Maintenance

CONVEYOR SYSTEM MAINTENANCE PROCEDURES (Page 2) Safety | Tips | Glossary | Home | Back | Next

Preventive Maintenance

Preventive maintenance consists of two basic things. It consists of inspection and servicing of the equipment on regular intervals. Doing these two things will eliminate a lot of system down time due to equipment failure.

1. Inspection

Become familiar with the equipment before there is a problem. Walk the system to learn where everything is. Watch how equipment is functioning, how it sounds and how it smells. Read this manual completely and follow its recommendations.

Listening to how the equipment sounds when it is running can tell you things that you cannot see. If a piece of equipment that normally is quiet, begins to make noise, there is a chance that a problem is developing or already exists. The type of noise can even give you a hint as to the type of problem. A squeaking sound usually means that a bearing is going bad. Hissing sounds indicate air leaks in the pneumatic system. A rattle indicates that something might be loose.

Pay attention to smells. If the smell of the equipment changes, something could be wrong. In most cases the change will be due to overheating due to overloading or lack of lubricant.

Observe how the equipment works. Accumulation conveyor backs up when down stream conveyors stop, and it releases product after the conveyor restarts. Notice where product stops with reference to photo eyes and ends of conveyors. Watch the brake-meter belts to see how they are functioning. Check the guard rail to see that they are in the right location and do not cause jam points. Examine the belts, and their lacings, on conveyor to see that they are in proper shape. Watch the blade stops to see that they are operating properly. Observe the boxes on the system and how they are being conveyed. If boxes are backing up on a particular conveyor when the conveyor downstream is running clear, then something may be wrong.

Touch is important. If a motor housing is too hot to touch for more than a few seconds, it could mean there is a problem. If there is unusual vibration, you will know it because you know what the vibration level was before.

2. Cleaning

It is important to keep the conveyor as clean as possible. What this means is to not allow dust, dirt, cardboard or plastic pieces to accumulate around bearings, pulleys, rollers, sprockets, chain and special devices. Cleaning should be done when the equipment is not running. If this type of material is allowed to accumulate it can lead to major problems. Despite the seals on bearings, it is still possible for dust and dirt to enter a bearing. Pieces of cardboard or plastic pressing up against a belt or pulley can cause conveyor belts to track improperly. If sticky material is allowed to accumulate on rollers and pulleys it will also affect belt tracking.

Wipe up any grease or oil spilled on the conveyor or floor area around the conveyor. Grease and oil that gets on drive belts and conveyor belts could reduce the driving force of that belt due to slippage. Oil and grease on the floor is a natural safety hazard. Old parts and equipment from the conveyor should be removed from the work area when maintenance work is done.

Routinely clean the lenses of photo eyes.

Always replace any safety devices removed during maintenance procedures.

3. Equipment Adjustments

Part of the preventive maintenance procedures is making necessary adjustments to equipment when required. Materials stretch when under tension. This includes both belts and chain. Vibration causes things to move. Material that gets caught up in equipment can cause those devices to move from their position. Moving parts wear. Because of those items listed above, mechanical and electrical equipment will require adjusting from time to time. It is always better to be able to make minor adjustments to something thereby extending its life, than to let it get so far out of adjustment that it fails or causes a safety hazard.

Items that should be inspected and adjusted accordingly are:

1. Chain tensions
1. Drive chains
2. Clutch brake
3. Belt tension
1. Flat belts
2. V-belts
4. Belt tracking
5. Driving force transmitted to rollers in live roller conveyor
1. V-belt driven live roller
2. Zone accumulation
6. Pneumatics
1. Air pressure settings
2. Filter regulator lubricators
3. Response setting of accumulation zones

See section D.1 for adjustment information on above items.

4. Lubrication

Lubrication is an important part of preventive maintenance. If those components requiring lubrication are maintained properly they should not fail or show excessive wear except under extreme loading conditions. There are three basic components within this system that require lubrication.

1. Gearboxes: All gearboxes used in this system are worm gear reducers. These are shipped with the proper amount of oil for the mounting position and their input speeds.
1. The factory filled lube is a non-toxic rust inhibiting AGMA 8 compound gear oil, suitable for ambient temperatures of +50^oF or above 125^oF.
2. Worm gear reducer oil must be used to obtain satisfactory gear and worm operating lift. Select the proper type oil from the recommended lubricant chart (Page -MP 5-) depending on expected ambient temperature.
0. For ambient temperatures below 15^oF or above 125^oF contact Electra's factory or nearest distributor for recommendations.
1. Worm gear reducer oils and compounds in accordance with AGMA specifications are commercially available from all major oil companies.
3. Before placing the reducers in operation install vented breathers in the highest position on the gear housing. If mounting position is changed from the installed position, consult the oil level and mounting positions chart (found in manufacturer's bulletins section) to obtain proper oil level.

