on the conveyors.
8. Screenbox - Grease bearings.
9. Screenbox - Inspect the screen springs, chutes, bolts and wedges.
10. Screenbox - Inspect the liners and wear rubbers.
11. Belt feeder and hopper - Visually inspect the roller, skirting and seal rubbers, liner / wear
plates and feeder discharge chute condition.
12. Hopper - Inspect and tighten if necessary the fixing bolts on the hooper flares.
13. Hopper - Check the tension of the hopper mesh (if fitted). Refer to 5.4 Installation and
removal of the optional vibrating grid mesh.
14. Grid - Inspect the grid bars bolt tension and the hydraulic function.
15. Tracks - Inspect the gearbox oil levels.
16. Tracks - Inspect the track chain tension.
17. Tracks - Move the machine using the tracks 10m in both directions to prevent the chain
ceasing. Refer to 4.4 Moving machine on the tracks
18. General - Inspect all hose conditions.
19. General - Inspect all liners and rubbers for wear.

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WARNING
1. Do the weekly maintenance checks and procedures. Refer to 6.4.2 Weekly maintenance
schedule.
2. Screenbox - Inspect the screen tuning.
3. Belt feeder and hopper - Replace the feeder gearbox oil.
4. Tracks - Inspect the track bolt and sprocklet bolt tension.

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WARNING
1. Do the 250 hour maintenance checks and procedures. Refer to 6.4.3 Every 250 hour
maintenance schedule.
2. Hydraulics - Replace the hydraulic tank breather, fuel tank breather and hydraulic return line
filter.

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WARNING
1. Do the 500 hour maintenance checks and procedures. Refer to 6.4.4 Every 500 hour
maintenance schedule.
2. Hydraulics - Replace the hydraulic fluid and suction filters.
3. Tracks - Replace the gearbox oil. Refer to 6.17 Track gearbox.

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6.5 Engine oil
NOTICE
Make sure that the oil is filled correctly to avoid contamination as this will
damage the equipment.
WARNING

source.
chemicals.

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1. Check engine oil level.

1
2. Drainage Point.
3. Refill if necessary.
2 1
Refer to 6.19 Lubricants and fluids or the engine

4. For engine oil specification.->
manufacturer’s handbook.

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6.6 Diesel fuel
NOTICE
Make sure that the fuel is filled correctly to avoid contamination as this will
damage the equipment.
WARNING

source.
chemicals.
1. Check fuel level.on the gauge.

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2. If necessary refill diesel tank.

3. Clean around the filler cap before opening.
4. Make sure when the diesel tank is refilled,
a hose or funnel is used to avoid spillage.
5. Drain water from the diesel water trap.

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6.7 Hydraulic fluid
DANGER
HAND.
WARNING
machine maintenance.
NOTICE
RISK OF CONTAMINATION
Clean up any spills after performing these operations, with a spill kit that conforms to your
local and national regulations.
Make sure that filters are disposed of correctly in a way that meets the local and national
environmental regulations.
1. Check the hydraulic fluid level.

2. Clean around the filler cap before opening.
2
3. Fill if necessary.

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6.8 Engine coolant
NOTICE
Make sure that the coolant is filled correctly to avoid contamination as this
will damage the equipment.
Make sure that the coolant has cooled before you open the cap as this
may cause serious injury.
1. Remove the bolts and cover plate.

2. Check engine coolant level and refill if
necessary.
3. Install the cover plate into position and
tighten the bolts.
NOTICE
Make sure that all power pack covers are replaced, if not material may fall
into the into the power pack and cause damage, this will invalidate the
warranty.

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6.9 Air cleaner servicing
WARNING
Note A fault message will display on control screen if there is an air filter blockage.
WARNING
INHALATION, DUST HAZARD

Breathing or inhaling dust particles could cause serious injury or death.
Make sure all necessary precautions are taken to reduce the risk of
breathing in dust particles.
1. Check air filter indicator at the control

panel display screen.
2. If the air filter icon is red then renew the

filter.
3. Regardless of condition of service indicator, remove outer element from air cleaner as shown
and use a vacuum suction cleaner. Make sure the filter is cleaned away from the filter
housing. Never clean inner element.
4. After 5 cleaning services, replace both the inner and outer elements.
Note Service indicators show when the elements need to be replaced, not cleaned.
5. If air cleaner indicator shows on the control panel whilst machine running, change the filters.
6. Press the reset button on the air cleaner if the indicator switch has operated

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.
7. Open the clips.

8. Remove the cover.
6 7
9. Remove the primary air cleaner.
SANDVIK MINING & CONSTRUCTION
10.Only remove and replace the secondary

air cleaner after five services.
11.Clean the inside with a dry cloth. Install

the filters.

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12.Install the cover and close the clips.
NOTICE
When the engine has operated in environments that are dusty or dirty, the
air cleaner elements may require more frequent servicing than stated in the
maintenance schedules. If not this may cause damage to the machine.

