10 SERVICE INFORMATION AND PROCEDURES 10.1 SERVICE SCHEDULE SERVICE SCHEDULE- HOPPER PROCEDURE PER DAY BETWEEN SHIPS MONTHLY ox MONTHS PER Grease Points Hydraulic Fluid Level Check x Hydraulic Fluid Test * Gate Knife Cleaning Air Conditioner Fins Wash down (Oil Tank Cooler Fins Wash Down Cladding Wash Down ‘Spout Gearbox Fluid Change Lanolin Based Spray Down (Compressor Service" * Refer section 9.8 “* Refer compressor section 8.1 SERVICE SCHEDULE- DUST COLLECTOR SERVICE TASK BETWEEN SHIPS. MONTHLY ‘Si MONTHS. PER YEAR Check compressed airlines for loaks (Check pulse valves are all pulsing (Check pressure gauge line is not plugged ‘Spot check for bag leaks Check pulse system hoses and clamps for leaks (Check accuracy of indicating equipment Inspect fiter unit for product build up Full inspection of bags for damage Check ducting for product build up (remove duct sec- tions as required), (Check fan isolation mount bolts are secure: Run fan up and check for excessive vibration Page & Macrae Ltd | 150 9001-2008 Doc 1419 3510.2 FLUID SCHEDULE Tem [BRAND [TYPE [QUANTITY Hydraulic [eit [46 98 Litres Fluid system 60 Litres tank Surface |Prolan_| Presenv- Protect lanolin | ative Spray | based spray 10.3 GREASING WHEEL BEARING GREASING: ‘The hopper bogie wheel bearings are sealed units that require periodical cleaning and repacking with grease WHEEL PIVOT BUSHES: ‘The Whee! Bogey pivots on a greased pin and bushes as shown in the photo (see fig 10.3.1). Tho grease point for tho bushes is reached Figure 10.3.1 Pivot grease point 10,4 PRESERVATIVE SPRAY DOWN Use marine preservative spray (lke CRC Long Life) to spray galvanized dust collection ducting This will prevent premature failure of the surface protection, The Loading Spout extemal surfaces should also be sprayed, 10,5 DISCHARGE ACCUMULATOR HYDRAULIC FLUID CHARGE Attar the Electro/hydraulics have been isolated and locked out above, there still remains hazard associated with stored hydraulic pressure. At this stage, the spout service platform may be accessed by ane person only who will be required to discharge the accumulator. Pull the discharge lever soit is pointing across. This will ‘empty the accumulator and vent the hydraulic system pressure. After these steps have been taken, more than one person may access the ‘spout service platform. Figure 10.5.1 This picture shows the accumulator discharge valve in the operating position. To DISCHARGE the accumulator and make it safe for the servicing of the hydraulics, move handle 1/4 turn anticlockwise (to horizontal) 10.6 ISOLATE ELECTRO- HYDRAULICS ‘This hopper uses hydraulic cyinders to open and close the Hopper Discharge Gate, The rapid closing movement and fail-safe systems both require a stored volume of high pressure hydraulic fluid. This stored volume of fluid is a hazard to anybody performing service on the Discharge Gate or the Hydraulic Systems. To eliminate this hazard, the Electro/hydraulics must be properly isolated. 1, On the operators Left Hand Control, switch the HYDRAULICS switch to OFF. 2, Press the E-STOP in and tag (lock) i out, Page & Macrae Ltd | 150 9001-2008 Doc 1419 3610.7 HYDRAULIC TANK FILL PROCEDURE REQUIREMENTS: + The immediate area ofthe filler cap should be cleaned prior to opening to avoid ‘contamination of the surrounding area. + Clean fluid pouring funnel and adequate fluid should be on hand, + Wheels should be retracted, + Discharge gates should be closed, + Remove the filer cap and add ol to raise the oil level to half way up the fluid level sight glass. NOTE: 2 litres of oll should raise the fluid level by 1 centimetre. 10,8 HYDRAULIC FLUID TESTING RECOMMENDED SYSTEM SAMPLING FREQUENCY CHART ‘SYSTEMS WITH TARGET CLEANLINESS 17/15/12 OR LOWER ‘System | <2000 psi | 2000-3000 psi | >3000 psi Pressure |(140 bar) | (140-210 bar) | (210 bar) Bhours of | 4 months |3 months operation per day ‘Over’ | 3monihs [2 months hours of operation perday ‘SYSTEMS WITH TARGET CLEANLINESS 19/16/13 OR HIGHER ‘System | <2000 psi | 2000-8000 psi | >8000 psi Pressure | (140 bar) | (140-210/bar) | (210 bar) ‘months months NOTE: INITIAL COMMISSIONING OR MAJOR REBUILD Large system (2000 litres (530 USgal) or more) and systems with servo valves: + Sample fluid before start-up + Sample fluid during first day running + Sample fluid after one week + Sample tld after one month operation Other systems + Sample during first day running + Sample after one month operation ‘SYSTEMS IN DISTRESS OR IMMEDIATELY AFTER A MAINTENANCE EVENT: (Qe. Increased heat, erratic operation, unusual sound, ete.) + Immediate In all sampling situations itis critical that the ‘systems be in operation or just shut down when the sample is taken. This assures thatthe fluid is. turbulent and that the contamination in the system is circulating and available to be captured in the sample bottle, (Once the cleanliness level has been achieved and confirmed, normal maintenance practices dictate that a system be resampled at regular intervals to reconfirm that the proper cleanliness level is being maintained. It the cleanliness level code value rises, meaning the system is running dirtier than it shoul, the first thing to check i if new ingression is entering the system. Check to be sure that all access, doors are closed and that the vent fters are fitted and operational. Next, check to see if the filters are on bypass; t so, raplace them with the appropriate genuine Vickers fier elements. Lastly, it may be necessary to add a fer to the system. The most common solution is to add a Bhours of [6 months |4 months | 4 months re circulating loop (Pump, motor and fter) to the operation reservoir. por day ‘Over8 [months |Smonths | 2months After any maintenance activities which may hours of introduce contamination, such as hose operation replacement or pump repair, a new sample should por day be taken to confirm that the target cleanliness level is stil being maintained. Page & Macrae Ltd | 150 9001-2008 Doo 1419 3710.9 WELDING ON THE HOPPER Prior to any welding, the Chromed Hydraulic Rods must be fully wrapped to prevent welding spark Before any welding is carried out on the hopper burn markings and damaging the rods. the following recommendations must be adhered to: WHEEL BOGEY: Ensure welding earth is attached to the steel part being welded, Do NOT allow the earth current to ‘ross through the wheel bearings, LOADING SPOUT: Refer to Loading Spout Manual (Page 18) for details HOPPER WALL STIFFENERS: ‘These should not be welded. These are Sumiten 0 high tensile steel (refer fig 10.9.1) Figure 10.9.1 1. Sumiten 80 High Tensile Stee! Hopper Stiffeners GENERAL HYDRAULICS: ‘There are Hydraulic Cylinders located in the wheel cabinet and also in the hopper discharge gates. Figure 10.9.2 Location of Chromed Hydraulic Rods, Protect prior to welding. Page & Macrae Ltd | 150 9001-2008 Doc 141910.10 TROUBLE SHOOTING ‘SYMPTOM RESOLUTION Hydraulic pump | Check € STOP is not pushed in, will not start ‘Check power is connected to the hopper. ‘Check that the HYDRAULICS is switched to ON. ‘Check Main Console that "Phase Rotation Fault” ight should be OFF, iit is ON, this means the power connection extension lead has been wired in a Unconventional rotation. If light is on, go to the incoming power phase reversal ‘switch and switch to the opposite direction. (FORWARD or BACKWARDS) Discharge gate moves slowly or erraticaly "Accumulator discharge valve has been left open. Check that this is closed. Refer t0 10.5.1). Hydraulic Fluid level is low. (Refer to 10.7) - HYDRAULIC TANK FILL PROCEDURE Hydraulic accumulator nitrogen pre-charge level is wrong (too high or too low). Contact hydraulic serviceman to check the pre-charge. Refer to 2.2 and 4.3, Gale is not strong enough to open orshut ‘Severe build up on the roller / blade suriace of the gate blade or rollers. This will need to be cleaned off Gate will not move ‘Check that E STOP is not pushed in ‘Check main power is connected (tty the internal cabin lights) ‘Check Main Console that "Phase Rotation Fault’ light should be OFF. Wit is ON, this means the power connection extension lead has been wired in a Lunconventional rotation, Ilight is on, go to the incoming power phase reversal switch and switch to the opposite direction, (FORWARD or BACKWARDS) ‘Check console HYDRAULICS witch Is ON. Listen to pump, to check pump is running. ‘Check fluid level. If hydraulic fluid level is low, refer to 10.7 - HYDRAULIC TANK FILL PROCEDURE. ‘Accumulator discharge valve has been left open. Check that this is closed. Refer 4.3.1 - DISCHARGE ACCUMULATOR HYDRAULIC FLUID CHARGE. ‘The pressure sensoritransducer located on