Chicago Blanket Blaster CT.pdf

Blanket Blaster CT Preventive Maintenance

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Chapter 4

PREVENTIVE MAINTENANCE

Various components and parts of the Blanket BlasterTM spreader/feeder/folder require scheduled attention to assure long life and trouble-free operation. The Preventive Maintenance (PM) Schedule below outlines all of the PM tasks required at regular intervals. All tasks are the responsibility of maintenance personnel unless otherwise indicated.

Since operators run the machines, they should be trained on site to visually inspect common areas daily and notify maintenance personnel when problems are found, such as worn or broken ribbons.

All PM intervals are based on 8-hour/day operation. Increase the PM frequency for two- or three-shift operations.

Preventive maintenance should only be done when the power is turned OFF at the main disconnect switch. Specific preventive maintenance that requires the unit to be running should be done with extreme caution and attention to detail.

PM Task Table

FREQUENCY OF TASKS BASED ON 40 HOURS PER WEEK OPERATION

Preventive Maintenance Tasks Operator Maintenance Unit Condition

4.1 DAILY (8 Hours)

Watch and Listen for Anything Abnormal X Running

General Cleanliness X Off/Disconnect Power

Check Safety Equipment X X Running

4.2 WEEKLY (50 Hours)

Check and Clean All Photosensors and Reflectors X Off/Disconnect Power

Check and Clean Inverters X Off/Disconnect Power

Check Feeder Unit For String Accumulation X Off/Disconnect Power

Check Feeder Unit Pneumatic Clutch/Brake Roller Alignment X Off/Disconnect Power

Lubricate Feeder Unit Upper Spreader Rail X Off/Disconnect Power

Check Feeder Unit Spreader Clamp Linear Assembly Bearings X Off/Disconnect Power

Inspect Air Filter/Auto Drain Units X Off/Disconnect Power

Check Air Pressure Settings X Off/Power Connected

Check Belt and Ribbon Condition and Tension X Running

4.3 MONTHLY (200 Hours)

Check Setscrews X Off/Disconnect Power

Check Upper and Lower Spreader Belts Condition and Tension X Off/Disconnect Power

Inspect Drive Belt Condition X Off/Disconnect Power

Check and Grease Bearings X Off/Disconnect Power

Check Folder Unit First and Third Crossfold Air Cylinders X Running

4.4 SEMI-ANNUAL (1000 Hours)

Clean Air Filter/Auto Drain Units X Off/Disconnect Power

Clean and Lubricate Drive Chains X Off/Disconnect Power

4.5 ANNUAL (2000 Hours)

Check All Electrical Connections X Off/Disconnect Power

Check Insulation Resistance to Earth Ground X Off/Disconnect Power

Preventive Maintenance Blanket Blaster CT

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4.1 Daily PM (8 Hours)

WARNING

Do not repair or correct any of these conditions without reading and understanding the REPAIR chapter.

Only qualified personnel should troubleshoot and repair the unit.

Make sure the power is turned OFF at the main disconnect switch.

Follow lockout/tagout procedures approved for your site. Follow local regulations. Failure to do so could result in serious injury.

Watch and Listen for Anything Abnormal

Perform only when the unit is

RUNNING.

Use extreme caution.

Operators and maintenance personnel should learn to understand the usual sights and sounds around the machine. For example, when there is a noise at a roll, the bearings may be worn or other mechanical problems may exist. Stop the machine immediately and follow-up with the necessary maintenance or repair.

General Cleanliness

It is important to prevent the buildup of lint, dirt, dust and foreign material in the machine. General cleanliness prevents damage to components, jamming and soiling flatwork.

Keep the area as well as the machine as clean as possible.

Required Tools Soft, lint-free cloth Vacuum cleaner or compressed air

Perform only when the unit is OFF with power disconnected.

Turn power OFF at the feeder unit main disconnect switch.

CAUTION

NEVER use compressed air on or around electronic components.

Damage can result.

Check and clean the below listed items daily.

Drive shaft rollers and bearings.

Face of the clutch/brake roller.

