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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
Bruchstraße 1
D-45883 Gelsenkirchen
GERMANY
Inspection and Maintenance.doc

Tel.: +49 209 50316 0
Fax: +49 209 50316 288
info@schade-lagertechnik.de
www.schade-lagertechnik.de
2014-07-04

Product:
Wagon unloading system
Project:
Client:
SPCC Ilo Peru
SCHADE-no.: 20.312

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

1.1 

Use of maintenance manual ............................................................................................................... 4 

1.2 

Illustrations .......................................................................................................................................... 4 

1.3 

Contact address .................................................................................................................................. 4 

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

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 

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 

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 

Lubrication ....................................................................................................................................... 28 

6.1 

General lubrication instruction .......................................................................................................... 28 

6.2 

Special lubrication instructions .......................................................................................................... 28 

Inspection and Maintenance.doc

2014-07-04

2

Product:
Wagon unloading system
Project:
Client:
SPCC Ilo Peru
SCHADE-no.: 20.312

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

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

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 

Inspection and Maintenance.doc

2014-07-04

3

312 1 Notes on this document For questions about this document please call the contact address given below.2 maintenance personnel for inspection and maintenance of the machine the service personnel Illustrations All illustrations in this document are for illustrative representation. Depending on the machine type and model variations from the exemplary representation are possible. as well as any rights of disposal such as copying and distribution rights belong exclusively to SCHADE Lagertechnik GmbH Bruchstraße 1 D-45883 Gelsenkirchen GERMANY Inspection and Maintenance.de www. to the annexed drawings and other documents.: 20.schade-lagertechnik.3 Contact address All rights to this document.1 Use of maintenance manual This maintenance manual is used:   1. 1.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.: +49 209 50316 0 Fax: +49 209 50316 288 info@schade-lagertechnik. The original drawings listed in the text are to be used for all work on the machine.doc Tel. 1.de 2014-07-04 4 .

WARNING! WARNING! Machine repairs are allowed only by trained and competent personnel. especially make drives safe against restarting. If the red “BATF” LED is on. REPLACEMENT OF THE BATTERY SHOULD BE CARRIED OUT WITH THE POWER SWITCHED ON DANGER! While maintenance only authorized persons are allowed to stay in the working area of the machine. operation by untrained personal is not allowed. The discharge area is not allowed for access during operation. DO NOT SWITCH OFF THE POWER TO THE CPU WHILE THIS LED IS ON AS THE PROGRAMME AND ALL DATA MAY BE LOST.312 2 Safety instructions DANGER! DANGER! Switch-off the machine during all necessary maintenance-.: 20.doc 2014-07-04 5 . repair. To avoid a threatening or occurred dangerous motion the EMERGENCY-OFF switch has to be set at once. Personnel entrusted with work on the machine must have read the operating instructions and in particular the chapter on safety before beginning work. After maintenance and repair work all safety devices are to be re-set. WARNING! As the machine is defect a danger sign has to be displayed and the machine has to be made safe against unauthorized switching-on.and cleaning work. Inspection and Maintenance.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. Use protective equipment wherever required by the circumstances or by law. WARNING! The machine shall be operated by trained persons only. Even for short time. this indicates that the CPU battery is not present or faulty and requires fitting or replacement.

1 Plant overview.doc 2014-07-04 6 .312 3 Components and parts of the machine The following components and parts belong to the machine: 3.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. Rail level The facility includes (a. … ) 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) g e f a h k c e L m f i h b Inspection and Maintenance. c.: 20. b.

Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.: 20. b. c.312 3. … ) 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) a b d c Inspection and Maintenance.doc 2014-07-04 7 . material dump area The facility includes (a.2 Plant overview.

Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.doc 9 2014-07-04 8 8 .: 20.3 Parts of the wagon tippler (1) End ring structure (2) Ballast (3) Main pivot bearings (4) Side beam (5) Tippler clamp (6) Wear plate for wagon contact (7) Platform (8) Drive unit (9) Platform supports 2 4 3 5 1 6 not shown (10) Cable loop (11) Limit switches (12) Tippler hydraulics 7 9 8 (1) End ring structure (2) Ballast (3) Main pivot bearings (4) Side beam (5) Tippler clamp (6) Wear plate for Wagon 3 (7) Platform (8) Drive unit (9) Platform supports 1 1 2 2 5 4 3 not shown (10) Cable loop (11) Limit switches (12) Tippler hydraulics 6 7 8 Inspection and Maintenance.312 3.

Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.doc 2014-07-04 9 .: 20.312 3.4 Parts of the wagon run back stop (1) Handle (2) Cover (3) Rail support (4) Wheel stop (5) Shaft 1 2 3 4 5 Inspection and Maintenance.

.................5  Cable loop ........................3  Tippler clamps ....................................................  4................................ 18  Inspection and Maintenance..........................................................4  Main pivot ............................ 17  4......doc 2014-07-04 10 .....Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no...........: 20............................................................................. 16  4......................................................................6  Platform supports .. Fehler! Textmarke nicht definiert......................................................................................................................................................................................................................................2  Tippler Drive ................................................1  Pivot frame tippler structure ..................................................... 14  4.... 13  4.312 4 Inspection 4......

railing R .Wear Size (thickness of rubber.Leakproof Valves Piping Fluid container P . bearing.Tension Conveyor belt Machine chain Rope Cable reel / trolley A . brake.Alignment Example Rails Pivot Conveyor belt C .Completeness Several Parts as Bolts. forward / reverse Pulley. Safety devices. cable tray) Mech. Functional check Flash light Emergency stop Emergency pull rope T . idler Cable reel S .doc 2014-07-04 Code AA1 AA2 AA3 AC1 AD1 AD2 AD3 AD4 AD5 AD6 AF1 AF2 AF3 AL1 AL2 AL3 AP1 AR1 AT1 AT2 AT3 AW1 AW2 AW3 BM1 BO1 BP1 BR1 BR2 BR3 BS1 BS2 BS3 BS4 BS5 BT1 BT2 BT3 BT4 CA1 CB1 DA1 DB1 11 . swaying A .Tighten or Loosened Re-Tighten bolt connection components Check for loose bolts.: 20. glass) F . gratings) Surfaces (Paintwork. after repair T .Protective devices Cover. brake. after repair D . hydraulic oil Inspection and Maintenance. Parts (pulley.Loudness Higher / lower than normal C Noise level check B . coupling.Overheating Motor. Replace damaged bolts with new bolts W . (safety signs.312 Check Feature A .g. bearing. rail end. e.Mobility Movability O .Safety devices Sensor (obstacle. wear plate) Surface (grooves) Form (out of round) M . cover.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.Operating temperature Motor. wheels) Electrical parts (cable.g. idler.Rotation Winch. coupling.Filling level Hydraulic oil A Oil container Visual check Grease container L .Modulation Consistently.Pollution Layer of dust or dirt R .Damages Welds for cracks Steel parts (machine teeth. slack rope) B Signal horn. sensor) Safety parts. On-unwinding Motor. hydraulic oil D Temperature check B . harrow tine.Operating mode ON / OFF. fault P .Right components e.

Gauge Visual check. Functional check 12 Month out-of-order 3 Rail B .: 20.Alignment Visual check.Nuts . Tightening torques completeness 12 Month out-of-order Inspection and Maintenance.Nuts . Functional check 12 Month out-of-order 8 Fastening buffer A . Rail plate Visual check. Tightening torques completeness 12 Month out-of-order 6 Buffer rail A Visual check. Functional check 12 Month out-of-order 4 Fastening rail A .Washer. Tightening torques completeness 12 Month out-of-order 9 Fastening buffer A .Nuts . Functional check 12 Month out-of-order 2 Rail A . Description 7 9 Maintenance (action) Maintenance (Interval) Operating mode 1 Rail A + B .Alignment Visual check. Functional check 12 Month out-of-order 7 Buffer rail B Visual check.Washer.Nuts . Rail plate Visual check.doc 2014-07-04 12 .Washer. Rail plate Visual check.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.Washer. Rail plate Visual check. Tightening torques completeness 12 Month In action 5 Fastening rail B .312 Rails 1 2 3 4 5 3 6 8 Pos.

