Chicago Separator Model Cascade CT.pdf

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CASCADE™

Sheet Separator

Cascade Preventive Maintenance

4-1

Preventive Maintenance Schedule beginning

Chapter 4

PREVENTIVE MAINTENANCE

Various components and parts of the Cascade™ separator 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 Tables

Daily, Weekly, Monthly Tasks

FREQUENCY OF TASKS BASED ON 40 HOURS PER WEEK OPERATION

Preventive Maintenance Operator Maintenance Unit Condition

4.1 DAILY (8 Hours)

Watch and Listen for Anything Abnormal X Running

General Cleanliness X Off/Disconnect Power

Clean the Pick Bin X Off/Disconnect Power

Check Safety Equipment X X Running

4.2 WEEKLY (50 Hours)

Check and Clean Photosensors and Reflectors X Off/Disconnect Power

Check and Clean Inverters X Off/Disconnect Power

Clean and Lubricate Grooved Bearing Rails and Bearings X Off/Disconnect Power

Check Pick Clamp Mounting Screws and Setscrews X Off/Disconnect Power

Inspect Air Filter/Auto Drain X Off/Disconnect Power

Check Air Pressure Setting X Off/Disconnect Power

Check Ribbon Condition and Tension X X Running

4.3 MONTHLY (200 Hours)

Check Setscrews X Off/Disconnect Power

Clean and Lubricate Drip Conveyor Drive Chain X Off/Disconnect Power

Inspect Drive Belt Condition X Off/Disconnect Power

Check Pneumatic Lubricator Oil Level X Off/Disconnect Power

Preventive Maintenance Cascade

4-2

Semi-Annual, Annual Tasks

FREQUENCY OF TASKS BASED ON 40 HOURS PER WEEK OPERATION

Preventive Maintenance Operator Maintenance Unit Condition

4.4 SEMI-ANNUAL (1000 Hours)

Check and Grease Load Clamp Lift and Pivot Bearings X Off/Disconnect Power

Clean Air Filter/Auto Drain X Off/Disconnect Power

Check and Clean Pinch Roll Conveyor Motor X Off/Disconnect Power

Change Lift Clamp and Drip Conveyor Motors Gearbox Oil 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

Cascade Preventive Maintenance

4-3

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 a unit. For example, when there is a noise at a roll, the bearings may be worn or other mechanical problems may exist. Stop the unit 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 unit. General cleanliness prevents damage to components, jamming and soiling flatwork.

Keep the area as well as the separator 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.

1. Turn power OFF at the main disconnect switch.

CAUTION

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

2. Check and clean the below listed items daily.

• Drive shaft rollers and bearings.

• Ribbons.

• General components.

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

Preventive Maintenance Cascade

4-4

Clean the Pick Bin

Required Tools Grabber Vacuum cleaner

Perform only when the unit is OFF with power disconnected.

NOTE: Depend ing on the nature/condition of the flatwork being processed, multiple daily clearings may be required.

1. Turn power OFF at the main disconnect switch.

2. Open the pick bin access door.

3. Use the provided grabber to remove any small items that have become packing into corners or other areas of the pick bin.

4. Check for debris from flatwork, such as EKG tabs or other such items.

5. Use a vacuum to remove all such debris and anything else that has accumulated.

Check Safety Equipment

Perform only when the unit is

RUNNING.

Use Extreme Caution.

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

Check that all 4 red safety STOP buttons bring the operation of the unit to a complete halt. For more information, refer to Start-Up on page 3-8.

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

Cascade Preventive Maintenance

4-5

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.

Check and Clean 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 Photosensors on page 5-8.

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

Perform only when the unit is OFF with power disconnected.

1. Turn power OFF at the main disconnect switch.

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

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

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

Preventive Maintenance Cascade

4-6

Check and Clean Inverters

Check and clean the inverters and their cooling fins (Figure 4-2) 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.

1. Turn power OFF at the main disconnect switch.

2. Open the electrical box door.

CAUTION

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

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

3. Check and clean all inverters and their cooling fins with a vacuum cleaner.

4. Close and secure the electrical box door.

Figure 4-2: Inverters in the electrical box.

Clean and Lubricate Grooved Bearing Rails and Bearings

Required Tools Cloths: soft, lint-free Oil: SAE 90 Vacuum cleaner or compressed air

Perform only when the unit is OFF with power disconnected.

1. Turn power OFF at the main disconnect switch.

2. Use a clean, lint-free cloth to thoroughly wipe down the grooved bearing rails for the load clamp and the pick clamps (Figure 4-3, A). Make sure they are free of string and lint.

3. Use compressed air and/or a vacuum cleaner to make sure the bearing blocks

(B) are also free of lint and debris.

