20312 Maintenance Wagon-tippler en-rev3

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

Inspection and Maintenance.doc 2014-07-04

INSPECTION

and MAINTENANCE MANUAL

WAGON TIPPLER Client:

Southern Peru Copper Corporation

Contractor:

SCHADE Lagertechnik GmbH Tel.: +49 209 50316 0 Bruchstrae 1 Fax: +49 209 50316 288 D-45883 Gelsenkirchen [email protected] GERMANY www.schade-lagertechnik.de


Inspection and Maintenance.doc 2014-07-04 2

1 Notes on this document ................................................................................................................... 41.1 Use of maintenance manual ............................................................................................................... 41.2 Illustrations .......................................................................................................................................... 41.3 Contact address .................................................................................................................................. 42 Safety instructions ............................................................................................................................ 53 Components and parts of the machine .......................................................................................... 63.1 Plant overview, Rail level .................................................................................................................... 63.2 Plant overview, material dump area .................................................................................................... 73.3 Parts of the wagon tippler ................................................................................................................... 83.4 Parts of the wagon run back stop ....................................................................................................... 94 Inspection ........................................................................................................................................ 104.1 Tippler Structure ................................................................................................................................ 134.2 Tippler Drive ...................................................................................................................................... 144.3 Tippler platform ................................................................................................................................. 154.4 Tippler Clamp .................................................................................................................................... 164.5 Tippler Main Pivot ............................................................................................................................. 174.6 Platform supports .............................................................................................................................. 184.7 Hydraulic Power Unit (Part 1) ........................................................................................................... 194.8 Hydraulic Power Unit (Part 2) ........................................................................................................... 204.9 Dust suppression .............................................................................................................................. 214.10 Safety label ....................................................................................................................................... 224.11 Control desk and HMI-Screens ......................................................................................................... 234.12 Electrical devices .............................................................................................................................. 235 Maintenance and supervision instruction .................................................................................... 245.1 General maintenance and supervision instruction ............................................................................ 245.2 Special maintenance and supervision instructions ........................................................................... 245.2.1 Bolted connections ............................................................................................................................ 245.3 Maintenance Electric ......................................................................................................................... 265.3.1 Electrical and mechanical limit switches ........................................................................................... 265.3.2 PLC and Common Control ................................................................................................................ 265.3.3 Processor Fault ................................................................................................................................. 265.3.4 Digital Input Fault .............................................................................................................................. 265.3.5 Digital Output Fault ........................................................................................................................... 276 Lubrication ....................................................................................................................................... 286.1 General lubrication instruction .......................................................................................................... 286.2 Special lubrication instructions .......................................................................................................... 28



7 Spare and Wear parts list ............................................................................................................... 298 Drawings (appended) ...................................................................................................................... 329 Documents of sub supplier (appended) ....................................................................................... 339.1 REXROTH Hydraulic power unit ....................................................................................................... 339.1.1 General Commissioning Instructions ................................................................................................ 339.1.2 Operating Instructions ....................................................................................................................... 339.1.3 Drawings ........................................................................................................................................... 339.1.4 Component Data Sheets ................................................................................................................... 339.1.5 After Sales ......................................................................................................................................... 339.2 BIJUR DELIMON Grease Lubrication ............................................................................................... 339.2.1 Lubrication O&M Manual GSE 49149 ............................................................................................... 339.3 ENVIROFLO Dust suppression ........................................................................................................ 339.3.1 LOWARA eSV Pumps O&M ............................................................................................................. 339.3.2 LOWARA Float Switch ...................................................................................................................... 339.3.3 PROMINENT Delta O&M .................................................................................................................. 339.3.4 AIRPEL Water Filter .......................................................................................................................... 339.3.5 DANFOSS Solenoid Valves O&M ..................................................................................................... 339.3.6 PNR Spray Brochure ......................................................................................................................... 339.3.7 Drawings ........................................................................................................................................... 339.4 ICONSYS Electric HMI Screens ....................................................................................................... 339.4.1 Schematics & Diagrams .................................................................................................................... 339.5 SKF Bearing ...................................................................................................................................... 349.5.1 Mounting Instructions ........................................................................................................................ 349.5.2 Transport Instructions ....................................................................................................................... 34



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 Bruchstrae 1 Fax: +49 209 50316 288 D-45883 Gelsenkirchen [email protected] GERMANY www.schade-lagertechnik.de



2 Safety instructions

DANGER!