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6.10 Inspect the hydraulic return filter indicator
DANGER
HAND.
1. Remove the access plate. 1 2

2. Check the filter condition indicator on top
of the filter housing. If the service indicator
is red, replace the hydraulic return filter,
refer to 6.13 Hydraulic tank filters.
NOTICE
Make sure that all power pack covers are replaced, if not material may fall into
the into the power pack and cause damage, this will invalidate the warranty.

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6.11 Grease the bearings
Only apply grease where indicated. Using suitable equipment, the bearings must be re-
greased according to the maintenance schedule. Refer to 6.19 Lubricants and fluids for the
types.
NOTICE
NEVER USE GREASE CONTAINING MOLYBDENUM. DOING SO MAY
CAUSE DAMAGE TO MACHINE PARTS AND WILL INVALIDATE ANY
WARRANTY.
The following diagram gives details of the grease points.
A A
A
A. Conveyor grease points

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B. Screen box bearings

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6.12 Fuel filters
WARNING

source.
chemicals.
Open the drain.
Note When the diesel water trap is cleaned

out, the fuel system will have to be re-
primed.

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6.13 Hydraulic tank filters
DANGER
HAND.
WARNING
source.
chemicals.

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NOTICE
Make sure that the filters/Oil are disposed of in the correct way that meets your
local and national regulations.
1. Remove the access plate.

2. Filter condition indicator on the return filter
housing. If the service indicator is red, 1 2
replace the hydraulic return filter.
3. Remove the filter housing cover and filter.
4. Install the new filter and cover. Make sure
the o-rings are in position. Install and
tighten the bolts.
5. Changing the hydraulic tank suction filter,

when tank is drained for fluid renewal and
cover removed.
6. Check the hydraulic tank vent and filler
cap. 5 6

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6.14 Conveyors
6.14.1 Conveyor precautions
WARNING
PERSONNEL 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.
DO NOT attempt to adjust conveyor belt tension without first undertaking
proper instruction and/or obtaining adequate supervision.
If necessary seek clarification from your supervisor and or a Sandvik
representative, before attempting ANY operations or maintenance. Failure
to do so may also invalidate the manufacturers warranties.
If clothing, tools, or any body parts become entangled in machinery,
IMMEDIATELY press an emergency stop button to disengage all power.
Operate controls to relieve pressure. Switch off engine and implement
lockout procedures.
WARNING
FALLING HAZARD
Some maintenance requires working from height. Falling from heights
could cause serious injury or death.
When working at height, make sure of the following:
NOTICE
Before tensioning or tracking conveyor belts, make sure there are no
obstructions or excess material on the belts. If the belts are ripped or torn,
do not operate the machine until the damage is repaired.
Do not overtighten the belt as this will cause damage to the drum bearings.

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6.14.2 Feed conveyor belt
DANGER
ENTANGLEMENT HAZARD
Working in close proximity to running machinery could cause
(PPE) is worn during maintenance and repair, Refer to 1.14
Emergency stop locations
WARNING
PERSONNEL HAZARD
Make sure the hopper is empty before you begin maintenance.
1. Remove securing fasteners from access

doors. 1 2
2. Raise the each side and end access

doors.

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3. Remove bolts and conveyor drum guards

at each side.
4. Loosen the two bearing clamp bolts on 4 5

both sides of the machine.
5. Adjust the belt tension as necessary by
turning the adjuster equally.
6. Make sure that both sides are adjusted

equally and the conveyor is aligned
correctly.
7. Make sure that the conveyor belt is in the
centre of the drum
8. Tighten the bearing clamp bolts when the 6 7
belt is central and the tension is correct.
9. Install all guards and secure with bolts and washers.

10.Close the side and end access doors and secure with bolts and washers.
DANGER
temporarily removed for set-up, maintenance or repair purposes MUST be
refitted and checked immediately upon completion of the maintenance or
repair work.
control devices.

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6.14.3 Main conveyor belt
DANGER
ENTANGLEMENT HAZARD
Working in close proximity to running machinery could cause
(PPE) is worn during maintenance and repair, Refer to 1.4 Personal
protective equipment (PPE)
WARNING
PERSONNEL HAZARD
Note Make sure the conveyor is empty before you begin maintenance.

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1. Remove the side plates and guard.

3 2
2. Loosen the two bearing clamp bolts on
3. Release lock nut and adjust the belt
tension as necessary by turning the
adjusters.
correctly.
centre of the drum.
6. Tighten the bearing clamp bolts when the
1
7. If necessary repeat the procedure.
DANGER
repair work.
control devices.

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6.14.4 Side conveyor belts
DANGER
ENTANGLEMENT HAZARD
Working in close proximity to running machinery could cause serious injury
or death.
(PPE). Refer to 1.4 Personal protective equipment (PPE)
WARNING
PERSONNEL HAZARD
carrying out any maintenance procedures. Refer to 4.7 Lockout
and tag procedure and 4.7 Lockout and tag procedure.

