Qh440 Manual Eng

Original Instructions
QH440-en-050112
Operator’s Manual
qh440
Issue 2
qh440
©Copyright 2011 Sandvik
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.
Hearthcote Road, Swadlincote, Derbyshire, DE11 9DU, United Kingdom

Tel: +44 (0) 1283 212121, Fax: +44 (0) 1283 217342
www.sandvik.com
QH440-en-050112
qh440 OPERATOR’S MANUAL - DESIGN AND BUILD
Machine information
Serial number
Engine serial number
Date of build
Copyright © Sandvik Mining and Construction

QH440-en-050112
OPERATOR’S MANUAL - DESIGN AND BUILD qh440
Declaration of Conformity
We hereby declare that the machinery
Machine Nomination, Type of machine:
Diesel
Crusher
is in conformity with the following Directives, Standards and Codes

2006/42/EC Machinery Directive
2004/108/EC Electro-Magnetic Compatibility (EMC)
2006/95/EC Low Voltage Directive (LVD)
EC Type-examination and Certificates

ISO21873-2:2009
Technical file
We assure that documentation have been compiled in accordance with 2006/42/EC Annex VII
Phil Coleman, PDC Group Engineering Manager , Swadlincote

is authorized to make the technical file available on request by competent authority of the EC Member
States in accordance with 2006/42/EC. The documents will be delivered as electronic files.
Paul Colton, Operations Director, Swadlincote

confirms the manufacturing process to ensure compliance of the manufactured machinery with the
technical file.
This declaration remains valid as long as no modification is carried out without the
PDQXIDFWXUHU¶VZULWWHQDJUHHPHQW
Date: 01 / 07 / 2011
Phil Coleman Paul Colton

PDC Group Engineering Manager Operations Director
Manufacturer: Sandvik Mining and Construction,

COMPANY, ADDRESS
Hearthcote Road,
Swadlincote
DE11 9DU
Sandvik Mining and Construction document template: Declaration of Conformity 30 Nov 2009 - English www.sandvik.com

QH440-en-050112
CONTENTS
1. SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
1.1. Safety essentials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
1.1.1. Safety labels and signals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
1.1.2. Signal words - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
1.1.3. General hazard symbol - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
1.1.4. Safety hazards pertaining to the equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
1.1.5. Colour coded safety signs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
1.1.6. Symbols for prohibited actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
1.1.7. Symbols for mandatory actions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
1.1.8. Symbols for hazards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
1.2. Features for operator safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
1.3. Environmental safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

1.3.1. Hazardous materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
1.3.2. Battery disposal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
1.3.3. Machine disposal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
1.4. Personal protective equipment (PPE) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
1.5. Hazard exclusion zones - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
1.6. Measured noise levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
1.7. Vibration levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
1.8. Organizational safety measures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
1.9. Personnel qualifications, requirements and responsibilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
1.10. Safety advice regarding specific operational phases - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

1.10.1. Standard Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
1.10.2. Blockage or malfunction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
1.10.3. Unguarded areas - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
1.11. Special work, including equipment maintenance, disposal of parts, and hazardous materials - - - - - - - - 28
1.11.1. Securing equipment before performing maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
1.11.2. Maintenance site conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
1.11.3. Replacement & removal of components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
1.11.4. Climbing and falling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
1.11.5. Safety considerations during maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
1.11.6. Safety considerations during cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
1.11.7. Removal of safety devices, guards and decals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32
1.11.8. Surrounding structures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32
1.11.9. Safety when refuelling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32
1.12. Specific hazards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

1.12.1. Electrical energy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
1.12.2. Automotive batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
1.12.3. Gas, dust, steam, smoke and noise - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35
1.12.4. Welding or Naked Flames - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35
1.12.5. Hydraulic equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
1.12.6. Hazardous substances - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36
1.13. Safety decals - Locations. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
Copyright © Sandvik Mining and Construction 5

QH440-en-050112
CONTENTS
2. TRANSPORTATION & TECHNICAL DATA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41

2.1. Special considerations for transport - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
2.1.1. Machine preparation for transport - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
2.1.2. Tracking machine on or off transport vehicle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
2.2. Application & limitations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48

2.2.1. Common applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48
2.3. Technical specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

2.3.1. Feed hopper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
2.3.2. Feed Conveyor Belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
2.3.3. Main Conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
2.3.4. Lubrication Tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
2.3.5. Power Pack - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
2.3.6. Tracks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
2.3.7. Operating dimensions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
2.3.8. Total weight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
2.3.9. Machine specification plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
2.4. Machine Transportation Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51
3. PRODUCT OVERVIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
3.1. Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
3.1.1. Standard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
3.1.2. Optional items - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
3.1.3. Future options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
3.2. Main Components - Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55
4. COMMISSIONING AND SHUT DOWN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

4.1. General Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
4.2. Pre-Commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59
4.2.1. Pre-Start Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59
4.3. Main control devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

4.3.1. Electrical controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
4.3.2. Display screen and soft keys - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
4.3.3. Set date, time and Language - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
4.3.4. Radio remote control for tracks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
4.3.5. Remote control battery recharging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
4.3.6. Wired umbilical track control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
4.4. Engine starting procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67

4.4.1. Before starting engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67
4.4.2. Engine start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68
4.5. Initial screen display icons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
4.6. Stopping machine in an emergency - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 70

4.6.1. Emergency stop locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71
4.6.2. Operation of an emergency stop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71
4.6.3. To reset an emergency stop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72
6 Copyright © Sandvik Mining and Construction

QH440-en-050112
CONTENTS
4.7. Tracking (moving) procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73

4.7.1. Before moving the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73
4.7.2. Moving the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 74
4.7.3. Tracking using wired umbilical control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 74
4.7.4. Radio remote control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 75
4.8. Preparing the crusher for operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
4.9. Jacking legs set-up procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81

4.9.1. Lower jacking legs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81
4.9.2. Raising jacking legs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 83
4.10. Shut down the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85

4.10.1. Automatic mode shut down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
4.10.2. Manual mode shut down - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85
4.11. Lockout and tag procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88

4.11.1. How to fit a single tag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88
4.11.2. To remove a single tag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88
4.11.3. How to fit a gang tag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
4.11.4. To remove a gang tag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
5. OPERATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91
5.1. Operations - minimum safety requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92
5.2. Machine crushing mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93
5.3. Methods of operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 95
5.4. Automatic mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 96

5.4.1. Feeder start and stop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 96
5.4.2. Automatic operation - additional control screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 96
5.4.3. Automatic mode screen 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 97
5.4.4. To stop the crusher in automatic mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 97
5.5. Manual mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 98

5.5.1. Feeder start and stop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
5.5.2. To stop the crusher in manual mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
5.5.3. Feed conveyor manual speed adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
5.5.4. Feed conveyor automatic speed control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
5.6. Daily calibration of crusher wear parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101
5.7. Close side setting gap [CSS] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 102
5.8. Feeding material into machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103

5.8.1. Before starting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103
5.8.2. Loading hopper with material - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103
5.8.3. Cone crusher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103
5.9. Feed conveyor metal detector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 104
6. MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 107
6.1. Maintenance - minimum safety requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 108

QH440-en-050112
CONTENTS
6.2. Scheduled maintenance intervals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110

6.2.1. Daily maintenance schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110
6.2.2. Weekly maintenance schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 111
6.2.3. First 50-80 Hours maintenance schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 112
6.2.4. 160 Hours maintenance schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 112
6.2.7. 1000 Hours maintenance schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 113
6.2.8. 2000 Hours or 1 year maintenance schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 114
6.3. Maintenance procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115

6.3.1. Location of compartments for maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115
6.3.2. Fluid drain points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116
6.3.3. Track gearbox oil - check top up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117
6.3.4. Track gearbox oil - replace - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 118
6.3.5. Fuel tank - check top up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119
6.3.6. Hydraulic tank - check top up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 120
6.3.7. Crusher lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 120
6.3.8. Clutch lubrication tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 121
6.3.9. Engine air cleaner - servicing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 121
6.3.10. Hydraulic filters and tank air vent - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 122
6.3.11. Crushing chamber - inspect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 123
6.3.12. Crusher belt drive tensioner - Inspect/adjust - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 124
6.3.13. Bearings - grease - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 124
6.3.14. Belt scraper - adjust - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 125
6.3.15. Tracks - inspect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 126
6.3.16. Track tension - check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 126
6.3.17. Track tension - increase - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 127
6.3.18. Track tension - reduce - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 128
6.3.19. Crusher liners - replace - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 128
6.3.20. New crusher liners - Reset datum - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 128
6.4. Lubricants and fluids - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 130
6.5. Maintenance screens and machine fault codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 132

6.5.1. Maintenance screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 132
6.5.2. Machine fault codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 136
6.6. Diagnostic screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 141

6.6.1. Outputs diagnostic screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 142
6.6.2. Speeds diagnostic screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 142
6.6.3. Tracks diagnostic screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 142
6.6.6. Clutch diagnostic codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 143
6.6.4. Inputs diagnostic screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 143
6.6.5. Clutch diagnostic screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 143
7. TROUBLE SHOOTING GUIDE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 145

7.1. Common problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 146
7.1.1. Machine faults displayed on screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 146
8. ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147
8.1. Engine manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 148

QH440-en-050112
CONTENTS
9. ELECTRICAL & HYDRAULIC INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 151

9.1. Electrical Diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 152
9.1.1. Electrical Page 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 152
9.1.2. Electrical Page 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 153
9.1.3. Electrical Page 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 154
9.1.4. Electrical Page 4 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 155
9.1.5. Electrical Page 5 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 156
9.1.6. Electrical Page 6 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 157
9.1.7. Electrical Page 7 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 158
9.1.8. Electrical Page 8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159
9.1.9. Electrical Page 9 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 160
9.1.10. Electrical Page 10 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 161
9.1.11. Electrical Page 11 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 162
9.1.12. Electrical Page 12 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 163
9.1.13. Electrical Page 13 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 164
9.1.14. Electrical Page 14 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 165
9.1.15. Electrical Page 15 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 166
9.1.16. Electrical Page 16 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 167
9.1.17. Electrical Page 17 (tier 4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 168
9.1.18. Electrical Page 18 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 169
9.1.19. Electrical Page 19 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 170
9.1.20. Electrical Page 20 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 170
9.1.21. Electrical Page 21 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 171
9.1.22. Electrical Page 22 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 172
9.2. Hydraulic Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 173
10. O.E.M. PRODUCT DOCUMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 175

10.1. Documents - original equipment manufacturer and data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176
10.1.1. Tracks - Strickland - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176
10.1.2. Hydraulic power take-off (clutch) - PT Tech (HPTO14) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176
10.1.3. Engine (manual supplied separately). - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176
10.1.4. Sandvik CH440 cone crusher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176
10.1.5. Data documents - Hazardous substances - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176
11. SPARE PARTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 179

11.1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 181
11.1.1. Ordering procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 181
11.1.2. Safety decals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 181
11.2. Main assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 182
11.3. Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 184
11.4. Chassis assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 186
11.5. Tank tower frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 188
11.6. Ladder (8 rung) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 190
11.7. Diesel fuel tank assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 192
11.8. Hydraulic tank assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 194

QH440-en-050112
CONTENTS
11.9. Power pack assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 196
11.10. Powerpack end covers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 200
11.11. Powerpack base, top, sides - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 202
11.12. Powerpack seals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 204
11.13. Feed conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 206
11.14. Feed hopper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 210
11.15. Main conveyor - lower - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 212
11.16. Main conveyor upper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214
11.17. Feeder drive unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 217
11.18. Track assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 218
11.19. Track parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 219
11.20. Jacking leg - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 220
11.21. Walkway assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 222
11.22. Ladder (7 rung) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 224
11.23. Cone assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 226
11.24. Drive guard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 228
11.25. Lubrication tank assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 230
11.26. Clutch lubrication tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 232
11.27. Drive tensioner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 233
11.28. Idler pulley assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 234
11.29. Control box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 236
11.30. Electrical components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 238
11.31. Overband magnet option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 241
11.32. Water pump option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 243
11.33. Auto-lubrication option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 245
11.34. Fuel pump option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 246
11.35. Machine servicing kits - (3a engine) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 247
11.36. Machine servicing kits - (3b engine) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 249

QH440-en-050112
qh440 OPERATOR’S MANUAL
1. Safety

QH440-en-050112
OPERATOR’S MANUAL - 1 SAFETY qh440
1.1. Safety essentials
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.
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.
1.1.1. Safety labels and signals
This section includes explanations of safety symbols, signs, signals and labels used on the product
and information for use.

QH440-en-050112
qh440 OPERATOR’S MANUAL - 1 SAFETY
1.1.2. 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.
1.1.3. General hazard symbol
This general 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.
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.
• ENSURE 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.

QH440-en-050112
• Replace any illegible or missing safety instructions and safety labels before operating the
equipment.
• Ensure replacement parts include safety instructions and labels.
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 remove Limited or restricted

Do not weld
safety guard access

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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

Read the Safe distance
lockout
manual from hazard
equipment

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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:
Electrical
Crushing Crushing Chemical burn electrical shock/
hazard - hands hazard - feet hazard hazard electrocution
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 Hanging load

Magnet hazard Impact hazard Tipping hazard
hazard hazard
Drill
Explosion High pressure Hot surface
General hazard entanglement
hazard hazard hazard
hazard
Noise hazard

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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.
Emergency stop circuit is up to 30V DC series circuit and hard wired

to remove power from the Electronic Control Unit (ECU) Engine
management system and stop the engine. To avoid electric shock or
cutting injury, you MUST wait at least ten seconds after activating an
emergency stop to allow the system to release its residual charge.
Safety guards have been installed to prevent death or serious injury.

DO NOT remove, modify, or alter any safety guard. Make sure that all
safety guards are secured in their correct positions.
DO NOT use this equipment if any safety guards or devices have
been removed or NOT installed properly.
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.

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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 HAZARD!
Diesel spillage MUST be cleaned up immediately due to fire hazard.
Follow local and national regulations.
ONLY use lubricating oils recommended in the maintenance

schedule or OEM manuals.
Read and understand the instructions and information in 10.1.5.

Data documents - Hazardous substances.
WARNING
POSION 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.
ENSURE 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 section 10. O.E.M. Product Documents, of
this manual when working with components or substance that may
contain chemicals.
Use leak proof containers when draining fluids.

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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.

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1.4. Personal protective equipment (PPE)
DANGER
ENTANGLEMENT HAZARD!
Working in close proximity to running machinery could cause
DO NOT work close to machinery unless it is completely stopped.
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), Refer to 1.4. Personal protective equipment (PPE)
Minimum required personal protective equipment (PPE)
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

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1.5. Hazard exclusion zones
Figure 1-1: Hazard exclusion zone
A = Access area to the machine controls, only when not loading material.
C = 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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1.6. 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.
AWAITING NOISE TESTING RESULTS
Figure 1-2: Measured Noise Levels
The indicated measured noise levels are at 1m (3.5ft) and 7m (23ft) using a Castle GA101/701 meter
with an empty machine all systems running situated on the factory assembly line. Product and local
conditions will have an affect on the noise levels experienced.

QH440-en-050112
1.7. Vibration levels

There are NO circumstances where an operator should need to be on or touching the machine when
it is running.

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1.8. Organizational 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.
ENSURE 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.

QH440-en-050112
1.9. 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 9.1. Electrical Diagrams.
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 9.2. Hydraulic Diagram.

QH440-en-050112
1.10. Safety advice regarding specific operational phases
1.10.1. 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 unauthorized 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.
1.10.2. 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 10.1.4. Sandvik CH440 cone crusher or
contact your nearest dealer for assistance.
1.10.3. 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. Ensure safety devices and guards are all
installed correctly before lock out is removed.

QH440-en-050112
DANGER
ENTANGLEMENT HAZARD!
Working in close proximity to running machinery could cause
DO NOT work close to machinery unless it is completely stopped.
DO NOT wear, loose clothing or jewellery of ANY kind.
Long hair MUST BE tied back.
DO NOT reach in to unguarded machinery.
ALWAYS wear at least the minimum (CE approved) Personal
Protective Equipment (PPE), Refer to 1.4. Personal protective
equipment (PPE).

QH440-en-050112
1.11. Special work, including equipment maintenance, disposal of parts, and
hazardous materials
Observe adjustment, maintenance and service intervals detailed

throughout this manual, unless:
• - Failure of warning lights, horns, gauges, or indicators calls for
immediate action.
• - Adverse conditions require more frequent servicing.
USE ONLY Original Equipment Manufacturer's (OEM) recommended
replacement parts and equipment.
Enure only properly trained personnel undertake these tasks.
1.11.1. 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.
Implement tag and lockout procedures.
Attach hazard sign(s) to equipment in appropriate positions to alert
all personnel of potential hazards.

QH440-en-050112
1.11.2. 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.
1.11.3. 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.
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.

QH440-en-050112
1.11.4. Climbing and falling
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.
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.
1.11.5. Safety considerations during maintenance
It is essential that you take the following steps to ENSURE 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.

QH440-en-050112
The fastening of loads and instructing or guiding of crane operators

should be entrusted to qualified persons only.
NEVER work or stand under suspended loads.
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 ensure any safety device such as locking wedges,
securing chains, bars, or struts are utilized as indicated in
throughout this manual.
Ensure 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.
1.11.6. Safety considerations during cleaning
This equipment 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.

QH440-en-050112
1.11.7. 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.
1.11.8. 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.
1.11.9. 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.

QH440-en-050112
1.12. Specific hazards
1.12.1. Electrical energy
External considerations and hazards
When working with the equipment, maintain a safe distance from overhead electric lines. If overhead
cables are in the vicinity, a risk assessment MUST be completed prior to operating the equipment.
Ensure you follow local and national regulations.
DANGER
ELECTROCUTION HAZARD!
Contact with overhead electric lines will cause serious injury or
death.
If your equipment comes into contact with a live wire, you MUST:
- Vacate the area.
- Warn others against approaching and touching the equipment;
- Report the incident and have the live wire shut off.
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.

QH440-en-050112
1.12.2. Automotive batteries
Automotive batteries contains sulphuric acid, an electrolyte which

can cause severe burns and produce explosive gases when being
charged.
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.
Recharge batteries in a well ventilated area.
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.

QH440-en-050112
1.12.3. Gas, dust, steam, smoke and noise
DANGER
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, ENSURE there is sufficient ventilation or provide
forced ventilation.
Observe ALL local and national safety regulations. Contact your
local authority for additional information.
1.12.4. 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.
The battery MUST BE isolated and disconnected.

