Chicago Small Piece Folder Model Air XL.pdf

Air ChiCAgo® CT (STANDArD / XW / XL / XXL)

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Air Chicago CT (Standard/XW/XL/XXL) Preventive Maintenance

4-1

Chapter 4

PrEvENTivE MAiNTENANCE Various components and parts of the Air Chicago® CT 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 Tables

Daily, Weekly, Monthly Tasks

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 and Clean Photosensors X Off/Disconnect Power

Check Safety Equipment X X Running

4.2 WEEKLY (50 hours)

Check and Clean Inverter X Off/Disconnect Power

Polish Metal Surfaces X Off/Disconnect Power

Check Drive Belt Condition and Tension X Off/Disconnect Power

Check and Grease Stacker Door Bearings X Off/Disconnect Power

Lubricate Stacker Door Linkages X Off/Disconnect Power

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

Check Air Pressure Settings X Off/Power Connected

Check Ribbon Condition and Tension X Running

4.3 MoNThLY (200 hours)

Check Setscrews X Off/Disconnect Power

Clean and Lubricate Drive Chains X Off/Disconnect Power

Check and Clean Drive Motors X Off/Disconnect Power

Preventive Maintenance Air Chicago CT (Standard/XW/XL/XXL)

4-2

Semi-Annual, Annual Tasks

FrEQuENCY oF TASKS bASED oN 40 hourS PEr WEEK oPErATioN

Preventive Maintenance Tasks operator Maintenance unit Condition

4.4 SEMi-ANNuAL (1000 hours)

Clean and Lubricate Threaded Rods X Off/Disconnect Power

Clean Air Filter/Auto Drain X Off/Disconnect Power

Inspect Gear Reduction Unit 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

4-3

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 required Tools Cloth: soft, lint-free Vacuum cleaner or compressed air

Perform only when the unit is oFF with power disconnected.

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.

1. Turn power OFF at the main disconnect switch.

2. Use a vacuum cleaner or compressed air supply to clean the following:

• Ribbons

• General Components

• Conveying modules, as required

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

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.

4-4

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 three red safety STOP buttons and both sections of the air permeable barrier (wire guard) all bring the operation of the machine to a complete halt and depressurize the compressed air system.

For more information, refer to the OPERATING GUIDELINES chapter, Standard Operating Procedures section, Start-Up procedure.

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

Check and Clean Photosensors

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

For information on photosensor location, refer to the OPERATING PRINCIPLES chapter, Electrical System section, Control System subsection.

required Tools Cloth: soft, lint-free Compressed air Screwdriver

Perform only when the unit is oFF with power disconnected.

3. Remove the screws which secure the top cover and position it out of the way.

4. Raise the rear panel.

5. Use compressed air to blow off loose debris on each photosensor.

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

7. Lower and secure the rear panel.

8. Replace and secure the top cover.

Figure 4-1: Inlet photosensors at the front of the unit.

4-5

Check and Clean inverter

Check and clean the inverter and its 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 rear left endframe door.

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.

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

4. Close and secure the rear left endframe door.

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.

Figure 4-2: The inverter is located in the left endframe of the unit.

4-6

Polish Metal Surfaces required Tools Cloth: soft, lint-free Furniture polish

Perform only when the unit is oFF with power disconnected.

To minimize friction, several surfaces on the machine (Figure 4-3) must be polished with a furniture polish. The areas that need attention are:

• The bottom of the primary skis. Spray a rag with the polish. Lift the wire guard on top, slip the rag under each ski, and slide it back and forth.

• The sensor cover plate at the first crossfold.

• The receiving shelf at the second crossfold.

• The top of the stacker doors.

Check Drive belt Condition and Tension

Perform only when the unit is oFF with power disconnected.

Remove the right endframe panels. Check the condition and tension of the feed ribbon and stacker drive belts. For more information, refer to the REPAIR chapter, Chains and Belts Section, and the appropriate belt tension adjustment procedure. Replace and secure the right endframe panels.

Figure 4-3: Polishing the specified metal surfaces helps maintain smooth operation.

4-7

Check and grease Stacker Door bearings

Weekly greasing of the stacker door bearings (Figure 4-4) helps 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.

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

Perform only when the unit is oFF with power disconnected.

1. Turn power OFF at the main disconnect switch.

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.

Figure 4-4: Use care not to over lubricate the stacker bearings.

4-8

Lubricate Stacker Door Linkages

There are several points (Figure 4-5) that must be lightly lubricated on the stacker linkage which operates the trap doors. The points indicated include:

• Two on the arms on the doors

• Three connections on the linkage

• The shaft on which the linkage pivots

• The stacker ribbon idler roll pivot bolt at both ends of the roll.

required Tools Oil/spray lubricant Screwdriver

Perform only when the unit is oFF with power disconnected.