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1. Remove the end and side guards.

2. Loosen the two bearing clamp bolts on
1
turning the adjusters.
correctly. 2 3
centre of the drum.

DANGER
repair work.
control devices.

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6.14.5 Tail conveyor belt
DANGER
ENTANGLEMENT HAZARD
or death.
(PPE). Refer to 1.4 Personal protective equipment (PPE)
WARNING
PERSONNEL HAZARD

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1. Remove the two guards.

2. Loosen the two bearing clamp bolts on 1
turning the adjusters.
correctly.
centre of the drum.
3 2

DANGER
repair work.
control devices.

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6.14.6 Belt scrapers
Check the belt scrapers on all the conveyors and adjust them if necessary.
WARNING
FALLING HAZARD
case, ensure the following:
1. Loosen the pivot bolt.

1 2
2. Put a spanner on the adjuster hold it,
loosen and remove the clamp bolt.
3. Rotate the adjuster with the spanner to the
next slot and install and tighten the clamp
bolt.
4. Tighten the pivot bolt.
5. Loosen the bolts and move the flexible

scraper UP as necessary. Tighten the
bolts to secure.

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6.14.7 Inspecting / adjusting belt sealing rubbers
WARNING
FALLING HAZARD
WARNING
PERSONNEL HAZARD
Switch off at isolation point, refer to 4.6 Shut down the machine.
Implement tag and lockout procedures, refer to 4.7 Lockout and tag
procedure.
Check the following:
1. Feed conveyor. 2. Main conveyor

3. Tail conveyor 4. Side conveyor
If adjustment is necessary do the procedure that follows.
5. Loosen the bolts.

6. Move the sealing strip as necessary.
Make sure there is no clearance between
the conveyor belt and the strip.
6 5
7. Tighten the bolts.

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6.14.8 Optional magnetic conveyor
DANGER
STRONG magnet field, do not go near it if you have a pacemaker, as

this may cause death.
WARNING
PERSONNEL HAZARD
1. If the optional magnet conveyor is fitted, with the conveyor stationary inspect and remove
pieces of metal on the magnet conveyor that may cause blockages round rotating parts.
2. Follow maintenance instructions in the magnet manufacturer’s handbook

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6.15 Installation and removal of the screenbox mesh
WARNING
PERSONNEL HAZARD
The bottom mesh is the final filter the material will go through and will exit on to the fines
collector, or larger sized material not passing through a mesh or perforated plate will exit
through one of the other grade conveyors.
Change the mesh or perforated plate if:
• It is damaged or worn, replace meshes or perforated plate
• It is necessary to output a different size of material, change for different sizes.
To fit the screen meshes or perforated plate, proceed in the following manner:

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6.15.1 Set up access to the screenbox
WARNING
PERSONNEL HAZARD
1. Start the machine -> Refer to 4.3 Engine starting procedure.
Refer to 4.5.6 Set up the main conveyor and

3. Raise the main conveyor fully ->
screen-box height.
4. Lower the fines conveyor fully -> Refer to 4.5.4 Fines conveyor
DANGER
Make sure that all the locating pins are installed correctly before
maintenance is started, if not this could cause injury or death.
WARNING
carrying out any maintenance procedures. Refer to 4.6 Shut down
the machine and 4.7 Lockout and tag procedure.

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5. Install the fines conveyor locating pins and

the clips.
6. Install the main conveyor locating pins or

the hooks correctly.
7. Install the locating pins.

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6.15.2 Removal of the screenbox mesh
DANGER
ENTANGLEMENT HAZARD
or death.
(PPE).
WARNING
FALLING HAZARD
WARNING
PERSONNEL HAZARD
procedure.

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1. Decrease the tension in the mesh.

2. Position the ratchet latch then move the
levers to loosen the mesh tension.
3. Make sure the mesh is unhooked from the

tension spring bar.
4. Move the mesh to the side as shown and
up.

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6.15.3 Installation of the screenbox mesh
DANGER
ENTANGLEMENT HAZARD
or death.
(PPE).
WARNING
FALLING HAZARD
WARNING
PERSONNEL HAZARD
procedure.

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1. Install and move the mesh to the side and

down as shown.
2. Make sure the mesh is hooked in position
on the tension spring bar and in the mesh
hook.
3. Position the ratchet latch then move the

levers to tighten the mesh.
Note Apply equal tension to both sides. Mesh tension should be checked after 4 hours of
running, then daily.
A Fixed mesh hook

D Screen mesh
B Tension adjusting bar
E Tensioning ratchet
C Rubber capping

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6.15.4 Screen mesh tension and adjustments
DANGER
ENTANGLEMENT HAZARD
or death.
(PPE).
WARNING
FALLING HAZARD
1. Check condition of screen mesh and

tension as necessary, on both sides.
2. Top and bottom mesh, tighten the
ratchets.

