Maintenance Wagon-Tippler En-Rev3

Product: Wagon unloading system
Project:
Client: SPCC Ilo Peru
SCHADE-no.: 20.312
INSPECTION
and
MAINTENANCE MANUAL
WAGON TIPPLER
Client:
Southern Peru Copper Corporation
Contractor:
SCHADE Lagertechnik GmbH Tel.: +49 209 50316 0

Bruchstraße 1 Fax: +49 209 50316 288
D-45883 Gelsenkirchen info@schade-lagertechnik.de
GERMANY www.schade-lagertechnik.de
Inspection and Maintenance.doc 2014-07-04

Project:
SCHADE-no.: 20.312
1 Notes on this document ................................................................................................................... 4

1.1 Use of maintenance manual ............................................................................................................... 4
1.2 Illustrations .......................................................................................................................................... 4
1.3 Contact address .................................................................................................................................. 4
2 Safety instructions ............................................................................................................................ 5
3 Components and parts of the machine .......................................................................................... 6

3.1 Plant overview, Rail level .................................................................................................................... 6
3.2 Plant overview, material dump area.................................................................................................... 7
3.3 Parts of the wagon tippler ................................................................................................................... 8
3.4 Parts of the wagon run back stop ....................................................................................................... 9
4 Inspection ........................................................................................................................................ 10

4.1 Tippler Structure................................................................................................................................ 13
4.2 Tippler Drive ...................................................................................................................................... 14
4.3 Tippler platform ................................................................................................................................. 15
4.4 Tippler Clamp .................................................................................................................................... 16
4.5 Tippler Main Pivot ............................................................................................................................. 17
4.6 Platform supports .............................................................................................................................. 18
4.7 Hydraulic Power Unit (Part 1) ........................................................................................................... 19
4.8 Hydraulic Power Unit (Part 2) ........................................................................................................... 20
4.9 Dust suppression .............................................................................................................................. 21
4.10 Safety label ....................................................................................................................................... 22
4.11 Control desk and HMI-Screens ......................................................................................................... 23
4.12 Electrical devices .............................................................................................................................. 23
5 Maintenance and supervision instruction .................................................................................... 24

5.1 General maintenance and supervision instruction ............................................................................ 24
5.2 Special maintenance and supervision instructions ........................................................................... 24
5 . 2 .1 Bolted connections ............................................................................................................................ 24
5.3 Maintenance Electric ......................................................................................................................... 26
5 . 3 .1 Electrical and mechanical limit switches ........................................................................................... 26
5 . 3 .2 PLC and Common Control ................................................................................................................ 26
5 . 3 .3 Processor Fault ................................................................................................................................. 26
5 . 3 .4 Digital Input Fault .............................................................................................................................. 26
5 . 3 .5 Digital Output Fault ........................................................................................................................... 27
6 Lubrication ....................................................................................................................................... 28

6.1 General lubrication instruction .......................................................................................................... 28
6.2 Special lubrication instructions .......................................................................................................... 28
Inspection and Maintenance.doc 2014-07-04 2

Project:
SCHADE-no.: 20.312
7 Spare and Wear parts list ............................................................................................................... 29
8 Drawings (appended)...................................................................................................................... 32
9 Documents of sub supplier (appended) ....................................................................................... 33

9.1 REXROTH Hydraulic power unit ....................................................................................................... 33
9 . 1 .1 General Commissioning Instructions ................................................................................................ 33
9 . 1 .2 Operating Instructions ....................................................................................................................... 33
9 . 1 .3 Drawings ........................................................................................................................................... 33
9 . 1 .4 Component Data Sheets ................................................................................................................... 33
9 . 1 .5 After Sales ......................................................................................................................................... 33
9.2 BIJUR DELIMON Grease Lubrication ............................................................................................... 33
9 . 2 .1 Lubrication O&M Manual GSE 49149 ............................................................................................... 33
9.3 ENVIROFLO Dust suppression ........................................................................................................ 33
9 . 3 .1 LOWARA eSV Pumps O&M ............................................................................................................. 33
9 . 3 .2 LOWARA Float Switch ...................................................................................................................... 33
9 . 3 .3 PROMINENT Delta O&M .................................................................................................................. 33
9 . 3 .4 AIRPEL Water Filter .......................................................................................................................... 33
9 . 3 .5 DANFOSS Solenoid Valves O&M..................................................................................................... 33
9 . 3 .6 PNR Spray Brochure......................................................................................................................... 33
9 . 3 .7 Drawings ........................................................................................................................................... 33
9.4 ICONSYS Electric HMI Screens ....................................................................................................... 33
9 . 4 .1 Schematics & Diagrams .................................................................................................................... 33
9.5 SKF Bearing ...................................................................................................................................... 34
9 . 5 .1 Mounting Instructions ........................................................................................................................ 34
9 . 5 .2 Transport Instructions ....................................................................................................................... 34