doc Visual check.Side beam structure . 12 Month Out-of-order 2 Platform Visual check.Wear Parts .drive 3 Month Out-of-order 4 Wear Parts .Position End of Tip .Pivot Frame . Noise level check. Functional check 1 Week In action 12 Month Out-of-order 1 Pivot Frame .: 20.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.fixed blocking Wear Visual check. 3 Month In action Inspection and Maintenance.Sensor 4 Maintenance (action) Maintenance (Interval) Operating mode Visual check. Functional check 3 Month Out-of-order 3 Tippler Clamp .Position Level “0” .Grease Points .Rack section Visual check. Tightening torques 2014-07-04 13 . Functional check. Functional check 12 Month Out-of-order 5 Grease points Visual check.End ring structure .312 4.Position End of Return Visual check. Description 1 2 3 4 5 6 Tippler structure .Tippler Clamp . Functional check.wagon support bracket .Platform . Functional check 3 Month Out-of-order 6 Sensor .1 Tippler Structure 1 3 3 3 3 4 5 5 2 6 2 6 Pos.Bolted connections 1 Pivot Frame structure .

Hydraulic Oil Check .Oil temperature . Greasing out-of-order Inspection and Maintenance.Pinion Visual check.Hydraulic Oil Change Oil . Pos.: 20.doc 2014-07-04 14 .Braked Hydraulic Motor .1 REXROTH Hydraulic power unit”.further Oil change out-of-order 2 Pinion Cleaning. Description Maintenance (action) Maintenance (Interval) Operating mode 1 2 Tippler drive . Functional check 1 Week In action 1 Braked Hydraulic Motor first inspection according to the manufacturer document 00 Hours / 0 Month In action / out-oforder 1 Braked Hydraulic Motor further Inspection according to the manufacturer document 00 Month In action / out-oforder 1 Braked Hydraulic Motor . Noise level check.2 Tippler Drive 1 1 1 2 1 1 1 For further information see documentation of the sub supplier “9.Oil Level .Oil Quality out-of-order 1 Braked Hydraulic Motor .312 4.first Oil change .Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.

Wheel locating angle . 2014-07-04 15 .Washer.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.Roller bracket Visual check.Bracket Visual check. 12 Month In action 2 Roller bracket .Wear .Rails .3 Tippler platform 1 2 Under Tippler Platform 3 Maintenance (action) Maintenance (Interval) Operating mode Tippler Platform . Tightening torques completeness 12 Month out-of-order 2 Wheel locating angle .Bolted connections .Wear parts Visual check.: 20. Description 1 2 3 4 Inspection and Maintenance.Roller . Functional check 1 Week In action 1 Rail Fastening . Noise level check. Functional check 12 Month In action 3 Upper locating block . Rail plate .Alignment Visual check.doc Visual check. Functional check.Running behaviour 12 Month Out-of-order Pos.Alignment .Upper locating block .Nuts . Functional check.312 4.

: 20.Clamp Cylinder .Bolted connections Visual check Functional check 12 Month Out-of-order 4 Clamp Bracket .Trunnion .Clamp Bracket .Pads .Bolted connections Visual check Functional check 12 Month Out-of-order 5 Pads . Functional check 1 Week In action 1 Clamp Cylinder .4 Tippler Clamp 1 3 2 6 2 3 5 4 Maintenance (action) Maintenance Operating (Interval) mode Tippler Clamp .doc 2014-07-04 16 .Clamp Arm .Pivot .Pivot . Description 1 2 3 4 5 6 Inspection and Maintenance.Wear Plats Visual check Noise level check.Wear Visual check Functional check 12 Month Out-of-order 6 Wear Plats .Clamp Beam .Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.Bolted connections Visual check Functional check 12 Month Out-of-order 3 Clamp Beam .312 4.Wear Visual check Functional check 12 Month Out-of-order Pos.Bolted connections Visual check Functional check 12 Month Out-of-order 2 Clamp Arm .Pivot .