1. Turn power OFF at the main disconnect switch.

2. Remove the screws which secure the lower portion of the rear protective panel and swivel it up.

3. Remove the inner protective panel.

4. Apply a drop of oil or a brief spray with a lubricant in a pressurized can.

5. Replace and secure the inner protective panel.

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

6. Reposition and secure the rear protective panel.

Figure 4-5: Regular lubrication keeps the stacker door components working smoothly.

4-9 inspect Air Filter/Auto Drain unit

Perform only when the unit is oFF with power disconnected.

The combination air filter/auto drain with automatic drain unit (Figure 4-6) 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 4-16.

Check Air Pressure Settings

Maintaining proper incoming and internal air pressures helps keep the machine operating at peak efficiency. The machine has a total of 4 air gauges/pressure regulators. Each must be checked.

Perform only when the unit is oFF with power connected.

use Extreme Caution.

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

1. Turn power ON at the main disconnect switch. Wait about 45 seconds for the machine to go through the boot up process.

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

3. Press and hold the START button about 5 seconds until the CHI•Touch screen dis-plays the Air Pressure Low message. It is not necessary to start the machine.

4. Allow a few seconds for the compressed air system to pressurize.

5. Remove the right rear endframe panel.

Figure 4-6: The air filter/regulator/drain is under the right front of the unit, beneath the inlet ribbons.

4-10

6. Locate the pressure gauges. Three are at the front of the unit (Figure 4-7) and one is located inside the right endframe (Figure 4-8). They should be set as listed below:

A Incoming/High Air Pressure*

70 psi (485 kPa) b Low Air Pressure 40 psi (275 kPa) C Crossfold Air Pressure 50 psi (345 kPa) D Stacker Air Pressure 60 psi (415 kPa)

* For XW units: 80 psi (550 kPa)

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

7. Replace and secure the right rear endframe panel.

Check ribbon Condition and Tension

NOTE: Ribbons that break should be replaced immediately.

While the machine is off

Perform only when the unit is oFF with power disconnected.

Check the condition of the rubberized feed ribbons. Feel the surface: it should be uneven. If the surface is smooth, the rubberized surface has worn and the ribbons should be replaced.

Check the Tev-Tex primary fold ribbons. If they are dirty, use glass cleaner to clean them. Be sure to dry the ribbons carefully before folding towels.

While the machine is running

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.

With the machine operating, check all ribbons for proper placement, tracking, tension (no visual sagging), and general condition (smoothness, fraying, and tears). For more information, refer to the REPAIR chapter, Ribbons section for the appropriate ribbon tension adjustment/ replacement procedure.

Figure 4-8: Stacker air pressure regulator inside the right endframe.

D

Figure 4-7: Air pressure regulators at the front of the unit.

A b

C

4-11

Figure 4-9: Make sure the setscrews are sufficiently tightened.

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

Setscrews (Figure 4-9) hold sprockets, bearings, and other rotating parts securely in place. Check and make sure that all setscrews are tight.

required Tools Allen wrench set

Perform only when the unit is oFF with power disconnected.

4-12

Clean and Lubricate Drive Chains

All drive chains (Figure 4-10, Figure 4-11) require monthly maintenance. These include the:

• Main drive chain

• Primary fold ribbon drive roll chain

• Transfer ribbon drive roll chain

• Primary skis drive chains

• Primary ski main drive chain

Carefully inspect the condition of each chain and check its tension. Replace any chain that shows signs of excessive wear and can no longer be adjusted.

For information on adjusting tension, refer to the REPAIR chapter, Chains and Belts section and the appropriate Chain Tension Adjustment procedure.

required Tools Cloth: soft, lint-free Oil: SAE 90 grade

Perform only when the unit is oFF with power disconnected.

1. Turn the power OFF at the main discon-nect switch.

2. Remove both right endframe panels.

3. Clean off old lubricant from the drive chains.

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

5. Replace and secure the endframe panels.

6. At the front of the unit, locate the primary ski main drive chain (Figure 4-11).

7. Clean off old lubricant from the drive chain.

8. Lightly lubricate the chains with a good quality SAE 90 grade oil.

Figure 4-11: Primary fold skis drive chain on the inner wall of the right endframe.

Figure 4-10: Most drive chains are located inside the right endframe.

4-13

Check and Clean Drive Motors

The main drive motor (Figure 4-12, A) and primary fold ski drive (B) motors require monthly cleaning to ensure proper operation.

required Tools Vacuum cleaner

Perform only when the unit is oFF with power disconnected.