Between the clutch roller and lower inlet conveyor belt drive.

Inlet conveyor drive and idler rollers.

Spreader rail, clamps, and grooved bearings.

Ribbons.

Receiving shelves.

General components.

Make sure that there is no lint, tape or string build-up.

Check photosensors for excessive dust.

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4-3

Check Safety Equipment

Perform only when the unit is

RUNNING.

Use extreme caution.

The machine should never be operated without all safety guards in place and all safety devices working properly.

Check that all 10 red safety STOP buttons, the feeder unit crossbeam sensors and mass sensors, as well as the folder unit red wire safety guard, all bring the operation of the machine to a complete halt and depressurize the compressed air system.

For more informat ion, refer to the OPERATING GUIDELINES chapter, Daily Operating Procedures section, Start-Up procedure.

NOTE: Repair any faulty safety devices before continuing to operate the unit.

4.2 Weekly PM (50 Hours)

WARNING

Do not repair or correct any of these conditions without your site. Follow local regulations. Failure to do so could result in serious injury.

4-4

Check and Clean All Photosensors and Reflectors

Most control problems can be avoided by keeping the photosensors (Figure 4-1) and reflectors clean.

For information on photosensor/reflector location, refer to the OPERATING PRINCIPLES chapter, Electrical System section, Control System subsection for each unit.

Required Tools Soft, lint-free cloth Vacuum cleaner or compressed air

Perform only when the unit is OFF with power disconnected.

Use compressed air to blow of loose debris on each photosensor and reflector.

Wipe each photosensor and reflector with a soft, lint-free cloth.

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Check and Clean Inverters

In both units, check and clean the inverters and their cooling fins weekly with a vacuum cleaner.

Failure to do so may void your warranty.

Required Tools Vacuum cleaner

Perform only when the unit is OFF with power disconnected.

Turn power OFF at the feeder unit main disconnect switch.

The feeder unit inverters are located in its right endframe (Figure 4-2). The folder unit inverters are located in its left endframe.

CAUTION

Failure to clean the inverter and its cooling fins could void the warranty.

Never use compressed air on or around electronic components. Doing so may damage them.

Check and clean each inverter and its cool-ing fins with a vacuum cleaner.

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Figure 4-1: Photosensors and reflectors must be kept clean and lint-free.

Figure 4-2: Inverters in the right endframe of the feeder unit.

4-5

Check Feeder Unit For String Accumulation

Required Tools Compressed air or vacuum cleaner

Perform only when the unit is OFF with power disconnected.

Check the feeder unit pneumatic clutch/brakes and their rollers (Figure 4-3) for accumulated string and lint on the drive shafts, rollers and bearings. Pay particular attention to the narrow gap between the center and side rollers (A).

Remove any string or other debris. Use a vacuum cleaner or compressed air as necessary.

The rollers must be clean. This is critical for proper machine operation.

Check Feeder Unit Pneumatic Clutch/Brake Roller Alignment

Perform only when the unit is OFF with power disconnected.

Make sure the pneumatic clutch/brake rollers are seated evenly against each other (Figure 4-3, B). It is very important that these components are aligned parallel for proper corner clutching.

For more information regarding adjustment, refer to the REPAIR chapter, Inlet Section section, Pneumatic Clutch/Brake Roller Adjustment procedure.

Figure 4-3: Make sure the clutch brake rollers are seated evenly against each other.

A

B

B

B

4-6

Lubricate Feeder Unit Upper Spreader Rail

Required Tools Clean lint-free cloth Dry silicon lubricant

Perform only when the unit is OFF with power disconnected.

Turn power OFF at the feeder unit main disconnect switch.

Use a small amount of dry silicon lubricant on a clean, dry, lint-free cloth and wipe the upper spreader rails (Figure 4-4, A) after each 50 hours of operation.

Place a small amount of lubricant on the cloth.

Work the carriage back and forth, lightly holding the cloth so that the grooved bear-ings (Figure 4-5) pick up the lubrication.

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Figure 4-4: Lightly lubricate the upper spreader rail weekly.