Lubrication check 12 Month out-of-order Structure .312 4.Pivot Stool .Grease Visual check.Bolts Visual check Tightening torque 12 Month out-of-order Pos.Bolts Visual check.Bolts Visual check. Functional check 1 Week In action 1 Locking Assembly .Surface Visual check.Bearing Structure .: 20.Shear Block . Noise level check 12 Month out-of-order 3 Bearing . Functional check.Locking Assembly . Noise level check.Shear Block .Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. Description 1 2 3 4 5 6 7 4 5 6 7 Inspection and Maintenance.just able Bolt .Jacking Screws .Pivot Shaft .Pivot Stool . Functional check. Tightening torque Functional check 3 Month out-of-order 2 Pivot Shaft .doc 2014-07-04 17 .5 Tippler Main Pivot 3 7 2 4 5 1 7 6 Maintenance (action) Maintenance (Interval) Operating mode Tippler Main Pivot .

Lower Locating Block .Wear Visual check 12 Month out of order 2 Roller Support Ramp .doc 2014-07-04 18 .Jacking Screws .Wear Visual check 12 Month out of order Visual check Functional check 12 Month out of order Visual check Tightening torque 12 Month out of order Pos.: 20.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.moveable Parts 4 Bolts Inspection and Maintenance.6 Platform supports 3 2 1 4 Maintenance (action) Maintenance (Interval) Operating mode Platform Support .Roller Support Ramp . Description 1 2 3 4 3 Jacking Screws .312 4.Bolts Visual check Noise level check Functional check 1 Week In action 1 Lower Locating Block .

Shutdown 420 L 12 Month out of order 5 Cooler .Aggregate .Warning 530 L .Hydraulic Cylinder .7 Hydraulic Power Unit (Part 1) 5 4 1 3 1 2 1 For further information see documentation of the sub supplier “9.1 REXROTH Hydraulic power unit”.312 4.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.Hoses .Piping . Description 1 2 3 4 5 1 2 Piping .doc Visual check Visual check. Maintenance (action) Maintenance Operating mode (Interval) Hydraulic power unit .Oil Tank Oil Level .Dust Fluid Level Cleaning 12 Month out of order Inspection and Maintenance.Movement Visual check.Cool Fluid .Leakage . 705 L .: 20.Surface .Leakage .Condition 3 Hoses . Noise level check.Cooler Visual check. 2014-07-04 19 . Functional check 1 Week In action Hydraulic cylinder .max. Functional check 12 Month out of order 12 Month out of order 12 Month out of order Pos.Leakage .Condition 4 Aggregate .

Noise level check.Lubrication Visual check Noise level check Functional check 12 Month out of order 6 Braked Hydraulic Motor . Functional check 1 Week In action 6 Braked Hydraulic Motor .Bolted connections Visual check Tightening torques 12 Month out of order 6 Braked Hydraulic Motor .Braked Hydraulic Motor Visual check.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. Description 6 Inspection and Maintenance.Brake Visual check Noise level check Functional check 12 Month out of order Pos.doc 2014-07-04 20 . Maintenance (action) Maintenance Operating mode (Interval) Hydraulic power unit .8 Hydraulic Power Unit (Part 2) 6 6 For further information see documentation of the sub supplier “9.: 20.1 REXROTH Hydraulic power unit”.312 4.

312 4.: 20. Description Maintenance (action) Maintenance Operating mode (Interval) 1 2 3 4 Fluid tank Piping hoses Spray nozzle Completeness Visual check.doc 2014-07-04 21 .Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. Functional check 1 Week In action 2 3 Piping hoses Tightening torques 12 Month out of order 2 3 Piping hoses Leakage 12 Month In action Inspection and Maintenance. Pos.9 Dust suppression 4 4 4 For further information see documentation of the sub supplier “9.1 ENVIROFLO Dust suppression”.

Functional check 1 Week In action 2 SIGNS on Plates Tightening torques 12 Month out of order Inspection and Maintenance.10 Safety label Pos. Description Maintenance (action) Maintenance Operating mode (Interval) 1 SIGNS for: Prohibition.312 4.: 20. Warning. Obstruction Completeness Visual check. Mandatory.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.doc 2014-07-04 22 .