Project:
SCHADE-no.: 20.312
1 Notes on this document

For questions about this document please call the contact address given below.
1.1 Use of maintenance manual

This maintenance manual is used:
 maintenance personnel for inspection and maintenance of the machine
 the service personnel
1.2 Illustrations
All illustrations in this document are for illustrative representation. Depending on the machine type
and model variations from the exemplary representation are possible. The original drawings listed in
the text are to be used for all work on the machine.
1.3 Contact address

All rights to this document, to the annexed drawings and other documents, as well as any rights of
disposal such as copying and distribution rights belong exclusively to
SCHADE Lagertechnik GmbH Tel.: +49 209 50316 0

Bruchstraße 1 Fax: +49 209 50316 288
D-45883 Gelsenkirchen info@schade-lagertechnik.de
GERMANY www.schade-lagertechnik.de

Project:
SCHADE-no.: 20.312
2 Safety instructions
Switch-off the machine during all necessary maintenance-, repair- and

cleaning work, especially make drives safe against restarting. To avoid a
threatening or occurred dangerous motion the EMERGENCY-OFF switch
DANGER! has to be set at once.
If the red “BATF” LED is on, this indicates that the CPU battery is not pre-
sent or faulty and requires fitting or replacement.
DO NOT SWITCH OFF THE POWER TO THE CPU WHILE THIS LED IS ON AS
THE PROGRAMME AND ALL DATA MAY BE LOST.
DANGER! REPLACEMENT OF THE BATTERY SHOULD BE CARRIED OUT WITH THE
POWER SWITCHED ON
While maintenance only authorized persons are allowed to stay in the work-
ing area of the machine. The discharge area is not allowed for access during
DANGER! operation.
The machine shall be operated by trained persons only. Even for short time,
WARNING! operation by untrained personal is not allowed.
As the machine is defect a danger sign has to be displayed and the machine
WARNING! has to be made safe against unauthorized switching-on.
Machine repairs are allowed only by trained and competent personnel.

WARNING!
After maintenance and repair work all safety devices are to be re-set.
WARNING!
Use protective equipment wherever required by the circumstances or by

law.
Personnel entrusted with work on the machine must have read the operating
instructions and in particular the chapter on safety before beginning work.

Project:
SCHADE-no.: 20.312
3 Components and parts of the machine

The following components and parts belong to the machine:
3.1 Plant overview, Rail level

The facility includes (a, b, c, … ) and machines/assemblies supplied by SCHADE:
 an entry track (a)
 local control panel (b) and operator control panel (c)
 tippler entry and exit clearance sensors (e+f)
 a wagon tippler (g)
 a wagon run back stop (h)
 an exit track (i)
 hydraulic power unit (k)
 centralized lubrication system (L)
 dust suppression system (m)
e f
a h
c k L m
e f
h
b

Project:
SCHADE-no.: 20.312
3.2 Plant overview, material dump area

The facility includes (a, b, c, … ) and machines/assemblies not supplied by SCHADE:
 Plant Operator control room and access (a)
 Tipped material area (b)
 Bulk material (c)
 FEL (front end loader)(s) (d)
b
d

Project:
SCHADE-no.: 20.312
3.3 Parts of the wagon tippler

(1) End ring structure
(2) Ballast 2
(3) Main pivot bearings
(4) Side beam 4 3
1 5
(5) Tippler clamp
(6) Wear plate for wagon contact
(7) Platform
(8) Drive unit
(9) Platform supports
6
not shown
(10) Cable loop
(11) Limit switches
(12) Tippler hydraulics 7
(1) End ring structure

(2) Ballast 1 2 1 2
(3) Main pivot bearings
(4) Side beam 5
(5) Tippler clamp
(6) Wear plate for Wagon 4
(7) Platform 3 3
(8) Drive unit
(9) Platform supports
not shown
(10) Cable loop 6
(11) Limit switches
(12) Tippler hydraulics
8 9 8

Project:
SCHADE-no.: 20.312
3.4 Parts of the wagon run back stop

(1) Handle
(2) Cover 1
(3) Rail support
(4) Wheel stop 2
(5) Shaft 3
4
5

Project:
SCHADE-no.: 20.312
4 Inspection
4.1 Pivot frame tippler structure .......................................................................................................... 13
4.2 Tippler Drive .................................................................................................................................... 14
4.3 Tippler clamps ................................................................................................................................. 16
4.4 Main pivot ........................................................................................................................................ 17
4.5 Cable loop ....................................................................................... Fehler! Textmarke nicht definiert.
4.6 Platform supports ........................................................................................................................... 18