QH440-en-050112
1.12.5. 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.
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.
Hydraulic and compressed air lines MUST be laid and fitted

properly. Ensure no connections are interchanged. The fittings,
lengths and quality of the hoses MUST comply with the technical
requirements.
ONLY fit replacement components of a type recommended by the
manufacturer.
ALWAYS practice extreme cleanliness when servicing hydraulic
components. Ensure all measures are taken to avoid spillage and
leaks.
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.
1.12.6. Hazardous substances
Refer to 1.3. Environmental safety and 10.1.5. Data documents - Hazardous substances

QH440-en-050112
7 2 8 6 5 1 28 34 8 22 7 1 12 19 34 3 2
qh440
2 3 8 32
1.13. Safety decals - Locations.
QH440-en-050112
36 DE1053
35 DE1062
34 DE1058
33 DE1074
27 2 27 34 7 3 2 4 8 26 26 26 13 11 25 4 31 30 32 DE1076
31 DE1075
30 DE0053
29 885-0267-00

28 DE7047
27 DE6049
26 DE6041
25 DE6050
24 DE6048
23 DE6021
22 DE7039
21 DE1043
20 DE6018
19 DE6014
18 DE6040
17 DE6038
16 DE6039
15 DE6024
14 DE6037
13 DE6005
12 DE6036
11 DE6013
10 DE6019
9 DE6020
8 DE6011
7 DE0027
6 DE6007
5 DE6006
7 2 8 6 5 29 1 36 28 13 33 8 7 1 12 19 34 2 3 4 DE6015
3 DE6004
21
2 DE6000
22 20 10 9 23 18 24 35 14 16 17 15 1 DE1007
37
ITEM No. DECAL No.
DE7060 KIT
OPERATOR’S MANUAL - 1 SAFETY
DANGER DANGER
FALLING MATERIAL HAZARD ENTANGLEMENT HAZARD
Do not walk near material DO NOT reach into the
discharge areas conveyor
Risk of serious head injury or Risk of serious injury
death SWITCH OFF, LOCKOUT AND
HARD HAT AND EYE TAGOUT machine before
PROTECTION must be worn at opening or removing guards
all times when working in the
vicinity of the machine
DE6004
DE6000
1. DE1007 2. DE6000 3. DE6004
WARNING DANGER DANGER

TIPPING HAZARD TIPPING HAZARD
FALLING HAZARD
Work at any height can be Maximum tracking gradient 20
dangerous.
CRUSHING HAZARD DUE TO degrees front to back
Do not climb into the machine MACHINE ROLL-OVER CRUSHING HAZARD DUE TO
without fall protection in place MACHINE ROLL-OVER
SWITCH OFF, LOCKOUT AND Risk of serious injury or death
TAGOUT machine before
commencing any maintenance DO NOT track on left to right
work. Ensure proper procedures are gradients which are over 10%
in place to prevent falls
DE6006
DE6015
4. DE6015 5. DE6006 6. DE6007
WARNING SERVICE & MAINTENANCE

CRUSHING HAZARD
Do not place hands or feet
under jacking legs. Risk of Check engine oil and hydraulic oil
serious injury
KEEP HANDS AND FEET
levels daily
CLEAR before lowering or
raising jacking legs
DE6011
7. DE0027 8. DE6011 9. DE6020

NOTICE
SERVICE & MAINTENANCE WARNING

IMPACT HAZARD
STOP THE EQUIPMENT AND DO NOT allow spring loaded
door to be opened unrestrained
LOCKOUT POWER SOURCE Risk of injury
BEFORE PERFORMING
LUBRICATION MAINTENANCE OR
ADJUSTMENTS 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. Personal protective equipment includes
hard hat, safety glasses, hearing protection, dust mask, close
DE6013 fitting overalls, safety boots industrial gloves and high visibility
DE6019 vest.
DE6036
10. DE6019 11. DE6013 12. DE6036
DANGER NOTICE SERVICE & MAINTENANCE

SKIN INJECTION HAZARD PRIOR TO TRANSPORT
Hydraulic fluid under pressure can 1. Fasten all loose items CHECK CONDITION OF FILTERS
penetrate the skin causing serious
injury. DO NOT use your hand. Use 2. Check the plant for loose or ON A REGULAR BASIS
a piece of cardboard to check for
leaks
damaged parts Change elements when indicators
NEVER perform maintenance tasks Make repairs as found show red
on pressurised systems necessary to ensure that all
If fluid is injected under the skin
parts are safely secured during Refer to operators manual for
seek medical help immediately
DE6005 transport correct grades of oil
DE6037
DE6024
13. DE6005 14. DE6037 15. DE6024
NOTICE NOTICE
Read and understand operators LOCKOUT PROCEDURE
1. Switch off engine
NOTICE
manual and all safety signs
before using or maintaining 2. Remove the ignition key
3. Keep the ignition key on STOP AND LOCKOUT PLANT
machine.
If you do not understand the person during lockout BEFORE MAINTENANCE
information in the manual 4. Place appropriate
consult your supervisor, the maintenance warning signs (ie.
owner or manufacturer tagout) DE6040
5. NEVER work alone
DE6039
DE6038
16. DE6039 17. DE6038 18. DE6040

SERVICE & MAINTENANCE
WARNING DAILY CHECKS

Clean air filter
Check hydraulic oil level
Check engine oil level
Check water level
EXCEEDS 90dB(A) Check for leaks
May cause loss or degredation WEEKLY CHECKS
of hearing over long periods of Check condition of conveyor belts and other
time moving parts
Proper hearing protection must
be worn
Check oil level in feeder (see operation manual)
Clear any obstructions in the grizzly bars and jaws
BATTERY
Check tension on the fly wheel drive belts
Grease all bearings (see operation manual)
Clear any build up of dust from the oil cooler and
ISOLATION
DE6014
the radiator using compressed air
Check all bolts and panels and secure in place
DE6018
SWITCH
19. DE6014 20. DE6018 21. DE1043
SERVICE & MAINTENANCE SERVICE & MAINTENANCE

Ensure hydraulic oil is filled to DRIVE GUARDS MUST BE
middle of guage when cold FITTED BEFORE UNIT IS
STARTED
DE6021 DE6048
22. DE7039 23. DE6021 24. DE6048

QH440-en-050112
WARNING
BURN HAZARD
Hot surface
Exhaust will become hot when
machine is running.
Contact may cause burn
Do not touch
50
60 49
DE 60
DE
DE6041
25. DE6050 26. DE6041 27. DE6049
QH440
28. DE7047 29. 885-0267-00 30. DE0053
LOW
HYDRAULIC
SULPHUR RAD SUMP HYD DIESEL
OIL
DIESEL
31. DE1075 32. DE1076 33. DE1074

R R F R F
E E E E R
A A E A O
FEEDER R R D R N
MAIN CON E T
GREASE POINT GREASE F F R S
GREASE POINT E E U S
DE1058
POINT E
D
E
D
I
N
P
P
U
P
E E / O P
R R O R O
U T R
MAIN CON DE1058 DE1058
F F T T
GREASE POINT L
A
L
A
L
E L
DE1058
R R G E
E E S G
DE1053
S
34. DE1058 35. DE1062 36. DE1053

QH440-en-050112

QH440-en-050112
2. Transportation & technical data

QH440-en-050112
OPERATOR’S MANUAL - 2 TRANSPORT & TECHNICAL DATA qh440
2.1. Special considerations for transport
WARNING
Transport the machine utilizing 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. Ensure all appropriate permits,
licenses and endorsements are obtained and maintained before
transporting.
2.1.1. Machine preparation for transport
WARNING
PERSONNEL HAZARD!
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 4.11. Lockout and tag procedure.
Visually check machine to ensure there is no component damage. Ensure all personnel are away
from the machine, drives, tracks and auxiliary equipment.
Ensure cone crusher, feeder and conveyor belts are free of material, remove if necessary.
Ensure engine pre-start checks are carried out in accordance with engine manufacturer's instruction
manual.

QH440-en-050112
qh440 OPERATOR’S MANUAL - 2 TRANSPORT & TECHNICAL DATA
WARNING
FALLING HAZARD!
Falling from heights could cause serious injury or death.
Some of the steps in this procedure requires working at height,
ensure the following applies when working off the ground:
- Maintenance platforms are in place.
- All hand rails are fixed in position.
- All ladders are lowered and fixed in position.
- A safety harness is worn.
1. Start the engine -> Refer to: 4.4. Engine starting procedure.
2. At display P0000, press button 4 to select

machine set up mode and enable the
auxiliary hydraulic system.
3. Raise the jacking legs fully -> Refer to:4.9. Jacking legs set-up procedure.
4. Lower each hopper side using the individual

‘rear feeder flare’ control levers.

QH440-en-050112
5. Remove clips and pins from the conveyor 5

supports.
6. Lower the feed conveyor into transport

position using the ‘feeder in/out’ control
lever.
7
7. Fit pins and R clips that secure feed
conveyor in the transport position.
8. Press button 4 to exit setup mode.

8
9. Stop engine, lockout and tag out -> Refer to: 4.11. Lockout and tag procedure.

QH440-en-050112
10. Remove clips and bars from each hopper

side and store them.
10
13
11
11. Lower the level sensor into the transport
position.
12. Release the clips and remove the wedges,
12
then lower each side of the feed box.
13. Lower the end of the feed box.
14
14. Disconnect the lighting mast cable and
remove the mast.
15. Locate the mast in the transport bracket
15

QH440-en-050112
16. Remove 2 bolts from each side and pivot

the dust suppression water sprays down
into the transport position. Leave secured
with one bolt at each side and ensure bolts 16
are placed in a safe position for
transportation, such as the toolbox.
17. Remove pins and lower the handrails to the

transport position. Place pins in a safe
place for transportation, such as the
toolbox.
17
19
18. Pivot the lower part of the ladder up and

secure with the pins and clips.
19. Push the ladders inward into the transport 18
positions and secure with the pin and clip.
20. When finished, press button 4 again to de-

select machine set up mode. 20

QH440-en-050112
2.1.2. Tracking 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, 10m (33ft).
Carry out a thorough site inspection prior to commencing ANY
machine tracking (moving) operations.
1. Follow start up and tracking procedure, refer to 4.7. Tracking (moving) procedure. The
machine can be driven on or off the transport vehicle at the pre-set tracking speed.
2. Before tracking machine off a transport vehicle ensure all temporary sealing and transport straps
and chains are removed.
3. After tracking machine onto transport vehicle ensure 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.
4. Lower jacking legs sufficiently to support the weight of the machine and spread the load, refer to
4.9. Jacking legs set-up procedure.

QH440-en-050112
2.2. Application & limitations
This machine has been designed and constructed to reduce minerals such as stone to a
predetermined size. It must not be used for any other purpose without first contacting the Sandvik
technical department. DO NOT operate until the manual and all instructions supplied with the
machine are read and fully understood.
2.2.1. Common applications
This list is by no means exhaustive. Please contact Sandvik Mining and Construction for further
information on any materials not indicated below.
• Granite.
• Slate.
• Bricks.
• Limestone.

QH440-en-050112
2.3. Technical specification
2.3.1. Feed hopper
Nominal capacity 6,3m³ (8.25yd³)

Capacity with extensions 8,4m³ (11yd³)
Rear loading height 3531mm (11.7ft)
Loading with rear door lowered 3105mm (10.2ft)
Rear loading width 2605mm (8.7ft)
Rear loading with extensions 3645mm (12ft)
Material 10mm (3/8in) thick hopper and Hardox liners
Metal detector Up and over metal detector
2.3.2. Feed Conveyor Belt
Head drum diameter Ø371mm (Ø14.5in)

Hydraulic drive 80cm³ (4.9in³) piston motor
Gearbox 31:1, 8000Nm (5900 lbf-ft)
Tail drum diameter Ø265mm (Ø10.5in)
Width 1200mm (47in)
Length (endless) 13 150mm (43.2ft)
Specification (EP630) 4ply: 6mm (1/4in) top cover, 2mm (3/32) bottom cover
2.3.3. Main Conveyor
Head drum diameter Ø371mm (Ø14.5in)

Hydraulic drive 630cm³ (38.5 in³) motor
Tail drum diameter Ø265mm (Ø10.5in)
Width 1200mm (47in)
Length (endless) 21 600mm (70.1ft)
Specification (EP630) 4ply 6mm (1/4in) top cover, 2mm (3/32in) bottom cover
Discharge height 3734mm (12.3ft)
2.3.4. Lubrication Tank
Capacity 250 litres (66 US gall)

Flow meter Fixed displacement flow meter
Oil cooler Hydraulically driven oil cooler

QH440-en-050112
2.3.5. Power Pack
Engine Caterpillar C13, Tier 3A

Engine power 328kW (440 HP)
Speed 1800 RPM
Diesel tank size 900 litres (238 USgall)
Hydraulic tank size 900 litres (238 USgall)
Crusher drive PT Tech 355mm (14in) wet clutch c/w twin PTO
Drive belts 2 sets of 5 banded belts (spc6300)
2.3.6. Tracks
Length (centres) 3715mm (12.2ft)

Overall length 4528mm (14.1ft)
Track shoe width 500mm (19.5ft)
Tracking speed ?m/s (?ft/s)
hydraulic motor 90cm³ (5.5in³) bent axis
Gearbox ratio 124:1
2.3.7. Operating dimensions
Length 16 469mm (54.1ft)

Width - standard 2626mm (8.6ft)
Width with hopper extensions 3759mm (12.4ft)
Height 4972mm (16.4ft)
2.3.8. Total weight
Total weight (std) 50,08 tonne (55.2 US ton)

Weights and dimensions are for standard units unless
Refer to specification plate on machine.
otherwise stated.
2.3.9. Machine specification plate

QH440-en-050112
2.4. Machine Transportation Dimensions

Dimensions shown in millimetres and (approximate feet and inches).
H
F E
G D
Figure 2-1: Transportation Dimensions
A. 2950mm (9ft-8in)
B. 3844mm (12ft-7in)
C. 17503mm (57ft-in)
D. 4524mm (14ft-10in)
E. 3701mm (12ft-2in)
F. 6434mm (21ft-1in)
G. 2954mm (9ft-8in)
H. 1954mm (6ft-5in)

QH440-en-050112
This page is intentionally blank

QH440-en-050112
3. Product overview

QH440-en-050112
OPERATOR’S MANUAL - 3 PRODUCT OVERVIEW qh440
3.1. Features
3.1.1. Standard
The QH440 is a tracked, self contained cone crusher with an on-board diesel engine and features
the following:
• ‘I’ beam chassis construction for maximum durability.
• Heavy duty, hydraulically positioned feed conveyor with Hardox liners.
• Up and over metal detector, providing cone protection from tramp material.
• Variable speed feed conveyor.
• Four jacking legs to aid stability and maintenance.
• 13 litre diesel engine with direct drive ensuring maximum power delivery and fuel efficiency.
• Machine is designed for ease of mobility, rapid set up time and transportation.
• CH440 Sandvik cone installed with a choice of six concaves and a CSS range of 8mm to 48mm
(0.3 to 1.9in) allowing a feed size up to 215mm (8.5in).
• 8 available bush settings giving an eccentric throw range from 16mm to 44mm (0.6 to 1.7in).
• Capable of up to 388 tonne/h (427 US ton/h).
3.1.2. Optional items
Current optional extra items:

• Water suppression pump.
• Magnet.
• Hopper extensions.
• Tropical high ambient package.
• Arctic low ambient package down to -20°C (-4°F).
• Arctic low ambient package down to -30°C (-22°F).
• Pull cords emergency stop on main conveyor.
• Central auto lubrication.
• Diesel refueling pump.
3.1.3. Future options
Optional items that may be available in future

• Rubber lined hopper.
• Hanging screen.
• Wheeled dolly.
• Fire suppression.
• 345kw Volvo engine.

QH440-en-050112
qh440 OPERATOR’S MANUAL - 3 PRODUCT OVERVIEW
3.2. Main Components - Overview

L
C
H
K
I
I
E I B F
A. Chassis with tracks B. Hydraulic tank

C. Feeder conveyor D. Jacking legs
E. Control cabinets F. Main output conveyor
G. Drive guard and belt tensioner H. Cone crusher and feed box
I. Maintenance walkway J. Cone lubrication tank
K. Powerpack L. Hopper

QH440-en-050112

QH440-en-050112
4. Commissioning and shut down

QH440-en-050112
OPERATOR’S MANUAL - 4 COMMISIONING & SHUT DOWN qh440
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
1.5. Hazard exclusion zones.

QH440-en-050112
qh440 OPERATOR’S MANUAL - 4 COMMISIONING & SHUT DOWN
4.2. Pre-Commissioning
4.2.1. Pre-Start Instructions
WARNING
PERSONNEL HAZARD!
carrying out these pre-start checks. Refer to 4.11. Lockout and tag
procedure
WARNING
FALLING HAZARD!
Some of the steps in this procedure require working at height, if this
is the case, ensure the following:
NOTICE RISK OF PROPERTY DAMAGE.

It is recommended that set up of this machine be carried out by a
representative of Sandvik Mobile Screening and Crushing Ltd. or by
a qualified representative of the dealer.

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.
1. Ensure this manual is read and understood.

2. Do not attempt to start this machine until you are aware of all aspects of its operation.

QH440-en-050112
3. Remove any temporary sealing and transport straps.
4. Visually inspect machine for the following:
• There are no signs of impact damage.
• All safety guards / safety devices are in place and secure.
• 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. Ensure all bolts and fixings are tight and all guards are in place with all safety devices operating
correctly.
7. Ensure crusher chamber, feeder and conveyor belts are free of material.
8. Carry out a full daily maintenance routine, Refer to 6.2.1. Daily maintenance schedule.
9. Remove all tools and equipment from the operational area.
10. Ensure all personnel is away from the machine, drives, tracks and auxiliary equipment.
11. Ensure pre-start checks outlined in the engine instruction manual are completed.
12. Ensure skirting rubbers and scrapers are in good condition and will work properly.
13. Remove any lockout tags from the machine if safe to do so, refer to 4.11. Lockout and tag
procedure.

QH440-en-050112
4.3. Main control devices
4.3.1. Electrical controls
b c d e
Figure 4-1: Electrical control box
a. Display screen and soft keys.

b. Reset emergency stops prior to engine start.
c. Emergency stop.
d. Locker light.
e. Engine ignition.