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6.16 Tracks
6.16.1 Inspection of the tracks
WARNING
1. Check the track rollers and idler wheels for

possible leakage. 2 1
2. Check the track surface of the track
rollers, idler wheels, track shoes and drive
sprockets for wear and loose mounting
bolts.
3. Listen for abnormal noises when the
machine is moving slowly.
4. To adjust the track tension -> Refer to 6.18 Vibrating grid in hopper [option]

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6.16.2 Track adjustment
WARNING
PERSONNEL HAZARD
Grease under pressure can cause serious injury.
Never unscrew a track adjuster valve by more than a ½ turn, when the
track is under tension.
Note After maintenance or over time the track will become slack and will have to be adjusted.
1. The adjustment of the tracks operates

through a grease tensioning cylinder.
2. When the cylinder is filled with grease it
extends and pushes the spring tension
and the idler, forward.
2 3
3. The grease is filled through the track
adjuster grease valve.

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6.16.3 Track tension check
In order to establish if the track requires tensioning, move machine 10m (33ft) forwards and
backwards on level ground to allow the tracks to adopt their natural degree of tension. Refer to
4.4 Moving machine on the tracks.
Note Do not slew the machine.
NOTICE
It is important the track is not tensioned too tightly as this places
excessive loads on the gearbox and idler bearings. It will also lead to
accelerated wear and premature failures.
1. Use a straight edge and measure the maximum droop of the track.
2. Sag ‘A’ should not exceed 30mm (1.2in).
SAN00019

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6.16.4 Increasing the track tension
1. Remove inspection cover on side of track

frame.
2. Make sure track adjuster valve is tight.
3. Attach special grease gun connector to a
grease gun and fit it onto the track
2 3
adjuster valve.
4. Pump grease into adjuster valve until

droop of the track is correct, Refer to 6.19
Lubricants and fluids. 4
5. Recheck the track tension, refer to 6.16.3
Track tension check.
6. Clean off any excess grease and install
the inspection cover.
6.16.5 Releasing the track tension
1. Remove inspection cover on side of track 1

frame.
2. Check droop of track, refer to 6.16.3
Track tension check.
3. Loosen track adjuster valve, by turning it
ONLY A HALF turn anti-clockwise.
3
4. Grease should slowly escape from track
tensioning cylinder and the track slacken.
5. When satisfactorily tensioned, tighten
track adjuster valve.
6. Install inspection cover.

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6.17 Track gearbox
Note Machine must be on level horizontal ground to check and fill gearbox.
WARNING

source.
chemicals.
NOTICE
Make sure that the gearbox oil is filled correctly to avoid contamination as
this will damage the equipment.

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6.17.1 Check and fill gearbox
1. Move the machine, refer to 4.4 Moving

machine on the tracks, until gearbox is in
the upright position. Two upper plugs
should be level. 1 2
2. Remove the upper plugs, check and top

up level with threaded hole with suitable
oil, refer to 6.19 Lubricants and fluids
3. Install and tighten plugs.
6.17.2 Drain gearbox oil
1. Move the machine, refer to 4.4 Moving

machine on the tracks, until gearbox is in
the upright position. The drain plug
should be at the bottom.
2. Remove the upper plugs then the drain
plug.
3. Allow oil to thoroughly drain into a
suitable container. Refer to 6.19
Lubricants and fluids for quantity.
1 2
4. Install drain plug and fill, refer to Make
sure that the gearbox oil is filled correctly
to avoid contamination as this will
AN00017
damage the equipment..

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6.18 Vibrating grid in hopper [option]
1. After the first 50 hours of operation, clear the vibrating grid bars and check all the securing
bolts are tight. Tighten bolts if required to the correct general maximum torque settings.
2. These bolts and all other fasteners should be checked periodically and any that become loose
tightened also.
6.18.1 General torque reference chart
The table shows guidelines for torque settings for metric coarse threads.
General maximum torque setting Nm
Fastener grade
Size
8.8 10.9 12.9
M4 3.04 4.31 5.15

M5 6.03 8.48 10.2
M6 10.3 14.71 17.65
M8 25 35 42
M10 50 70 85
M12 85 120 145
M16 210 290 350
M20 410 570 690
M22 530 750 -
M24 710 1000 1196
M30 1400 2010 2403
M36 2481 3491 4197
M42 3991 5609 6727

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6.19 Lubricants and fluids

A list of Substances Hazardous to Health associated with this equipment can be found in
section 10. Information and Data sheets.
Maximum Ambient
Manufacturer - equivalent Sandvik
Reference volume or temperature
specifications part no
quantity range
Univar Caflon HDA pre-

Engine coolant 17lt All CN8015
mixed
290 lt Ultra low sulphur Diesel

Diesel - CN6004
(76 US gall) Also refer to engine manual
-10 to + 50°C Shell Rimula Super

