E-Tech Rail System Clean Storage.pdf

E-Tech System Manual Customer # E2286

Biloxi VAMC WSD

Biloxi, MS.

This is a guideline for preventative maintenance scheduling for E-Rail Monorail Systems.

The lubrication and inspection frequencies are suggestions that are based on a 40 hour work week, so if your plant has a double shift operation, those frequencies should be doubled.

This is strictly a maintenance schedule. You will find a more in depth description about the maintenance of each part of the monorail system within their respective sections.

Preventative Maintenance

Preventative Maintenance Schedule

DESCRIPTION

Track Routine Rail Inspection X Rail X Rail Splice Connections X Back Drop Links X Rail Hangers X Rail Support X Building Structure X

Switches Switch Inspection X Switch Adjustment X

Trolleys Lube Yoke To Load Bar Connection X Trolley Wheels And Bearings X Trolley Yokes, Load Bars, & Hooks X Trolley Yokes To Trolley Load Bar Connection Hardware X Trolley To Sling Connection Hardware X

Stops/Indexers X

Openers/Closers/Stabilizers X

Lifts Check Basic Lift Operations & Adjustments X Inspect Cable Fray & End Connections X Check Safety Stops X Check Alignment Of Upper And Lower Stubs With Live Rail X Check Hardware X Lube Sheaves X Check Pneumatic Package For Proper Operation, Leaks X Replace Cylinder Seals X

Slings Trolley To Sling Connection Hardware X Sling Ring Suspension Chain X Sling Cord Assemblies X Auto Open Sling Cord Slugs X Auto Open Sling/Trolley Latches & Pin Assemblies X Auto Open Sling/Trolley Springs X Sling Material X Sling Straps X Sling Ropes & Rope Closures X Sling Rings X

Controls Adjust Sensors X Clean Cooling Fan Filters X Calibrate Scales X

General Inspect System For Unusually Worn Or Loose Hardware X

DAILY

(8 HRS)

SCHEDULED INTERVALS

WEEKLY

(40 HRS)

MONTHLY

(173 HRS)

QUARTERLY

(520 HRS)

SEMI‐

ANNUALLY

(1040 HRS)

ANNUALLY

(2080 HRS) AS NEEDED

Preventative Maintenance Schedule

DESCRIPTION

Cart Dumper Hydraulic Reservoir Check Fluid Level X Lubricate Hydraulic Cylinders X Hydraulic Cylinders Check For Dirt Or Grease Buildup X Hydraulic Hoses & Fittings Check For Leakage X Lubricate Bearings X Check Bearings For Dirt Or Grease Buildup X Inspect Cylinder Pins X Inspect Motor X

Wind Up Fold Table WUFT Lubricate Reducer & Inspect Reducer / Drive components X Lubricate Bearings X Inspect Bed Liner X

Conveyors Inspect Belting Tracking X Inspect Belting For Tension and Laced Conditions X Check Oil Level X Lubricate Pillow Block/Flange Bearings X Check For Loose Hardware, Rollers, & For Other Hazards X Check Drive Sheaves & Sprockets Including Set Screws X Check Drive Chain For Proper Tension & Lubrication X Change Oil X

Trolley Speed Controller Inspect System For Unusually Worn Or Loose Hardware X Check Basic Operation X

RailServer Update Spare Server with current Ghost Image X Swap Active Server with Spare Server X

SCHEDULED INTERVALS

DAILY

(8 HRS)

WEEKLY

(40 HRS)

MONTHLY

(173 HRS)

QUARTERLY

(520 HRS)

SEMI

ANNUALLY

(1040 HRS)

ANNUALLY

(2080 HRS) AS NEEDED

Preventative Maintenance

Caution: Before performing any maintenance on switches, disconnect all the air lines at the air cylinder actuator. Switches can move automatically and without warning.

Proper Switch maintenance and adjustment will result in a more efficient, quieter, safer system and longer trolley wheel life.