Project:
SCHADE-no.: 20.312
Check Feature Example Code

A - Alignment Rails AA1
Pivot AA2
Conveyor belt AA3
C - Completeness Several Parts as AC1
Bolts, Safety devices, e.g. after repair
D - Damages Welds for cracks AD1
Steel parts (machine teeth, harrow tine, cable tray) AD2
Mech. Parts (pulley, idler, wheels) AD3
Electrical parts (cable, sensor) AD4
Safety parts, (safety signs, cover, gratings) AD5
Surfaces (Paintwork, glass) AD6
F - Filling level Hydraulic oil AF1
A Oil container AF2
Visual check Grease container AF3
L - Leakproof Valves AL1
Piping AL2
Fluid container AL3
P - Pollution Layer of dust or dirt AP1
R - Right components e.g. after repair AR1
T - Tighten or Loosened Re-Tighten bolt connection AT1
components Check for loose bolts. AT2
Replace damaged bolts with new bolts AT3
W - Wear Size (thickness of rubber, wear plate) AW1
Surface (grooves) AW2
Form (out of round) AW3
M - Mobility Movability BM1
O - Operating mode ON / OFF, fault BO1
P - Protective devices Cover, railing BP1
R - Rotation Winch, On-unwinding Motor, forward / reverse BR1
Pulley, idler BR2
Cable reel BR3
B S - Safety devices Sensor (obstacle, rail end, slack rope) BS1
Functional check Signal horn, BS2
Flash light BS3
Emergency stop BS4
Emergency pull rope BS5
T - Tension Conveyor belt BT1
Machine chain BT2
Rope BT3
Cable reel / trolley BT4
C A - Loudness Higher / lower than normal CA1
Noise level check B - Modulation Consistently, swaying CB1
D A - Operating temperature Motor, brake, coupling, bearing, hydraulic oil DA1
Temperature check B - Overheating Motor, brake, coupling, bearing, hydraulic oil DB1

Project:
SCHADE-no.: 20.312
Rails
1
2 3
4 5
6 7
8 9
Maintenance
Pos. Description Maintenance (action) Operating mode
(Interval)
Rail A + B Visual check,
1 12 Month out-of-order
- Gauge Functional check
Rail A Visual check,
- Alignment Functional check
Rail B Visual check,
- Alignment Functional check
Fastening rail A Visual check,
4 - Nuts Tightening torques 12 Month In action
- Washer, Rail plate completeness
Fastening rail B Visual check,
5 - Nuts Tightening torques 12 Month out-of-order
Visual check,
6 Buffer rail A 12 Month out-of-order
Functional check
Visual check,
7 Buffer rail B 12 Month out-of-order
Functional check
Fastening buffer A Visual check,
Fastening buffer A Visual check,

Project:
SCHADE-no.: 20.312
4.1 Tippler Structure
1
3
3 3 3 4
5
5
6
4
2
6
Maintenance
(Interval)
Tippler structure
1 - Pivot Frame
2 - Platform Visual check,
3 - Tippler Clamp Noise level check, 1 Week In action
4 - Wear Parts Functional check
5 - Grease Points
6 - Sensor
Pivot Frame
1 Visual check, 12 Month Out-of-order
- Bolted connections
Tightening torques
Pivot Frame structure
- End ring structure Visual check,
1 12 Month Out-of-order
- Side beam structure Functional check,
- Rack section
Visual check,
2 Platform 3 Month Out-of-order
Functional check
Tippler Clamp
- drive
Wear Parts Wear
4 - wagon support bracket Visual check, 12 Month Out-of-order
- fixed blocking Functional check
Visual check,
5 Grease points 3 Month Out-of-order
Functional check
Sensor
- Position Level “0” Visual check,
6 3 Month In action
- Position End of Tip Functional check,
- Position End of Return

Project:
SCHADE-no.: 20.312
4.2 Tippler Drive

1
1
1 2
1
1
1
For further information see documentation of the sub supplier “9.1 REXROTH Hydraulic power unit”.
Maintenance
(Interval)
Tippler drive Visual check,
1 - Braked Hydraulic Motor Noise level check, 1 Week In action
2 - Pinion Functional check
first inspection according to the 00 Hours / In action / out-of-
1 Braked Hydraulic Motor
manufacturer document 0 Month order
further Inspection according to In action / out-of-
1 Braked Hydraulic Motor 00 Month
the manufacturer document order
Check
Braked Hydraulic Motor - Oil temperature
1 out-of-order
- Hydraulic Oil - Oil Level
- Oil Quality
Change Oil
Braked Hydraulic Motor
1 - first Oil change out-of-order
- Hydraulic Oil
- further Oil change
2 Pinion Cleaning, Greasing out-of-order