4. Apply a small amount of oil to a clean cloth and apply a thin film to the rails and bearings.

Figure 4-3: Make sure the grooved bearing rails and blocks are free of lint and debris.

A

B

A

B

Cascade Preventive Maintenance

4-7

Check Pick Clamp Mounting Screws and Setscrews

Required Tools Allen wrenches:

Perform only when the unit is OFF with power disconnected.

1. Turn power OFF at the main disconnect switch.

2. Open the pick bin door.

3. Check the pick clamp mounting screws (Figure 4-4, A) and setscrews (B) for tightness.

4. Tighten as necessary.

NOTE: If a setscrew is missing, contact the Factory Service Department.

Inspect Air Filter/Auto Drain

Perform only when the unit is OFF with power disconnected.

The combination air filter with automatic drain unit (Figure 4-5, A), located inside the rear endframe, 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 on cleaning the air filter/auto drain, refer to Clean Air Filter/Auto Drain on page 4-17.

Figure 4-5: Check the air filter/auto drain for dirt and condensate accumulation.

A

B

Figure 4-4: Check and tighten the pick clamp mounting screws and setscrews as necessary.

A

Preventive Maintenance Cascade

4-8

Check Air Pressure Setting

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

Perform only when the unit is OFF with power disconnected.

WARNING

Wear protective eye wear when working with compressed air components.

1. Turn ON the compressed air supply to the unit.

2. Open the right rear endframe door.

3. Check the incoming air pressure gauge (Figure 4-5, B) and make sure it is set to 85 psi (585 kPa).

4. Close and secure the right rear endframe door.

5. As appropriate:

• If the machine is to be run, leave the compressed air ON.

• If the machine is not going to be run, turn OFF the compressed air supply to the unit.

Check 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 the drip conveyor and pinch roll conveyor ribbons for proper placement, tracking, tension (no visual sagging) and general condition (smoothness, fraying, and tears).

For ribbon adjustment and replacement instructions, refer to REPAIR, and the appropriate section and procedure.

Cascade Preventive Maintenance

4-9

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.

Check Setscrews

Required Tools Allen wrench set

Perform only when the unit is OFF with power disconnected.

Setscrews (Figure 4-6) hold sprockets, bearings, and other rotating parts securely in place. Check and make sure that all setscrews are tight.

Figure 4-6: Make sure the setscrews are sufficiently tightened.

Preventive Maintenance Cascade

4-10

Clean and Lubricate Drip Conveyor Drive Chain

Required Tools Allen wrench: 5/32” Clean cloth SAE 90 grade oil

Perform only when the unit is OFF with power disconnected.

1. As appropriate:

• Remove the cart from the load area.

• Remove the back panel to the Autoload conveyor (Figure 4-7); this is best per-formed by two workers as the panel is heavy and awkward to handle.

2. Turn power OFF at the main disconnect switch.

3. Remove the left side interlock panel (Fig-ure 4-8, A), the drip conveyor drive chain guard (B), and the chain access panel (C).

4. Clean off old lubricant from the drip con-veyor drive chain (Figure 4-9) and lightly lubricate the chain with a good quality SAE 90 grade oil.

5. Check the drive chain for proper tension

6. If the drive chain is loose, adjust tension.

For more information, refer to Drip Con-veyor Drive Chain Tension Adjustment on page 7-16.

7. Replace the chain access panel, chain guard, and the left side interlock panel removed in Step 3.

WARNING

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

Figure 4-7: For safety, two workers should handle the Autoload rear panel.

Figure 4-8: Remove the left side interlock panel and necessary covers for access.

A

B

C

Figure 4-9: Drip conveyor drive chain at the left front of the machine.

Cascade Preventive Maintenance

4-11

A B

Figure 4-10: Periodic inspection of all drive belts is important to machine operation.

C

D

Inspect Drive Belt Condition

Required Tools Allen wrench: 5/32” Phillips screwdriver: #2/#3 Screwdriver

Perform only when the unit is OFF with power disconnected.

Carefully inspect the following drive belts (Figure 4-10):

• Dual Clamp Drive (A), and Lift (B),

• Pinch Conveyor Drive (C),

• Exit Conveyor Drive (D).

Preventive Maintenance Cascade

4-12

1. Turn power OFF at the main disconnect switch.

2. As appropriate:

• To inspect the dual clamp drive and lift belts, open the rear endframe doors.

• To inspect the pinch conveyor drive belt:

a) Open the pick bin door.

b) Remove the pick bin side plate (Figure 4-11).

c) Remove the pinch conveyor drive belt covers.

• To inspect the exit conveyor drive belt, remove the bottom exit conveyor drive belt cover.

3. Each belt should have the proper tension.

If any belt is damaged, replace the belt.

• If the tension on the belt cannot be adjusted, or the belt is skipping, replace the belt.