Switch Inspection:

1. Disconnect air lines to the switch actuator cylinder

2. Check the switch and stubs for loose or missing hardware

3. Check for free movement of the switch pivot rail. If the pivot rail does not move freely:

a. Inspect pivot rail and stub connections for any interference, adjust as necessary.

b. Check that the wear strip and channel are clear of lint and debris. If necessary replace wear strip.

c. Check the pivot bolt connection for free movement at the pivot rail sleeve. Lubricate connection and lubricate with Tri-Flow TF-20027 or similar spray lubricant.

d. Verify that the air cylinder moves freely and that it is not restricting movement of the pivot rail.

4. Inspect pivot bolt for damage or excessive wear. Lubricate pivot bolt/ sleeve connection with Tri-Flow TF-20027 or similar spray lubricant.

5. Inspect flexible coupler for cracks or breakage. (There are small, flat-head bolts that secure each end of the flexible coupler to both the pivot rail and stub rail, occasionally one is intentionally left out in order to avoid adding any torsion to the coupler, as this can effect switch alignment and coupler life.)

6. Inspect switch live rail, safety bar and stub rails for any damage and replace if necessary.

7. Check the switch for proper operation and adjust as necessary.

8. Reconnect the air lines.

9. Observe the switch in operation to verify any adjustments or repairs made.

Each stub connection on the open end of the switch must be adjusted individually.

The stub rail height and the gap between the pivot-switch rail and stub should be adjusted first if necessary before adjusting the left-to-right travel.

To adjust the stub height and gap:

1. Disconnect air lines to the switch actuator cylinder.

2. Move the switch over to the stub to be adjusted and loosen the two switch stub adjustment connections at the switch plate. The 3/8” bolt and coupler connection through the rail should not be loosened.

3. If the stub moves significantly when loosened there may be pressure (either towards or away from the switch) from the rail leading into the switch. Too much pressure will result in more frequent switch adjustment. Adjust the rail leading into the switch to relieve pressure and re-tighten both rail connections.

4. With both stub rail connections snug, check the elevation difference between the pivot switch rail and snub. If the sling travel is from the pivot switch rail to the stub, the stub should be slightly lower than the pivot switch rail. If the sling travel is from the stub to the pivot switch rail, the stub should be adjusted slightly higher than the pivot switch rail. Keep in mind that the pivot switch rail will sit slightly lower when loaded with a full sling. Some downward pressure may be necessary to properly adjust the rail.

5. Adjust the gap to approximately 1/16”. Ensure the pivot rail moves freely.

6. After adjusting the gap, retighten the stub connection hardware and verify that the elevation is still correct. If elevation adjustment is needed, adjust one stub rail connection at a time. Alternate raising or lowering one connection, while keeping the other snug. This will allow some height adjustment while retaining the gap.

7. Check the adjustment after the air lines have been reconnected, as this may affect the switch alignment.

8. Repeat the procedure for the other stub.

To adjust left-to right travel:

1. With the air disconnected, move the pivot switch rail to the side to be adjusted.

2. Keep pressure applied to the pivot rail and check each side of the pivot rail and stub. Each side should be even and flush with the other rail section.

3. The left-to-right travel adjustment for the pivot switch rail is located at the ends of the detent channel. If adjustment is needed, loosen the jam nut with a 9/16” wrench. Then use a 3/16” Allen wrench to adjust the end stop position either in or out. Make sure to re-tighten the jam nut after adjustment.

Check the adjustment after the air lines have be reconnected as this may affect the switch alignment.

4. Repeat the procedure for the opposite end.

The flexible coupler end of the switch (the slinky) is also adjustable. The pivot bolt can be adjusted vertically and the stub connection works in the same manner as the open end of the switch. The transition from the stub to the flexible coupler to the pivot switch rail should be smooth. If the coupler appears to have a vertical curve to it, the pivot switch rail elevation or stub elevation should be adjusted. Note: Sort On Rail switches are sometimes set up with a slight downhill slope to them to aide slow moving slings.

The flexible couple end of the switch does not typically require adjustment, unless the switch coupler has been replaced.

Remember to reconnect the air lines and make sure they are run to the correct fitting for proper switch operation. Once a switch has been adjusted, monitor it in operation to make sure it is working properly.

Trolleys

- Description

- Inspection / PM

In this section you will find:

Trolleys There are many different kinds of E-Tech Trolleys, but they all have the same high quality and dependability. They are electro-plated to provide a durable, corrosion-resistant finish that will last for years.