: 20. Horn) E-Stop. Functional check 1 Week In action 2 Signals (Flash beacon. Switches. Description Maintenance (action) Maintenance Operating mode (Interval) 1 Structure and surface of the Control desk and HMI-screen Completeness Visual check. Horn) E-Stop.12 Electrical devices Pos. Lamps. Sensor Completeness Visual check. REPLACEMENT OF THE BATTERY SHOULD BE CARRIED OUT WITH THE POWER SWITCHED ON Pos. Lamps. this indicates that the CPU battery is not present or faulty and requires fitting or replacement.11 Control desk and HMI-Screens DANGER! If the red “BATF” LED is on.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. DO NOT SWITCH OFF THE POWER TO THE CPU WHILE THIS LED IS ON AS THE PROGRAMME AND ALL DATA MAY BE LOST. Description 1 Signals (Flash beacon. Sensor Tightening torques of cables 12 Month out of order Inspection and Maintenance.312 4.doc 2014-07-04 23 . Functional check 1 Week In action 2 Inside the Control desk Tightening torques of cables Dust deposits 12 Month out of order Maintenance (action) Maintenance Operating mode (Interval) 4. Switches.

inform the SCHADESERVICE. Furthermore we recommend a yearly inspection by a SCHADE expert. dirt. 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. each bolt in the joint shall be additionally tightened by the calibrated wrench (torque) tightening method. Note – for protection during sea transport. It is important that all drives are part of the visible check.and cleaning work. inspection. To avoid a threatening or occurred dangerous motion the EMERGENCY-OFF switch has to be set at once. When all bolts are snug-tight. burrs and other defects which would prevent solid seating of the parts. Check for unusual noises.1 Bolted connections At the time of assembly. To ensure a long running operational safety of the machine we recommend making all maintenance-. or any other applied finish. the bolted joint contact surfaces are painted with the primer coat only. repair. Tight mill scale is not detrimental. loose rust. especially make drives safe against restarting. In the event of irregularities. DANGER! Repair is only allowed during switched–off machine and made safe against forbidden restarting. leaking of oil and quiet running.312 5 Maintenance and supervision instruction DANGER! 5. Machined surfaces shall be rough finished. This must be removed during site assembly of the Tippler.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. Torque tightening shall progress systematically from the middle of the joint outwards. oil. loose scale. General maintenance and supervision instruction Check the machine every day visibly.2 Special maintenance and supervision instructions 5 . All joint plates must be assembled using the Shop Trial Assembly match-marking.2 .: 20. DANGER! All changes including behaviour of the machine during operation. After maintenance and repair work the safety devices have to be re-fixed again and checked of their function. to recognise possible damage in the beginning and to avoid further damage. The wrench shall be returned to ‘touch up’ previously tightened bolts which may have been relaxed as a Inspection and Maintenance. Only spare parts manufactured or released by SCHADE shall be applied. the surfaces in contact shall be free of paint. 5. Machine repairs are only allowed by trained and competent personnel.1 Switch-off the machine during all necessary maintenance-. As the machine is defect a danger sign has to be hung up and has to be made safe against unauthorised switching-on again. or would interfere with the development of friction between them. Stop the machine at once and lock if necessary.and repairing work by SCHADE-SERVICE exclusively. report immediately to the competent authority / person. too. which cannot be repaired by the maintenance personnel.doc 2014-07-04 24 .

0 9.4 92. +10% -6%.: 20.6 21. nut and washer or washers shall be discarded and not re-used.M16 inclusive: M20 & M24: M30 & M36: -0%.1 144. +10% #1 Standard torque figures for unplated fasteners without any additional (above standard supply condition) or special thread lubricant being used.2 42.0 286. Bolt Size mm M12 M16 M20 M24 M30 M36 Specified Minimum Bolt Tension kN (kilonewtons) 49. the bolt. If after complete tightening of a joint.doc 2014-07-04 25 . +10% -10%.5 M12 . Bolts and nuts found to be in any way defective shall be discarded and replaced by new ones. Inspection and Maintenance.1 29. Installation of all structural joints shall be carried out under the supervision of the Schade shop/site engineer.0 418.4 14. a bolt or nut is slackened off for any reason.0 Tolerance on torque figures: Approximate Equivalent Torque for Required Minimum Bolt Tension Nm #1 118 295 576 994 1716 3000 Tonne-force 5.312 result of the subsequent tightening of adjacent bolts until all bolts are tightened to the correct torque.0 207.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.