the gate manifold on the service platform may not be reading high enough pressure to allow the opening process to start. Investigate if the control room HMI panel is showing a hydraulic pressure of at least 160 bar. This is the minimum pressure to start the cylinder opening the gate. Hopper Wheel Stystem will not lower (Chack locking pins are removed. Rafer to 2.5 LOWERING BACK ONTO FEET. ‘Check pump is running. ‘Check fluid level. If hydraulic level is low, refer to 10.7 - HYDRAULIC TANK FILL PROCEDURE. Check lower system selecting switch is on WHEEL JACKS Page & Macrae Ltd | 150 9001-2008 Doc 1419 39SYMPTOM RESOLUTION Hopper Wheel | Check locking pins are removed. Refer to 2.5 LOWERING BACK ONTO FEET. system will not [Check pump is running, ‘Check system selector valve is pointing to JACK. Refer to 2.5 LOWERING BACK ‘ONTO FEET. ‘Check Hopper is empty. ‘Check Fluid level. If hydraulic fluid level is low, refer to 10.7 - HYDRAULIC TANK FILL PROCEDURE. ‘Check the lower system selection switch is on WHEEL JACKS Loading Spout problems Refer to trouble shooting section of LOADING SPOUT MAINTENANCE MANUAL. ‘Spout will not move up or down ‘Check E STOP is not pushed in ‘Gheok power is connected to the hopper. ‘Check Main Gonsole that "Phase Rotation Fault light should be OFF. tfitis ON, this means the power connection extension lead has been wired in a unconventional rotation, If ight is on, go to the incoming power phase reversal switch and switch to the opposite direction. (FORWARD or BACKWARDS) ‘Open the main control console and observe all the starters are pointing up to on and all four breakers are on. Reset these if necessary. Loading Spout ‘Suction from the dust collector is too high for the airflow. There may be a restriction outer sock in the spout discharge point caused by material build up. Lower the spout fully and is folding up _| clean out any build up from the spout outlet. (sucking in) Hopper Jacking | Check Hydraulic pump Is running ‘system will not [Check hydraulic fluid level is correct, refer to 10.7 HYDRAULIC TANK FILL lower PROCEDURE. ‘Gheok for any obstructions stopping the hopper from lowering, Hopper Jacking | Check Hydraulic pump is running system will not raise ‘Check the hoppers empty ‘Check for any obstructions above the hopper Page & Macrae Ltd | 150 9001-2008 Doc 1419 4010,11 BILL OF PARTS BILL OF PARTS [err ouvir lou re = ova be [acon an creo eter [ms ster [bseter Forconace wasts eso Esa oe wo rea aL [vara seer ps ove conc [ros et Este asia feos rede [eom ot cri [sam soar fromurcoe [ea fea fra [anoiow soe ies Meer cra wae [sin ene Myc Mar conac jai ed iti et fewoion rer ope Pas Raton ia esos ogee news sar ano fan fer ieee st ag ins anon iu naar ope ona Spsy 8 Mesa wero i Co rome Sy feet aoa goose ues coxa Re iwskclos8veC eae weer fest femstoetnou = [west Poco harass ouck mse 7 Coo — a fierce fare sewopiat conmeourn ene Pc YoMoa [ora uonucrTsanatoe nts Pe YoNodue fsoant wooue sss wrur ——— at Peyote fogs moor aad opus esp connect sovow.cow conatsecsotosiing Jes ut buon operat Page srr rags oes hare hativior coment [swan ae TED fare ution porn ConaGHGcl BS Conn Weck NE fare Patan onponnt=Conac et BeOS cota Beck ND fare buon onpore Conic oct BCE Cora DoW wes rahevton- aba [vari pons sc les Paha a Shears oe fare akon em [swaraunta pakon cece [wre ton onpone TER FsWinraee eo acc lars futon congener Up js epee fies fasten comport [siwaourseset9 soc fare oo Congo Fsiwaoursess3Yetow les tun congener Ug sau arr Boa our lies fesse esw-xroan sence sw nob ange — wre Esean-omes eswemnsosun swarms — Ws rs ion Capon swoon FicTen we fare fuaneuon congener“ Ug esi a gh fare ton congener Ug [sivsoenrisrgh wes futon opener Ug SWS tig ran wes Pst buon congener Ug i ton era wre ton conser inetpte oc 2 lars [ers st Dan tear st Ge Ba soos conaccs eee] ced [omer Sets uM Ormst E3Ger — per I cng Page & Macrae Ltd | 150 9001-2008 Doc 1419 4Frc ay ighting ooh L020 nw Tango Pies forse walkway Ugh Fg Unser verandah LED 2F7 P65 [neo (nie sacon/Sounser Rost ROLPsounser cen pera vaive Fg app ave pug assem are Ierauic Pump Motor [2232 ab 1320 8354000 GOAT [wes aera) [ioaper Power supp) Nintisaspersvirey [scare [| Branca em ]FA600 PE972 (ul bre mmersion for ol iter water restance) buster Puss Vane. 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