Project:
SCHADE-no.: 20.312
4.3 Tippler platform
Under Tippler Platform 3
Maintenance
(Interval)
Tippler Platform
1 - Rails Visual check,
2 - Wheel locating angle Noise level check, 1 Week In action
3 - Upper locating block Functional check
4 - Roller bracket
Rail Fastening
Visual check,
- Nuts
1 Tightening torques 12 Month out-of-order
- Washer, Rail plate
completeness
- Alignment
Wheel locating angle
Visual check,
2 - Bolted connections 12 Month In action
Functional check
- Bracket
Upper locating block Visual check,
3 12 Month In action
- Wear parts Functional check,
Roller bracket
- Roller
2 - Wear Visual check, 12 Month Out-of-order
- Alignment Functional check,
- Running behaviour

Project:
SCHADE-no.: 20.312
4.4 Tippler Clamp

1
2 3
Maintenance Operating
Pos. Description Maintenance (action)
(Interval) mode
Tippler Clamp
1 - Clamp Cylinder
2 - Clamp Arm Visual check
3 - Clamp Beam Noise level check, 1 Week In action
4 - Clamp Bracket Functional check
5 - Pads
6 - Wear Plats
Clamp Cylinder
Visual check
1 - Trunnion 12 Month Out-of-order
Functional check
Clamp Arm
Visual check
2 - Pivot 12 Month Out-of-order
Functional check
Clamp Beam
Visual check
Functional check
Clamp Bracket
Visual check
Functional check
Pads Visual check
- Wear Functional check
Wear Plats Visual check
- Wear Functional check

Project:
SCHADE-no.: 20.312
4.5 Tippler Main Pivot
7
2
4
5
1
7
6
Maintenance
(Interval)
Tippler Main Pivot
1 - Locking Assembly
2 - Pivot Shaft
3 - Bearing Visual check,
Structure Noise level check, 1 Week In action
4 - Shear Block Functional check
5 - Pivot Stool
6 - Jacking Screws
7 - Bolts
Visual check,
Locking Assembly
1 Tightening torque 3 Month out-of-order
- Bolts
Functional check
Visual check,
Pivot Shaft
2 Functional check, 12 Month out-of-order
- Surface
Noise level check
Visual check,
Bearing
3 Functional check, 12 Month out-of-order
- Grease
Lubrication check
Structure
4 - Shear Block
Visual check
5 - Pivot Stool 12 Month out-of-order
Tightening torque
6 - just able Bolt
7 - Bolts

Project:
SCHADE-no.: 20.312
4.6 Platform supports
Maintenance Operating
Pos. Description Maintenance (action)
(Interval) mode
Platform Support
1 - Lower Locating Block Visual check
2 - Roller Support Ramp Noise level check 1 Week In action
3 - Jacking Screws Functional check
4 - Bolts
Lower Locating Block
1 Visual check 12 Month out of order
- Wear
Roller Support Ramp
2 Visual check 12 Month out of order
- Wear
Jacking Screws
Visual check
3 - moveable Parts 12 Month out of order
Functional check
Visual check
4 Bolts 12 Month out of order
Tightening torque

Project:
SCHADE-no.: 20.312
4.7 Hydraulic Power Unit (Part 1)

5
1 3
1 2
Maintenance
(Interval)
Hydraulic power unit
1 - Hydraulic Cylinder
Visual check,
2 - Piping
Noise level check, 1 Week In action
3 - Hoses
Functional check
4 - Aggregate
5 - Cooler
1 Hydraulic cylinder
- Leakage Visual check,
12 Month out of order
- Surface Functional check
- Movement
Piping
Visual check
2 - Leakage 12 Month out of order
- Condition
Hoses
Visual check,
3 - Leakage 12 Month out of order
- Condition
Oil Level
Aggregate - max. 705 L
4 12 Month out of order
- Oil Tank - Warning 530 L
- Shutdown 420 L
Cooler
Fluid Level
5 - Cool Fluid 12 Month out of order
Cleaning
- Dust

Project:
SCHADE-no.: 20.312
4.8 Hydraulic Power Unit (Part 2)
Maintenance
(Interval)
Visual check,
Hydraulic power unit
Noise level check, 1 Week In action
6 - Braked Hydraulic Motor
Functional check
Braked Hydraulic Motor Visual check
6 12 Month out of order
- Bolted connections Tightening torques
Visual check
6 Noise level check 12 Month out of order
- Lubrication
Functional check
Visual check
6 Noise level check 12 Month out of order
- Brake
Functional check

Project:
SCHADE-no.: 20.312
4.9 Dust suppression
For further information see documentation of the sub supplier “9.1 ENVIROFLO Dust suppression”.
Maintenance
(Interval)
1 Fluid tank
Completeness
2 Piping
Visual check, 1 Week In action
3 hoses
Functional check
4 Spray nozzle
2 Piping
Tightening torques 12 Month out of order
3 hoses
2 Piping
Leakage 12 Month In action
3 hoses