AB

Figure 4-5: Lightly lubricate the spreader rail grooved bearings.

Check Feeder Unit Spreader Clamp Linear Assembly Bearings

Perform only when the unit is OFF with power disconnected.

In the feeder unit, check the grooved bearings in the assembly by taking the spreader clamp (Figure 4-5, B) in hand and shaking it from side to side. If there is free-play in the carriage, the grooved bearings need to be replaced.

For more information, refer to the REPAIR chapter, Spread Section, Upper Spreader Clamp Grooved Bearing Replacement procedure.

4-7

Inspect Air Filter/Auto Drain Units

Perform only when the unit is OFF with power disconnected.

The combination air filter with automatic drain unit located inside the left endframe of the feeder unit (Figure 4-6, A) and at the right front of the folder unit (Figure 4-7) should be inspected on a weekly basis.

A visible coating of dirt or condensate on the filter element surface or excessive pressure drop is an indication that cleaning is necessary.

For instructions within this chapter on cleaning each machine’s air filter/auto drain, refer to the Semi-Annual PM section, Clean Air Filter/ Auto Drain Units procedure.

Check Air Pressure Settings

Maintaining proper incoming and internal air pressures helps keep the machine operating at peak efficiency.

Perform only when the unit is OFF with power connected.

Use extreme caution.

WARNING

Wear protective eyewear when working with compressed air components.

Turn ON the compressed air supply to the machine.

Move to the left side of the feeder unit and open the left endframe door.

Check the incoming air pressure gauge (Figure 4-6, B) and make sure it is set to 80 psi (550 kPa).

Close and secure the left endframe door.

Turn power ON at the main disconnect switch of the feeder unit. Then, turn power ON at the main disconnect switch of the folder unit.

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Figure 4-6: Feeder air filter/auto drain in left endframe of the unit.

A

B

Figure 4-7: Folder air filter/auto drain at right front of unit.

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Wait about 45 seconds for each unit to go through the boot up process. When it is fin-ished, “Start to reset Estop (Air)” displays in each CHI•Touch screen (Figure 4-8).

Press and release the START button. The CHI•Touch screen displays “Air pressure low”.

Allow the compressed air system to pressurize. When each machine is ready, “Paused” displays in its CHI•Touch screen.

It is not necessary to start either unit.

Looking in from the front of the feeder unit, locate the pressure regulators at the back, toward the left and the center (Figure 4-9). They should be set as listed in the table below:

A Low Pressure 60 psi (415 kPa)

B Spreader Clamps Back Pressure

60 psi (415 kPa)

NOTE: These settings are pre-set at the factory. Air pressures can be changed to meet the needs of different weights of flatwork.

The spreader clamps back pressure regulator only needs to be checked and/or adjusted in the case of a specific machine performance problem. Refer to the RE- PAIR chapter, Compressed Air System section, Spreader Clamp Back Air Pres-sure Adjustment procedure.

Move to the folder unit.

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Figure 4-9: Air pressure regulators at the center and left rear of the machine.

AB

Figure 4-8: The Skyline Blanket CHI•Touch screen.

4-9

WARNING

Use protective eyewear and make sure that the compressed air supply connection is secure.

Locate the pressure gauges at the front of the right endframe (Figure 4-10, A, B, C), above the delivery table (E), near the first crossfold drive motor (F), and at the discharge end of the folder (G). The air pressure gauges should be set as listed below.

A Incoming Air Pressure 80 psi (550 kPa)

B Primary Fold Air Blast-LO 40 psi (275 kPa)

C Primary Fold Air Blast-HI 75 psi (515 kPa)

D Counterpoint Air Blast 25 psi (170 kPa)

E First Crossfold Blade 60 psi (415 kPa)

F First Crossfold Strip 70 psi (480 kPa)

G Third Crossfold Lifting Fingers

60 psi (415 kPa)

NOTE: These settings are pre-set at the factory. Air pressures can be changed to meet the needs of different weights of flatwork.

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Figure 4-10: Primary and crossfold air pressure gauges.