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 has to be set at once.

DANGER!

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. 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 work-ing area of the machine. The discharge area is not allowed for access during operation.

WARNING!

The machine shall be operated by trained persons only. Even for short time, operation by untrained personal is not allowed.

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.

WARNING!

Machine repairs are allowed only by trained and competent personnel.

WARNING!

After maintenance and repair work all safety devices are to be re-set.

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.



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)

a h

f

c

e

b

g

i

e

k

h

f

L m



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)

a

b

c

d



3.3 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 not shown (10) Cable loop (11) Limit switches (12) Tippler hydraulics

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

1

2

5

6

8

4

9

1

4

5

3

7

8

2 1 2

3

6

8 9

7

3



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



4 Inspection

4.1 Pivot frame tippler structure .......................................................................................................... 134.2 Tippler Drive .................................................................................................................................... 144.3 Tippler clamps ................................................................................................................................. 164.4 Main pivot ........................................................................................................................................ 174.5 Cable loop ....................................................................................... Fehler! Textmarke nicht definiert.4.6 Platform supports ........................................................................................................................... 18



Check Feature Example Code

A Visual check

A - Alignment RailsPivot Conveyor belt

AA1AA2 AA3

C - Completeness Several Parts as Bolts, Safety devices, e.g. after repair

AC1

D - Damages Welds for cracksSteel parts (machine teeth, harrow tine, cable tray) Mech. Parts (pulley, idler, wheels) Electrical parts (cable, sensor) Safety parts, (safety signs, cover, gratings) Surfaces (Paintwork, glass)

AD1AD2 AD3 AD4 AD5 AD6

F - Filling level Hydraulic oilOil container Grease container

AF1AF2 AF3

L - Leakproof ValvesPiping Fluid container

AL1AL2 AL3

P - Pollution Layer of dust or dirt AP1R - Right components e.g. after repair AR1T - Tighten or Loosened components

Re-Tighten bolt connectionCheck for loose bolts. Replace damaged bolts with new bolts

AT1AT2 AT3

W - Wear Size (thickness of rubber, wear plate) Surface (grooves) Form (out of round)

AW1AW2 AW3

B Functional check

M - Mobility Movability BM1O - Operating mode ON / OFF, fault BO1P - Protective devices Cover, railing BP1R - Rotation Winch, On-unwinding Motor, forward / reverse

Pulley, idler Cable reel

BR1BR2 BR3

S - Safety devices Sensor (obstacle, rail end, slack rope) Signal horn, Flash light Emergency stop Emergency pull rope

BS1BS2 BS3 BS4 BS5

T - Tension Conveyor beltMachine chain Rope Cable reel / trolley

BT1BT2 BT3 BT4

C Noise level check

A - Loudness Higher / lower than normal CA1B - Modulation Consistently, swaying CB1

D Temperature check

A - Operating temperature Motor, brake, coupling, bearing, hydraulic oil DA1B - Overheating Motor, brake, coupling, bearing, hydraulic oil DB1



Rails

Pos. Description Maintenance (action) Maintenance (Interval) Operating mode

1 Rail A + B - Gauge Visual check, Functional check 12 Month out-of-order

2 Rail A - Alignment Visual check, Functional check 12 Month out-of-order

3 Rail B - Alignment Visual check, Functional check 12 Month out-of-order

4 Fastening rail A - Nuts - Washer, Rail plate

Visual check, Tightening torques completeness

12 Month In action

5 Fastening rail B - Nuts - Washer, Rail plate


12 Month out-of-order

6 Buffer rail A Visual check, Functional check 12 Month out-of-order

7 Buffer rail B Visual check, Functional check 12 Month out-of-order

8 Fastening buffer A - Nuts - Washer, Rail plate



9 Fastening buffer A - Nuts - Washer, Rail plate



2

8

7

4

6

3

5

9

31



4.1 Tippler Structure


1 2 3 4 5 6

Tippler structure - Pivot Frame - Platform - Tippler Clamp - Wear Parts - Grease Points - Sensor