Should this occur. the red Fault LED and the yellow Stop Led on the CPU will be illuminated.1 Electrical and mechanical limit switches Check the function of the mechanical limit switches. The most likely faults encountered with the PLC are failure of an input or output due to voltage transients or overload. the inductive switches. Should this occur.3 . the Input Unit will most probably be faulty and should be changed. Check that the relevant LED is illuminated on the front of the Input Unit. which can become loose due to vibration etc. The Central Processor has its own built in check routine and a failure of the total system will cause the processor to stop. With the signal present at the Input terminal.3 . then the relevant card should be replaced following investigation and correction to the cause of the fault. perhaps clean and re-adjust them. WARNING! 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 control). Investigate the Fault status by clicking on “Processor Status” on the left-hand box of the software window 5 .3 Processor Fault Connect a portable computer. With the computer on line the signals can be monitored within the software.3 .3 Maintenance Electric 5 . or with the LED Off. the rotation impulse encoders weekly.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. 5 . a signal satisfying the conditions of the software rung will be shown highlighted in green on the screen.3 . DO NOT SWITCH OFF THE POWER TO THE CPU WHILE THIS LED IS ON AS THE PROGRAMME AND ALL DATA MAY BE LOST.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. WARNING! After finishing the maintenance and cleaning work an examination of control and safety devices has to be done.doc 2014-07-04 26 . the ultrasonic sensors.4 Digital Input Fault Connect the portable computer as above and go On-Line 123456- Check the Input signal is present at the Panel terminals using a multimeter.312 5. select the project programme and go to the “On-Line” Image. 5 . Inspection and Maintenance. Check that the signal measured in 1 is present at the input terminal on the Input module. this indicates that the CPU battery is not present or faulty and requires fitting or replacement. not recognised by the software. A lost signal will be the result of a broken or loose wire.: 20. WARNING! If the red “BATF” LED is on. and the green Run LED will extinguish. REPLACEMENT OF THE BATTERY SHOULD BE CARRIED OUT WITH THE POWER SWITCHED ON. This is detected and all outputs are switched off.

2- Check for voltage at the output side of the terminal using a multimeter. the relevant operand will be highlighted in green on the screen. IMPORTANT! SWITCH OFF THE PLC BEFORE REMOVING OR INSERTING ANY MODULES.5 Digital Output Fault The most likely problem with an output is a solenoid not functioning.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. the output module is faulty and should be changed.: 20. If the output is shown in green but no output is obtained.312 5 . In this case the first check should be on the output fuse. this should be illuminated when the output is on. If the fuse is intact then the following procedure should be followed:1- Connect the portable computer as above and go on-line. When the segment logic is satisfied. If voltage is present. 4- If the LED does not illuminate. 3- Check for the LED on the output module. Inspection and Maintenance. monitor the segment of the software control programme. check for broken or loose plant connections. Each solenoid coil is protected by a 2-amp fuselink in the associated terminal.3 .doc 2014-07-04 27 . follow the circuit diagrams and check for broken or loose connections within the panel. If this is the case.

2 Special lubrication instructions There is an automatic grease lubrication unit for the end rings. brakes. By reaching this level a refilling is necessary. for Lub. etc. The client has to take care of the existing of suitable and safe equipment on the machine for lubrication and control work. = No. CAUTION! Oil change and lubrication is only allowed when machine is switched off and made safe against switching on again. of Documentation of sub supplier No. 705 L ISO VG 68 REXROTH Hydraulic tank BIJUR DELIMON Grease Pivot Inspection and Maintenance. Qty.2 Lub. The min. Qty. gears. These intervals are only proposals from our experience. oil or grease change and maintenance work has to be done as per manufacturer instructions. The lubrication points have to be cleaned every 3 years and refilled again with grease: Motors. 6. Interval for the greasing of the end rings: every 4 working hours .1 9. but it could be necessary to modify them when the machine has been in operation for some time.: 20.312 6 Lubrication 6. Point 9. Typ Method each point HLP Mineral Oil max.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. During eventually occurring oil sort change only use oil and grease allowed by the manufacturer. For further Information see No. Lub.1/2 hour greasing. CAUTION! The application of different sorts of oil (mixing) may lead to an early component defect. grease level has to be adjusted at 100 mm over the bottom.1 General lubrication instruction All lubrication points and lubrication containment levels shall be controlled weekly and checked for function and tightness.doc Check Changing interval first normal monthly monthly 2014-07-04 28 . 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.