B

C

D

E

F

G

A

4-10

Check Belt and Ribbon Condition and Tension

Perform only when the unit is

RUNNING.

Use extreme caution.

WARNING

Never touch any part of the unit while it is moving.

Serious injury could result.

Check heck the inlet belt and discharge ribbons on the feeder unit, and all ribbons sets on the folder unit, for proper placement, tracking, tension (no visual sagging) and general condition (smoothness, fraying, and tears).

For belt and/or ribbon adjustment and replacement instructions, refer to the REPAIR chapter and the appropriate section and procedure.

4.3 Monthly PM

(200 Hours)

WARNING

Do not repair or correct any of these conditions without your site. Follow local regulations. Failure to do so could result in serious injury.

4-11

Check Setscrews

Required Tools Allen wrench set

Perform only when the unit is OFF with power disconnected.

Setscrews (Figure 4-11) hold sprockets, bearings, and other rotating parts securely in place. Check and make sure that all setscrews on the entire machine are tight.

Figure 4-11: Make sure the setscrews are sufficiently tightened.

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Figure 4-13: Inspect all belts near the center of the feeder unit.

AC

B

C

Figure 4-12: Inspect all belts on both sides of the feeder unit.

A

A

C

B

Check Feeder Unit Upper and Lower Spreader Belt Condition and Tension

Perform only when the unit is OFF with power disconnected.

Turn power OFF at the main disconnect switch.

Open both the left and right feeder unit endframe doors.

Carefully inspect the four sets of lower spreader belts (one black set, one white set on each side) (Figure 4-12, A).

Move to the front of the machine.

Carefully inspect the upper spreader belt (Figure 4-13, A).

Each belt should have the proper tension.

If any belt is damaged replace the belt.

For more information on adjusting belt tension and/or replacing belts, refer to the REPAIR chapter, Spread Section section and the appropriate procedure.

Close and secure both endframe doors.

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4-13

Inspect Drive Belt Condition

Carefully inspect condition of the drive belts on both units. These include the:

Feeder unit lower spreader drive belts (one in each endframe) (Figure 4-12, B).

Feeder unit black inlet drive belt (Figure 4-13, B).

Feeder unit red transfer system drive belts (Figure 4-13, C).

Feeder unit discharge conveyor drive belt (Figure 4-12, C).

Folder unit main drive belt (Figure 4-14, A).

Folder unit delivery drive belt (Figure 4-14, B). Note that this belt is located on the opposite side of the machine from the crossfold discharge.

Folder unit second crossfold drive belt (Figure 4-15, A).

Folder unit third crossfold drive belt (Figure 4-15, B).

Figure 4-14: Folder unit main drive belt and delivery drive belt in right endframe.

A

B

C

Required Tools Wrenches:

7/16” 1/2”

Perform only when the unit is OFF with power disconnected.

Turn power OFF at the feeder unit main disconnect switch.

Open any endframe doors or remove covers as necessary for access.

Check each belt for proper tension.

If the tension on a belt cannot be adjusted, or the teeth are skipping, replace the belt.

If any belt shows excessive wear or is damaged, replace it.

For more information on adjusting belt tension and/or replacing belts, refer to the REPAIR chapter and the appropriate section and procedure.

Replace any covers. Tighten bolts se-curely.

Close and secure any endframe doors.

WARNING

Never operate the unit unless all safety covers are in place and all safety equipment is working correctly.

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Figure 4-15: Folder unit crossfold drive belts at the front of the unit under the inlet conveyor.

4-14

Check and Grease Bearings

Regularly grease bearings to help ensure smooth operation and dependability. A special high temperature lubricant is required to properly grease all bearings. It is important that only Shell Darina® SD 2 grease or its equivalent be used.

Use of unsuitable grease can cause bearing lockup or failure. Problems can also result if the new grease is incompatible with the grease that is already in the bearings.

Failure to use the correct lubricant will void the factory warranty.

CAUTION

Before using a grease other than Shell Darina® SD 2, check with the factory service department to verify that the grease meets specifications and is compatible with the grease already in the bearings.

