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The Extendible Conveyor is designed to operate with a minimum of maintenance. The preventive maintenance procedures listed below provide an easy means of determining the operational status of the conveyor. The preventive maintenance procedures result in identification of possible trouble areas so the condition will not deteriorate to the point where a failure is likely to occur.
(1) Objective of Program
The objectives of the Preventive Maintenance check list is to assure the equipment is working at maximum efficiency over long periods of time and eliminate costly repairs and downtime.
(2) Need for Standard Preventive Maintenance Procedures
To ensure effective control over maintenance operations and to permit comparability between equipment as a means of evaluating the maintenance program. Preventive Maintenance Procedures are criteria which may be applied at all equipment locations.
(1) Categories
Preventive maintenance can be divided into three categories, each of which is represented by aseparate type of checklist.
a. Inspection Checklists
These check lists specify those activities which call for the highest level of mechanical and electrical skill. These checklists are primarily concerned with inspection and adjustments, though tightening and cleaning activities may be included when delicate or complex equipment is involved. Inspection checklist activities are limited to weekly, monthly, quarterly, semiannually and annual intervals. DURING AN INSPECTION, NEVER TOUCH A MOVING BELT OR ROTATING PART
b. Cleaning and Lubricating Checklists
These checklists are primarily concerned with cleaning, lubricating and tightening activities. These jobs do not require as high a level of technical skill as those appearing on inspection checklists. Performance frequencies for Cleaning and Lubricating Checklist activities are also limited to monthly, quarterly, semiannual and annual intervals
c. Routine Preventive Maintenance Checklists
These checklists are concerned with all of the activities listed above, but are normally directed at a level of skill between that required for inspection checklists and that required for cleaning and lubricating checklists. Inspection and adjustment work assigned at this level is less complex than work listed on inspection checklists: Performance frequencies for Routine Preventive Maintenance Checklist activities are, in most cases, limited to daily, weekly and biweekly intervals.
It is recognized that conveyors may be installed in locations not staffed to carry out the complete maintenance program. Where qualified personnel are not available, the preventive maintenance program should be limited to performing the cleaning and lubricating and routine preventive maintenance routes only. The inspection routines can be assigned to the operator.
NOTE: Preventive maintenance instructions and checklists issued by the Stewart Glapat Corporation, shall be followed; except that manufacturer's maintenance stipulation for parts covered by warranty shall be followed during the warranty period.
(Performed by Operator)
(1) Check operation of conveyor controls. Ensure that all "STOP" pushbuttons operate properly. Also ensure that all limit switches function properly.
(2)Clean any accumulation of dust and/or dirt from the conveyor surfaces and remove any accumulation of debris. Do this with the conveyor belt stopped. Never touch a moving belt or rotating part.
(3)Ensure belt is tracking properly. NEVER TOUCH A MOVING BELT.
(1) (Safety) Observe all safety precautions. Turn off conveyor except when operations must be performed with equipment running. NEVER TOUCH A MOVING BELT OR ROTATING PART.
(2) (Examine Controls and Wiring) With the conveyor shut down and disconnected, look for damage to conduit and wiring. DO NOT TOUCH LOOSE WIRES.
(3) (Examine Motor and Reducer) With the conveyor shut down, look for damage to motor and reducer housings. Look for evidence of lubricant leakage from gearcase. If leakage is detected, check for proper oil level. Add oil if required. (Lubricant: Texaco Multigear EP-85W-140 or equivalent). . .
(4) (Clean Conveyor) Remove any accumulated debris from beneath the surfaces of the conveyor. MAKE SURE CONVEYOR IS LOCKED OUT.
(5) (CLEAN UP) Restore conveyor to its original status. Ensure all inspection equipment is removed from work area. Initiate repair work orders as required. Report serious deficiencies to the maintenance supervisor.
(1) (EXAMINE PULLEYS & BEARINGS) With the conveyor running, listen for abnormal noise coming from any pulley assembly or bearing. All pulley bearings should be lubricated every four to six weeks. Tighten set screws as needed. NEVER TOUCH A ROTATING PART. USE A METAL ROD TO TRANSMIT SOUND TO YOUR EAR AND NOTE ANY EXCESSIVE BEARING NOISE. NEVER REACH UNDER OR INTO THE CONVEYOR WHEN THE BELT IS RUNNING. FOR ACCESS TO SOME PULLEYS, COVERS MUST BE REMOVED IN MATING BOOM SECTIONS. USE METAL ROD TO REACH THROUGH ACCESS WINDOWS TO CONTACT BEARINGS. SEE ASSEMBLY DRAWINGS FOR LOCATIONS.
(2) (EXAMINE BELT) With the conveyor running, look for damage to belt or belt lacing. Remove any raveled edges or cord that might catch on pulley assemblies. Also repair or replace belt lacing that show physical damage. NEVER PERFORM ANY WORK ON THE BELT WHILE IT IS MOVING.