CN6098
(14 to 122°F) 15W - 40
Engine Oil
10 lt -35 to + 25°C
(2.6 US gall) Rimula (Cold) 5W - 30 CN5704
(-31 to + 77°F)
Alternative Engine Refer to engine

- -
Oil manufacturer’s handbook
-10 to + 50°C
Shell Tellus T46 S2 V46 CN6074
(14 to 122°F)
450 lt -25 to + 25°C 825.0156-

Hydraulic System Shell Tellus T32 S2 V32
(119 US gall) (-13 to 77°F) 00
-35 to + 15°C Shell Tellus Arctic 32 S4 VX

CN5700
(-31 to + 59°F) 32
Grease lubrication
Shell Gadus S3 V220C 2
points and track - - CN6073
grease
tension
-20 to + 50°C
SKF LGHB2 Grease CN6109
(-4 to 122°F)
Auto lubrication
-
system option
Arctic to -30°C
Shell Aeroshell 33 CN5702
(-22°F)
Screen box
- - Exxon Unirex N 3 Grease CN6012
bearings
- Shell Spirax S2 G 80W-90 CN6100

5 lt
Track gearbox
(1.3 US gall)
- Exol Athena EP90 Gear Oil -
Feeder Drive 1.2 lt (0.32 US -10 to +50°C

Shell Spirax S2 G 80W-90 CN6100
Gearbox gall) (4 to 122°F)

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6.20 Machine error messages and fault codes
When the system detects a fault, a message is

displayed on the screen.
Each fault is identified by a fault code number,

description and icon.
Code Message Trigger Action
Stop
101 emergency stop activated
Engine
umbilical handset, engine Stop button pressed on umbilical handset / Stop

102
stop requested bypass link removed Engine
Radio tracking handset, Stop

103 Stop button pressed on track handset
engine stop requested Engine
Radio feeder/grid handset, Stop

104 Stop button pressed on smaller radio handset
engine stop requested Engine
Coolant level sensor output is high or sensor

Engine shutdown due to Stop
105 disconnected. Engine loom green/white wire.
low coolant level Engine
12V = FAULT
Engine shutdown due to Engine oil pressure switch has closed to GND. Stop
106
low oil pressure Engine loom green/yellow wire, 0V = FAULT. Engine
Engine shutdown due to Engine temperature switch has closed to GND. Stop
107
high engine temperature Engine loom blue/yellow wire, 0V = FAULT. Engine
Engine shutdown due to

Alternator output is less than 11.5 Volts. Engine Stop
108 alternator voltage being
loom brown/yellow wire, <11.5V = FAULT Engine
too low to charge battery
Engine warning, water in Water in fuel switch has closed to GND. Engine Warning
109
fuel detected loom white/orange wire, 0V = WARNING only
Engine warning, blocked Blocked filter swithc has closed to GND. Engine Warning
110
air filter loom blue/white wire, 0V = WARNING only
Dual channel emergency stop, one channel only

emergency stop positive Stop
111 has opened. Engine loom red/yellow wire, 0V
side only activated Engine
= FAULT
Dual channel emergency stop, one channel only

emergency stop negative Stop
112 has opened. Engine loom brown/white wire,
side only activated Engine
12V = FAULT

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Fault with Fuel solenoid Fuel solenoid relay is not working correctly. Warning
113
relay Replace relay. only
Fault with Fuel solenoid Fuel solenoid relay is not working correctly. Warning
114
relay Replace relay. only
Hydraulic oil temperature

Hydraulic temperature sensor is reading > 79
warning, hydraulic oil Warning
115 degrees. 4-20mA sensor read into I/O module.
temperature > 79 only
20mA = 100degrees C.
degrees for 10 seconds
Hydraulic oil temperature

Hydraulic temperature sensor is reading > 84
error, hydraulic oil Stop
116 degrees. 4-20mA sensor read into I/O module.
temperture > 84 degrees Engine
20mA = 100degrees C.
for 30 seconds
Hydraulic oil temperature Stop

117 Hydraulic temperature sensor disconnected.
sensor is not connected Engine
Hydraulic oil level is low Hydraulic oil level switch is not closed to GND. Stop
119
for > 30seconds 12V = FAULT. Engine
Fines wheel speed is too Speed wheel is not seeing conveyor belt Stop
120
low turning. Feeder
Downstream machine is Downstream input on panel detected 12V. Stop

121
requesting pause Pause feeder Feeder
Stockpile sensor seeing

Stockpile sensor detected too high pile of Stop
122 too high stockpile, stop
material. Feeder
feeder
Stockpile sensor Stop

123 Stockpile sensor disconnected
disconnected Feeder
No CAN messages being

Communication problem with I/O module. Stop
124 received from I/O module
Check wiring to I/O module. Engine
(unit used to drive valves)
No CAN messages being

Communication problem with radio receiver. Warning
125 received from Radio
Check wiring to radio receiver only
Receiver
Electrical problem with I/O module detected electrical problem with

Warning
126 Left Hand Track Reverse solenoid coil. Check solenoid coil resistance.
only
Valve Check wiring to coil.
I/O module detected electrical problem with

Electrical problem with Warning
127 solenoid coil. Check solenoid coil resistance.
Check Valve only
Check wiring to coil.