QH440-en-050112
4.3.2. Display screen and soft keys
a a
P0000
f c d c b
Figure 4-2: Display screen and soft keys
Navigation through menus is achieved using relevant ‘soft keys’ as follows:

a. Numbered keys (1 to 8) to select and deselect options displayed as an icon on screen next to
relevant numbered key.
b. When up and down arrows displayed to adjust settings of current selected item.
c. When left or right page number arrows are displayed to navigate to other screen pages.
d. OK - For diagnostic use and accepting changes to configuration.
e. ESC - Return to previous menu, option or home page, press repeatedly to page back.
f. Screen page number and sequence reference.

QH440-en-050112
4.3.3. Set date, time and Language
1. At screen P0000, press and hold ESC until

the information screen display is shown.
2. To select the language, press button 3 until

the required language is displayed. Repeat
to cycle through the languages available. 2
3. To adjust the date and time, press and hold

button 8 until the hour time on the left
changes to red. The data being changed is
displayed in red. 3
4. To adjust the hour time, press up or down

arrows as required.
4
5. Press right arrow to move to next setting

minutes, then seconds, day, month, year
and adjust as required using the up or down
arrows.
5
6. Use the left arrow to move back if required.

6
7. To store the data, when the time and date

have been set, finally press the right arrow
until no red numbers are displayed and the
seconds time runs.
7
8. Press ESC to return to previous display.

8

QH440-en-050112
4.3.4. Radio remote control for tracks
f g
e
c
a b h
A B
Figure 4-3: Radio remote control
a. Lever forward or back to control track A.

b. Lever forward or back to control track B.
c. Stop engine button.
d. Mode selection switch - feeder or track.
e. Radio remote control switch, turn ON/OFF.
f. Alarm ON/OFF button (black).
g. Synchronise radio control to machine button (green).
h. Yellow and blue direction markers
To move the machine using the tracks, refer to 4.7. Tracking (moving) procedure.

QH440-en-050112
4.3.5. Remote control battery recharging
1. Open the control box cabinet door and

remove the charging unit from the holder.
2. Remove the battery from the radio remote

control.
3. Fit the battery into the charge unit.
4 7
4. Connect charge unit plug into socket.
5. To charge the battery, press ‘CHARGE’.

5
6. For quick recharge of the battery, press
‘FAST CHARGE’
6
7. Place charge unit into holder whilst it is
charging.
8
8. When battery charge cycle is complete,
‘READY’ illuminates green.

QH440-en-050112
4.3.6. Wired umbilical track control
b b e
Figure 4-4: Wired umbilical track control
a. Umbilical control ON/OFF switch.

b. Individual track controls.
c. Double track control for moving in straight line.
d. Emergency stop button.
e. Yellow and blue direction markers.
To move the machine using the tracks, refer to 4.7. Tracking (moving) procedure.

QH440-en-050112
4.4. Engine starting procedure
4.4.1. Before starting engine
Make sure all emergency stops are re-set, providing it is safe to do so, refer to 4.6.3. To reset 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.
Ensure machine is NOT tagged out. DO NOT start machine if it is
tagged out.
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 to
right or 20° front to back. Both tracks MUST BE in contact with firm
level ground, suitable for carrying the machine weight.
NOTICE COLD START

When starting machine in temperatures of 0°C (32°F) or below, run
all systems at idle speed for 15 minutes to allow hydraulic oil to
reach working temperature (DO NOT feed material into machine
during this time). DO NOT change the engine speed while any
systems are running. DO NOT operate systems contrary to these
instructions.

QH440-en-050112
4.4.2. Engine start
Note: Ensure all scheduled maintenance checks are carried out, Refer to 6.2. Scheduled
maintenance intervals.
1. Open the left hand cabinet door and turn

battery isolation switch to the ON position.
1
2. Open the right hand cabinet door and turn

ignition key clockwise to the first ‘RUN’
position. 2
3. Press the emergency stop reset button.

4. Lights will flash for several seconds and 3
alarm will start.
5. Turn ignition key fully clockwise to the

‘START’ position and hold until engine
starts. The pre-start alarm will sound prior to 5
the engine starting.
6. Release key slowly, which will return to
‘RUN’ position, when the engine starts. 6
7. Engine will run at idling speed.
8. The screen will display initial page P0000.
NOTICE RISK OF PROPERTY DAMAGE

Engine speed is preset at the factory and must not be tampered
with.
When machine is switched off wait a minimum of 60 seconds before
the start sequence is run again - An error code may show if started
before the 60 second time has elapsed.

QH440-en-050112
4.5. Initial screen display icons
c
f
h g
Figure 4-5: Initial display
a. Use the machine for crushing, refer to 5.2. Machine crushing mode.
b. Move the machine on the tracks, refer to 4.7. Tracking (moving) procedure.
c. View the fault log, press button 3.
d. Alter the machine configuration for crushing, refer to 4.8. Preparing the crusher for operation
or for transport, refer to 2.1. Special considerations for transport.
e. View engine information, press button 5.
f. Machine settings - Access code required, refer to 6.5. Maintenance screens and machine fault
codes.
g. Fuel level shown as a % of maximum.
h. Machine diagnostics, refer to 6.6. Diagnostic screens.

QH440-en-050112
4.6. Stopping machine in an emergency
The machine can be stopped in an emergency by pressing ANY emergency stop button
located on electrical control panel, along each side of the machine or on the wired umbilical
control.
WARNING! PERSONNEL HAZARD

Ensure all persons in the area of the machine are fully trained in how
to use the emergency stops and their locations.

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4.6.1. Emergency stop locations
Figure 4-6: Emergency Stops
4.6.2. Operation of an emergency stop
1. Push emergency stop button to stop

machine.
2. Turn the ignition key and isolation switch to the OFF position as soon as possible.
3. Lockout and tag if required, refer to 4.11. Lockout and tag procedure

QH440-en-050112
4.6.3. To reset an emergency stop
WARNING! PERSONNEL HAZARD

Ensure the reason for the use of the emergency stop has been
cleared or rectified before the emergency stop is reset.
1. Turn emergency stop clockwise and

release.

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4.7. Tracking (moving) procedure
4.7.1. 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).
• Ensure loading / unloading site is clear of non essential personnel. Erect barriers around the
area and post warning signs where site conditions warrant this, or perform necessary risk
assessments.
• Loading/ unloading must only be carried out on firm flat ground.
• For the weight of the machine, refer to the specification plate fixed to the machine.
• When tracking, the operator 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.
• Tracking must only be carried out on firm ground.
• For safety reasons, it is essential to check all around machine prior to and during tracking, for
obstacles or personnel which may be endangered by moving the machine.
DANGER
MOVING MACHINE HAZARD!
Persons on machine or in exclusion zones when moving machine,
may cause serious injury or death.
DO NOT UNDER ANY CIRCUMSTANCES move the machine when
ANY persons are standing on the machine or in the exclusion zones.
NOTICE RISK OF PROPERTY DAMAGE

Ensure jacking legs are raised before machine is tracked. If the legs
are not raised, damage may occur to the machine and surrounding
area.
WARNING! RADIO INTERFERENCE HAZARD.

There is a small possibility the radio frequency on the remote
controllers may operate other machinery. Please use the wire
connected umbilical controller if this is a problem.

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4.7.2. Moving the machine
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 to
right or 20° front to back. Both tracks MUST BE in contact with firm
level ground, suitable for carrying the machine weight.
There is a short delay to allow the conveyor tail to automatically raise before the tracks
operate
1. Start the engine. -> Refer to 4.4. Engine starting procedure.
2
2. Select tracking mode button 2, on display
screen page P0000.
3. Select track control option either the

umbilical, button 1, or the radio remote,
button 2, on display screen P2000.
3
4. Selected icon is highlighted green
5. If the icon is grey the function is unavailable.
Refer to 4.7.3. Tracking using wired

6. For the umbilical track control option. ->
umbilical control.
7. For the radio remote track control option. -> Refer to 4.7.4. Radio remote control.
4.7.3. Tracking using wired umbilical control
For more information, also refer to 4.3.6. Wired umbilical track control.

The tail section of the conveyor will raise to clear the ground but
visually check it is clear before moving the machine.

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1. Switch the control ON. 1

2. Use the switches with a single arrow to
control individual tracks.
3. Use the double arrow switch to control both
tracks at the same speed to travel straight. 4
2 2
4. The direction of travel is shown by the
yellow and blue direction markers on the
machine and on the control.
5. In the event of an emergency press the
emergency stop.
3
4.7.4. Radio remote control
For more information, also refer to 4.3.4. Radio remote control for tracks.

The tail section of the conveyor will raise to clear the ground but
visually check it is clear before moving the machine.
1. Switch the radio remote control to 1.
2. Wait until the green light flashes 2

consistently.
3. Synchronise the radio control to the

machine, press green button.

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5
4 4
4. Use the levers to control individual tracks.
7
5. Use both levers together to control both
tracks at the same speed to travel straight.
6
6. The direction of travel is shown by the
yellow and blue direction markers on the
machine and on the control.
7. In the event of an emergency press the stop
button.
4 4
5
Note: The Radio Remote Handset must be fully recharged at regular intervals. Use the
correct instructions for the controller refer to 4.3.5. Remote control battery
recharging.

QH440-en-050112
4.8. Preparing the crusher for operation

Note: Ensure Sandvik service personnel are available at the initial set up the machine.
WARNING
FALLING HAZARD!
Some parts of this procedure require working at height, therefore
ensure maintenance platforms are in place, all hand rails are fixed in
raised working position, all ladders are lowered and fixed in position
and a safety harness is worn.
WARNING
PERSONNEL HAZARD!
Stop machine, isolate, remove ignition key and tag out as required,
before preparing crusher for operation. Refer to 4.11. Lockout and
tag procedure.
1. Pull the ladders out into the working 1

positions and secure with the pin and clip.
2. Pivot the lower part of the ladder down and
secure with the pins and clips.

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3. Lift the handrails to the raised working

position and secure with pins, transported
loose in tool box.
4
6
4. Raise the end of the feed box.

5. Raise and secure each side to the end
using the wedges then fit pins into wedges.
5
6. Pivot the level sensor into the working
position and secure.
7. Remove the lighting mast from the transport

bracket.
8. Install mast into the working position, 8
secure in the working position and connect
the cable. 7

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9. Position the dust suppression water sprays

in the working position and secure with 3
bolts each side. 9
10. Remove tag if safe to do so -> Refer to: 4.11. Lockout and tag procedure.
11. Start the engine if safe to do so -> Refer to: 4.4. Engine starting procedure.
When the engine is running and all checks are

complete, display P0000 will be shown.
12. Press button 4 to select machine set up

mode and enable the auxilliary hydraulic 12
system.
13. Raise each hopper side using the

individual ‘rear feeder flare’ control levers.
13
14. Secure each hopper side in the raised

position with the bar and secure with the
clip.
14

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15
15. Remove R clips and pins that secure feed
conveyor in the transport position.
16. Raise the feed conveyor into working

position using the ‘feeder in/out’ control
lever.
16
17. Fit pins and clips to secure feed conveyor

in one of the working positions desired.
18. Two pins must be fitted and secured with 17
clips. Do not rely on the hydraulic cylinders
to support the conveyor.


QH440-en-050112
4.9. Jacking legs set-up procedure
4.9.1. Lower jacking legs
WARNING
CRUSHING HAZARD!
Personnel near or on machine whilst lowering jacking legs, may
cause serious injury or death.
DO NOT UNDER ANY CIRCUMSTANCES operate 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!
Carry out a thorough site inspection prior to commencing ANY work
operations.
Start the engine, refer to 4.4. Engine starting procedure.

Note: Front jacking leg shown, rear leg similar.
1. Press button 4 to select machine set up

mode and enable the auxilliary hydraulic 1
system.
2. .Slacken the transport clamping bolt.

Note: Machine MUST be on a level 2
surface before operating jack leg
levers.
Note: Jacking legs are used only to
stabilise the machine in addition to
the tracks when crushing.
3. Operate the lever to lower the rear jacking

legs to stabilise the machine. The blue
direction marker indicates the rear of the
machine.
4. Operate the lever to lower the front jacking
legs. The yellow direction marker indicates
the front of the machine.
Note: Operate jack legs uniformly.
4
3

QH440-en-050112
5
5. If the jacking legs are to be used to assist
with machine mainenance, Remove the ‘R’
clips and retention bars from their storage
holders.
6. Lower the inner legs as required, using the
levers as above, until the suitable holes are
visible.
7. Install retention bars into holes in the
lowered leg. 8
8. Secure the bars with the ‘R’ clips.
Note: DO NOT operate machine whilst
ONLY supported by the jack legs.
7
6
SAN00006


QH440-en-050112
4.9.2. Raising jacking legs
WARNING
CRUSHING HAZARD!
Personnel near or on machine whilst raising jacking legs, may cause
DO NOT UNDER ANY CIRCUMSTANCES operate 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!
Carry out a thorough site inspection prior to commencing ANY work
operations.
Note: Front jacking leg shown, rear leg similar.
1. If the jacking legs have been used to assist

with machine mainenance and the retention
bars have been fitted, proceed as follows.
2. Remove ‘R’ clips.
3. Remove the retention bars from holes in the
lowered leg.
Note: The legs may require lowering
slightly, as described above, to 2
enable the retention bars to be
released.
4. Place retention bars into their storage
holders.
3
5&6
SAN00006

QH440-en-050112
5. Ensure machine is on and in set up mode,
refer to 4.4. Engine starting procedure
and 4.8. Preparing the crusher for
operation.
6. Operate the lever to raise the rear jacking
legs. The blue direction marker indicates the
rear of the machine.
7. Operate the lever to raise the front jacking
legs. The yellow direction marker indicates 7
the front of the machine.
Note: Operate jack legs uniformly. 6
8
8. Tighten the transport clamping bolt.


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4.10. Shut down the machine
4.10.1. Automatic mode shut down
If the machine is operating in automatic mode, proceed as follows:

1. Stop loading material into the feeder and wait until there is no more material on or in the
machine.
2. Wait for all material to fully discharge from feeder, crusher chamber and all conveyor belts.
3. Return to screen page P4000 by pressing

left button as required. 3
4. Automatic operation screen page P4000 will

be displayed.
5. To stop the automatic operation and shut

down the machine, press button 1. The stop
icon will be highlighted. The alarm will sound 5
prior to the automatic shut down.
The machine components will stop in the following sequence:

• Feed conveyor.
• Main output conveyor.
• Engine speed reduced.
• Crusher.
• Lubrication system.
There is a delay before each component stops.
4.10.2. Manual mode shut down
If the machine is operating in manual mode, proceed as follows:

When shutting down the machine in manual mode, it is ESSENTIAL
that the following steps are followed in the order shown, to prevent
damage to the machine. The controls will only allow the correct
sequence to be followed and there is a delay between sequence
steps.

QH440-en-050112
1. Stop loading material into the feeder and wait until there is no more material on or in the
machine.
2. Wait for all material to fully discharge from feeder, crusher chamber and all conveyor belts.
3. Return to screen P9001, page 3 using the

left or right arrow buttons as required. 3
4. Manual mode screen P9001 shown.
5. Stop the feed conveyor, press button 5.

Wait until it stops completely before
continuing. 5
6. Return to screen P9000 page 2, press left

arrow button. 6
7. Manual mode display screen P9000 shown.
8. Stop the main conveyor, press button 3.

Wait until it stops completely before
continuing. 8
9. Stop the crusher, press button 2. The

engine will reduce in speed then crusher will
stop. Wait until it stops completely before
continuing. 9

QH440-en-050112
10. Stop the lubrication system, press

button 1.
10
11. Press ESC as required to return to initial

display screen. 11
12. Stop engine by turning ignition key to

‘OFF’ position. 12

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4.11. Lockout and tag procedure
4.11.1. How to fit a single tag
1. Ensure ignition key is in the ‘OFF’ position.

Remove the ignition key and keep it with
you.
1
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
2
machine.
4. Use a gang tag if more than one person is

at work on the machine, refer to 4.11.3.
How to fit a gang tag.
4
4.11.2. To remove a single tag
1. Ensure ALL maintenance and work has been completed and no persons are on or near the
machine.
2. Remove your single lock or tag from isolation switch, refer to 4.11.2. To remove a single tag.
3. Replace the ignition key.
4. If a gang tag for multiple locks or tags has been used, refer to 4.11.4. To remove a gang tag.

QH440-en-050112
4.11.3. How to fit a gang tag
1. Ensure ignition key is in the ‘OFF’ position.

Remove key and keep secure until all
personnel working on the machine have 1
finished and are clear from it.
2. Make sure the isolation switch is in the OFF

position. 2
3. Attach the gang tag as shown.

4. Each person attaches their lock to the gang
tag BEFORE they start work. 3, 4
4.11.4. 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 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.

QH440-en-050112

QH440-en-050112
5. Operations

QH440-en-050112
OPERATOR’S MANUAL - 5 OPERATIONS qh440
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
Operating this machine generates dust. Breathing or inhaling silica
dust particles will cause death or serious injury.
Ensure suitable breathing equipment is used throughout ANY
operational activities. ALL necessary precautions MUST be taken to
reduce the risk of breathing dust or particles.
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 1.5. Hazard exclusion zones.
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.
For general information and the operating principles of the cone crusher, refer also to the 10.1.4.
Sandvik CH440 cone crusher. The CH440 cone crusher instructions are intended for a crusher
installed and operated in a static position with different controls but are included for information and
reference.

QH440-en-050112
qh440 OPERATOR’S MANUAL - 5 OPERATIONS
5.2. Machine crushing mode
1. Follow at least the minimum safety Refer to 5.1. Operations - minimum safety
requirements during all operational requirements.
activities->
Refer to 5.3. Methods of operation and any
2. Ensure machine is set for operation-> outstanding scheduled maintenance checks
are completed, refer to 6. Maintenance.
3. Start the engine-> Refer to 4.4. Engine starting procedure.
4. The mode selection screen will be

displayed.
5. Select plant crushing operation mode menu, 5

press button 1.

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6. The crushing screen will be shown.
b c d
j i h g
a. Desired gap setting CSS. b. Current gap setting CSS.
c. Dimension ‘A’. d. Lubrication oil temperature.
e. Lubrication oil flow rate. f. Fuel tank level gauge as a % value.
g. Engine speed. h. Engine load as a % value.
i. Hydraulic fluid ‘Hydroset’ pressure. j. Hydraulic fluid temperature.