Project:
SCHADE-no.: 20.312
4.10 Safety label
Maintenance
(Interval)
SIGNS for: Completeness
1 Prohibition, Mandatory, Warn- Visual check, 1 Week In action
ing, Obstruction Functional check
2 SIGNS on Plates Tightening torques 12 Month out of order

Project:
SCHADE-no.: 20.312
4.11 Control desk and HMI-Screens
If the red “BATF” LED is on, this indicates that the CPU battery is not present
or faulty and requires fitting or replacement.
DO NOT SWITCH OFF THE POWER TO THE CPU WHILE THIS LED IS ON AS
DANGER! THE PROGRAMME AND ALL DATA MAY BE LOST.
REPLACEMENT OF THE BATTERY SHOULD BE CARRIED OUT WITH THE
POWER SWITCHED ON
Maintenance
(Interval)
Completeness
Structure and surface of the
1 Visual check, 1 Week In action
Control desk and HMI-screen
Functional check
Tightening torques of cables
2 Inside the Control desk 12 Month out of order
Dust deposits
4.12 Electrical devices
Maintenance
(Interval)
Signals (Flash beacon, Horn) Completeness
1 E-Stop, Switches, Lamps, Visual check, 1 Week In action
Sensor Functional check
Signals (Flash beacon, Horn)
2 E-Stop, Switches, Lamps, Tightening torques of cables 12 Month out of order
Sensor

Project:
SCHADE-no.: 20.312
5 Maintenance and supervision instruction
Switch-off the machine during all necessary maintenance-, repair- and cleaning
DANGER! work, especially make drives safe against restarting. To avoid a threatening or
occurred dangerous motion the EMERGENCY-OFF switch has to be set at once.
5.1 General maintenance and supervision instruction

Check the machine every day visibly, to recognise possible damage in the beginning and to avoid further
damage. It is important that all drives are part of the visible check. Check for unusual noises, leaking of oil
and quiet running.
All changes including behaviour of the machine during operation, report im-
DANGER! mediately to the competent authority / person. Stop the machine at once and
lock if necessary.
In the event of irregularities, which cannot be repaired by the maintenance personnel, inform the SCHADE-
SERVICE.
To ensure a long running operational safety of the machine we recommend making all maintenance-, inspec-
tion- and repairing work by SCHADE-SERVICE exclusively. Furthermore we recommend a yearly inspection
by a SCHADE expert, too.
Only spare parts manufactured or released by SCHADE shall be applied.
Repair is only allowed during switched–off machine and made safe against
DANGER! forbidden restarting.
As the machine is defect a danger sign has to be hung up and has to be made safe against unauthorised
switching-on again.
Machine repairs are only allowed by trained and competent personnel.
After maintenance and repair work the safety devices have to be re-fixed again and checked of their func-
tion.
5.2 Special maintenance and supervision instructions

5 .2 .1 Bolted connections
At the time of assembly, the surfaces in contact shall be free of paint, or any other applied finish, oil, dirt,
loose rust, loose scale, burrs and other defects which would prevent solid seating of the parts, or would inter-
fere with the development of friction between them. Tight mill scale is not detrimental. Machined surfaces
shall be rough finished.
Note – for protection during sea transport, the bolted joint contact surfaces are painted with the pri-
mer coat only. This must be removed during site assembly of the Tippler.
All joint plates must be assembled using the Shop Trial Assembly match-marking.
Hand tighten all bolts in the joint in a staggered pattern from the middle (stiffest section) of the joint outwards
until they are snug-tight. When all bolts are snug-tight, each bolt in the joint shall be additionally tightened by
the calibrated wrench (torque) tightening method.
Torque tightening shall progress systematically from the middle of the joint outwards.
The wrench shall be returned to ‘touch up’ previously tightened bolts which may have been relaxed as a
Project:
SCHADE-no.: 20.312
result of the subsequent tightening of adjacent bolts until all bolts are tightened to the correct torque.
Installation of all structural joints shall be carried out under the supervision of the Schade shop/site engineer.
Bolt Size Specified Minimum Bolt Tension Approximate Equivalent Torque for
mm Required Minimum Bolt Tension
kN Tonne-force Nm
(kilonewtons) #1
M12 49.4 5.0 118
M16 92.1 9.4 295
M20 144.0 14.6 576
M24 207.0 21.1 994
M30 286.0 29.2 1716
M36 418.0 42.5 3000
Tolerance on torque figures: M12 - M16 inclusive: -0%, +10%

M20 & M24: -6%, +10%
M30 & M36: -10%, +10%
#1 - Standard torque figures for unplated fasteners without any additional (above standard supply condi-
tion) or special thread lubricant being used.
If after complete tightening of a joint, a bolt or nut is slackened off for any reason, the bolt, nut and washer or
washers shall be discarded and not re-used. Bolts and nuts found to be in any way defective shall be dis-
carded and replaced by new ones.