If any other grease is being considered:

Check with the Chicago Dryer Company service department to verify that the grease meets specifications and is compatible with the grease already in the bearings.

Follow directions on the grease gun pack-aging for other filling methods (dispenser, suction).

Be sure to grease the:

Four spreader belt shaft bearings in each feeder unit endframe (Figure 4-16, A).

Conveyor pivot bearings at each end (B).

Clutch roller upper pulley shaft bearings

(C) at each end.

Clutch shaft bearings (D) at each end of the clutch shaft.

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Figure 4-16: Roll bearings with grease fittings are located throughout the unit.

A A

B

C

A

D

4-15

Main drive pulley bearing inside (Figure 4-17, A).

Main drive pulley bearing outside (Figure 4-17, B).

Delivery drive bearings (Figure 4-17, C).

Roll bearings: primary drive (Figure 4-17, D) intermediate drive (E), primary idler (F), and intermediate idler (G).

Crossfold bearings (Figure 4-18).

NOTE: Check all bearings which have grease fittings and lubricate them as necessary following this procedure.

Required Tools Clean, lint-free cloth Grease gun Shell Darina® SD 2 Grease or equivalent Wrench: 1/2”

Perform only when the unit is OFF with power disconnected.

Turn power OFF at the main disconnect switch.

Remove any protective covers, panels or endframe doors as necessary (For example, the inlet mechanism protective covers (Figure 4-19).

Wipe the old grease from the bearings.

Insert the grease gun nozzle firmly onto the grease fitting.

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Figure 4-18: Folder unit, crossfold bearings, both sides.

Figure 4-17: Primary fold bearings.

B

A

C

D

E

F

G

Figure 4-19: Safety covers must be removed to gain access to some grease fittings.

4-16

CAUTION

Over-lubrication will destroy the bearing seals and cause premature failure.

Add lubricant slowly until a slight bead of lubricant forms at the seal. As soon as the bead forms, stop adding grease to prevent damage from over-lubrication.

CAUTION

Failure to wipe off excess lubricant will cause lint to adhere to the bearings and may cause premature failure.

Immediately wipe off the grease from the bearing. Failure to do so can cause lint accumulation and premature bearing failure.

Replace or close and secure any protective covers, panels, or endframe doors.

WARNING

Never operate the unit unless all safety covers are in place and all safety equipment is working correctly.

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Check Folder Unit First and Third Crossfold Air Cylinders

On the folder unit, one air cylinder controls the movement of the first crossfold blade (Figure 4-20) and another controls the movement of the third crossfold lifting fingers (Figure 4-21).

Perform only when the unit is

RUNNING.

Use extreme caution.

In each case the mechanism must move up and down quickly, but must not hit at either end of its travel.

For more information on adjusting the air flow valves for this cylinder, refer to the REPAIR chapter, Compressed Air System section, First Crossfold Blade Air Cylinder Adjustment procedure or Third Crossfold Lifting Finger Air Cylinder Adjustment procedure.

Figure 4-20: The first crossfold air cylinder controls movement of the blade.

Figure 4-21: The third crossfold air cylinder controls movement of the lifting fingers.

4-17

4.4 Semi-Annual PM

(1000 Hours)

WARNING

Do not repair or correct any of these conditions without reading and understanding the REPAIR chapter.

Only qualifi ed personnel should troubleshoot and repair the unit.

Make sure the power is turned OFF at the main disconnect switch.

Follow lockout/tagout procedures approved for your site. Follow local regulations. Failure to do so could result in serious injury.

Clean Air Filter/Auto Drain Units

Each unit’s air fi lter with auto drain requires periodic cleaning to maintain maximum fi ltering effi ciency and to avoid excessive pressure drop.

The cleaner the compressed air supply, the less maintenance will be required. A visible coating of dirt or condensate on a fi lter element surface or excessive pressure drop is an indication that cleaning is necessary.

WARNING

Before disassembling the air fi lter/auto drain, turn off the air supply and depressurize the system and fi lter.