QH440-en-050112
5.3. Methods of operation

The crusher start up has an automatic mode which should normally be used.
The manual crusher start up mode may be used if desired but components of the machine must be
started and stopped in the correct sequence. The machine controls will only allow the correct
sequence by highlighting the next step when available.
DO not start the machine if it is full of material. Clear any material

away before starting.
Select the automatic or manual method of operation as follows:
1. For automatic operation press button 5, 1

then refer to 5.4. Automatic mode
2. For manual operation press button 6, then 2

refer to 5.5. Manual mode

QH440-en-050112
5.4. Automatic mode
Each sequence of the operation will be highlighted as it starts. A warning is activated prior to each
function starting in the following sequence:
• Cone lubrication system starts and oil is pre-heated if required.
• Crusher starts, when cone lubrication system is functioning correctly.
• The ‘Hydroset’ system adjusts the crusher to the desired setting.
• Main output conveyor starts and the speed increases to the preset speed.
The automatic screen 1 will be displayed:
Figure 5-1:
5.4.1. Feeder start and stop
1. When the crusher is at operating speed, the

feeder icon will flash, press start button 5.
A warning is activated prior to starting. 1
2. Press button 5 again to stop.
5.4.2. Automatic operation - additional control screens
3. Press right arrow to view next screen.

4. Press left arrow to return to previous
screen. 4 1

QH440-en-050112
5.4.3. Automatic mode screen 2
a b c d e
a. Feed material level set point. b. Close side setting CSS.

c. Crusher speed. d. ‘Hydroset’ pressure.
e. Current material level in feeder box.
5.4.4. To stop the crusher in automatic mode
To stop the crusher normally when auomatic mode is being used, refer to 4.10.1. Automatic mode
shut down.

QH440-en-050112
5.5. Manual mode
Each operation will not be enabled until the parameters of the previous operation are satisfactory.
The machine components can only be started in the following sequence:
1. The manual operation screen will be shown.
2. Start the lubrication system, press button 1. 2
3. Start the crusher when possible, press

button 2. The crusher icon will flash when 3
the lubrication system is operating correctly.
4. Start the output conveyor when possible,

press button 3. The conveyor icon will flash 4
when the crusher is operating at the set
speed.
5. Adjust the engine speed and crusher speed

if required, press up arrow button to
increase speed or the down arrow to 5
decrease the speed.
6. Engine speed and load are displayed.
7. When the output conveyor is operating, go

to next screen page, press right arrow 7
button.

QH440-en-050112
5.5.1. Feeder start and stop
8. When the crusher is at operating speed, the

feeder icon will flash to indicate it can be
started, press button 5. A warning is 8
activated prior to starting.
9. Press button 5 again to stop.
5.5.2. To stop the crusher in manual mode
To stop the crusher normally when manual mode is being used, refer to 4.10.2. Manual mode shut
down.
5.5.3. Feed conveyor manual speed adjustment
10. To increase the feed rate speed, press

button 6. 10 + 11
11. To decrease the speed, press button 7.
Speed is shown as a % of maximum.
5.5.4. Feed conveyor automatic speed control
12. To set up the feed box level sensor to

control the feed conveyor, press right arrow 12
button to go to the next screen page.

QH440-en-050112
13. The crusher feed box level sensor adjustment screen page will display:
a b c d e
a. Feed material level set point. b. Close side setting CSS.

c. Crusher speed. d. ‘Hydroset’ pressure.
e. Current material level in feeder box.
14. To Enable the level sensor to control the

feeder, press button 5 and the icon will be
highlighted. 14
15. To adjust the maximum level of material in

the feeder box, press button 1 to raise the
upper level allowed. 15
16. To lower the maximum level of material,

press button 2.
16
17
17. The maximum level distance is displayed.

QH440-en-050112
5.6. Daily calibration of crusher wear parts

To monitor the wear rate of the crusher components, provide correct close side setting gap
dimension for product output, the crusher should be calibrated daily before the start of crushing.
1. From a crusher operation screen, press

right arrow button repeatedly until the last
screen page is displayed. 1
2. To calibrate the wear parts of the crusher,

press button 5. 2
3. Refer to the messages on screen to follow

the progress of the daily calibration and
wear monitoring. 3
4. The current amount of wear on the cone 4

crusher wear parts will be shown.

QH440-en-050112
5.7. Close side setting gap [CSS]
The size of the output material is adjusted by changing the CSS gap, this can be carried out from a
screen page where the CSS adjustment icon is displayed. This can be done whilst the crusher is
running.
1. The gap setting is adjusted by raising or

lowering the inner cone.
2. To increase the gap and material output
size, press button 2. 2+3
3. To reduce the gap and material output size,
press button 3.
4. The desired new gap setting is displayed

below the indicator.
5. The current gap setting is shown at the top
and adjusts to the desired setting. The
indicator shows the progress as the 4 5
adjustment takes place, pointing upward
vertical when set.

QH440-en-050112
5.8. Feeding material into machine
5.8.1. Before starting
Follow at least the minimum safety requirements during all operational activities, refer to 5.1.
Operations - minimum safety requirements.
Ensure machine is set for operation, refer to 4.8. Preparing the crusher for operation.
Ensure any outstanding scheduled maintenance checks and operation are completed, refer to 6.
Maintenance.
5.8.2. Loading hopper with material
Ensure cone crusher, output conveyor and feed conveyors are started, refer to 5.3. Methods of
operation.
Ensure the following applies when loading material into the hopper:
• Material should preferably be screened and fed by a conveyor from a stockpile or primary jaw
crusher, into the feed conveyor hopper.
• Place material carefully into the hopper from a height no greater than 300mm (12in) above the
hopper.
• Ensure feeder is evenly loaded over its entire length to maximise production.
• DO NOT over fill hopper.
• Avoid start / stop operations of the feed conveyor.
• Supply material into hopper steadily and constantly to give maximum output and minimum
wear.
• DO NOT load any material that is larger than 80% of the cone crusher inlet opening.
5.8.3. Cone crusher
If any material finds its way into the cone crusher that is larger than 80% of the cone crusher inlet
STOP machine immediately, refer to 4.6. Stopping machine in an emergency.
Lockout and tag the machine, refer to 4.11. Lockout and tag procedure, before removing the large
material with appropriate lifting equipment.
NOTICE! NEVER use excavators, under any circumstances, to force material into the feeder
as the machine will be damaged. Any damage occurred from this action will invalidate any
Sandvik manufacturers’s warranty.
The feed box above the crushing chamber should have material evenly distributed around it.
The crushing chamber should always be full of material and choke fed when crushing.

QH440-en-050112
5.9. Feed conveyor metal detector
A metal detector is positioned over the feed conveyor to warn of metal from entering the cone
crusher.
Any metal or non crushable material will cause damage to the crusher, therefore great care should
be taken to prevent any such material being present in the mineral supplied to the feed conveyor.I
1. If metal is detected on the feed conveyor

the conveyor will stop, an alarm will occur
and a red detect light will illuminate on the 1
metal detector control box.
2. A warning error message will also be

displayed, fault number ??
3. Wait until all the material in the crusher has

been passed to the output conveyor.
4. Lockout machine -> Refer to 4.11. Lockout and tag procedure
5. From the maintenance platform, locate and

clear the metal from the feed conveyor. To
locate metal under the detector it can be
raised.
6. When the metal has been removed from the

feed conveyor, press the red reset button on
the metal detector control box. 6
7. If it is safe to do so, start the feed conveyor, 7

press button 5.

QH440-en-050112
QH440-en-160112
Maintenance Manual
qh440
QH440-en-050112
qh440

Tel: +44 (0) 1283 212121, Fax: +44 (0) 1283 217342
www.sandvik.com
QH440-en-050112
6. Maintenance

QH440-en-050112
OPERATOR’S MANUAL - 6 MAINTENANCE qh440
6.1. Maintenance - minimum safety requirements
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 ensure the best possible performance from your machine
by reducing the chances of breakdowns.
For maintenance schedules and procedures relating to Original Equipment Manufacturers, refer to
10. O.E.M. Product Documents
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.
DO NOT stand on machine whilst it is in operation.
carrying out any maintenance procedures. Refer to 4.10. Shut down
the machine
Ensure 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.

QH440-en-050112
qh440 OPERATOR’S MANUAL - 6 MAINTENANCE
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.
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.
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.

QH440-en-050112
6.2. Scheduled maintenance intervals
WARNING
PERSONNEL HAZARD
Follow the instructions of section 6.1. Maintenance - minimum
safety requirements, before any maintenance schedule is started.
Refer to the Original Equipment Manufacturer (OEM) maintenance manuals for specific equipment
scheduled maintenance intervals that are not listed in this section. Refer to 10. O.E.M. Product
Documents.
For service kit information and part numbers, refer to 11.35. Machine servicing kits - (3a engine).
6.2.1. Daily maintenance schedule
WARNING! Follow the maintenance safety instructions at the start of section 6, before
starting this maintenance schedule.
Make sure that these checks are carried out before the machine is started each day.
Daily maintenance schedule (minimum requirements)

1. Do the daily engine maintenance, such as coolant level, service indicators and drain any
water from the primary fuel filter. Refer to the separate engine operation and maintenance
manual.
2. Do the daily cone crusher maintenance. Refer to 10.1.4. Sandvik CH440 cone crusher.
3. Do the daily power take-off (clutch) maintenance. Refer to 10.1.2. Hydraulic power take-off
(clutch) - PT Tech (HPTO14).
4. Clean any dirt from around the tank air vents and engine air filters.
5. Check air cleaner rubber seals - Inspect and clean as necessary.
6. Check air pre-cleaner - Inspect and clean as necessary.
7. Diesel tank - Check top up level. Refer to 6.3.5. Fuel tank - check top up.
8. Track gearbox - Check there are no oil leaks.
9. Hydraulic tank - Check top up level. Refer to 6.3.6. Hydraulic tank - check top up
10. Clutch lubrication tank - Check the condition of the air vent and top up oil if required. Refer to
6.3.8. Clutch lubrication tank.
11. Crusher oil - Check top up. Refer to 6.3.7. Crusher lubrication.
12. Emergency stops - Make sure all operate & reset. Refer to 4.6.2. Operation of an
emergency stop
13. Crusher chamber - Ensure it is free of any obstructions.
14. Crusher lubrication system - Inspect hoses for signs of damage or leaks.
15. Walk around the machine and do a visual inspection.

QH440-en-050112
Daily maintenance schedule (minimum requirements)

16. Safety guards - Make sure they are all present and secure.
17. Hydraulic, water and diesel hoses - Check for signs of damage or leaks.
18. Driven equipment - Inspect for damage or wear, including any optional equipment.
6.2.2. Weekly maintenance schedule
Make sure that these checks are repeated each week.
Weekly maintenance schedule (minimum requirements)

1. Do the daily maintenance schedule. Refer to 6.2.1. Daily maintenance schedule
2. Do the weekly engine maintenance, such as checking drive belts,hoses and clamps. Refer to
the separate engine manufacturer’s maintenance manual.
3. Do the weekly cone crusher maintenance. Refer to 10.1.4. Sandvik CH440 cone crusher.
Schedule continued
4. Cone crusher chamber - Inspect. Refer to 6.3.11. Crushing chamber - inspect.
5. Conveyor belts, drums, rollers and other moving parts - Inspect for damage or wear.
6. Belt drive tensioner - Inspect. Refer to 6.3.12. Crusher belt drive tensioner - Inspect/adjust
7. Feeder conveyor and cone rock box - Remove any obstructions.
8. All panels - Ensure they are in place and secure.
9. Oil cooler and engine coolant radiator - Clear any build up of dust or dirt.
10. Bearings - Grease. Refer to 6.3.13. Bearings - grease
11. Feeder conveyor belt sealing rubbers - Check/adjust.
12. Main conveyor, wear liners - Inspect.
13. Belt scraper - Adjust. Refer to 6.3.14. Belt scraper - adjust
14. Track gearbox - Check oil level. Refer to 6.3.3. Track gearbox oil - check top up
15. Track machine 50m (164ft) in both directions to prevent chain seizure. Refer to 4.7. Tracking
(moving) procedure
16. Track - Check & adjust if required. Refer to 6.3.15. Tracks - inspect

QH440-en-050112
6.2.3. First 50-80 Hours maintenance schedule
Make sure that this procedure is done at the first 50-80 hours running of the machine.
First 50-80 Hours maintenance schedule (minimum requirements)

1. Replace the hydraulic fluid filter elements supplied with the machine, kit number
QH440HYDFILTER2. Refer to 6.3.1. Location of compartments for maintenance and
6.3.10. Hydraulic filters and tank air vent for filter locations.
• Cone crusher lubrication tank In-line filter element (1 off).
2. Do the cone crusher checks and maintenance, refer to ‘running-in’ section in, 10.1.4.
Sandvik CH440 cone crusher
6.2.4. 160 Hours maintenance schedule
Make sure that this procedure is repeated every 160 hours
160 Hours maintenance schedule (minimum requirements)

1. Do the 160 hours cone crusher maintenance. Refer to 10.1.4. Sandvik CH440 cone
crusher
Make sure that this proceure is repeated every 250 hours.
250 Hours maintenance schedule, 3A engine only - (minimum requirements)
Service kit number QH440CAT3A250 for 3a engine only

1. Do the weekly maintenance schedule. Refer to 6.2.2. Weekly maintenance schedule.
2. Do the 250 hours engine maintenance, including:
• Engine oil and engine oil filter change
• Fuel filters replace (primary and secondary)
• Clean crankcase breather canister
Refer also to the engine manufacturer’s operation & maintenance manual.

QH440-en-050112
Make sure that this procedure is repeated every 500 hours.
Service kit number QH440CAT3A500 for 3a engine or QH440CAT3B500 for 3b engine

1. Do the weekly maintenance schedule. Refer to 6.2.2. Weekly maintenance schedule.
1. For the 3a engine do the 250 hours maintenance schedule, refer to 6.2.5. 250 Hours
maintenance schedule.
2. Do the 500 hours power take-off (clutch) maintenance, including:
• Drain and replace clutch oil, replace clutch oil filter, replace clutch air breather.
Refer also to 10.1.2. Hydraulic power take-off (clutch) - PT Tech (HPTO14).
3. Do the engine 500 hours maintenance schedule. Refer also to engine manufacturer’s
maintenance manual.
4. Replace engine air filters, primary and secondary,.refer to 6.3.9. Engine air cleaner -
servicing
5. For the 3b engine replace the primary, secondary and in-line fuel filters, as listed in the 3b
500 hours service kit.
6. Replace the hydraulic fluid filter elements, Refer to 6.3.1. Location of compartments for
maintenance and 6.3.10. Hydraulic filters and tank air vent for filter locations.
7. Replace cone crusher lubrication oil and filters, refer also to 6.3.7. Crusher lubrication.
8. Replace cone crusher lubrication air filter and top hat, refer to 10.1.4. Sandvik CH440 cone
crusher.
9. Drain off any water and sediment fron the fuel tank and hydraulic tank.

1. Do the 500 hours maintenance schedule. Refer to 6.2.6. 500 Hours maintenance
schedule.
2. Do the 1000 hours cone crusher maintenance. Refer to 10.1.4. Sandvik CH440 cone
crusher.
3. Do the 1000 hours power take-off (clutch) maintenance. Refer to OEM maintenance
manual. Refer to 10.1.2. Hydraulic power take-off (clutch) - PT Tech (HPTO14).

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Schedule continued
4. Track gearbox oil - Replace. Refer to 6.3.3. Track gearbox oil - check top up.
6.2.8. 2000 Hours or 1 year maintenance schedule
2000 Hours or 1 year maintenance schedule (minimum requirements)
Service kit number QH440CAT3A2000 for 3a engine or QH440CAT3B2000 for 3b engine

1. Do the 500 hours maintenance schedule. Refer to 6.2.6. 500 Hours maintenance
schedule. In addition, also change the hydraulic fluid, refer to 6.4. Lubricants and fluids.
2. Do the engine 2000 hours inspection and maintenance. Refer to engine manufacturer’s
operation & maintenance manual.
3. Do the cone crusher 2000 hours maintenance. Refer to 10.1.4. Sandvik CH440 cone
crusher.
Schedule continued
4. Drain and replace engine coolant.
5. Replace fumes disposal filter element (3b engine only)

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6.3. Maintenance procedures
WARNING
PERSONNEL HAZARD
Follow the instructions of section 6.1. Maintenance - minimum
safety requirements, before any maintenance procedure is started.
6.3.1. Location of compartments for maintenance
The engine and hydraulic compartment locations are shown below, to aid maintenance procedures.
7
6
5 4
8
Figure 6-1: Engine/hydraulic compartment locations
Key
1. Engine compartment 2. Power take-off (clutch)
3. Engine air cleaner 4. Clutch lubrication tank
5. Fuel tank 6. Hydraulic tank
7. Radiator compartment 8. Powerpack pressure filter compartment

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6.3.2. Fluid drain points
The fluid drain points are located below the hydraulic cabinet.
A A
4
3
2
1
Figure 6-2: Fluid drain points
Key
1. Engine coolant system drain 2. Engine oil sump drain
3. Hydraulic fluid drain 4. Diesel fuel tank drain

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6.3.3. Track gearbox oil - check top up
starting this maintenance procedure.
1. Move the machine, Refer to 4.7. Tracking
(moving) procedure, until gearbox (A) is in
its upright position. Top up plug (B) should
be to the left and the drain plug (C) at the B A
D
bottom of the gearbox.
Note: To prevent oil contamination clean
around top up plug (B) before
opening.
2. Remove top up plug (B), oil level (D) should
be level with the bottom of the top up plug
threaded hole (B).
3. Top up if required to correct oil level (D),
allow any surplus to drain before installing
and tightening top up plug (B).
C
4. For lubrication information, refer to section SAN00017
6.4. Lubricants and fluids.

5. Repeat for track gearbox on the other side.

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6.3.4. Track gearbox oil - replace
1. Move the machine, Refer to 4.7. Tracking
(moving) procedure, until gearbox (A) is in
its upright position. Top up plug (B) should
be to the left and the drain plug (C) at the
bottom of the gearbox.
Note: To prevent oil contamination clean B A
around top up plug (B) and drain D
plug (C) before removing.
2. Using a suitable container to catch the oil,
remove top up plug (B), and drain plug (C),
discard drain plug (C).
3. Allow oil to thoroughly drain.
4. Install and tighten new drain plug (C).
5. Fill gearbox through top up hole (B), allow
surplus oil to drain to correct level (D).
6. For lubrication information, refer to section SAN00017
C
6.4. Lubricants and fluids.
7. Install and tighten top up plug at (B).
8. Clean any oil residue from gearbox.
9. Repeat for track gearbox on the other side.

QH440-en-050112
6.3.5. Fuel tank - check top up
WARNING
FLAMABLE LIQUID HAZARD

Diesel fuel is flammable therefore is easily ignited and fires or
explosions can result.
Smoking, open flames, sparks and welding is strictly prohibited
while refueling.
Protective Equipment (PPE), refer to 1.4. Personal protective
equipment (PPE).
F
A
E
SAN00024
Figure 6-3: Fuel and hydraulic tanks
1. Check fuel level (B) in Diesel fuel tank (A).

2. Clean around filler cap (C) before opening, to prevent fuel contamination.
3. If fuel is required, remove filler cap (C) and top up as necessary, refer to section 6.4. Lubricants
and fluids. Install and tighten the filler cap.

QH440-en-050112
6.3.6. Hydraulic tank - check top up
1. Refer to Figure 6-3: Fuel and hydraulic tanks.
2. Check hydraulic fluid level (E) in hydraulic tank (D).
3. Clean around cap (F) before opening to prevent fluid contamination.
4. If hydraulic fluid is required, remove cap (F) and top up as necessary.
5. For hydraulic fluid information, refer to section 6.4. Lubricants and fluids.
6. Install and tighten cap (F).
7. Replace hydraulic filters, air vent element and change the hydraulic fluid at the correct service
interval, refer to 6.2. Scheduled maintenance intervals.
6.3.7. Crusher lubrication
1. Check crusher lubrication oil level (A). C
2. Clean around cap (B) before opening to

prevent oil contamination.
3. If crusher lubrication oil is required, remove
cap (B) and top up as necessary, refer to
section 6.4. Lubricants and fluids.
4. Install and tighten cap (B).
5. Replace the tank air vent (C) and change
the lubrication oil at the correct service
interval, refer to 6.2. Scheduled
A
SAN00025

QH440-en-050112
6.3.8. Clutch lubrication tank
1. Check clutch lubrication oil level (A).

C
2. Clean around cap (B) before opening, to
prevent oil contamination. B
3. If clutch lubrication oil is required, remove

cap (B) and top up as necessary, refer to
section 6.4. Lubricants and fluids.
4. Install and tighten filler cap (B).
5. Clean area around the air vent (C) and
check the condition of the breather.
6. Replace the tank air vent (C) and change
the lubrication oil at the correct service
interval, refer to 6.2. Scheduled A
6.3.9. Engine air cleaner - servicing
A fault message will display on control screen if there is an air filter blockage.
Note: When the engine is operated in environments that are dusty or dirty, the air cleaner
elements may require more frequent servicing than that stated in the maintenance
schedules
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.

QH440-en-050112
.
1. Locate the air cleaner, see Figure 6-1:

Engine/hydraulic compartment
locations.
2. Release the four clips (A) that attach the air
cleaner cover (B).
3. Remove the air cleaner cover.
4. Replace the primary air filter (C).

5. To gain access to the secondary air filter,
(not shown), the primary air filter must be
removed.
6. Replace the secondary air filter.
7. Install the air cleaner cover.
8. If an air filter blockage message is shown

on the control screen, it will be necessary to
press the reset button.
6.3.10. Hydraulic filters and tank air vent

QH440-en-050112
Below is shown the hydraulic filter locations on the machine. Refer to 11. Spare Parts, for servicing
kits and filter elements.
Filters
1. Hydraulic filters in the tank are shown. 3
2. Suction filters (x2)

3. Return filter element (x3) 6
4. Dispose of old filters correctly, to comply

with local and national regulations.
Tank air vent
5. Raise cover plate and inspect service

indicator / tank air vent if it has turned red
replace.
Note: If optional oil cooler is fitted, it
must be in the raised position &
cover plate removed to access the
air vent.
6. Remove the cap of the air vent.
7. Install new air vent filter element
8. Install the air vent cap.
2
6.3.11. Crushing chamber - inspect
starting this maintenance procedure..
Note: Inspection of the crushing

chamber must be carried out
regularly and records kept of the
results. This gives the operator an
indication of uneven and or oval
wear over time.
1. Inspect crushing chamber upper groove
area in four opposing points, for excessive
wear and or damage.
2. Inspect crushing chamber lower groove
area in four opposing points, for excessive 1
wear and or damage.
2
For further information also refer to section
10.1.4. Sandvik CH440 cone crusher. SAN00022

QH440-en-050112
6.3.12. Crusher belt drive tensioner - Inspect/adjust
1. Open the drive guard.

2. Visually Inspect for the following:
• Condition of the v-belt.
• Any slippage on the pulleys.
• V-belt tracking off the pulleys.
3. If required, take up any slack in the v-belt, slacken the lock nuts then increase the length of the
turnbuckle.
4. Lock the turnbuckle in position by tightening the lock nuts.
5. Close the drive guard.
6.3.13. Bearings - grease
Note: Many bearings are sealed-for-life which reduces maintenance time and cost. Only
apply grease where indicated.
Updated image required

B
A
C
Figure 6-4: Grease points
A. Main conveyor grease points (both sides).
B. Drive jockey bearing grease point.
C. Feeder conveyor bearing grease point (on feeder conveyor side only, opposite to side shown).

QH440-en-050112
1. Inject the correct amount of grease into

each grease point (A). Refer to 6.4. A
Lubricants and fluids for the quantity and
recommended grease type.
2. Repeat for each grease point location listed
at Figure 6-4: Grease points.
6.3.14. Belt scraper - adjust
FALLING HAZARD
When working at height use a maintenance platform, with handrails
and ladders fixed in place. Ensure a safety harness is used.
1. At the top of the main conveyor assembly,

slacken the bolts (A) on both sides of the
belt scraper (B).
2. Adjust the belt scraper position and tighten
the bolts.

QH440-en-050112
6.3.15. Tracks - inspect
1. Carry out a visual inspection of the track

and tracking components on both sides of
the machine for any signs damage or wear, A
pay particular attention to the following:
2. Complete track pad assembly (A) - Check
and tighten pad bolts if necessary
3. Gearbox and motion control (B) - Check for E
any signs of oil leakage.
4. Sprockets (C) - Check sprocket bolts and
D
tighten if necessary. C
5. Rollers (D) - Tighten if necessary. SAN00018 B
6. Idler and tensioner (E).
Note: In order to inspect all of the tracks it will be necessary to inspect the visible upper
section then move the machine to inspect the remainder. Refer to 4.7. Tracking
(moving) procedure.
6.3.16. Track tension - check
B
SAN00019
1. Move the machine, refer to 4.7. Tracking (moving) procedure, a short distance forward and
backward on level ground to allow tracks to adopt their natural tension.
2. Stop the machine, refer to 4.10. Shut down the machine.
3. Measure dimension A, the droop (C) of the track using a long straight edge (B). Droop should not
exceed 30mm (1.2in).

QH440-en-050112
6.3.17. Track tension - increase
NOTICE DO NOT over tension the track as this places excessive loads on the
gearbox and idler bearings, which will lead to accelerated wear and
premature failures.
C
1. Track adjustment operates through a
tensioning system.
B
2. Grease nipple (A) is filled with grease.
3. It enters a valve arrangement (B) which D
extends. A
4. This pushes the spring tension unit (C) and

moves the idler (D), forward, increasing the
track tension.
5. Remove inspection cover (E) on side of

track frame.
6. Ensure grease nipple is secure.
7. Attach grease gun connector (F), to the
grease nipple.
8. Pump grease into tensioning system until
track droop is correct.
9. Recheck track tension, Refer to 6.3.16.
Track tension - check.
10. Add additional grease if required and
repeat.
11. Clean off any escaped grease, and install
E F
inspection cover (E).

QH440-en-050112
6.3.18. Track tension - reduce
WARNING
PERSONNEL HAZARD!
Grease under high pressure, could penetrate the skin causing
NEVER unscrew a grease nipple by more than half a turn, when
track is under tension.
1. Remove inspection cover (A) on side of

track frame.
2. Slacken grease nipple (B), half a turn,
anticlockwise.
Note: If track fails to loosen, apply a little
pressure to the idler end of the
tensioner system.
3. Grease will escape slowly from track
tensioning cylinder / grease nipple and track
tension will reduce.
4. Tighten grease nipple (B).
5. Recheck track tension, Refer to 6.3.16.
Track tension - check.
6. Remove additional grease if required and A B
repeat.
7. Clean off any escaped grease and install
inspection cover (A).
6.3.19. Crusher liners - replace
To replace the crusher liners, refer to 10.1.4. Sandvik CH440 cone crusher.
6.3.20. New crusher liners - Reset datum
1. When the crusher liners have been replaced the datum position between the mantle and the
concave ring requires to be reset so that the wear rate can be monitored. This datum is also
required to ensure that the correct gap, Closed Side Setting (CSS), dimension can be provided
by the system.
2. Push button 1 on the main screen P0000 to 2

select plant crushing operation mode.

QH440-en-050112
3. Press the right arrow button to scroll

through four screens until P4003 screen is
reached.
3
4. Cone information and calibration screen

P4003
5
5. Push button 6 to reset crusher liners datum.
6. A security page appears. To activate the

reset datum operation, use the numbered
buttons at the side of the display to enter the
same 4 digit security code obtained to
access the maintenance screens. Refer to
section 6.5.1. Maintenance screens.
5

QH440-en-050112
6.4. Lubricants and fluids
NOTICE RISK OF EQUIPMENT DAMAGE.

Only use lubricants, fluids, filters and parts recommended by the
Original Equipment Manufacturer (OEM) otherwise accelerated wear
or damage could result.
Never use grease containing Molybdenum. This may cause damage
to the machine components and will invalidate the warranty.
Make sure that oils and fluids are cleaned and disposed of correctly in
a way that meets the local and national environmental regulations.
Lubricants and fluids used in manufacture:
Maximum Ambient Supplier Sandvik

Lubricant/Fluid Viscosity
volume temperature specification Part No
Univar Caflon HDA
35 litres antifreeze
Engine coolant - CN7999
(9-¼ US gal) (Also refer to engine
manual)
Cone lubrication 250 litres Shell Omala S4
CN6155
oil (66 US gal) GX150
Diesel fuel 900 litres Shell agricultural gas
- CN6004
Low sulphur (238 US gal) oil
Engine Oil Normal 15W-40 Shell Rimula R4T L CN7898
(Also refer to 40 litres
engine manual (10.6 US gal) Down to Shell Rimula R6
5W-30 CN7998
for alternatives -30°C (-22°F) LME
-25 to 25°C
Shell Spirax S3 TLV CN8000
Clutch 80 litres (-13 to 77°F)
lubrication oil (21 US gal) -35 to 15°C CAT TDTO cold
0W-20 CN8003
(-31 to 59°F) weather
Normal ISO VG 46 Shell Tellus S2 V46 CN6074
825.015
Hydraulic 900 litres -20°C (-4°F) ISO VG 32 Shell Tellus S2 V32
6-00
system (238 US gal)
Shell Tellus S4 VX
-30°C (-22°F) CN5700
32
General grease
lubrication Shell Gadus S3
As required CN6073
points and track V220C 2
tension
Torque arm Exxon Unirex N 3
As required CN6012
bearings grease (LGHQ3)
5 litres Exol Ethena EP90
Track gearbox CN6100
(1.3 US gal) gear oil

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Alternative lubricants and fluids:
Lubricant/Fluid Ambient temperature Viscosity Supplier specification

Mobilfluid 424
-10 to +50°C
Clutch Shell Spirax S4 TXM
(14 to 122°F)
lubrication oil 20W-30 Vermeer VMF Gold
-25 to +25°C (-13 to 77°F) 10W-20 or 75W-80 Mobilfluid LT
Note: * Please contact Sandvik Screen & Crushers Ltd. Technical Department before
using this oil.
A list of substances hazardous to health associated with this equipment can be found in 10.1.5. Data
documents - Hazardous substances.

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6.5. Maintenance screens and machine fault codes
The following maintenance screens describe the ‘Tech’ mode. This allows each function of the
machine to be operated independently of other functions. The functions can only be accessed after
a security code is entered.
6.5.1. Maintenance screens
1. Push button 6 on the main screen to access 1

the maintenance screen.
2. A security page appears. To gain access to 2 3

the maintenance screens, a 4 digit security
code supplied by Sandvik is to be entered.
3. To obtain the 4 digit security code, contact
Sandvik quoting the reference number (A)
on screen.
4. Enter the 4 digit security code, using the
numbered buttons at the sides of the display
screen.
5. Push the OK button.
6. When the correct code is entered, access is
granted. If the incorrect code is entered,
access is denied for 60 seconds before 5
another attempt can be made.
7. Once the maintenance screen is activated
by the security code, the warning siren and
flashing beacon operates..
Note: The warning siren and flashing beacon become active and there is a 10 second
delay before any function can be operated.
8. Maintenance screen 1 is displayed > Refer to Figure 6-5: Maintenance screen 1

QH440-en-050112
C D E F
Figure 6-5: Maintenance screen 1
Key:
A. Lubrication pump on/off B. Lubrication oil heater on/off

C. Esc - return to main screen D. Scroll forward to next screen
E. Engine speed decrease F. Engine speed increase
G. Auxiliary functions H. Individual function status on/off (green/red)
Note: The function status indicator (H) will be lit red if the function is inactive (off) or green
if the function is active (on).

QH440-en-050112
A
J
C
H
G
F
I K D B
Key:
A. Main output conveyor on/off B. Engine speed increase

C. Enable clutch D. Engine speed decrease
E. Open, Hydroset lower (increase CSS) F. Feed conveyor speed decrease
G. Close, Hydroset raise (reduce CSS) H. Feed conveyor speed increase
I. Scroll back to previous screen J. Feed conveyor on/off
K. Scroll forward to next screen L. Individual function status on/off (green/red)
Note: The function status indicator (L) will be lit red if the function is inactive (off) or green

QH440-en-050112
A E
B
F
C
G
D I
Key:.
A. Beacon on/off B. Siren on/off

C. Lubrication oil cooler on/off D. Scroll back to previous screen
E. Parameter list F. Air blower control on/off
G. Main hydraulic oil cooler on/off H. Individual function status on/off (green/red)
I. Scroll forward to next screen
Note: The function status indicator (9) will be lit red if the function is inactive (off) or green

QH440-en-050112
A
E
D G F
Key:.
A. Reset stored faults B. Reset default parameters

C. Reset service D. Scroll back to previous screen
E. Fan speed activate F. Fan speed increase
G. Fan speed decrease H. Individual function status on/off (green/red)
Note: The function status indicator (H) will be lit red if the function is inactive (off) or green
6.5.2. Machine fault codes
When the system detects a fault, a message is displayed on screen. Each fault is identified by a fault
number and a fault description.
There are three categories of faults:
• Red faults - stop the machine
• Blue faults - stop the feeder
• Engine faults.

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Red
fault Red fault
No
1. Machine stops
2. Radio stop pressed
3. Low hydraulic oil level
4. High hydraulic oil temperature
5. CSS below safe operating position
6. Lubrication oil flow low
7. Lubrication oil temperature high
8. CSS position sensor fault
9. Engine speed low feeder unavailable
10. Counter shaft lubrication oil pressure low
11. Fuel low level warning
12. Crusher slippage warning
13. Main conveyor speed critical
14. Fines conveyor speed critical
15. Re-circulation conveyor speed critical (if fitted)
16. Transfer conveyor pressure critical (if fitted)
17. Lubrication flow critical
18. Lubrication oil level low
19. Controller unit 2 unavailable
20. Lubrication oil temperature low
21. Cone position sensor input too low
22. Cone position sensor input too high
23. Clutch oil level low
24. Clutch fault
25. Cone lubrication temperature sensor fault
26. Hydraulic oil temperature sensor unavailable
27. Lubrication filter blockage
28. Hydroset below operating position
29. Unable to disengaging clutch
30. Clutch pressure low

QH440-en-050112
Red
fault Red fault
No
31. Crusher slippage critical
32. Manual handset stop pressed
33. Cone shaft position below minimum operating limits
34. CSS below operating limits
Blue
fault Blue fault
No
1. Stock conveyor speed low
2. Radio track joy stick fault
3. Radio unavailable
4. Hydraulic oil temperature warning
5. Lubrication oil temperature warning
6. Unable to lower shaft
7. Unable to raise shaft
8. Manual track handset fault
9. Unable to achieve css position
10. Lubrication tank temperature low
11. Sensor input signal too high
12. Sensor input signal too low
13. Main conveyor pull stop
14. Fault number list
15. Left track valve fault
16. Right track valve fault
17. Feed conveyor valve fault
18. Metal detected in feed conveyor
19. Node 3 unavailable
20. Unable to calibrate lower position
21. Unit 3 sensor supply unavailable
22. Unable to recover position
23. Fault number

QH440-en-050112
Blue
fault Blue fault
No
24. Hydraulic temperature sensor unviable
25. Transfer conveyor pressure sensor unviable
26. Hydroset pressure sensor unviable
27. Position sensor unviable
28. Lubrication tank temperature sensor unavailable
29. Lubrication return temperature sensor
30. Unavailable
31. CSS lower output unavailable
32. CSS raise output unavailable
33. Lubrication pump output unavailable
34. Hydraulic oil cooler output unavailable
35. Main conveyor output unavailable
36. Lubrication oil cooler output unavailable
37. Hydraulic oil temperature sensor unavailable
38. Waiting for lubrication flow
39. High engine load
40. Manual track off line
41. Over pressure fan switch undetected
42. Unable to set engine speed
Engine
fault Engine fault
No
1. Fuel temperature
2. Fuel rate
3. Retarder solenoid current
4. Ether injection control solenoid
5. 8 volt dc supply
6. 5 volt sensor dc power supply
7. Engine oil pressure
8. Boost pressure sensor

QH440-en-050112
Engine
fault Engine fault
No
9. Atmospheric pressure
10. Engine coolant temperature
11. Throttle position
12. Engine speed
13. Secondary engine speed
14. Fuel pressure
15. Intake manifold air temp
16. Injector actuation pressure
17. Engine timing
18. Air inlet heater relay
19. System voltage
20. Check programmable parameters
21. J1939 data link
22. Communications
23. Engine coolant level
24. Inlet air temperature
25. Fuel temperature
26. Auxiliary temperature
27. Auxiliary temperature sensor
28. High auxiliary pressure
29. Auxiliary pressure sensor
30. Cylinder injector 1

QH440-en-050112
6.6. Diagnostic screens
Push and hold the OK button (F) to access the

diagnostic main screen.
The following diagnostic information is available:.
A D
B
E
Figure 6-9: Diagnostic main screen
Key:.
A. Outputs from control B. Speed of Crusher, engine and main conveyor

C. Tracks D. Inputs to control
E. Clutch F. OK (home)
To return to the main screen, push the OK button.

Push the numbered button for the required diagnostic information.

QH440-en-050112
6.6.1. Outputs diagnostic screens
1. There are four screens detailing output

diagnostic information.
2. To navigate through each screen press the
right arrow button for the next screen.
3. Press left arrow for the previous screen.
4. Press the ESC button to return to the
4 3 2
6.6.2. Speeds diagnostic screen
1. The speeds shown on the diagnostic screen

are for the following:
• Main conveyor speed (m/min.).
• Clutch speed (RPM).
• Crusher speed (RPM).
6.6.3. Tracks diagnostic screen
1. TBD ??

QH440-en-050112
6.6.4. Inputs diagnostic screens
1. There are four screens detailing input

diagnostic information.
2. To navigate through each screen press the
right arrow button for the next screen.
3. Press left arrow for the previous screen.
4 3 2
6.6.5. Clutch diagnostic screen

6.6.6. Clutch diagnostic codes
The following clutch diagnostic codes are displayed on the clutch diagnostic screen:
Fault
SPN FMI Clutch diagnostic description
No
1. 521500 4 Low voltage at clutch controller
2. 521501 5 Machine ignition voltage missing at clutch controller
3. 521502 11 Input speed missing
4. 521503 4 Pressure transducer fault
5. 521503 3 Pressure transducer fault
6. 521504 18 Clutch oil pressure fault
7. 521505 18 Clutch oil pressure fault while engaged
8. 521506 16 Clutch oil temperature fault
9. 521507 16 Clutch oil temperature fault while engaged

QH440-en-050112
Fault
SPN FMI Clutch diagnostic description
No
10. 521508 16 Clutch oil filter clog
11. 521509 16 Clutch oil filter clog while engaged
12. 521510 5 PWM coil fault
13. 521510 6 PWM coil fault
14. 521511 5 ON/OFF coil fault
15. 521511 6 ON/OFF coil fault
16. 521512 5 Equipment safety fault while disengaged
17. 521513 5 Equipment safety fault while engaged
18. 521514 16 Engagement prevented because of engine speed
19. 521515 18 Engine stalled while attempting engagement
20. 521516 16 Disengagement prevented because of engine speed
21. 521517 1 Clutch shock load with lockout
22. 521518 0 Clutch overload
23. 521519 0 Clutch overload with lockout
24. 521520 11 Clutch in lockout - due to other reason

QH440-en-050112
7. Trouble shooting guide

QH440-en-050112
OPERATOR’S MANUAL - TROUBLE SHOOTING GUIDE qh440
7.1. Common problems
The section that follows lists some of the common problems that can occur with the machine. If any
of these occur, carry out the checks listed:
7.1.1. Machine faults displayed on screen
This section is under construction, if assistance is required please contact your nearest Sandvik
dealer.

QH440-en-050112
qh440 MAINTENANCE MANUAL
8. Engine

QH440-en-050112
MAINTENANCE MANUAL - ENGINE qh440
8.1. Engine manual
The engine manufacturer supplies a manual which should refered to for further information on the
engine fitted to the machine.

QH440-en-050112
QH440-en-250811
Maintenance Manual
qh440
Machines with Caterpillar Tier 3A engine
QH440-en-050112
qh440

Tel: +44 (0) 1283 212121, Fax: +44 (0) 1283 217342
www.sandvik.com
QH440-en-050112
9. Electrical & Hydraulic Information

QH440-en-050112
MAINTENANCE MANUAL
ELECTRICAL & HYDRAULIC INFORMATION (TIER 3A ENGINE) qh440
9.1. Electrical Diagrams
9.1.1. Electrical Page 1

QH440-en-050112
MAINTENANCE MANUAL
qh440 ELECTRICAL & HYDRAULIC INFORMATION (TIER 3A ENGINE)
FootCR:-----Copyright © Sandvik Mining and Construction 153

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL
Gateway/Data Logger
GW3000

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL
Gateway/Data Logger
GW3000

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL
9.1.17. Electrical Page 17 (tier 4)

QH440-en-050112
MAINTENANCE MANUAL

QH440-en-050112
MAINTENANCE MANUAL
A102B
MC88
A102A RADIO
7XA
K6 K10
K7 K8 K9 K12 K13
K1 K11 K2 K3 K4 T1 1X1 K14
LAYOUT OF PANEL LID
A101
1S1 JDP 3S1 2S1 4S1

QH440-en-050112
MAINTENANCE MANUAL
X10B
X47A
X10A
LAYOUT OF PANEL SIDES
X31B
Handset
GX1
X23A
X31A
X40A
HCP
MAX
20A

QH440-en-050112
MAINTENANCE MANUAL
PL10
PL09
PL11
PL07
PL08
PL04
PL05
PL06
PL01
PL02
PL03

QH440-en-050112
MAINTENANCE MANUAL
9.2. Hydraulic Diagram

QH440-en-050112

QH440-en-050112
10. O.E.M. Product Documents

QH440-en-050112
MAINTENANCE MANUAL - O.E.M. AND DATA DOCUMENTS qh440
10.1. Documents - original equipment manufacturer and data
Please ensure you read this section carefully. It contains information supplied by original equipment
manufactures of components and hazardous stubstances used in the machine, therefore Sandvik
has reservations for misprints.
10.1.1. Tracks - Strickland
10.1.2. Hydraulic power take-off (clutch) - PT Tech (HPTO14)
10.1.3. Engine (manual supplied separately).
10.1.4. Sandvik CH440 cone crusher
• Operator’s Manual
• Maintenance Manual
• Wear Parts
• Spare Parts.
10.1.5. Data documents - Hazardous substances
• Univar Caflon HDA antifreeze concentrate

• Shell Omala Oil S4 GX 150
• Diesel - ultra low sulphur CAT-CN7834
• Shell Agricultural Gas Oil (Diesel fuel)
• Shell Rimula R4 TL
• Shell Rimula R6 LME
• Shell Spirax S3 TLV
• Cat TDTO cold weather 0W-20
• Shell Tellus S2 V46
• Shell Tellus S2 V32
• Shell Tellus S4 VX 32
• AeroShell grease 33
• Shell Gadus S3 V220C 2 grease
• Exxon Mobil Unirex N3
• Exol Athena EP90
• Mobilfluid 424
• Shell Spirax S4 TXM
• Mobilfluid LT

QH440-en-050112
QH440-en-050112
Parts Manual
qh440
Issue 1
QH440-en-050112

QH440-en-050112
qh440 PARTS MANUAL
11. Spare Parts

QH440-en-050112
qh440

Tel: +44 (0) 1283 212121, Fax: +44 (0) 1283 217342
www.sandvik.com
QH440-en-050112
qh440 INTRODUCTION
11.1. Introduction
11.1.1. Ordering procedure
The following illustrations indicate spare parts available for order, identify relevant part/s and provide the
following detail during the ordering process.
This ensures correct delivery of replacement parts with a minimum delay:
• Machine, model and serial number.
• Year of manufacture.
• Part number identified from the parts list.
• Part description identified from the parts list.
• Issue reference of manual, iIllustration title and page number.
• Quantity required.
11.1.2. Safety decals
For location and part numbers. refer to Safety section: 1.13. Safety decals - Locations.

QH440-en-050112
QH440 OVERVIEW
MAIN ASSEMBLIES qh440
11.2. Main assemblies
QH440 OVERVIEW
6
2
10
7
4
12
8
5
1
3

QH440-en-050112
qh440 QH440 OVERVIEW
MAIN ASSEMBLIES
item part no. qty description Remarks

1 1 chassis assembly See CA0131
2 1 tank tower frame See CA0130
3 1 feeder conveyor See CC0038

4 1 drive tensioner See CB0070
5 1 control cabinet assembly See CA0109
6 1 main conveyor assy SeeCD0063

7 1 drive guard See CJ0080
8 1 cone and adaptor ring assembly See CJ0079
9 1 walkway assembly See CA0137
10 1 lubrication tank - clutcht See CB0132
11 1 lubrication tank - cone See CJ0081
12 QH4403ALRCWO 1 tier 3a lrc powerpack assembly
12a QH4403BWO 1 teir 3b powerpack assembly *option

QH440-en-050112
QH440 OVERVIEW
OPTIONS qh440
11.3. Options
Item Part no. Qty Description Remarks
1 overband magnet assembly See CA0144
1 water pump assembly See CA0143
1 fuel pump kit See CB0162
1 autolube assembly See CB0078
1 arctic package -20°C -4°F See CB0164

1 arctic package -30°C -22°F See CB0165
CB0164 Low ambient -20°C (-4°F)
item part no qty description remarks
825.0156-00 Tellus T32 hydraulic oil hydraulic
A24150000 3 oil cooler baffle - arctic option
CN7998 Shell rimula R6 LME 5W-30 engine
CN6155 Shell omala HD 150 cone
CN8000 Shell spirax S3 TLV clutch

CN7999 Univar caflon HDA antifreeze coolant
CN6073 Shell albida ep2 grease
CN6004 red diesel (low sulphur) fuel
CB0165 Low ambient -30°C (-22°F)
item part no. qty description remarks
CB0174 1 Webasto water heater kit
CN5700 hydraulic oil HM32 (artic) [ Tellus oil 32 ] hydraulic

CN6155 Shell Omala HD150 cone
CN8003 Cat arctic TDTO clutch oil clutch
CN7998 Shell rimula R6 LME 5W-30 engine
CN7999 Univar Caflon HDA antifreeze coolant
CN6073 Shell Albida ep2 grease
CN6004 red diesel (low sulphur) fuel
A24150000 3 oil cooler baffle - arctic option

QH440-en-050112

QH440-en-050112
CA0131
CHASSIS ASSEMBLY qh440
11.4. Chassis assembly
CA0131
28
27
11
9
19
5
5
46
22
37
29
49
42
6
4
21
43
41
1
17
36
25
16
38
10
30
3
18
8
24
2
12
38
40
13
7
14
35

QH440-en-050112
qh440 CA0131
CHASSIS ASSEMBLY

1 10-16-4670 1 divertor valve
2 A14460000 2 rear jacking leg cover
3 A20130000 2 rear chassis slider assy

4 A22570000 1 feeder unit pivot arm
5 A22920000 1 welded chassis assembly
6 A22950000 1 feeder pivot beam

7 A22960000 1 feeder slide ram rear beam
8 A22980000 1 feeder slide beam
9 A23030000 1 power pack support assy
10 A23040000 1 power pack support assy
11 A23100000 1 turnbuckle mouting bracket
12 A23110000 2 feeder slide tele leg inner
13 A23120000 2 feeder slide tele leg outer
14 A23150000 1 lubrication coller mtg plate
16 A23710000 1 lubrication assy cover plate

17 A23720000 1 lubrication assy cover mtg angle
18 A24140000 1 oil cooler cover
19 A24460000 1 1488mm unistrut cable tray cut from a2445

20 A24480000 1 2550mm length cut from 3m unistrut cable tray a24450000
21 A27300000 1 rear cable tray
22 B15730000 1 rear case drain return manifold

23 B15780000 1 rear return manifold
24 4 jacking leg assembly See CA0005
25 1 track and mounting frame See CA0075
27 EL9686 4 led working lamp 12/24v
28 EL9789 4 steel cased e stop
29 EL9843 1 control panel (mc24)
30 EX5015 1 asa0367 ah11 oil cooler
31 HA99000022 3 spray nozzle, complete assembly
35 HR1025 2 double acting ram 1250 closed ctrs, 1072 stroke
36 HV8062 1 3/8 bsp pilot operated check valve
37 HV8599 1 1.3mm orifice adaptor assembly
38 HV8601 2 1/4" bsp double p.o check valve lcp-dns-g014-fp
39 J10470000 1 spraybar
40 PN1154 2 midgrade lock out pin
41 PN1155 2 feeder roller pin
42 PN1227 4 feeder pivot pin
43 PY1037 2 rear chassis slider detail
46 A25010000 2 pipe clamp extension
47 HHK0111 1 chassis hose kit

48 HV8581 1 lubrication system relief
49 A26410000 2 lubrication tank side guards

QH440-en-050112
CA0130
TANK TOWER FRAME qh440
11.5. Tank tower frame
CA0130
22
18 10 6
21
16
25
10 3
15 1
23
5
8 24 19
17
13
2 11 12
20
14

QH440-en-050112
qh440 CA0130
TANK TOWER FRAME

1 14-04-1146 2 siren
2 A21590000 1 support bracket l.h.
3 A22100000 2 conveyor support arm assy tier iv

4 A22580000 1 tank tower frame
5 A22650000 1 walkway central railing
6 A22670000 1 magnet arm front cross beam

7 A22680000 1 tank base pad
8 A22690000 1 base pad (diesel tank)
9 A22700000 1 base pad (hydraulic tank)
10 A22710000 2 magnet support frame (drive side)
11 A22720000 1 maintenance platform
12 A22730000 1 hose cover plate
13 A22740000 1 gate
14 A22750000 1 support bracket r.h.
15 A22760000 1 tank base pad

16 A23130000 1 conveyor cross member assy tier iv
17 A24580000 1 maintenance platform
18 B15580000 1 flashing beacon mounting bracket r.h.s.

19 B15590000 1 flashing beacon mounting bracket l.h.s.
20 1 ladder (8 rung) See CA0168
21 1 tier iv hydraulic tank assembly See CB0128

22 1 tier iv diesel tank assembly See CB0129
23 EL9764 2 beacon
24 EL9787 1 emergency stop control box
25 PN1228 4 feeder pivot pin

QH440-en-050112
CA0168
LADDER (8 RUNG) qh440
11.6. Ladder (8 rung)
CA0168
5
7
1
3

QH440-en-050112
qh440 CA0168
LADDER (8 RUNG)
1 A21440000 1 platform access chassis ladder support bracket
2 A24670000 1 access ladder support arm
3 A24740000 1 ladder support- box section

4 A24690000 1 access ladder lower section
5 A24700000 1 access ladder - 4 rung top section
6 PN1233 2 ladder pivot locking pin
7 FAHC1023 2 4mm r-clip x 80mm
Some pins and fasteners missing from assembly?

QH440-en-050112
CB0129
DIESEL FUEL TANK ASSEMBLY qh440
11.7. Diesel fuel tank assembly
CB0129
3 6
1
8
10
9 9

QH440-en-050112
qh440 CB0129
DIESEL FUEL TANK ASSEMBLY

1 10-12-0012 1 3/4" dowty seal mbds 112v
2 10-22-4006 1 tank air breather (o-sa075g2l03a)
3 10-22-4010 1 dieseltank cap

4 10-22-4012 1 tank sieve
5 10-23-5008 2 level gauge 10" (254 ctr)
6 14-05-0149 1 fuel level sensor

7 B15030000 1 diesel tank assy
8 B15040000 1 tier iv diesel tank top cover assy
9 B15050000 2 tier iv diesel tank access cover gasket
10 B15060000 1 diesel tank assy detail

QH440-en-050112
CB0128
HYDRAULIC TANK ASSEMBLY qh440
11.8. Hydraulic tank assembly
CB0128
6
5 7
2
3
15
19
13 18
16 17

QH440-en-050112
qh440 CB0128
HYDRAULIC TANK ASSEMBLY

1 B14990000 1 hydraulic tank assy
2 B15010000 1 hydraulic tank assy detail
3 B15020000 1 hydraulic tank assy detail

4 10-21-0030 3 return filter mpf1842ag1a10hbt
5 10-21-0031 3 return filter element
6 10-12-0020 3 1 1/4" dowty seal mbds 120v

7 10-01-1128 3 1 1/4" adaptor m/m
9 10-12-0012 1 3/4" dowty seal mbds 112v
13 10-23-5028 1 low level sensor guage
15 10-21-0007 2 2 1/2" suction filter 90 micron
16 10-12-0016 1 1 " dowty seal
17 10-09-0022 1 plug
18 HV8577 2 2" bsp low pressure ball valve
19 10-51-0350 2 hydraulic tank access cover c/w gasket

QH440-en-050112
CB0123
POWER PACK ASSEMBLY qh440
11.9. Power pack assembly
CB0123
34
15
32
26
31
14
45
16
47
53
25 46
5
23 17
1
19
36
24
35 33
6
22
38 4 32
39 3
7
37 31 8 9 10 11 12

QH440-en-050112
qh440 CB0123
POWER PACK ASSEMBLY

1 10-21-0320 2 sauer danfoss (fhp320-2 ba g2 a25 n e7) - for 130b
3 B12310000 1 cat c13 tier 4 engine support
4 B12360000 1 battery holder to suit el9716 12v hd batteries

5 B12370000 1 battery clamp to suit el9716 12v hd batteries
6 B14050000 1 tier iv c13 air filter shroud
7 B14540000 1 c13 tier 4 clutch brace

8 B14550000 2 c13 tier 4 clutch brace 8mm spacer
14 B15830000 1 tier 1v flood light base assy
15 B15840000 1 tier 1v flood light mast assy
16 B15850000 1 tier 1v flood light transport brkt assy
17 B15880000 1 mounting bracket(fuse b0x)

19 B16000000 1 tier 4 proportional valve mtg brkt
22 B16520000 1 tier iv pp bulkhead blanking plt
23 B16820000 1 external double filter brkt

24 B16870000 1 external filter shroud assy rear
25 B16880000 1 external filter shroud front
26 B16920000 1 powerpack handrail

31 1 end covers assembly See CB0086
32 1 base frame, top and side covers assembly See CB0093
33 1 clutch drive powerpack sealing rubber kit See CB0184
34 EL9686 2 led working lamp 12/24v durite pt no 0-420-70
35 EL9716 2 12 volt heavy duty 725 battery
36 EL9862 1 qh440 cat 3a control system
37 EN9621 1 psd 12 air cleaner assembly long horizontal (blue media)
38 EN9623 1 90 elbow / adaptor (38mm outlet)
39 EN9624 1 in line check valve (38mm/50mm)
42 EN9922 2 o' ring i/d ø127mm, 3mm dia material
45 FAN30 1 m30 full nut
46 FD1003 2 800n gas strut
47 FD1505 4 gas strut fork end
49 HHK0093 1 qh440 power pack hose kit
53 HV8589 1 sauer danfoss proportional fan control hic, allowing reverse flow

QH440-en-050112
CB0123
POWER PACK ASSEMBLY qh440
27
40
18
41
52
28
21
51
29
20
50
13
41
48
29
30
43
44

QH440-en-050112
qh440 CB0123
POWER PACK ASSEMBLY
ref. part no. qty. description remarks

2 10-24-1131 2 sauer danfoss load sensing series 45 axial pump 130cc
13 B14620000 1 bracket assy - tier iv clutch filter
18 B15960000 1 c13 tier 3a turbo cover arrgt

20 B16240000 1 p.t. tech 14" manifold mounting bracket
21 B16440000 1 cat c9 fuel filter bracket
27 B17130000 1 c13-3a belt guard