Project:
SCHADE-no.: 20.312
5.3 Maintenance Electric

5 .3 .1 Electrical and mechanical limit switches
Check the function of the mechanical limit switches, the inductive switches, the ultrasonic sensors, the rota-
tion impulse encoders weekly, perhaps clean and re-adjust them.
The machine is not allowed to be operated with defective or electrical bypassed

safety devices (do not change the program in the software of the programmable
WARNING! control).
After finishing the maintenance and cleaning work an examination of control and
WARNING! safety devices has to be done.
5 .3 .2 PLC and Common Control

The Common Control system requires no maintenance except for annual inspection for dust deposits and
check on the security of connections, which can become loose due to vibration etc.
The most likely faults encountered with the PLC are failure of an input or output due to voltage transients or
overload. Should this occur, then the relevant card should be replaced following investigation and correction
to the cause of the fault.
The Central Processor has its own built in check routine and a failure of the total system will cause the pro-
cessor to stop. This is detected and all outputs are switched off. Should this occur, the red Fault LED and the
yellow Stop Led on the CPU will be illuminated, and the green Run LED will extinguish.
If the red “BATF” LED is on, this indicates that the CPU battery is not present or faulty
and requires fitting or replacement.
WARNING!
DO NOT SWITCH OFF THE POWER TO THE CPU WHILE THIS LED IS ON AS THE
PROGRAMME AND ALL DATA MAY BE LOST.
REPLACEMENT OF THE BATTERY SHOULD BE CARRIED OUT WITH THE POWER

SWITCHED ON.
5 .3 .3 Processor Fault
Connect a portable computer, select the project programme and go to the “On-Line” Image.
Investigate the Fault status by clicking on “Processor Status” on the left-hand box of the software window
5 .3 .4 Digital Input Fault

Connect the portable computer as above and go On-Line
1- Check the Input signal is present at the Panel terminals using a multimeter.
2- Check that the relevant LED is illuminated on the front of the Input Unit.
3- Check that the signal measured in 1 is present at the input terminal on the Input module.
4- A lost signal will be the result of a broken or loose wire.
5- With the computer on line the signals can be monitored within the software, a signal satisfy-
ing the conditions of the software rung will be shown highlighted in green on the screen.
6- With the signal present at the Input terminal, not recognised by the software, or with the LED
Off, the Input Unit will most probably be faulty and should be changed.

Project:
SCHADE-no.: 20.312
5 .3 .5 Digital Output Fault

The most likely problem with an output is a solenoid not functioning. In this case the first check should be on
the output fuse. Each solenoid coil is protected by a 2-amp fuselink in the associated terminal.
If the fuse is intact then the following procedure should be followed:-
1- Connect the portable computer as above and go on-line.
2- Check for voltage at the output side of the terminal using a multimeter. If voltage is present,
check for broken or loose plant connections.
3- Check for the LED on the output module, this should be illuminated when the output is on. If
this is the case, follow the circuit diagrams and check for broken or loose connections within
the panel.
4- If the LED does not illuminate, monitor the segment of the software control programme.
When the segment logic is satisfied, the relevant operand will be highlighted in green on the
screen. If the output is shown in green but no output is obtained, the output module is faulty
and should be changed.
IMPORTANT! SWITCH OFF THE PLC BEFORE REMOVING OR INSERTING ANY MODULES.

Project:
SCHADE-no.: 20.312
6 Lubrication
6.1 General lubrication instruction

All lubrication points and lubrication containment levels shall be controlled weekly and checked for function
and tightness. The lubrication points have to be cleaned every 3 years and refilled again with grease:
Motors, gears, brakes, etc. oil or grease change and maintenance work has to be done as per manufacturer
instructions; see 9 Documents of Sub Supplier
To refill or restore the filling capacity the same sort of oil as per “first filling of manufacturer” has to be applied
or complete exchanged.
During eventually occurring oil sort change only use oil and grease allowed by the manufacturer.
The application of different sorts of oil (mixing) may lead to an early com-
CAUTION! ponent defect.
Oil change and lubrication is only allowed when machine is switched off
CAUTION! and made safe against switching on again.
The client has to take care of the existing of suitable and safe equipment on the machine for lubrication and
control work.
6.2 Special lubrication instructions

There is an automatic grease lubrication unit for the end rings.
Interval for the greasing of the end rings: every 4 working hours - 1/2 hour greasing.
The min. grease level has to be adjusted at 100 mm over the bottom. By reaching this level a refilling is nec-
essary.
These intervals are only proposals from our experience, but it could be necessary to modify them
when the machine has been in operation for some time.
For further Information see No. = No. of Documentation of sub supplier
No. Qty. Lub. Point Lub. Qty. for Lub. Typ Check Changing interval
Method each point first normal
REXROTH HLP Mineral
9.1 Oil max. 705 L monthly
Hydraulic tank ISO VG 68
BIJUR DELIMON
9.2 Grease monthly
Pivot