too. too): Type: Number of items: The following lists gives a view of the most needed spare and wear parts.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. The mounting of the spare parts has to be done by the manufacturer or an instructed specialist.: Spare parts no.312 7 Spare and Wear parts list You are informed explicitly. which arise from the application of not “ORIGINAL SPARE PARTS” and “ACCESSOIRES” every liability from the side of SCHADE-Lagertechnik GmbH company is excluded. that spare parts and accessories not supplied by us. For damages. (mentioning page no. Please pay attention. 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. Indicate following data for spare parts order: Commission no.: Designation: Rating: Order no..: 20. that for individual and foreign parts there are special specifications for production and supply. With pleasure SCHADE advises you by the selection of these parts. are not checked and released by us. it is recommendable to keep important parts on stock. A perfect function of the machine is only guaranteed by the use of “ORIGINAL SPARE PARTS”. To be independent of delivery time in a case of damage. Spare / Wear Part Description 1 Wear part Upper locating block 2 Wear part Roller 3 Spare part Clamp Part-no. and we always offer you spare parts per newest prior art and newest legal prescriptions. 1 2 3 Inspection and Maintenance. Pos.doc 2014-07-04 29 .

2 Lower locating block 6708_02_004 1 2 Spare part Roller Support Ramp 6709_02_004 1 Spare part Pinion 1 6606_01_005 2 Braked Hydraulic Motor 2 Spare part 1 Spare part Locking Assembly 2 Spare part Bearing 1 Wear part 2 Wear part Pad Cover 6737_00_001 2 RfN7012 1 SNLD 6622_01_002 6622_01_003 1 6729_01_008 _____ 6729_01_039 1 2 2 Inspection and Maintenance. Spare / Wear Part 1 Wear part Description Part-no.: 20.doc 2014-07-04 30 .Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.312 Pos.

: 20. Cover Wear plates on wagon support bracket Wear plates on fixed blocking (lower) Inspection and Maintenance.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no. 1 2 3 Spare Part Wear Part Wear part Wear part Wear part Description Part-no.doc 2014-07-04 6666_02_004 / 6104_02_009 6742_01_007 / 6104_02_009 31 .312 1 1 1 1 2 3 Pos.

doc 2014-07-04 32 .: 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 Inspection and Maintenance.Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.

3 .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 WAGON TIPPLER CLAMP 2 PROXIMITY & VIBRATION MOTOR 2 WAGON TIPPLER CLAMP 3 PROXIMITY & VIBRATION MOTOR 3 TIPPLER EXIT WAGON RUN-BACK STOP RAIL TRACK SIGNALING SYSTEM DUST SUPPRESSION SYSTEM TIPPLER JUNCTION BOXES Inspection and Maintenance. 3 . 4 .: 20.6 PNR Spray Brochure 9 .3 PROMINENT Delta O&M 9 .4 AIRPEL Water Filter 9 . 1 . 3 . 3 .7 Drawings 9.1 Lubrication O&M Manual GSE 49149 9.1 .2 Operating Instructions 9 .3 ENVIROFLO Dust suppression 9 .1 REXROTH Hydraulic power unit 9 .4 ICONSYS Electric HMI Screens 9 .Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.3 . 1 .doc 2014-07-04 33 .5 After Sales 9.2 .312 9 Documents of sub supplier (appended) 9.2 BIJUR DELIMON Grease Lubrication 9 .3 .1 General Commissioning Instructions 9 .1 LOWARA eSV Pumps O&M 9 . 1 .2 LOWARA Float Switch 9 .4 Component Data Sheets 9 . 3 .3 Drawings 9 .5 DANFOSS Solenoid Valves O&M 9 .1 .

doc 2014-07-04 34 .: 20.1 Mounting Instructions 9 .312 9.5 .5 SKF Bearing 9 .2 Transport Instructions Inspection and Maintenance.5 .Product: Wagon unloading system Project: Client: SPCC Ilo Peru SCHADE-no.