Visual check, Noise level check, Functional check

1 Week In action

1 Pivot Frame - Bolted connections

Visual check, Tightening torques

12 Month Out-of-order

1

Pivot Frame structure - End ring structure - Side beam structure - Rack section

Visual check, Functional check, 12 Month Out-of-order

2 Platform Visual check, Functional check 3 Month Out-of-order

3 Tippler Clamp - drive 3 Month Out-of-order

4 Wear Parts - wagon support bracket - fixed blocking

Wear Visual check, Functional check


5 Grease points Visual check, Functional check 3 Month Out-of-order

6

Sensor - Position Level 0 - Position End of Tip - Position End of Return

Visual check, Functional check, 3 Month In action

1

5

2

2

3

5

3 3 3

4

4

6

6



4.2 Tippler Drive

For further information see documentation of the sub supplier 9.1 REXROTH Hydraulic power unit.


1 2

Tippler drive - Braked Hydraulic Motor - Pinion


1 Week In action

1 Braked Hydraulic Motor first inspection according to the manufacturer document 00 Hours / 0 Month

In action / out-of-order

1 Braked Hydraulic Motor further Inspection according to the manufacturer document 00 Month In action / out-of-order

1 Braked Hydraulic Motor - Hydraulic Oil

Check - Oil temperature - Oil Level - Oil Quality

out-of-order

1 Braked Hydraulic Motor - Hydraulic Oil

Change Oil - first Oil change - further Oil change

out-of-order

2 Pinion Cleaning, Greasing out-of-order

1 21

1

11

1



4.3 Tippler platform


1 2 3 4

Tippler Platform - Rails - Wheel locating angle - Upper locating block - Roller bracket


1 Week In action

1

Rail Fastening - Nuts - Washer, Rail plate - Alignment



2 Wheel locating angle - Bolted connections - Bracket

Visual check, Functional check 12 Month In action

3 Upper locating block - Wear parts Visual check, Functional check, 12 Month In action

2

Roller bracket - Roller - Wear - Alignment - Running behaviour

Visual check, Functional check,


3

2

1

Under Tippler Platform



4.4 Tippler Clamp


1 2 3 4 5 6

Tippler Clamp - Clamp Cylinder - Clamp Arm - Clamp Beam - Clamp Bracket - Pads - Wear Plats

Visual check Noise level check, Functional check

1 Week In action

1 Clamp Cylinder - Trunnion - Bolted connections

Visual check Functional check 12 Month Out-of-order

2 Clamp Arm - Pivot - Bolted connections


3 Clamp Beam - Pivot - Bolted connections


4 Clamp Bracket - Pivot - Bolted connections


5 Pads - Wear Visual check Functional check 12 Month Out-of-order

6 Wear Plats - Wear Visual check Functional check 12 Month Out-of-order

1

3

6

4

5

2

2

3



4.5 Tippler Main Pivot


1 2 3 4 5 6 7

Tippler Main Pivot - Locking Assembly - Pivot Shaft - Bearing Structure - Shear Block - Pivot Stool - Jacking Screws - Bolts


1 Week In action

1 Locking Assembly - Bolts

Visual check, Tightening torque Functional check


2 Pivot Shaft - Surface

Visual check, Functional check, Noise level check


3 Bearing - Grease

Visual check, Functional check, Lubrication check


4 5 6 7

Structure - Shear Block - Pivot Stool - just able Bolt - Bolts

Visual check Tightening torque 12 Month out-of-order

6

1

4 2

3

5

7

7



4.6 Platform supports


1 2 3 4

Platform Support - Lower Locating Block - Roller Support Ramp - Jacking Screws - Bolts