Project:
SCHADE-no.: 20.312
7 Spare and Wear parts list

You are informed explicitly, that spare parts and accessories not supplied by us, are not checked and re-
leased by us, too.
The assembly and/or the application of those products may change the given by construction properties of
our machine in a negative way and may impair the active and/or passive safety.
For damages, which arise from the application of not “ORIGINAL SPARE PARTS” and “ACCESSOIRES”
every liability from the side of SCHADE-Lagertechnik GmbH company is excluded.
Please pay attention, that for individual and foreign parts there are special specifications for production and
supply, and we always offer you spare parts per newest prior art and newest legal prescriptions.
Indicate following data for spare parts order:
Commission no.:
Designation:
Rating:
Order no.:
Spare parts no. (mentioning page no., too):
Type:
Number of items:
The following lists gives a view of the most needed spare and wear parts. A perfect function of the machine
is only guaranteed by the use of “ORIGINAL SPARE PARTS”. The mounting of the spare parts has to be
done by the manufacturer or an instructed specialist. To be independent of delivery time in a case of dam-
age, it is recommendable to keep important parts on stock.
With pleasure SCHADE advises you by the selection of these parts.
Spare /
Pos. Description Part-no.
Wear Part
1 Wear part Upper locating block
2 Wear part Roller
3 Spare part Clamp

1 2

Project:
SCHADE-no.: 20.312
Spare /
Wear Part
1 Wear part Lower locating block 6708_02_004 2
2 Spare part Roller Support Ramp 6709_02_004
1
1 Spare part Pinion 6606_01_005
2
Braked Hydraulic
2 Spare part 6737_00_001
Motor
1 Spare part Locking Assembly RfN7012 2
1
2 Spare part Bearing SNLD
6622_01_002
1 Wear part Pad
6622_01_003 1
6729_01_008
2 Wear part Cover _____
6729_01_039
2
1

Project:
SCHADE-no.: 20.312
1
1
Spare Part
Wear Part
1 Wear part Cover
2 Wear part Wear plates on wagon support bracket 6666_02_004 / 6104_02_009
3 Wear part Wear plates on fixed blocking (lower) 6742_01_007 / 6104_02_009

Project:
SCHADE-no.: 20.312
8 Drawings (appended)
Family Tree 6000_00_003

Assembly of 14m Pivot Frame Tippler 6035_02_007
Assembly of Pivot Frame Tippler Structure 6095_02_002
Assembly of Platform 6100_02_003
Assembly of Tippler Main Pivot (Non-Locating) 6101 _02_002
Assembly of Tippler Main Pivot (Locating) 6101_02_001
Assembly of Tippler Clamp 6102_02_006
Assembly of Tippler Drives (Left Hand) 6103_02_006
Assembly of Tippler Drives (Right Hand) 6103_02_007
Assembly of Tippler Spill Plates and Wear Plates 6104_02_009
Assembly of Tippler Cable Loop 6105_02_003
Assembly of Tippler Limit Switches 6106_02_003
Assembly of Ultrasonic Sensors 6107_02_003
Assembly of Grout and Packing 6108_02_003
Assembly of Platform Support 6115_02_003
Assembly of Tippler Fixed Blocking 6130_02_003
Assembly of Tippler Ballast 6186_02_002
Assembly of Platform Walkways 6198_02_002
Assembly of Tippler Electrics 6340_00_002
Assembly of Tippler Hydraulics 6400_00_002
Assembly of Tippler Lubrication 6410_00_002
End Ring Structure (Driven) 6561_02_007
End Ring Structure (Driven) 6562_02_007
Side Beam Structure 6565_02_009
Platform Structure 6566_02_007
Rack Section 6602_01_005
Clamp Bracket 6692_02_003
Rack Tooth Template 6739_01_002
Wagon Spill Plate 6746_02_001

Project:
SCHADE-no.: 20.312
9 Documents of sub supplier (appended)
9.1 REXROTH Hydraulic power unit

9 .1 .1 General Commissioning Instructions
9 .1 .2 Operating Instructions
9 . 1 .3 Drawings
9 . 1 .4 Component Data Sheets
9 . 1 .5 After Sales
9.2 BIJUR DELIMON Grease Lubrication

9 .2 .1 Lubrication O&M Manual GSE 49149
9.3 ENVIROFLO Dust suppression

9 . 3 .1 LOWARA eSV Pumps O&M
9 .3 .2 LOWARA Float Switch
9 . 3 .3 PROMINENT Delta O&M
9 . 3 .4 AIRPEL Water Filter
9 .3 .5 DANFOSS Solenoid Valves O&M
9 .3 .6 PNR Spray Brochure
9 . 3 .7 Drawings
9.4 ICONSYS Electric HMI Screens