28 B17170000 1 cat c13 tier 3a fuel fitler bracket (prime pump)
29 BT9985 1 pt tech wet clutch - hpto14 flex housing assy
30 BT9986 1 pt tech torsional coupling to suit cat c13
40 EN9754 1 qh440 engine kit c13 3a
41 EN9921 2 ‘o' ring i/d ø82.5mm, 3mm dia material
43 EX7008 1 becool radiator complete
44 EX7014 1 3-tube wire wound oil cooler becc0126380
48 HF9917 1 pt-tech wet clutch filter assembly
50 HP8828 1 19cc anti-clockwise pump

51 HP8860 1 63cc sae b 13 tooth cw pump
52 HP8863 1 tandem pump

QH440-en-050112
CB0086
POWERPACK END COVERS qh440
11.10. Powerpack end covers
CB0086
3
2
15
10
18
11
5
17
16
2
18 19
14
12
7 4
6
13

QH440-en-050112
qh440 CB0086
POWERPACK END COVERS
item part number qty description remarks

1 881.0084-00 1 latch
2 B12420000 1 after-treatment cover
3 B12430000 1 tier iv r/h support frame

4 B12480000 1 tier iv p/p removable panel
5 B12520000 1 tier iv p/p support plt
6 B13920000 1 tier iv c13 pt-tech cover

7 B13950000 1 tier iv c13 pt-tech pulley guard frame
8 B13960000 1 tier iv c13 pt-tech air filter mount
9 B13970000 2 tier iv c13 air filter mounting bracket
10 B14330000 1 after-treatment side door vent assy
11 B15210000 1 tier iv pp after-treatment side door
12 B15770000 1 pt-tech pulley guard
13 B16830000 1 tier iv c13 pt-tech cover (type 2)
14 B17670000 2 powerpack door catch (long)
15 CB0196 2 locking bolt assy (tier 4 power pack doors)

16 FD1005 1 500nm gas strut
17 FD1505 2 gas strut fork end
18 FD2007 2 door handle

19 FD2102 2 hinge

QH440-en-050112
CB0093
POWERPACK BASE, TOP, SIDES qh440
11.11. Powerpack base, top, sides
CB0093
17
12
3
2
5 15
6 4
18
13 1
10

QH440-en-050112
qh440 CB0093
POWERPACK BASE, TOP, SIDES

1 B12460000 1 tier 4 modular power pack base
2 B12510000 1 tier iv radiator cross member
3 B12580000 1 tier iv radiator access door

4 B12600000 2 tier iv support brace
5 B14080000 1 tier iv upper access door
6 B14090000 1 tier iv lower access door

7 B14180000 1 tier iv top door stabilising arm
8 B14190000 1 tier iv stabilising arm guide
9 B14810000 1 tier iv pt tech rad mesh guard
10 B14820000 1 tier iv pt tech rad panel
11 B15180000 1 tier iv core section upper frame
12 B15190000 1 tier iv core section l/h support
13 B15220000 1 tier iv pp lower infill panel
14 B17330000 1 tier iv top door stabilising arm not illustrated
15 B17340000 1 tier iv door catch brkt

17 FD2102 4 hinge
18 FD7048 3 southco door latch - e3-106-195

QH440-en-050112
CB0184
POWERPACK SEALS qh440
11.12. Powerpack seals
CB0184
1 873.1026.6100 1 extruded door seal 6100mm long

2 RU1388_1585 2 extruded door seal 1585mm long
3 RU1388_700 2 extruded door seal 700mm long

QH440-en-050112

QH440-en-050112
CC0038
FEED CONVEYOR qh440
11.13. Feed conveyor
CC0038
16
20
1
57
46
36
44
21
48
17
51
59
13
18
19
10
49
40
43
9
42
45
31
39
28
32
22
29
12
25
3
4
26
14
11
38
53
52
47
60
7
50
28
33
54
37
56
41
23
24
8
6
5
38
27
30

QH440-en-050112
qh440 CC0038
FEED CONVEYOR
Too many items !!
1 BT1004 2 bearing
2 BT2006 2 65mm flange mounted y bearing
3 BT6549 1 gearbox
4 C11880000 1 gearbox end cover
5 C14100000 1 head drum nip guard assy.
6 C14110000 1 nip guard
7 C14640000 1 drum scraper mtg bracket
8 C15820000 1 feeder conveyor frame
9 C15830000 1 feeder hopper d.s side section mtg frame
10 C15840000 2 slide assembly retention bracket
11 C15850000 1 feeder gearbox mounting bracket
12 C15860000 2 feeder pivot bracket
13 C15870000 2 belt tensioner cover plate
14 C15890000 1 feeder hopper n.d.s side section mtg frame
16 C15940000 1 feeder tail drum guard

17 C15950000 1 feeder tail drum guard door
18 C15960000 1 feeder tail section under guard
19 C16040000 1 feeder tail section under guard

20 C16050000 2 feeder tail drum tension arm assy
21 C16120000 1 feeder rear cover plate
22 C16270000 2 feeder side panel access door

23 C16280000 2 feeder side panel rubber clamp plate
24 C16290000 2 feeder end panel rubber clamp plate
25 C16300000 2 feeder end panel access door

26 C16310000 1 feeder end panel extension d.s
27 C16320000 1 feeder end panel extension n.d.s
28 C16450000 2 feeder return roller guard
29 C16480000 1 feeder d.s. side panel
30 C16490000 1 feeder d.s. side panel
31 C16550000 2 metal detector mounting bracket
32 C16560000 2 metal detector clamp plate

33 CBHD120013150 1 feeder belt 1200x13150
36 CR9015 1 paddle drum
37 CR9017-1 1 feeder con. drive drum assembly
38 CR9022 22 impact roller
39 CR9096 2 spiral tracking return roller
40 CR9097 1 tracking roller
41 D4080000 2 rosta se 27 scraper mtg bracket
42 FAB1006 1 m10 u bolt 50mm ctrs 75mm
43 FAB12X120 2 m12x120 bolt
44 FAB16X60T 34 m16 x 60 t-bolt
45 FAN12 4 m12 hex nut
46 FAN30 10 m30 full nut

QH440-en-050112
CC0038
FEED CONVEYOR qh440
48 FD2105 3 hinge 3 + 2 hole
49 FD7052 2 door latch - e3-106-065
50 MA2021 1 metal detector ma3000 24v unit
51 PN1210 2 adjuster bolt
52 PY1048 1 1200 wide head drum scraper blade
53 PY1061 2 low friction impact bar
54 PY1062 4 850lg low friction impact bar

56 RU5501 2 rosta support se27
57 C16860000 1 rear top panel
58 PY1030 4 impact bar 55mm deep x 1500mm long
59 RU1393 2 super red rubber 6000x150x10
60 HHK0096 1 feeder conveyor hose kit

QH440-en-050112

QH440-en-050112
CC0039
FEED HOPPER qh440
11.14. Feed hopper
CC0039
Illustration required

QH440-en-050112
qh440 CC0039
FEED HOPPER

1 C15800000 1 feeder hopper d.s side section
2 C15720000 1 feeder l/h wing extension
3 C15750000 4 feeder wing extension lift link 2

4 C15740000 4 feeder wing extension lift link 1
5 HR2545 2 wing extension lift ram
6 C15730000 1 feeder r/h wing extension

7 C15310000 8 feeder bin side access cover large
8 C15320000 2 feeder bin side access cover small
10 PN1231 2 feeder wing extension lock pin
11 C15880000 1 feeder hopper n.d.s side section
13 C15920000 10 feeder rubber clamp plate
15 C16190000 1 hopper rear door wear plate lower
16 C16200000 1 hopper rear door wear plate upper
17 C16170000 2 hopper side door wear plate lower
18 C16180000 2 hopper side door wear plate upper

19 C16210000 1 catflap assembly
20 C16430000 1 feeder rubber rear clamp plate
22 C15930000 1 feeder spider section

24 C15910000 1 feeder hopper rear upper section dtl
25 C15810000 1 feeder hopper rear section

QH440-en-050112
CD0063
MAIN CONVEYOR - LOWER qh440
11.15. Main conveyor - lower
CD0063
45 28 37 35
33 26
24 43 38
36
42
34 49
41 46 31
27 40
44 25
32
14 3
51
15 1
18
16
19 39
119
20
17 30 50
47 48
5
7
29
2
6
4
11
12
22 8
23 21 10
9 13
1 BT1010 2 bearing plummer sy60tr
2 CR1004 6 30° roller bracket
3 CR9015 1 paddle drum
4 CR9047 10 sandvik t/conv cent roller
5 CR9081 14 sandvik c10 wing impact roller 238mm face
6 CR9085 3 conv disc roller
7 D15160000 1 cone crusher main con base frame.
8 D15230000 1 main conv. transport lift bar
9 D17330100 42 lower bracket
10 D17480000 1 outer flare bottom panel nds
11 D17490000 1 inner flare bottom panel assy nds


QH440-en-050112
qh440 CD0063
MAIN CONVEYOR - LOWER

14 D17520000 1 outer flare bottom panel ds
15 D17530000 1 inner flare bottom panel assy ds

18 D17560000 2 wear plate

21 D17600000 1 inner flare bottom panel support bracket nds
22 D17610000 4 inner flare bracket
23 D17630000 1 inner flare bottom panel support bracket ds
24 D17640000 1 feed boot side assy d.s.
25 D17650000 1 feed boot side assy n.d.s
26 D17660100 1 feed boot back
27 D17670000 1 feed boot front support leg d.s.
28 D17680000 1 feed boot back leg d.s
29 D17690000 1 feed boot front leg n.d.s
30 D17700000 1 feed boot back leg n.d.s

31 D17710000 1 feed boot side wear plate d.s
33 D17730000 1 feed boot side wear plate n.d.s

35 D17750000 1 feed boot back wear plate


43 D17870100 2 feed boot sealing - backing strip
46 D18160000 1 main conveyor side nip guard

47 D18170000 1 main conveyor side nip guard
48 D6770000 1 bearing support - outer slide - r.h.s
49 D6780000 1 bearing support outer slide - l.h.s
50 D6790000 2 bearing support slide
51 PY1042 4 feeder conveyor base impact bar
119 FAB16X60T 20 m16 x 60 t-bolt

120 HHK0097 1 main conveyor hose kit

QH440-en-050112
CD0063
MAIN CONVEYOR UPPER qh440
11.16. Main conveyor upper
99
64
61
62
98
71
96
73
9
53
6
97
89
20
75
74
101
93
88
72
85
67
100
55
87
95
105
72
78
94
103
84
102
54
63
76
80
69
104
77
2
4
60
92
90
87
83
68
66
79
57
59
65
58
91
56
59
86
70
Too many items!

QH440-en-050112
qh440 CD0063
MAIN CONVEYOR UPPER

4 CR9047 10 sandvik t/conv cent roller
6 CR9085 3 conv disc roller

9 D17330100 42 lower bracket
22 D17610000 4 inner flare bracket

52 12-76-0100 28 dust cover tie down
53 14-05-0099 1 conveyor speed wheel
54 A7720000 2 spray bar fixing bracket
55 BT2006 2 65mm flange mounted y bearing
56 BT5030 1 2517/50 taper lock bush
57 BT5011 1 2517/55 taper lock bush
58 BT6516 1 tx180 drive coupling insert
59 BT6517IPT 2 tx180f drive coupling
60 C14640000 1 drum scraper mtg bracket

61 CBHD216001200 1 main conveyor belt
63 CR9016-1 1 main con. drive drum assembly

64 CR9084 4 tracking roller 19ejbctxa7 76mm*180mm
65 D0190000 2 5000 motor bracket top plate
66 D15400000 1 head drum mounting plate

67 D15410000 1 head drum mounting plate
68 D15480000 1 head drum guard plate
69 D15490000 1 head drum nip plate
70 D15940000 1 motor mounting bracket
71 D17290000 1 main con upper frame
72 D17320000 6 main conveyor - wear plate
73 D17360000 1 main conveyor - inner flare mid panel nds
74 D17370000 1 outer flare top panel assy nds
75 D17380000 1 inner flare top panel assy nds
78 D17450000 1 inner flare mid panel assy ds
79 D17460000 1 outer flare top panel assy ds
80 D17470000 1 inner flare top panel assy ds
81 D17590000 1 inner flare mid panel support bracket nds
82 D17620000 1 inner flare mid panel support bracket ds
83 D18130000 1 spray bar mtg angle
84 D18140000 1 spray bar mtg plate
85 D18150000 1 conveyor spray bar mtg angle

86 D18780000 1 sonar mounting bracket arrgt
87 D4080000 2 scraper mtg bracket
88 D5130000 2 adjuster bolt cover plate

QH440-en-050112
CD0063
MAIN CONVEYOR UPPER qh440
89 F2730000 2 re-circ fines conv return roller guard
90 HA 99000010 3 wa035 water nozzle
91 HM1048 1 eaton 6000 motor 624.2cc
92 J10470000 1 spraybar
93 PN1210 2 adjuster bolt
94 PY1048 1 1200 wide head drum scraper blade
95 RU5501 2 rosta support se27
96 D17300000 1 outer flare mid panel nds

97 D17310000 1 inner flare mid panel nds
98 D17340000 1 outer flare mid panel nds
99 D17350000 1 inner flare mid panel nds
100 D17410000 1 outer flare mid panel ds
103 D17440000 1 outer flare mid panel ds
104 D17910100 6 dust cover support
118 EL9724 1 pull cord kit eyelet

120 HHK0097 1 hose kit

QH440-en-050112
qh440 CC0040
FEEDER DRIVE UNIT
11.17. Feeder drive unit

CC0040
5
2
8 4
1
3
1
6
7 9

1 BT3036 2 80 x 50 x 16 bearing
2 C12240000 1 motor adaptor boss
3 C12260000 1 bearing spacer
4 C16330000 1 motor adaptor shaft
5 HM8819 1 medium duty motor c/w parallel shaft and same side porting
6 RU1164 1 nitrile gasket

7 C15790000 1 feeder motor packing plt
8 HM2018 1 key
9 HV5003 1 3/4" 0.5 bar check valve

QH440-en-050112
CA0075
TRACK ASSEMBLY qh440
11.18. Track assembly
CA0075
4
1
1 A18420000 1 mounting frame
2 A13930000 4 track location dowel
3 UC7546-1 1 consolidated track 7: r/h assembly
4 UC7546-2 1 consolidated track 7: l/h assembly

QH440-en-050112
qh440 TRACK PARTS
11.19. Track parts
10
3 9
8
7
6
12
11
13 15
14

1 1 Gearbox and motor kit
2 FDG CAR-DRNPLG 2 Plug - fill & drain Not illustrated
3 1 Sprocket kit
4 6 Lower roller kit
5 1 Idler group kit (Items 6, 7, 8, 9 and 10)
6 1 Idler yolk kit
7 1 Spring kit
8 1 Tensioner kit
9 1 Grease tensioner kit
10 1 Adaptor - grease gun
11 TGT175-54-50OUC7135 1 Track - complete
12 TCA 64054-A 1 Track link assembly
13 1 Track shoe kit
14 1 Repair link kit
15 MPG 640-NS-1254-P 1 Master pin and collar kit
Quantities shown are per track

QH440-en-050112
CA0005
JACKING LEG qh440
11.20. Jacking leg
CA0005
7
1
10
12

QH440-en-050112
qh440 CA0005
JACKING LEG
1 A14180000 1 jacking leg outer
2 HR1069 1 jack leg ram
3 A4110000 1 jacking leg inner

4 FAB30X200 1 hex-head bolt - iso 4017 - m30x200
5 PN1085 1 top pin
6 FAN30N 1 m30 nylock nut
7 CA0004-FA1 14 fastener set
8 FAB10X30 1 m10 x 30 hex-head
9 FAW10NL 1 m10 nordlock washer set
10 PN1088 2 jacking leg locking pin
12 FAHC1022 2 r-clip
Note: Quantities shown are per jacking leg - 4 legs per machine

QH440-en-050112
CA0137
WALKWAY ASSEMBLY qh440
11.21. Walkway assembly
CA0137
33 26
19
18
20
16
17
22
4
28
21
11
29 3
45
31
37
23 41
27
42
14
34
43 32 13
40 5
6
15
10 44
12 9
25
39
7
2 24
35
30
1 36 38 8
1 12-30-0238 1 1" bsp solenoid valve
2 12-30-0239 1 24v dc coil

3 A20740000 1 walkway steps
4 A21100000 1 walkway railing assy

QH440-en-050112
qh440 CA0137
WALKWAY ASSEMBLY

5 A21140000 1 cover plate support assy
6 A22330000 2 n/d/side maintenance platform dtl

7 A23320000 1 walkway side support
8 A23330000 1 ds sideplate
9 A23350000 1 drive side floor plate

10 A23360000 1 maintenance platform cover
11 A23370000 1 railing assy
12 A23380000 1 access platform nds floor plate
13 A23390000 1 drive side cover plate
14 A23400000 1 non-drive side cover plate
15 A23410000 1 walkway assembly detail
16 A23420000 1 walkway assembly detail
17 A23430000 1 walkway railing assy
18 A23440000 1 walkway rail
19 A23450000 1 walkway rail and gate
20 A23460000 1 walkway railing and gate
21 A23470000 1 central railing detl tier iv

22 A23490000 1 platform support
23 A23500000 1 platform mtg brkt
24 A23510000 1 access platform support

25 A23520000 1 access door (platform)
26 A24040000 1 emergency stop bracket
27 A24500000 1 bracket
28 B12010000 1 hydraulic oil cooler top cover
29 B12020000 1 hydraulic oil cooler front cover
30 B15740000 1 front return manifold
31 1 ladder arrangement (7 rung) see CA0169
32 EL9566 1 1ms8-00018 fan-16-24v.dc brushless 85w 3800rpm inlet filter
33 EL9789 1 steel cased emergency stop

34 EX5015 1 asa0367 ah11 oil cooler
35 EX5030 1 gl140-3780-2 oil to water heat exchanger
36 HAC300044 1 35mm double pipe clamp assembly
37 HF9908 1 2 ½" air breather 10 micron (sa185g1l10a)

39 HV8062 1 3/8in bsp pilot operated check valve
40 RU1212 1 fan adaptor - 90 degree elbow reducer (filter - fan)
41 RU1213 1 fan adaptor - straight reducer (fan - cone)
42 10-16-4670 1 divertor valve
43 HV8581 1 lubrication system relief

44 A24750000 1 speed sensor cover
45 A25000000 1 platform

QH440-en-050112
CA0137
LADDER (7 RUNG) qh440
11.22. Ladder (7 rung)
CA0169
1
3

QH440-en-050112
qh440 CA0137
LADDER (7 RUNG)
1 A21440000 1 platform access chassis ladder support bracket
2 A24670000 1 access ladder support arm