Visual check Noise level check Functional check

1 Week In action

1 Lower Locating Block - Wear Visual check 12 Month out of order

2 Roller Support Ramp - Wear Visual check 12 Month out of order

3 Jacking Screws - moveable Parts

Visual check Functional check 12 Month out of order

4 Bolts Visual check Tightening torque 12 Month out of order

3

2

4

1



4.7 Hydraulic Power Unit (Part 1)



1 2 3 4 5

Hydraulic power unit - Hydraulic Cylinder - Piping - Hoses - Aggregate - Cooler


1 Week In action

1

Hydraulic cylinder - Leakage - Surface - Movement

Visual check, Functional check 12 Month out of order

2 Piping - Leakage - Condition

Visual check 12 Month out of order

3 Hoses - Leakage - Condition

Visual check, 12 Month out of order

4 Aggregate - Oil Tank

Oil Level - max. 705 L - Warning 530 L - Shutdown 420 L

12 Month out of order

5 Cooler - Cool Fluid - Dust

Fluid Level Cleaning 12 Month out of order

1

5

1

1 3

4

2



4.8 Hydraulic Power Unit (Part 2)



6

Hydraulic power unit - Braked Hydraulic Motor


1 Week In action

6 Braked Hydraulic Motor - Bolted connections Visual check Tightening torques 12 Month out of order

6 Braked Hydraulic Motor - Lubrication



6 Braked Hydraulic Motor - Brake



6

6



4.9 Dust suppression

For further information see documentation of the sub supplier 9.1 ENVIROFLO Dust suppression.


1 2 3 4

Fluid tank Piping hoses Spray nozzle

Completeness Visual check, 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

4

4

4



4.10 Safety label


1 SIGNS for: Prohibition, Mandatory, Warn-ing, Obstruction


1 Week In action

2 SIGNS on Plates Tightening torques 12 Month out of order



4.11 Control desk and HMI-Screens

DANGER!

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 THE PROGRAMME AND ALL DATA MAY BE LOST. REPLACEMENT OF THE BATTERY SHOULD BE CARRIED OUT WITH THE POWER SWITCHED ON


1 Structure and surface of the Control desk and HMI-screen


1 Week In action

2 Inside the Control desk Tightening torques of cables Dust deposits 12 Month out of order

4.12 Electrical devices


1 Signals (Flash beacon, Horn) E-Stop, Switches, Lamps, Sensor


1 Week In action

2 Signals (Flash beacon, Horn) E-Stop, Switches, Lamps, Sensor

Tightening torques of cables 12 Month out of order



5 Maintenance and supervision instruction

DANGER! 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 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.

DANGER! All changes including behaviour of the machine during operation, report im-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.

DANGER! Repair is only allowed during switchedoff machine and made safe against 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



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

mm Specified Minimum Bolt Tension Approximate Equivalent Torque for

Required Minimum Bolt Tension kN

(kilonewtons) Tonne-force Nm

#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.



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.

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).

WARNING!

After finishing the maintenance and cleaning work an examination of control and 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.

WARNING!

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 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.



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.



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.

CAUTION! The application of different sorts of oil (mixing) may lead to an early com-ponent defect.

CAUTION! Oil change and lubrication is only allowed when machine is switched off 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.

Method Qty. for each point

Lub. Typ Check Changing interval first normal

9.1 REXROTH Hydraulic tank Oil max. 705 LHLP Mineral ISO VG 68 monthly

9.2 BIJUR DELIMON Pivot Grease monthly



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.

Pos. Spare / Wear Part Description Part-no.

1 Wear part Upper locating block

2 Wear part Roller

3 Spare part Clamp

1 2

3



Pos. Spare / Wear Part Description Part-no.

1 Wear part Lower locating block 6708_02_004

2 Spare part Roller Support Ramp 6709_02_004

1 Spare part Pinion 6606_01_005

2 Spare part Braked Hydraulic Motor 6737_00_001

1 Spare part Locking Assembly RfN7012

2 Spare part Bearing SNLD

1

Wear part Pad 6622_01_0026622_01_003

2 Wear part Cover 6729_01_008

_____ 6729_01_039

1

2

1

2

1

2

1

1

2

2



Pos. Spare Part Wear Part Description Part-no.

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

1

2

3

1

1

1



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



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 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



9.5 SKF Bearing

9.5.1 Mounting Instructions 9.5.2 Transport Instructions