(3) (RETURN ROLLERS) Using a metal rod, contact the protruding ends of the hex shafts to listen for abnormal bearing noise. Remove window covers to gain access to some roller shafts. Never reach your hand through these windowns when the belt is running. Replace all covers when done. Never reach under the machine when the belt is running.
(4) (EXAMINE MOUNTING BOLTS) Check all drive motors by jogging units to ensure mounting bolts are tight. Check conveyor hold-down bolts to ensure conveyor will not come loose from floor hold-down devices.
(5) (ELECTRICAL CABLE REEL) Inspect electrical cable to ensure that cable is not pulling out from a cable connector. Also completely extend and retract the conveyor observing the recoil of the cable. If cable is sagging, completely extend the conveyor and attempt to add an additional wrap to the spring at the reel housing. (Do not over tension spring by over wrapping cable). See manufacturer's literature.
(6) (ELECTRICAL WIRING) Check all electrical conduit and fittings to ensure damage has not been done to the system. Fix damaged, loose or bare wiring or connections.
(7) (CLEAN UP) Restore conveyor to its original status. Ensure all inspection equipment is removed from work area. Initiate repair work orders as required. Report serious deficiencies to the maintenance supervisor.
(1) (CAM ROLLER LUBRICATION AND ADJUSTMENT) Inspect and adjust cam rollers. Both both front and rear cam support blocks have provisions for lubrication. Front blocks can be lubricated without guard removal. To lubricate rear cams, the rear guard must be removed. All cam rollers should be checked for proper adjustment. (See boom alignment instructions.) MACHINE SHOULD BE LOCKED OUT FOR THIS PROCEDURE.
(1) (CHANGE FLUID IN GEAR BOXES) Twice a year the gear head lubricant should be changed. The gear cases should be drained and cleaned. Fill units with Texaco Multigear EP-140 or equivalent. (Note: Cold weather applications may require a thinner grade oil).When adding oil to any gear box the following procedure should be followed:
1) Remove the oil level plug in the side of the box that controls the oil level height.
2)Remove the fill line plug located on the top of the gear box.
3)Add lubrication through the top fill line port.
4)Add lubricant until it runs out of the fluid level line hole. CAUTION: DO NOT OVER FILL GEAR BOX WITH OIL.
5)Replace both plugs in gear box. ELECTRICAL LOCKOUT REQUIRED.
(2) (EXAMINE MASTER CONTROL PANEL) Wipe dust from exterior of panel. Open panel door. Remove dust from interior of panel (DO NOT TOUCH WIRES). Look for burned wiring and loose terminal connections. Close panel.
(3) (OBSERVE DRIVE SECTION) With the conveyor running, carefully contact motor and reducer housing WITH METAL ROD to detect excessive vibration from bearings or gears. Listen for evidence of wear or damage to internal parts. DO NOT GO NEAR MOVING PARTS.
(4) (CLEAN BOOM ROLLER CHAINS) With the conveyor shut down and locked out, wipe dirt from chains and sprockets. Lubricate chain with a SAE #10 weight oil.
(5) (WHEEL BEARING INSPECTION AND LUBRICATION) If the conveyor is a traversing unit each wheel bearing should be inspected for wear, proper alignment, and tightness in wheel mount. All wheel bearings should be lubricated at least twice a year and quarterly if unit is traversed regularly. LOCK-OUT REQUIRED.
(6) (TRACK CLEAN OUT) If unit is of the traversing type with floor mounted track the rear track should be checked for build-up of dirt and debris. This should not be allowed to build-up where it interferes with conveyor wheels. Clean out slots are provided at each end of the track for removal of debris.
[LOCK-OUT REQUIRED.]
Lubrication points on the conveyor are confined to:
1.Pillow block, take-up, and flange bearings holding the main pulley assemblies.
2. Cam rollers and cam followers for guiding and supporting the booms as they extend and retract.
Each bearing has its own grease fitting and is accessible from either the front, rear or each side of the conveyor section. In order to lubricate the rear cam rolls and followers, the rear cover of the machine must be removed. All greasable joints have standard grease fittings and can be reached from one of the above locations.
The following grease lubrications are recommended for use with the grease gun for lubricating ball bearings.
Texaco Oil Co., Marfak_Multi_Purpose_2
Master Lubricants Co., Lubriko,_M-21
Imperial Oil, Ltd., Andok_280
Shell Oil Co., Nerita_#2
Standard Oil Co., (Ind.), Amolith_#1
Sun Oil Co., Sunoco_844-X
Socony-Mobil Co., Inc., Mobilux_#2
Keystone Lubricating Co., Keystone_44H
Atlantic Refining Co., Atlantic_#54
For the gear box on the drive unit, use Texaco Multigear Lubricate EP-85W-140 or equivalent. Weather conditions and temperature ranges may change this rating. To lubricate the roller chain drive, use any automotive SAE-10 lubricating oil.
Preventitive Maintenance
1. General
2. Preventive Maintenance Checklists
3. Preventitive Maintenence - Limited Use
4. Lubrication