• For more information on adjusting belt tension, refer to REPAIR and the ap-propriate section and procedure.

NOTE: The p i ck b in s ide plate must be re-installed or the machine’s pick operation will not work correctly.

4. Replace and secure all covers/protective panels; close and secure all doors.

WARNING

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

Figure 4-11: Remove the pick bin side plate to be able to get inside the bin.

Cascade Preventive Maintenance

4-13

A

B C

D

Figure 4-13: The lubricator is located inside the left center endframe.

Figure 4-12: Remove this cover to access the pneumatic lubricator.

Check Pneumatic Lubricator Oil Level

Required Tools Allen wrench: 5/32” Clean cloth Festo special oil Mild soap solution Screwdriver: small

Perform only when the unit is OFF with power disconnected.

An automatic device is used to keep the machine’s drip conveyor air cylinders lubricated and operating smoothly.

Each month or 200 hours of operation, check the oil level and condition in the pneumatic lubricator, which is located behind a cover panel on the left side of the machine (Figure 4-12).

NOTE: The rate of oil usage is very small. Just a few drops a week is sufficient to keep the air cylinders adequately lubricated.

Check Oil Level

1. Turn power OFF at the main disconnect switch.

2. Remove the cover panel.

3. Check the oil level and condition.

• If the oil level is below the lower win-dow (Figure 4-13, A), it must be topped off. See Adding Oil below.

• If the oil is cloudy, the bowl must be cleaned. See Cleaning on page 4-14.

4. If no maintenance is needed, replace and secure the left center endframe panel.

Adding Oil

1. Vent air from the bowl by opening the vent screw next to the droplet sight glass (Figure 4-13, B) until the air noise stops.

2. Unscrew the bowl by twisting counter-clockwise.

3. Add Festo special oil to within 1 inch of the top of the bowl.

4. Replace the bowl.

5. Tighten the vent screw.

6. Replace and secure the left center end-frame panel.

Preventive Maintenance Cascade

4-14

Cleaning

If any dirt or debris can be seen in the bowl, or if the oil is cloudy, the bowl must be cleaned and fresh oil added.

1. Vent air from the bowl by opening the vent screw next to the droplet sight glass (Figure 4-13, B) until the air noise stops.

2. Unscrew the bowl by twisting counter-clockwise.

3. Drain bowl; then clean using only soapy water.

4. Rinse thoroughly and dry.

5. Add fresh Festo special oil to within 1 inch of top.

6. Replace the bowl.

7. Tighten the vent screw.

8. Replace and secure the left center end-frame panel.

Adjusting the Droplet Rate

NOTE: The rate of oil usage is very small. Just a few drops a week is sufficient to keep the air cylinders adequately lubricated.

1. Adjust oil flow by turning the adjusting screw (Figure 4-13, C):

• Clockwise to decrease flow.

• Counterclockwise to increase flow.

2. Make adjustments in 1/8 to 1/4 turn incre-ments; avoid excessive changes.

3. The interval between drops may be ob-served in the oil droplet sight glass (D).

4. Replace and secure the left center end-frame panel.

WARNING

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

Cascade Preventive Maintenance

4-15

4.4 Semi-Annual PM

(1000 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 and Grease Load Clamp Lift and Pivot Bearings

Regularly grease the load clamp lift and pivot bearings (Figure 4-14) to help ensure smooth operation and dependability. A special high temperature lubricant is required to properly grease all bearings. It is important that only an EP, bentonite clay, NLGI 2, 1000 cSt viscosity grease 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 specified, check with the factory service department to verify that the grease meets specifications and is compatible with the grease already in the bearings.

Figure 4-14: Periodic greasing of the load clamp bearings helps ensure long bearing life.

Preventive Maintenance Cascade

4-16

If any other grease is being considered:

1. 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.

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

Required Tools Clean cloth Grease gun Grease: EP, bentonite clay, NLGI 2, 1000 cSt viscosity Ladder

Perform only when the unit is OFF with power disconnected.

1. Turn power OFF at the main disconnect switch.

WARNING

It will be necessary to stand on a sturdy ladder during this procedure. A fall could cause personal injury and/or damage the machine.

Use Extreme Caution.

2. Wipe the old grease from the bearing.

3. Insert the grease gun nozzle firmly onto the grease fitting.

CAUTION

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

4. 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.

5. Immediately wipe off the grease from the bearing. Failure to do so can cause lint ac-cumulation and premature bearing failure.

Cascade Preventive Maintenance

4-17

Figure 4-16: Replace the filter element and clean the other components using only soap and water.

A

B

C

D

Clean Air Filter/Auto Drain

The air filter with auto drain requires periodic cleaning to maintain maximum filtering efficiency 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 the filter element surface or excessive pressure drop is an indication that cleaning is necessary.