3 A24740000 1 ladder support- box section
4 A24690000 1 access ladder lower section
5 A24710000 1 access ladder - 3 rung top section

6 PN1233 2 ladder pivot locking pin
7 FAHC1023 2 4mm r-clip (80mm long)

QH440-en-050112
CJ0079
CONE ASSEMBLY qh440
11.23. Cone assembly
CJ0079
6 4 5
6
20
34
2 12
3
19
14
15
27
23
26
28
1
33
25
16
17
10 11
29
24
22
30
8
7
31
9
18
21
32

QH440-en-050112
qh440 CONE ASSEMBLY

1 XC200 1 ch4400 cone crusher complete
2 J10000000 1 rock box top chute assy
3 J10030000 1 rock box assy

4 J10160000 1 sonar mounting arm
5 J10170000 1 sonar mounting bracket
6 J10180000 1 sonar adjusting plate assy

7 J10310000 1 cone adaptor ring assy
8 J10320000 1 cone adaptor ring wear plate assy
12 J10470000 1 spraybar
13 J10890000 8 adaptor ring tapered washer
14 J10910000 2 30mm encoder ring
15 J10920000 1 30mm speed sensor mounting bracket

16 J9220000 1 lube drain pipe 90 elbow
17 J9490000 1 cone sensor cover
18 J9890000 4 antivibration mount mounting plate

19 J9920000 2 hopper wearplate
20 A7720000 2 spray bar fixing bracket
21 RU1295 4 trelleborg antivibration mount saw200b

22 RU1389 1 rear hanging rubber
23 RU1390 1 front hanging rubber
24 RU1391 1 nds hanging rubber
25 RU1392 1 ds hanging rubber
26 BT9932 1 spc 380 - 10 belt pulley
27 CJ0083 1 course chamber kit option
28 CJ0084 1 medium course chamber kit option
29 CJ0085 1 medium chamber kit option
30 CJ0086 1 medium fine chamber kit option
31 CJ0087 1 fine chamber kit option
32 CJ0101 1 extra course chamber kit option
33 EL9542 1 long stroke sensor
34 HA99000022 3 spray nozzle, complete assembly

QH440-en-050112
CJ0080
DRIVE GUARD qh440
11.24. Drive guard
CJ0080
7
10
2
11
6
8
5
1
13
12
14
3

QH440-en-050112
qh440 CJ0080
DRIVE GUARD

1 12-70-0023 2 strut
2 J10360000 1 drive guard top assy
3 J10370000 1 drive guard bottom assy

4 J10380000 1 access door
5 J10390000 1 access door
6 J10400000 1 drive guard gas strut mtg brkt

7 J11070000 1 drive guard end cap
8 FD2105 6 hinge 3 + 2 hole
9 J11080000 1 drive guard pulley cover
10 J11090000 1 drive guard pulley cover
11 881.0084-00 2 latch
12 FAW12 4 m12 flat washer
13 FASKT12X80 4 hexagon socket head cap screw
14 J11100000 1 stiffener bar

QH440-en-050112
CJ0081
LUBRICATION TANK ASSEMBLY qh440
11.25. Lubrication tank assembly
CJ0081
13 18 1
22
25
23
6
10
20
11
24 19
15 17 26 17
24
21
28 29
7 12
29 28

QH440-en-050112
qh440 CJ0081
LUBRICATION TANK ASSEMBLY

1 10-22-4006 1 tank air breather
2 10-23-5028 1 low level sensor gauge
4 A23340000 1 lubrication tank

5 A23570000 1 tank gasket
6 A23580000 1 tank lid
7 A23600000 1 lubrication tank mtg angle

8 A23800000 1 lubrication tank mtg brkt
9 A23860000 1 lubrcation filter mounting bracket
10 BT10119 1 lubrication heater pump bellhousing
11 BT10120 1 pk 350/04/04 housing - rotex r55.28.58sd x 80.22.22f & adapter plate
12 EL9558 1 n6 electrical 2 bar indicator to suit lmp and mps filters
13 EN1601 1 filler unit
15 HA03400044 1 3/4" bsp male/male adaptor
17 HADW03400 2 3/4" dowty washer
18 HF1035 1 flowmeter - mcnaught

19 HF9903 2 lubrication filter
20 HF9907 1 750 x 250 wire cloth mesh strainer
21 HF9909 1 in line filter assembly

22 HM1007 1 charlynn 4k395 aaa 006 motor
23 HM1011 1 74318-ks173 axial piston motor
24 HP1062 2 pump snp3/90d c1o7 (x38 cone)

25 HV8544 1 pilot operated relief valve assy
26 HV8581 1 system relief
27 HHK0095 1 lubrication tank hose kit not illustrated
28 HAN100001 2 1-¼in flange cfs104
29 HAN100006 2 1-½in 3000 series flange adapter

QH440-en-050112
CB0132
CLUTCH LUBRICATION TANK qh440
11.26. Clutch lubrication tank
CB0132
4 1
8
3
6

2 10-23-5028 1 low level sensor guage
3 B15700000 1 tank assy
4 B15710000 1 filler cap flange plate
5 B15720000 1 cover plate assy
6 B16220000 1 mounting angle
7 B16230000 1 mounting angle

8 EN1601 1 filler unit

QH440-en-050112
qh440 CB0070
DRIVE TENSIONER
11.27. Drive tensioner

CB0070
13
14
1
12
4 2
10 11 8
1 B11510000 1 tensioner arm assembly
2 B11520000 1 tensioner bearing adjuster plate

3 B11760000 1 belt tensioner arm mounting shaft
4 B17710000 1 bearing adjuster plate
5 BT10010 1 4545/3.15/16" taper lock bush

6 BT10107 2 optibelt redpower kraft band 5/spc 6700 endless length
7 BT2010 2 fy60tr multifunction sealed y flange bearing
8 BT5040 1 4545 / 60 taper lock bush
9 BT9991 1 spc 10 groove pulley 315 pcd
10 CB0071 1 active turnbukle assy
11 1 idler pulley assembly see CB0131
12 1 drive tension drum.assembly see CR9040
13 FAB16X70 1 m16 x 70 hex head

QH440-en-050112
CB0131
IDLER PULLEY ASSEMBLY qh440
11.28. Idler pulley assembly
CB0131
5
3
6 8
1 B11740000 1 idler pulley main shaft
2 B15510000 1 idler pulley mounting bracket assy
3 BT9991 1 spc 10 groove pulley 315 pcd
4 BT9994 2 60mm plummer bearing c/w bearing and sleeve
5 FAB16X70 4 m16 x 70 hex head
6 FAB24X75 4 m24x75 hex-head bolt
8 FAW24NL 4 m24 nordlock washer set

QH440-en-050112

QH440-en-050112
CA0109
CONTROL BOX qh440
11.29. Control box
CA0109
24
41
40
39
38
34
37
1
36
20
23
18
27
9
26
12
10
3
7 19
25
8
5
33
11
2
28
16
14
6
32
17

QH440-en-050112
qh440 CA0109
CONTROL BOX

1 A20700000 1 control cabinet assembly
2 HV8569 1 sauer danfoss pvg 5 bank valve assembly
3 HV8570 1 sauer danfoss pvg 4 bank vlave assembly

4 FD2118 2 1139mm length of 28mm polialhinge [ cut from fd2109 ]
5 A20850000 2 control cabinet door assembly
6 12-45-0110 2 dish recessed drop 't' handle

7 EL9681 1 crusher tier 4 control system
8 A22290000 1 pvg valve mounting bracket
9 FD1007 4 gas strut 600n
10 FD1503 4 gas strut eye
11 FP1000 1 steel pipe kit not illustrated
12 A22280000 1 pvg valve mtg bracket
14 HV1652 1 5 lever spool valve (d/a x 5, levers down, no relief, hpco)
16 HV1502 5 spool lever handle
17 EL9782 4 cabinet light

18 HV8004 4 3/4" bsp ball valve
19 A5020000 1 water manifold
20 EL9641 1 isolator switch assy

23 EL9786 1 wired tracking remote
24 EL9785 1 battery jump socket
25 HA03400055 2 3/4" bulkhead

27 HA1000072 2 1" bsp extended bulkhead
28 A770 00 00 1 spool indicator plate
32 HV8610 1 updated hydroset valve
33 HV8612 1 cetop 3 single valve
34 EL9775 1 pt-tech 14" clutch master unit - cmcmu-008-da
36 14-04-1030 1 radio remote kit eu (ce) - 434 mhz option
37 14-04-1035 1 radio remote kit japan - 429 mhz option
38 14-04-1040 1 radio remote kit us - 458 mhz option
39 14-04-1045 1 radio remote kit china - 419 mhz option
40 EL9933 1 radio remote kit south korea - 447 mhz option
41 EL9936 1 radio remote kit taiwan - 480 mhz option
42 HHK0094 1 control cabinet hose kit not illustrated

QH440-en-050112
ELECTRICAL COMPONENTS qh440
11.30. Electrical components
13
1
9 10 14 11 12
23
15 16 18 20, 21 22
17
Item Part no Qty Description Remarks
1 EL9873 1 Fuse box panel
2 EL9870 1 Engine harness loom Not illustrated

3 EL9876 1 Front extension cables Not illustrated
4 EL9884 1 Chassis lead kit Not illustrated
5 EL9893 1 Battery lead kit Not illustrated

6 EL9909 1 Clutch loom Not illustrated
7 EL9879 1 Hydraulic control cabinet loom Not illustrated
8 ?? 1 Reset button
9 ?? 1 Emergency stop
10 ?? 1 Diagnostic socket
11 ?? 1 Light switch
12 ?? 1 Engine ignition switch
13 ?? 1 Display screen (programmed)
14 ?? 1 Door latch
15 EL9908 1 Temperature sensor
16 14-05-0149 1 Fuel sender
17 ?? 1 Proximity sensor
18 14-04-1290 1 Proportional level sensor
19 ?? 1 Lead for proportional level sensor Not illustrated
20 EL9910 1 Transducer (0 to 160 bar)
21 EL9911 1 Transducer (0 to 9 bar)
22 ?? 1 Junction box, 8-way
23 EL9885 Chassis control panel

24 EL9886 Chassis panel harness not illustrated

QH440-en-050112
qh440 ELECTRICAL COMPONENTS
A102B
17
MC88
A102A RADIO
7XA
10, 11, 12, 13, 14, 15

1 2 3, 4 5 6 7 8 9 16
K6 K10
K7 K8 K9 K12 K13
1 2 Main power relay K1 and K11
2 1 Emergency stop relay K2
3 1 Drive lamps relay K3
4 1 Work lamps relay K4
5 2 down and up stream emergency stop relay K6 and K10

Up/down feeder relays K7 and K8, power slave relay K9,
6 5
track relays K12 and K13
7 1 Timer T1
8 1 Gateway
9 1 Led fuse holder
10 Blade fuse 5A
11 Blade fuse 10A
12 Blade fuse 15A
13 Blade fuse 20A
14 Blade fuse 25A
15 Blade fuse 30A
16 1 Soot sensor relay

17 1 Programmed controller

QH440-en-050112
ELECTRICAL COMPONENTS qh440
1 2
3 4

1 1 air blower relay (2K1)
2 1 drive lamp relay (2K2)
3 1 led fuse holder
4 1 blade fuse 10A
5 1 programmed controller

QH440-en-050112

QH440-en-050112
CA0144
OVERBAND MAGNET OPTION qh440
11.31. Overband magnet option
CA0144
1 1
1
4
1
1
1

QH440-en-050112
qh440 CA0144
OVERBAND MAGNET OPTION

1 MA1050 1 overband magnet
2 MA1060 2 10 link magnet chain
3 MA1065 2 16 link magnet chain

4 MA1001 4 tl 13 shackle connector
5 MA1056 4 magnet lifting eyebolt
6 10-16-0150 1 flow control valve

7 HH20000 1 magnet hose kit not illustrated

QH440-en-050112
CA0143
WATER PUMP OPTION qh440
11.32. Water pump option
CA0143
21 17
13
9
7 18
15 12
12
22 8
11
13
20
19
1 12
16 5
14
4
10

QH440-en-050112
qh440 CA0143
WATER PUMP OPTION

1 A10860000 1 base plate
2 A10870000 1 cover
3 BT5001 1 1610 / 32 taper lock bush

4 BT6543 2 hrc 110 coupling
5 BT6545 1 1610/15/16 taper lock bush
6 BT6546 1 h110n insert

7 HA03400044 1 ¾" bsp male/male adaptor
8 HA03400049 1 ¾" bsp male/male/female tee
9 HA03400058 1 ¾" barrel nut
10 HM1005 1 charlynn 2k155 baa motor(104-1387-006)
11 HP2004 1 water pump hypro 7560c
12 HP2006 3 1-¼" hose tail
13 HP2009 2 ¾" hose tail
14 HP2010 1 1-¼" f-f coupling
15 HP2011 1 1-¼" bsp f-f-f tee.

16 HP2012 1 suction filter
17 HP2013 1 water regulating valve
18 HP6004 1 ¾" bsp elbow connection

19 HV1011 1 single lever spool valve
20 HV1502 1 spool lever handle
21 RU1383 1 1" rubber hose

22 RU1384 1 1" rubber hose

QH440-en-050112
CB0078
AUTO-LUBRICATION OPTION qh440
11.33. Auto-lubrication option
CB0078
2 1
1 B12130000 1 dropsa 2kg pump box
2 B12140000 1 dropsa 2kg pump cover plt
3 B12160000 2 dropsa 2kg pump box brkt

4 BT10001 2 sd400 4 port secondary block
5 BT10080 1 sd110 dropsa 2kg pump set
6 BT10087 1 sd370 master block
7 BT10088 1 sd450 6 port secondary block

QH440-en-050112
qh440 CB0162
FUEL PUMP OPTION
11.34. Fuel pump option

CB0162
5
1
1 A1080 00 00 1 guard
2 EL2034 1 electrical kit
3 HF1034 1 diesel filter not illustrated
4 HP3001 1 fuel pump
5 RU6031 1 ¾" suction hose
2 HH20200 1 fuel pump hose kit not illustrated

QH440-en-050112
MACHINE SERVICING KITS - (3A ENGINE) qh440
11.35. Machine servicing kits - (3a engine)
250 hour intervals, refer to 6.2.5. 250 Hours maintenance schedule.
Kit QH440CAT3A250
part no. qty description remarks
EN1000 1 cat engine oil filter
EN1006 1 cat c13 fuel secondary filter
EN1001 1 fuel primary filter cat c9
EN9555 1 psd12 main element blue media
EN9556 1 donaldson safety element
Kit QH440CAT3A500
10-21-0321 2 s45 pressure filter element

10-21-0031 3 return filter element

HF9910 1 cone lube filter element (for hf9909)
HF9522 1 filter top hat 0-1199 to suit el9566

HF9908 1 2 1/2" air breather 10 micron (sa185g1l10a)
HF9920 1 spin on clutch filter
HF9523 1 clutch air breather

HF9524 1 hyd tank breather element
2000 hour intervals, refer to 6.2.8. 2000 Hours or 1 year maintenance schedule.
Kit QH440CAT3A2000




QH440-en-050112
qh440 MACHINE SERVICING KITS - (3A ENGINE)


HF1017 3 filter suction str1004sg1m90-2
10-21-0007 2 2 1/2" suction filter 90 micron

QH440-en-050112
MACHINE SERVICING KITS - (3B ENGINE) qh440
11.36. Machine servicing kits - (3b engine)
Kit QH440CAT3B50

EN1203 2 cat fuel filter

2000 hours intervals, refer to 6.2.8. 2000 Hours or 1 year maintenance schedule.
Kit QH4403B2000


EN1203 2 cat fuel filter

HF1017 3 filter suction str1004sg1m90-2
10-21-0007 2 2 1/2" suction filter 90 micron
EN9977 1 cat c13 filter element fumes disposal

QH440-en-050112

Qh440 Manual Eng

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Original Instructions

Hearthcote Road, Swadlincote, Derbyshire, DE11 9DU, United Kingdom

Copyright © Sandvik Mining and Construction

We hereby declare that the machinery

Machine Nomination, Type of machine:

is in conformity with the following Directives, Standards and Codes

EC Type-examination and Certificates

Phil Coleman, PDC Group Engineering Manager , Swadlincote

Paul Colton, Operations Director, Swadlincote

Phil Coleman Paul Colton

Manufacturer: Sandvik Mining and Construction,

Copyright © Sandvik Mining and Construction

1.2. Features for operator safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

1.3. Environmental safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

1.4. Personal protective equipment (PPE) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20

1.5. Hazard exclusion zones - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

1.6. Measured noise levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22

1.7. Vibration levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23

1.8. Organizational safety measures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24

1.9. Personnel qualifications, requirements and responsibilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

1.10. Safety advice regarding specific operational phases - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

1.12. Specific hazards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

1.13. Safety decals - Locations. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37

Copyright © Sandvik Mining and Construction 5

2. TRANSPORTATION & TECHNICAL DATA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41

2.2. Application & limitations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48

2.3. Technical specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

2.4. Machine Transportation Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

3.2. Main Components - Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

4. COMMISSIONING AND SHUT DOWN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

4.3. Main control devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

4.4. Engine starting procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67

4.5. Initial screen display icons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

4.6. Stopping machine in an emergency - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 70

6 Copyright © Sandvik Mining and Construction

4.7. Tracking (moving) procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73

4.8. Preparing the crusher for operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77

4.9. Jacking legs set-up procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81

4.10. Shut down the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85

4.11. Lockout and tag procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88

5.2. Machine crushing mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93

5.3. Methods of operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 95

5.4. Automatic mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 96

5.5. Manual mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 98

5.6. Daily calibration of crusher wear parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101

5.7. Close side setting gap [CSS] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 102

5.8. Feeding material into machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103

5.9. Feed conveyor metal detector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 104

Copyright © Sandvik Mining and Construction 7

6.2. Scheduled maintenance intervals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110

6.3. Maintenance procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115

6.4. Lubricants and fluids - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 130

6.5. Maintenance screens and machine fault codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 132

6.6. Diagnostic screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 141

7. TROUBLE SHOOTING GUIDE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 145

8 Copyright © Sandvik Mining and Construction

9. ELECTRICAL & HYDRAULIC INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 151

9.2. Hydraulic Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 173

10. O.E.M. PRODUCT DOCUMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 175

11. SPARE PARTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 179

11.2. Main assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 182

11.3. Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 184

11.4. Chassis assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 186

11.5. Tank tower frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 188