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Grid Down Valve only

Track Divert Valve only

Warning
130 Left Hand Track Forward solenoid coil. Check solenoid coil resistance.
only
Valve Check wiring to coil.

Aux Divert Valve only

Warning
132 Right Hand Track solenoid coil. Check solenoid coil resistance.
only
Forward Valve Check wiring to coil.

Warning
133 Right Hand Track solenoid coil. Check solenoid coil resistance.
only
Reverse Valve Check wiring to coil.

Plant Valve only

Grid Up Valve only

Spare Output only

Plant Valve only

Plant Valve only

Electrical problem with Oil Warning
Cooler Valve only

Plant Valve only

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Plant Valve only

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7. Trouble Shooting qa441
7. Trouble Shooting

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qa441 7. Trouble Shooting
7.1 Fault finding tables

Use the tables following to assist in finding a solution to the problem.
If an error message is displayed on the screen, refer to 6.20 Machine error messages and
fault codes for solution.

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7.1.1 Starting and running
Fault Problem Solution - Action
Isolation switch is in the Off Turn the Isolation switch to the on position
position (make sure it is not tagged out)
No charge in the battery Replace or recharge the battery
Disengage the E-Stop (make sure there are

Does not crank E-Stop engaged
no problems first)
Starter or alternator
Repair or replace the part/s
malfunction
Damaged electrical Cables Replace the cable
Check the fuel tank level re-fill as necessary

No fuel in the engine
check the pipes for leaks repair or replace
Blocked filters:
Clean or replace the filters as necessary.
Air, Oil, Fuel
The engine The glow plugs or the injectors

Consult an engine specialist
cranks but will malfunction
not start
Check for leaks repair as necessary. Refill
Coolant level low
engine with oil
Extreme - Temperature Make sure the oils and Fluids are correct for
conditions the temperature conditions
The Battery is not fully charged Replace or recharge the battery
High Oil pressure Check for a blockage in the system

Loss of power Blocked Filters:
or low engine Clean or replace the filters as necessary.
speed Air, Oil, Fuel, Hydraulic
Over heating see ‘Over heats quickly’
Check all filters and radiators. Inspect and

Blockages
clean
Check the coolant system for leaks repair if

Coolant level low
necessary. Refill coolant level.
Over heats
quickly
Check engine for leaks repair if necessary.
Engine Oil level Low
Refill the oil
Check hydraulic fluid system for leaks repair

Hydraulic Fluid low
as necessary. Refill hydraulic fluid

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7.1.2 Moving the machine on the tracks
The engine is OFF Start the machine
Make sure the machine is in track mode

No hydraulic drive function. Check for leaks, or damaged
components repair or replace as necessary
Umbilical lead disconnected Connect lead

Does NOT track
/ or one of the
Radio switched OFF Switch radio ON
Tracks does
NOT move
The Remote/Controller Failure See “Remote Controls/Control Panels”
Solenoid failure Repair or replace
Tracks plates/chain damaged Replace or repair
Motor seized Repair or replace as necessary
Check the legs for damage repair or replace

Stabilising jacking legs down
if necessary. Lift UP the legs
Slow or uneven
The track tension is low Tighten the tracks
track speed
Check for leaks and refill as necessary.
Low hydraulic pressure/flow
Check hydraulic system
One of the tracks tension is

Tighten the Track to the correct tension
not correctly set
Tracks do not
move at the
Check the hoses, pumps, valves and
same speed
Hydraulic system failure connections for leaks or damage replace
as necessary

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7.1.3 Conveyors - maintenance platforms - legs
The engine is OFF Start the engine
Check the filters, hoses, valves, pumps for

Hydraulic system failure damage. Make sure the hydraulic fluid
above the minimum level refill if necessary
The locating pins or other

locking equipment is still Remove the pins or equipment
Do NOT fold/Do
installed
NOT lift up or
down
The equipment is damage or Remove the blockage or repair the
blocked. equipment
Check the valve block, hoses and lever for

Lever Failure
damage replace or repair
Check the hoses, the connections and the

Hydraulic Ram Failure
seals, repair or replace as necessary
The engine is OFF Turn the machine ON
The valve is in the OFF

Turn ON the conveyor
position
Check the filters, hoses, valves, pumps and

The belt does the motors for damage. Make sure the
Hydraulic system failure
NOT move hydraulic fluid above the minimum level
refill if necessary
The belt is too loose Tighten the belt
Remove the blockage or align the belt as

The belt is blocked or stuck
necessary
Remove the blockage or repair as

Fold/Lift slow or Blocked or stuck
necessary
at a uneven
speed/The belt
moves slow or
the motors for damage. Make sure the
at a uneven Hydraulic system malfunction
hydraulic fluid above the minimum level
speed
refill if necessary
The belt tension is low Tighten the belt

The belt is
slipping
The rollers/bars are damaged Replace or repair as necessary
Rocking/moving
The locating pins or locking Install the locating pins or locking
while in
equipment is not installed equipment
operation.