9 . 4 .1 Schematics & Diagrams
SINGLE LINE DIAGRAMS
COMMUNICATION NETWORK
TERMINAL STRIP OVERVIEW
TERMINAL CONNECTION DIAGRAM
OPERATOR DESK
TOUCHSCREEN HMI
PLC COMMON CONTROL
HPU MAIN
HYDRAULIC POWER PACK
BOSCH REXROTH HYDRAULIC
MATERIAL HEIGHT DETECTOR
TIPPLER PROXMITY SWITCHES
TIPPLER ENCODERS
TIPPLER WARNING LIGHTS & HORN
LUBRICATION SYSTEM
TIPPLER ENTRY LOCAL CONTROL STATION
TIPPLER CLEARANCE ULTRASONIC SENSOR
WAGON TIPPLER CLAMP 1 PROXIMITY & VIBRATION MOTOR 1
TIPPLER EXIT WAGON RUN-BACK STOP
RAIL TRACK SIGNALING SYSTEM
DUST SUPPRESSION SYSTEM
TIPPLER JUNCTION BOXES

Project:
SCHADE-no.: 20.312
9.5 SKF Bearing

9 .5 .1 Mounting Instructions
9 .5 .2 Transport Instructions

Maintenance Wagon-Tippler En-Rev3

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Maintenance Wagon-Tippler En-Rev3

Uploaded by

Copyright:

Available Formats

Product: Wagon unloading system

SCHADE Lagertechnik GmbH Tel.: +49 209 50316 0

Inspection and Maintenance.doc 2014-07-04

1 Notes on this document ................................................................................................................... 4

2 Safety instructions ............................................................................................................................ 5

3 Components and parts of the machine .......................................................................................... 6

4 Inspection ........................................................................................................................................ 10

5 Maintenance and supervision instruction .................................................................................... 24

6 Lubrication ....................................................................................................................................... 28

Inspection and Maintenance.doc 2014-07-04 2

7 Spare and Wear parts list ............................................................................................................... 29

8 Drawings (appended)...................................................................................................................... 32

9 Documents of sub supplier (appended) ....................................................................................... 33

Inspection and Maintenance.doc 2014-07-04 3

1 Notes on this document

1.1 Use of maintenance manual

1.3 Contact address

SCHADE Lagertechnik GmbH Tel.: +49 209 50316 0

Inspection and Maintenance.doc 2014-07-04 4

Switch-off the machine during all necessary maintenance-, repair- and

Machine repairs are allowed only by trained and competent personnel.

Use protective equipment wherever required by the circumstances or by

Inspection and Maintenance.doc 2014-07-04 5

3 Components and parts of the machine

3.1 Plant overview, Rail level

Inspection and Maintenance.doc 2014-07-04 6

3.2 Plant overview, material dump area

Inspection and Maintenance.doc 2014-07-04 7

3.3 Parts of the wagon tippler

(1) End ring structure

Inspection and Maintenance.doc 2014-07-04 8

3.4 Parts of the wagon run back stop

Inspection and Maintenance.doc 2014-07-04 9

4.1 Pivot frame tippler structure .......................................................................................................... 13

4.2 Tippler Drive .................................................................................................................................... 14

4.3 Tippler clamps ................................................................................................................................. 16

4.4 Main pivot ........................................................................................................................................ 17

4.5 Cable loop ....................................................................................... Fehler! Textmarke nicht definiert.

4.6 Platform supports ........................................................................................................................... 18

Inspection and Maintenance.doc 2014-07-04 10

Check Feature Example Code

Inspection and Maintenance.doc 2014-07-04 11

Inspection and Maintenance.doc 2014-07-04 12

4.1 Tippler Structure

Inspection and Maintenance.doc 2014-07-04 13

4.2 Tippler Drive

2 Pinion Cleaning, Greasing out-of-order

Inspection and Maintenance.doc 2014-07-04 14

4.3 Tippler platform

Under Tippler Platform 3

Inspection and Maintenance.doc 2014-07-04 15

4.4 Tippler Clamp

Inspection and Maintenance.doc 2014-07-04 16

4.5 Tippler Main Pivot

Inspection and Maintenance.doc 2014-07-04 17

4.6 Platform supports

Inspection and Maintenance.doc 2014-07-04 18

4.7 Hydraulic Power Unit (Part 1)

Inspection and Maintenance.doc 2014-07-04 19

4.8 Hydraulic Power Unit (Part 2)

Inspection and Maintenance.doc 2014-07-04 20

4.9 Dust suppression

Inspection and Maintenance.doc 2014-07-04 21