1. Turn power OFF at the main disconnect switch.

2. Use a vacuum to clean out lint and dirt from the intake side of each motor.

3. Make sure each motor is free to turn with-out binding.

Figure 4-12: Removing lint and dirt from the intake side of each motor ensures proper operation.

A b

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.

4-14

Clean and Lubricate Threaded rods

Four threaded rods control the movement of the primary fold skis and side runners. These require periodic cleaning and lubrication to help ensure smooth operation.

required Tools Brush Cloth: soft, lint-free Lubricant: Thompson Linear Lube (Lubricant w/P.T.F.E.)

Screwdriver Wrench: 9/16”

Perform only when the unit is oFF with power disconnected.

1. Start the folder.

2. Use the CHI•Touch screen to move the skis to the narrowest position.

3. Stop the unit and turn power OFF at the main disconnect switch.

4. Loosen the nuts which hold the CHI•Touch screen in position (Figure 4-13, A) and swivel it up.

5. Loosen the screws which hold the CHI•Touch screen bracket in position (Figure 4-13, B).

6. Turn the bracket so that the screen is paral-lel with the left endframe and re-position the screen so that it is vertical.

7. Remove the four screws that secure the front cover.

CAuTioN be careful not to damage the wiring connecting the front cover to the unit.

8. Carefully lift the front cover and place it onto the air permeable barrier.

9. Use a soft, clean cloth to wipe the two threaded rods which control the primary fold skis.

10. Using a brush, apply a moderate amount of Thompson Linear Lube (lubricant w/ P.T.F.E.) to the threaded rods on the outer side of the bearing pack (Figure 4-14).

Figure 4-13: Reposition the CHI•Touch screen to more easily remove the front cover.

AA

b

Figure 4-14: Clean the primary fold ski threaded rods before adding fresh lubricant.

4-15

11. Under the unit, locate the threaded rods which control movement of the side run-ners. One will be towards the front of the unit; the other, closer to the center (Figure 4-15).

12. Repeat Steps 9 and 10 for these rods.

13. Reposition the front cover but do not re-install the screws.

14. Start the folder.

15. Use the CHI•Touch screen to move the skis to the widest position.

16. Stop the unit and turn power OFF at the main disconnect switch.

CAuTioN be careful not to damage the wiring connecting the front cover to the unit.

17. Carefully lift the front cover and place it on the air permeable barrier.

18. Using a brush, apply a small amount of the lubricant to the threaded rods on the inner side of the bearing pack for the both the primary fold runners and the side runners.

19. Carefully replace the front cover and se-cure it with the screws removed in Step 7.

20. Turn power ON at the main disconnect switch.

21. Start the folder.

22. Use the Use the CHI•Touch screen to move the skis in and out several times to spread the lubricant.

Figure 4-15: Locate the side runner threaded rods under the machine toward the front and toward the center.

4-16

Clean Air Filter/Auto Drain

The air filter 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 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 4-16, 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).

4. Pull down on the bowl case to remove

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

5. Take the polyurethane bowl (Figure 4-17, A) and rinse with ONLY water and house-hold soap.

6. Twist counterclockwise the black plastic base (Figure 4-17, B) which holds the filter element (C) in place.

7. Remove the filter element and discard.

8. Clean the other components (Figure 4-17, B, D) with ONLY water and household soap; then, dry with a soft,clean cloth.

9. Re-assemble the clean components, insert-ing a new filter element and twisting the filter 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 4-16: Press the plastic tab and twist the casing to line up the marks to remove the filter bowl from the machine.

b

A

Figure 4-17: All the components in the air filter assembly can be washed with alcohol, EXCEPT the bowl.

A b

C

D

4-17 inspect gear reduction unit required Tools Cloth: soft, lint-free Screwdriver

Perform only when the unit is oFF with power disconnected.

Visually inspect the main drive motor gear reduction unit on the inner wall of the right endframe (Figure 4-18) for leakage, accumulation of dirt, and general operating condition.

Accumulation of material on the reducer can lead to overheating and reduced life. Use a clean cloth to wipe down the surface of the unit.

Oil changes are not required. Oil should only be replaced when maintenance is performed that requires disassembly. If the oil is replaced, use Mobil SHC634.

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.

Figure 4-18: The gear reducer on the main drive motor.

4-18

Check All Electrical Connections

Over time, the continued stresses of use can cause electrical connects to become loose.

required Tools Screwdriver: small, thin

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. Open the right rear endframe and the elec-trical connection box doors.

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

4. Tighten any loose connections.

5. Close both doors.

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 folder’s ground connection.

Primary Folding is Erratic or Inaccurate

Inaccurate Fold

Inaccurate Fold

Stacker Conveyor Door Assy.

Index