QA441 - en - 240615
The drum bearings are

Replace the bearings
damaged
The belt is
Belt tension is too tight Reduce the tension in the belt
making too
much noise
Belt is not tracked correctly Align the belt as necessary
There is a blockage Remove the blockage

QA441 - en - 240615
7.1.4 Loading and operating
Machine is NOT set for

Set the Machine for operation
operation
NO or little
material is No Material on the Feeder Load material on the machine
output
Check the feeder, screen box and
Blocked conveyors for blockages. Remove the
Shut down immediately. Remove the

Screen box is blocked
blockage
The Feeder is full
of material Feeder is OFF Switch on Feeder
The screen box is OFF See “The screen box”
Conveyor speed is too fast Slow the conveyor speed

Material roll back
Product is too light or slippery Use a chevron belt
on conveyors
Conveyor angle is too steep Reduce angle as necessary
Move the machine to level ground or make

The ground in not level
the ground level
The Machine is Move the machine to firm ground or make

The ground is not firm
unstable or the ground more suitable
rocking from
side to side The stabilising legs, where Set the stabilising legs on firm level ground
applicable, are NOT set to help support the machine
Uneven or excessive loading Load the machine correctly
The screen box The screen box is blocked/ or Clear the blockage check both levels and
does NOT OFF make sure the screen box is ON
The screen box mesh is

Replace the mesh or clear the blockage
damaged or blocked
Product only exits
from one or The other conveyors are not Make sure the conveyors are set for
some conveyors functioning operation
No smaller product is loaded Change raw material mixture

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7.1.5 Screen box
The engine is OFF Turn the engine ON
Check operation mode is selected and turn

The screen box is OFF
the screen box ON
Does NOT
operate
Hydraulic system Failure
refill if necessary
Screen box blocked Remove the blockage
Screen media loose Inspect and re-tighten
The bearings are damaged Inspect, replace bearings if necessary
Inspect the screen box and repair the

The screen box is damaged
Excessive noise screen box if necessary
The screen box is blocked Remove the blockages
Check all the springs and replace as

The springs are damaged
necessary

Hydraulic system Malfunction
refill if necessary
Vibrates slow or
with uneven
Make sure the system is greased correctly
speed The drive shaft system
and inspect the parts for damage. Repair
malfunction
or replace as necessary
The screen box is blocked Remove the blockage

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7.1.6 Electrical, radio, umbilical controls
The machine is OFF Start the machine
The batteries in the remote are

Recharge the batteries
not charged
The remote control is NOT Follow the instruction on the back of the
programmed to the machine. remote
The umbilical cord is not

connect the umbilical connector
connected
Check the wires and components in the

The buttons do
control box/controllers/machine repair or
NOT work Electrical malfunction
replace as necessary. Check umbilical
or dummy plug is fitted.
Remove the blockage and clean the

The buttons are stuck or blocked
buttons
The incorrect mode has been

Change to correct mode
selected on the function switch
Check the equipment under control

Equipment malfunction (tracks, conveyors, feeder, etc.). Check
umbilical or dummy plug is fitted.
Follow the instruction on the back of the

The remote is not The remote control is NOT
remote. Check umbilical or dummy plug
communicating programmed to the machine.
is fitted
with the
machine
The batteries are not charged Replace or recharge the batteries
The machine is OFF Turn On the Machine

The warning
The lights/display are damaged Replace the lights/display
lights or the
display do NOT
Check the wires and components in the
work or
control box and machine repair or
intermittent Electrical malfunction
replace as necessary. Check umbilical
or dummy plug is fitted

QA441 - en - 240615
7.2 Problems not listed

If any problem persists after carrying out the recommended solution, or a problem arises that
is not on the fault code or fault finding lists, contact your local Sandvik service department
for further assistance.

QA441 - en - 240615
8. Engine qa441
8. Engine

QA441 - en - 240615
qa441 8. Engine
8.1 Engine in power pack

8.1.1 Engine manual
The engine manufacturer supplies a manual which should referred to for further information
on the engine fitted to the power pack of the machine.
8.1.2 Engine alternatives
Different power pack and engine configurations may be fitted to the machine.
Identify the engine type by referring to the serial plate of the machine and the following
information.
• 74kW engine identified on the machine serial

plate.
• Hydraulic pump detail shown ->
• 83kW engine identified on the machine serial

plate.
• 83kW engine on ‘EU’ CN8081 plate.
• Hydraulic pump detail shown ->

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9. Electrical and Hydraulic information qa441
9. Electrical and Hydraulic information

QA441 - en - 240615
qa441 9. Electrical and Hydraulic information
9.1 Schematic diagrams

9.1.1 Electrical schematic diagram
Refer to the electrical schematic document pdf file.
9.1.2 Hydraulic schematic diagram
Alternative engines can be fitted to this machine which have some differences in the
hydraulic systems. Refer to the appropriate hydraulic schematic diagrams pdf files.
Common schematic:
HD003105
74kW schematics:
HD003101, HD003102, HD003103, HD003104, HD003106.
83kW schematics:
HD003107, HD003108, HD003109, HD003110, HD003111

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10. Information and Data sheets qa441
10. Information and Data sheets

QA441 - en - 240615
qa441 10. Information and Data sheets
10.1 Original equipment manufacturer information

Please make sure you read this section carefully. It contains information supplied by original
equipment manufactures of components used in the machine, therefore Sandvik has
reservations for misprints.
• Strickland tracks
• Engine (manual supplied separately)

QA441 - en - 240615
10. Information and Data sheets qa441
10.2 Hazardous substances
• Univar Caflon pre-mixed - engine coolant
• Ultra low/Low sulphur Diesel fuel oil
• Shell Rimula - engine lubrication oil
• Shell Tellus S2 - hydraulic fluid
• Shell Tellus S4 VX - hydraulic fluid
• Shell Gadus S3 V220 C2 - grease
• Exol Ethena EP90 - track gear oil
• Shell Spirax S2 G 80W-90 - track gear oil
• Exxon Unirex N3 grease - screen box bearings
• SKF LGHB2 - auto lubrication system grease *
• Shell Aeroshell 33 - auto lubrication system grease *

QA441 - en - 240615
qa441 10. Information and Data sheets
10.3 Variations and options (if applicable)

• Eriez magnetic separator
• Auto lubrication system

QA441 - en - 240615

QA441 Operations Manual 24 06 15 English PDF

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QA441 Operations Manual 24 06 15 English PDF

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Original Instructions

Sandvik Construction Mobile Crushers and Screens Ltd.

1.2Features for operator safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

1.4Personal protective equipment (PPE) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

1.5Organisational safety measures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

1.6Personnel qualifications, requirements and responsibilities - - - - - - - - - - - - - - - - 18

1.8Special work, including maintenance, parts disposal and hazardous materials - - 21

1.11Hazard exclusion zones - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

1.12Measured noise levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34

Copyright © Sandvik Construction Mobile Crushers and Screens Ltd 1

1.14Emergency stop locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44

2. TRANSPORT & TECHNICAL DATA

2.2 Machine data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77

2.3 Transport dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80

3.3 Screening machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86

3.4 Main control devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87

3.5 Operational controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89

2 Copyright © Sandvik Construction Mobile Crushers and Screens Ltd

3.8 Reject grid radio control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 102

3.9 Track controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103

3.10 Machine working dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 104

4. COMMISSIONING & SHUT DOWN

4.2 Pre-commissioning instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 109

4.3 Engine starting procedure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 111

4.4 Moving machine on the tracks- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115

4.5 Preparing for screening operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 121

4.6 Shut down the machine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 146

Copyright © Sandvik Construction Mobile Crushers and Screens Ltd 3

5.2 Screening operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 155

5.3 Set up the conveyor speeds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 166

5.5 Radio remote grid operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 169

5.6 Switching off operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171

6.2 Reference information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 177

6.3 Maintenance schedules - power module maintenance - - - - - - - - - - - - - - - - - - - 178

6.4 Maintenance schedules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 181

4 Copyright © Sandvik Construction Mobile Crushers and Screens Ltd

6.6 Diesel fuel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 189

6.7 Hydraulic fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 191

6.8 Engine coolant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 192

6.9 Air cleaner servicing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 193

6.10 Inspect the hydraulic return filter indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - 196

6.11 Grease the bearings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 197

6.12 Fuel filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 200

6.13 Hydraulic tank filters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 201

6.14 Conveyors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 203

6.15 Installation and removal of the screenbox mesh - - - - - - - - - - - - - - - - - - - - - - - 215

6.16 Tracks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 223

6.17 Track gearbox - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 227

6.18 Vibrating grid in hopper [option] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 229

6.19 Lubricants and fluids - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 230

6.20 Machine error messages and fault codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - 231

Copyright © Sandvik Construction Mobile Crushers and Screens Ltd 5

7.2 Problems not listed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 244

9. ELECTRICAL AND HYDRAULIC INFORMATION

10. INFORMATION AND DATA SHEETS

10.2 Hazardous substances - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 251

6 Copyright © Sandvik Construction Mobile Crushers and Screens Ltd

1.1 Safety principles

1.1.1 Signal words

1.1.2 General hazard symbol

This general HAZARD or other hazard symbol identifies important

8 Copyright © Sandvik Construction

Read this manual and familiarize yourself with any associated