Required Tools Clean, soft cloth Mild detergent solution

Perform only when the unit is OFF with power disconnected.

1. Turn off the compressed air supply and depressurize the unit.

2. Turn power OFF at the main disconnect switch.

3. Press the black plastic tab on the side of the bowl case down (Figure 4-22, A) and rotate it left or right until the two marks on the bowl case light up with the single mark on the fi lter base (B).

4. Pull down on the bowl case to remove

it. The fi lter base does not need to be re-moved from the machine.

Figure 4-22: Press the plastic tab and twist the casing to line up the marks to remove the fi lter bowl from the machine.

4-18

5. Take the polyurethane bowl (Figure 4- 23, A) and rinse with ONLY water and household soap.

6. Twist counterclockwise the black plastic base (Figure 4-23, B) which holds the fi lter element (C) in place.

7. Remove the fi lter element and discard.

8. Clean the other components (Figure 4-23, B, D) with ONLY water and household soap; then, dry with a clean soft cloth.

9. Re-assemble the clean components, insert-ing a new fi lter element and twisting the fi lter base clockwise to lock it in position.

10. Re-attach the clean polyurethane bowl, lining up the marks as in Step 3.

11. Press up on the bowl and twist left or right until the plastic tap snaps into position.

Figure 4-23: All the components in the air fi lter assembly can be washed with alcohol, EXCEPT the bowl.

A

B

C

D

4-19

Clean and Lubricate Drive Chains

The five drive chains listed below require periodic maintenance:

Feeder unit discharge conveyor drive chain (Figure 4-24).

Folder unit main drive chain (Figure 4-14, C).

Folder unit pinch rolls drive chains (Figure 4-25).

Folder unit second-to-third crossfold and exit drive chains (Figure 4-26).

Carefully inspect the condition of the drive chains and check their tension. Replace any chain that shows signs of excessive wear or can no longer be adjusted. For information on adjusting tension, refer to the REPAIR chapter, the appropriate section and the appropriate procedure.

Required Tools Clean cloth SAE 90 grade oil Wrench: 1/2”

Perform only when the unit is OFF with power disconnected.

Turn the power OFF at the feeder unit main disconnect switch.

Access the feeder unit discharge conveyor drive chain by opening that unit’s left endframe door.

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Figure 4-24: Drive chain in the left endframe.

Figure 4-25: There are two drive chains for the pinch rolls.

Figure 4-26: Second-to-third crossfold and exit drive chain.

Access the folder unit main drive chain by opening that unit’s right endframe door.

Access the folder unit crossfold drive chains by removing the three protective covers at the rear of that unit.

Clean off old lubricant from the drive chains.

Lightly lubricate each chain with a good quality SAE 90 grade oil.

Close and secure endframe doors. Replace each cover. Tighten bolts securely.

WARNING

Never operate the unit unless all safety covers are in place and all safety equipment is working correctly.

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4-20

4.5 Annual PM

(2000 Hours)

WARNING

Do not repair or correct any of these conditions without your site. Follow local regulations. Failure to do so could result in serious injury.

Check All Electrical Connections

Over time, the continued heating and cooling process can cause electrical connects to become loose.

Required Tools Screwdriver: small, thin

Perform only when the unit is OFF with power disconnected.

Turn power OFF at the feeder unit main disconnect switch.

At the feeder unit, open the right endframe and the electrical box doors.

Test each wire’s connection by gently pulling on it.

Tighten any loose connections.

Close both doors.

At the folder unit, over the left endframe and the electrical box doors.

Test each wire’s connection by gently pulling on it.

Tighten any loose connections.

Close both doors.

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4-21

Check Insulation Resistance to Earth Ground

Required Tools Voltmeter

Perform only when the unit is OFF with power disconnected.

WARNING

Only a qualified electrician should make or correct any electrical connections in or to the unit.

Turn power OFF at the feeder unit main disconnect switch.

Connect a voltmeter between the feeder unit’s frame and a separate, known earth ground.

If there is a reading on the voltmeter, check and repair the feeder’s ground con-nection.

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