WARNING

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

Required Tools Cloth: clean, soft 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. Open the right rear endframe door (left as you face the rear of the machine).

4. Press the black plastic tab on the side of the bowl case down (Figure 4-15, A) and rotate it left or right until the two marks on the bowl case light up with the single mark on the filter base (B).

5. Pull down on the bowl case to remove

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

6. Take the bowl (Figure 4-16, A) and rinse with ONLY water and household soap;

then, dry with a soft,clean cloth.

7. Twist counterclockwise the black plastic base (Figure 4-16, B) which holds the filter element (C) in place.

8. Remove the filter element and discard.

9. Clean the other components (Figure 4-16, B, D) with ONLY water and household soap; then, dry with a soft,clean cloth.

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

11. Re-attach the clean bowl, lining up the marks as in Step 4.

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

13. Close and secure the right rear endframe door.

B

A

Figure 4-15: Press the plastic tab and twist the casing to line up the marks to remove the filter bowl from the machine.

Preventive Maintenance Cascade

4-18

Check and Clean Pinch Roll Conveyor Motor

The pinch roll conveyor motor requires periodic cleaning to ensure proper operation.

Required Tools Allen wrench: 5/32” Vacuum cleaner

Perform only when the unit is OFF with power disconnected.

1. Turn power OFF at the main disconnect switch.

2. Remove the pick bin cover panel and the pick bin side plate.

3. Use a vacuum to clean out lint and dirt from the intake side of the pinch roll con-veyor motor (Figure 4-17).

4. Make sure the motor is free to turn without excessive binding.

5. Replace and secure the pick bin side plate and the pick bin cover panel.

WARNING

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

Figure 4-17: Removing lint and dirt from the intake side of the motor ensures proper operation.

Cascade Preventive Maintenance

4-19

Change Lift Clamp and Drip Conveyor Motors Gearbox Oil

Change the oil in both specified motor gearboxes using a good quality PAG synthetic oil, viscosity 460.

Required Tools Allen wrench: 1/4” Flashlight Funnel Ladder Oil: synthetic PAC, viscosity 460, manufacturer-recommended brand Oil drain pan Oil filter paper Wrench: 5/16”

Perform only when the unit is OFF with power disconnected.

WARNING

It will be necessary to stand on a sturdy ladder during this procedure. A fall could cause personal injury and/or damage the machine.

Use Extreme Caution.

1. Turn power OFF at the main disconnect switch.

2. For changing the drip conveyor motor gearbox oil, as appropriate:

• For machines loaded by cart, remove the center cover panel (Figure 4-18).

• For machines loaded by hopper:

a) Open the pick bin door.

b) Remove the pick bin side plate (Figure 4-19).

c) Fold the lower section of the push plate back and use a 10” (255 mm) wood block to lift it up to access the push plate air cylinder rod (Figure 4-20).

Figure 4-19: Remove the pick bin side plate to be able to go inside the bin.

Figure 4-20: Use a wood block to raise the push plate for access to the push plate air cylinder rod.

Figure 4-18: Accessing the drip conveyer drive motor gearbox.

Preventive Maintenance Cascade

4-20

Figure 4-21: Reach under the push plate and remove the bolt which secures the air cylinder rod arm.

Figure 4-22: Use wood blocks to raise the push plate for access to motor mounting bolts.

A

AB

d) Reach under the push plate and remove the bolt which secures the air cylinder rod to the push plate (Figure 4-21).

e) Use two wooden blocks each about 26” (660 mm) to lift up the push plate (Figure 4-22, A) to access the gearbox oil change bolts.

3. Remove the fill plug (Figure 4-23, A) so that air can enter.

4. Place a can under the drain plug (Figure 4-23, B), and then remove the drain plug.

5. Drain all oil from the gear reduction unit.

6. Remove the level plug (Figure 4-23, C).

7. Add the synthetic PAC-460, oil, brand as recommended by the manufacturer, through the fill hole until the oil is even with the level plug hole.

NOTE: Be sure to install the original plug in the fill hole since this plug allows the gear reduction unit to “breathe.”

8. Reinstall the fill and level plugs.

9. After changing the drip conveyor gearbox oil, reverse Step 2.

Figure 4-23: The lift clamp motor at the top of the machine.

A

B

C

Figure 4-24: The drip conveyor motor under the push plate.

A

C

Cascade Preventive Maintenance

4-21

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.

1. Turn power OFF at the main disconnect switch.

2. Open the right endframe and the electrical box doors.

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

4. Tighten any loose connections.

5. Close both doors.

Preventive Maintenance Cascade

4-22

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.

1. Turn power OFF at the main disconnect switch.

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

3. If there is a reading on the voltmeter, check and repair the separator’s ground connection.

Unit Starts, Then Shuts Down

Sensor Locations

Index