A trolley breaks down into the wheels, yoke, loadbar and tab or hook and connection hardware.

The wheels are comprised of a precision ball bearing encased in a non-metallic tire. The bearings are sealed and do not require relubrication.

The frame, or yoke, of the trolley is cast from austempered steel.

Trolley Preventative Maintenance

All trolleys should be inspected for damage or wear, see the preventative maintenance schedule for frequency.

Important items to be checked are:

- Lubrication

- Trolley Wheel and Bearings

- Trolley Yokes, Load Bars and Hooks

- Trolley Yoke to Trolley Load Bar Connection Hardware

- Trolley to Sling Connection Hardware

- Auto Open Trolley Latch Pins

- Auto Open Trolley Latch Springs

Caution: Use proper lift and safety equipment while servicing the monorail equipment.

Note: The inspection information given here is not intended to limit inspection procedure but to provide information on what to include during an inspection.

Wheel Inspection: Inspect trolley wheels by lifting the trol-ley off of the rail so the wheels do not contact the monorail. Spin each wheel to make sure the bearings spin freely. Replace bearing if the wheel does not spin freely. Visually inspect the wheel and replace if the bearing is worn or cracked or if the tire is cracked or worn excessively. Make sure the wheel bolt and tire snap ring is in place and secure.

If wheel replacement is necessary, the wheel bolt should be reinstalled with an impact wrench and blue thread lock should be applied to the wheel bolt threads prior to reinstallation.

Yoke inspection: Inspect trolley yoke by lifting the trolley off the rail so the wheels do not contact the monorail. Rotate the yoke back and forth along the load bar connection axis making sure its movement is smooth. Grease this connection according to the maintenance schedule and make sure all washers are in place at the yoke to load bar connection. Also make sure the castle nut and cotter pin are in place and secure.

To ensure proper trolley performance, do not over tighten the yoke to load bar connection. Do this by finger tightening the castle nut on the yoke to load bar connection and back it off ½ a turn then insert the cotter pin. Cotter pins should not be reused.

Replace yoke if any part of it is damaged, bent or shows excessive wear.

Trolley to sling connection inspection: Inspect all trolley to sling connection hardware, i.e. clevis, clevis pin, circle cotter, washers, chains, shoulder bolts, hooks, lock nuts, and replace if damaged or worn excessively.

Load bar inspection: Visually inspect trolley load bar and replace if any part of it is damaged or bent. If the load bar is equipped with sling hooks, visually inspect the hook and hook hardware or welds and replace if worn or damaged.

If your load bar is equipped with an auto opening mechanism, inspect the auto open latch to make sure it opens freely and fully and the spring returns to the closed position. Make sure the latch pin, latch pin actuator, and latch pin spring are not damaged and that all hardware is secure.

The E-Rail trolley has been engineered for low maintenance. The trolley wheels do not need lubrication. However, the yoke to load-bar connection point may need a small “burst” of light weight aerosol grease every two to three years. In a warmer or more humid plant environment, the connection point may need lubrication on an annual basis. If the trolleys are not performing well in a gravity system, lack of grease as the load-bar to yoke connection point may be the cause of the problem. Note that the lube should be applied with a small diameter spray tube between the washer and load bar.

Stops & Indexers

- Preventative Maintenance

- Drawings and Part #’s

Stops & Indexers Stops control one trolley, while Indexers are designed to control two slings - with one or two trolleys each. Stops and Indexers provide the metering control required in automated systems.

Stops and Indexers can be equipped with sensors to signal the presence of a trolley. Actuation of the stops and indexers can be accomplished through manual or solenoid operated valves.

Stops and Indexers are mounted on hardened rail sections. There is a steel sleeve inserted in the rail section that guides the drop pin. The front (downhill side) pin and cylinder of an indexer is longer than the back (uphill side) pin and cylinder.

Stops and Indexers are power by air pressure. The blue hose going to a stop or indexer is the constant air, while the black hose is the variable air.

The following page goes over the Preventative Maintenance for stops and indexers.

Preventative Maintenance The indexers and stops are designed for low maintenance. The indexers may need to have a flow control adjustment made if trolleys are not being held back properly when an indexer goes to the “send” position. A flow control has been included on the upper port of the rear indexer cylinder.

This flow control should be adjusted so that the rear pin (A) always lowers before the front pin (B) rises when the indexer goes to the “send” position and the front pin lowers before the rear pin rises when the indexer goes to the “receive” position.

Indexers and stops supplied with sensors may need adjustment on a semi-annual basis. These sensors actuate a proximity sensor which indicates the presence of a trolley in the stop or indexer. If this sensor goes out of adjustment, there may result in control problems. The adjustment procedure for the indexer and stop sensor is the same as for the trolley sensors described in that section.

A B

Lifts Note: The adjustment procedure described below details the adjustments that are done following installation of the lift. Most of the adjustments described should not be necessary again unless there are major changes to the lift (i.e. the live rail and/or guiding is replaced). Refer to the preventative maintenance section for routine adjustments.

FIELD ADJUSTMENT PROCEDURE

2. Loosen the upper and lower guide brackets as well as the wing guides

7. Manually lower live rail about 1”

alignment.

17. Grease sheaves and any live rail and stub stop and safety pins.

18. Check cable clearance and check that all hardware is tight before returning lift to operation.

Slings

- Inspection

- Preventative Maintenance

Your facility may have soft-sided slings or slings with a rigid top called a sling ring. Slings can be loaded a number of ways depending on the needs of the facility. The top sling ring (if required) is fabricated from cold-drawn steel tube which is zinc plated for a durable finish. Slings are custom made not only for each facility but whether they are for clean or soiled linen.

Preventative Maintenance

The slings provided for your plant may have an automatic opening feature.

The automatic slings will have a special cord assembly which facilitates closing the sling through a latch mechanism on the sling frame or ring.

These assemblies should be checked quarterly for fraying. If the cords are frayed, a replacement should be installed to prevent accidental unloading of the sling.

All slings should be inspected quarterly for wear and damage. They should be replaced or repaired as needed.

Replacement cord assemblies are available from E-Tech for your slings.

Slings

Sling Inspection

Trolley to sling connection: Inspect all trolley to sling connection hardware, i.e. clevis, clevis pin, circle cotter pin, washers, chains, shoulder bolts, hooks and lock nuts. Replace any of these parts if damaged.

Material: Visually inspect sling material and straps for damage or loose stitching and replace or repair as required.

Sling cord: Visually inspect all sling cords and rope closures and replace them if they are frayed, worn or broken. Inspect the metal “bullet” and lanyard and replace if worn or damaged.* Also check that all of the knots are secure and that the bullet assembly hardware is tight.

Sling ring and sling yoke: Visually inspect sling rings, sling yoke, sling ring to sling yoke hardware, sling ring hardware and sling ring welds and replace any damaged, cracked, bent or worn parts. Inspect the sling latch to make sure it opens freely and fully, make sure the spring returns to the closed position. Make sure the latch, latch pin and latch pin spring are not damaged and all hardware is secure.*

Recommended Sling Inspection Procedure

1. General:

The sling assembly should be inspected for obvious sign of wear and damage. A log should be kept of inspections and repairs along with the date of the inspection and who made the inspection.

A. All plant personnel should be involved in general plant safety but good safety practice alone is not a substitute for periodic inspection of equipment.

B. All components should be inspected for cracks, bends, wear, or damage.

C. The sling should be inspected for tears in the fabric and straps.

-- If fabric is damage is present, determine the cause and make the necessary changes to prevent further damage.

2. Sling Cord:

The sling cord type and sling cord length are both very important to the proper function and the safety of the sling. Refer to the system manual or E-Tech’s Service Team to determine the proper part numbers and assembly.

A. The cord should not show any signs of wear. If wear is noted the cord should be replaced with a cord the meets E-Tech specifications.

B. A broken sling cord should be replaced outright, not repaired.

The sling should be inspected for knots and splices.

C. The lanyard should not show sign of wear or fraying.

3. Sling Ring to Sling Yoke Connection:

A. The pin or connection hardware should be inspected for wear and replaced if necessary.

B. The cotter pin should be inspected for wear or signs of damage and replaced if necessary.

4. Sling latch assembly.

A. Inspect for sign of wear or damage.

B. Check the movement of the latch.

-- Does it move freely?

-- Does the spring return it back into position?

* May not apply