 

RECOMMENDED LUBRICATION FOR WORM GEARS
MANUFACTURER	LUBRICANT NAME	AMBIENT TEMP. RANGE	A.G..M..A. RATING
Getty Refining Co.	Veedol Asreslude 98	+ 100 to + 150 F	8 EP
Getty Refining Co.	Veedol Asreslude 95	+ 50 to + 105 F	7 EP
Getty Refining Co.	Veedol Asreslude 90	+ 40 to + 100 F	6 EP
Getty Refining Co.	Veedol Asreslude 86	+ 25 to + 90 F	5 EP
Lubrication Eng. Inc.	Almasol 609	+ 45 to + 125 F	8
Lubrication Eng. Inc.	Almasol 608	+ 32 to + 105 F	7
Lubrication Eng. Inc.	Almasol 607	+ 15 to + 70 F	5
Mobil Oil Corp.	Mobilgear 634	+ 50 to + 110 F	8 EP
Mobil Oil Corp.	Mobil Extra Hecla Super	+ 50 to + 125 F	8
Mobil Oil Corp.	Mobil Cylinder 600 W	+ 32 to + 100 F	7
Mobil Oil Corp.	Mobilgear 634	+ 25 to + 75 F	5 EP
Shell Oil Co.	Omala 460	+ 40 to + 115 F	7 EP
Shell Oil Co.	Valvala J460	+ 40 to + 105 F	7
Shell Oil Co.	Omala 680	+ 50 to + 125 F	8 EP
Shell Oil Co.	Valvala J680	+ 50 to + 125 F	8
Texaco Inc.	Meropa 680	+ 45 to + 120 F	8 EP
Texaco Inc.	Meropa 680	+ 32 to + 100 F	7 EP
Texaco Inc.	Meropa 680	+ 15 to + 75 F	5 EP
SPECIAL BROAD TEMPERATURE RANGE LUBRICANTS
Electragear Inter'l Inc.	Electra Lube	+ 15 to + 125 F	--
Kendall	3 Star	- 10 to + 100 F	7
Mobil Oil Co.	Mobil SHC 634	0 to + 135 F	7 EP
Mobil Oil Co.	Mobil SHC 629	- 25 to + 100 F	5 EP
Mobil Oil Co.	Mobil SHC 626	- 40 to + 40 F	3 EP
SPECIAL COLD DUTY LUBRICANTS
Conoco	Polar Start 600	- 40 to + 10 F	--
Lubrication Eng. Inc.	Almasol 606	- 10 to + 40 F	3 EP
Mobil Oil. Co.	Mobil SHC 624	- 55 to 0 F	--
Mobil Oil Co.	Gargoyle Arctic Oil "C"	- 30 to + 5 F	--
Mobil Oil Co.	Mobilgear 627	- 10 to + 40 F	3 EP
Shell Oil Co.	Donax A.T.F.T.-6	- 55 to + 5 F	None

1. Ambient temperature range is based upon 1.0 service factor.

1. Above lubes are compounded for use in "Worm Gears." Some contain non-corrosive, extreme pressure. DO NOT USE lube that contains sulphur and/or chlorine that are corrosive to bronze gears. Extreme pressure lubes, in some cases, contain materials that are toxic. Avoid use of these lubes where they can result in harmful effects. If in doubt, consult your local lube supplier.

3. Only use A.G.M.A. rated worm gear lubes.

1. Drain and refill oil after first 100 hours of operation. Under normal operating conditions change oil every 2,000 hours of operation or every 6 months thereafter, which ever occurs first.
2. The maximum input HP rating as shown in the published rating tables (found in Manufacturer's bulletins section) is based on a stabilized oil bath temperature not exceeding 200^oF for normal ambiance. Higher oil bath temperatures or continued operation in excess of rated input HP will tend to shorten the useful life of a lubricant. For ambient temperatures in excess of 125^oF, special lubricants or de-rating of the reducer may be required. Consult the factory or local office with complete application engineering data if this occurs.

1. Roller Chain: Roller chain consists of a series of connecting traveling metallic bearings, which must be properly lubricated to obtain the maximum service life of the chain. The chain drive requires lubrication for six purposes.

ð To prevent galling of the pin-bushing joints

ð To cushion impact loads

ð To dissipate any heat generated

ð To flush away foreign materials

ð To lubricate chain-sprocket contract surfaces

ð To prevent rust or corrosion

1. A good grade of clean petroleum oil without additives, free flowing at the prevailing temperature, should be used. Some additives leave a varnish or gum deposit which prevents the oil from entering chain joints. Heavy oils and grease are generally too stiff to enter the chain joints and should not be used.
2. Apply oil periodically to chain using a brush. It should be applied to the face of the rollers and between link plates. Do not over lubricate, excessive oil will be thrown from chain at higher speeds.
3. The following table indicates the viscosity recommended for various surrounding temperatures: